A--T0GK1 - 406D9
MODIFICATIONS - METHOD(S) 406
From 01/07/2000, reference to model year discontinued for all vehicles .
Development of 406 range characterised by :
1 - STYLE
1 - 1 - LEVEL 1 (SR)
The level 1 saloons and estates are fitted with :
1 - 2 - LEVEL 2 (ST)
The level 2 saloons and estates are fitted with :
1 - 3 - LEVEL 3 (SV)
Level 406 3 are fitted with leather pack equipment as standard .
1 - 4 - ST PACK SPORT VERSIONS
The ST PACK SPORT versions are fitted with special equipment in relation to level 406 2 .
Exterior styling :
Interior styling :
Standard equipment :
Optional equipment :
2 - ENGINE EW12J4/L4
Introduction of the EW12J4/L4 engine with ML5T gearbox .
2 - 1 - IDENTIFICATION
Engine type reference plate including :
2 - 2 - DATA
engine type | EW12J4/L4 |
---|---|
legislation type | 3FZ |
number of cylinders | 4 |
bore x stroke (mm) | 86 x 96 |
capacity (cm3) | 2230 |
compression ratio | 10.8/1 |
maximum power : EU standards (KW) | 116 |
maximum power : standard DIN (HP) | 160 |
engine speed at max. power (r.p.m.) | 5650 |
maximum torque : EU standards (da.Nm) | 21.7 |
engine speed at max. torque (r.p.m.) | 3900 |
injection system | one-touch |
make | MAGNETI MARELLI |
type | 4MP |
catalytic converter | yes |
3 - ENGINE EW7J4/IFL5 (TAX INCENTIVE)
Introduction of the EW7J4/IFL5 engine with BE4 gearbox .
The engine structure is identical to that of the EW10J4 engine .
3 - 1 - IDENTIFICATION
Engine type reference plate including :
3 - 2 - DATA
engine type | EW7J4/IFL5 (tax incentive) |
---|---|
legislation type | 6FZ |
number of cylinders | 4 |
bore x stroke (mm) | 82.7 x 81.4 |
capacity (cm3) | 1749 |
compression ratio | 10.8/1 |
maximum power : EU standards (KW) | 85 |
maximum power : standard DIN (HP) | 115 |
engine speed at max. power (r.p.m.) | 5500 |
maximum torque : EU standards (da.Nm) | 16.3 |
engine speed at max. torque (r.p.m.) | 4000 |
injection system | multipoint |
make | SAGEM |
type | S2000 |
catalytic converter | yes |
4 - ENGINE EW10J4/IFL5 (TAX INCENTIVE)
Introduction of the EW10J4/IFL5 engine with BE4 gearbox .
The engine structure is identical to that of the EW10J4/L4 engine .
4 - 1 - IDENTIFICATION
Engine type reference plate including :
4 - 2 - DATA
engine type | EW10J4/IFL5 (tax incentive) |
---|---|
legislation type | RFN |
number of cylinders | 4 |
bore x stroke (mm) | 85 x 88 |
capacity (cm3) | 1997 |
compression ratio | 10.8/1 |
maximum power : EU standards (KW) | 100 |
maximum power : standard DIN (HP) | 136 |
engine speed at max. power (r.p.m.) | 6000 |
maximum torque : EU standards (da.Nm) | 19 |
engine speed at max. torque (r.p.m.) | 4100 |
injection system | one-touch |
make | MAGNETI MARELLI |
type | 4.8 P |
catalytic converter | yes |
5 - ENGINE EW10D/L4
The range is extended by the introduction of the EW10D/L4 engine ( Petrol direct injection) .
The EW10D engine is fitted with the BE4 manual gearbox .
Petrol direct injection permits operation with a lean mixture and thus reduction of petrol consumption .
In addition, the EW10D engine is fitted with 15° vtc (variable timing camshaft) identical to EW10J4 permitting improvement of the torque at low engine speeds .
This engine is characterised by 3 types of modification in relation the EW10J4 engine :
5 - 1 - IDENTIFICATION
Engine type reference plate including :
5 - 2 - DATA
engine type | EW10D/L4 |
---|---|
legislation type | RLZ |
number of cylinders | 4 |
bore x stroke (mm) | 85 x 88 |
capacity (cm3) | 1998 |
compression ratio | 11.4/1 |
maximum power : EU standards (KW) | 103 |
maximum power : standard DIN (HP) | 143 |
engine speed at max. power (r.p.m.) | 6000 |
maximum torque : EU standards (da.Nm) | 19.2 |
engine speed at max. torque (r.p.m.) | 4100 |
injection system | high pressure multipoint |
make | SIEMENS |
type | SIRIUS 81 |
catalytic converter | yes |
Quantity of oil with replacement of the filter cartridge: 4.25 litre(s) .
5 - 3 - MOTOR OPERATION
The petrol direct injection engine is controlled by the engine management ecu in line with two operating modes :
Uniform mixture operation :
This operating mode is similar to petrol indirect injection .
Stratified lean mixture operation :
The high pressure injection pump driven at the end of the camshaft, clutch side, delivers between 70 and 120 bars .
The injection rail is fitted with a pressure sensor and a pressure regulator permitting the return of fuel to the high pressure pump inlet to regulate the petrol pressure in the rail .
5 - 4 - ENGINE STRUCTURE
The pistons are specific with an adapted bowl at the injector jet .
The cylinder head with 4 valves per cylinder and 2 camshafts is specific ; The air inlet pipes (1) are incorporated in the cylinder head, their position is almost vertical .
The shape of the piston combined with the position of the air inlet pipes (1) and of the injector (2) create a swirl (inverse tumble) permitting the following actions :
5 - 5 - ENGINE CHECK
The engine management assembly is controlled by an ecu SIEMENS of the SIRIUS 81 type .
This ecu is fitted with a flash eprom memory .
In relation to the EW10J4 engine, this ecu controls the following additional functions :
5 - 6 - EXHAUST GAS EMISSION CONTROL
The exhaust line consists of :
The temperature sensors permit checking of the effectiveness of the pre-catalyst .
The proportional oxygen sensor enables the ecu to adjust the richness of the mixture .
Operation in lean mixture mode produces a large quantity of nitrogen oxide (nox) which the pre-catalyst cannot eliminate sufficiently. the role of the catalytic converter is to reduce the amount of nitrogen oxide in the exhaust gas .
The denox catalytic converter stores the nitrogen oxide during the phases of operation in lean mixture mode .
The engine management ecu estimates how full the catalytic converter is using the information supplied by the pre-catalyst downstream temperature sensor and triggers the switch to rich mixture mode ; The switch to rich mixture mode causes the release of the nitrogen oxide (nox) by providing hydrocarbons .
The downstream oxygen sensor permits detection of the end of purging (presence of hydrocarbons) .
6 - ENGINE ES9J4S/IFL5 (TAX INCENTIVE)
Replacement of the ES9J4S/L4 engine by the ES9J4S/IFL5 engine .
6 - 1 - DATA
engine type | ES9J4S/IFL5 (tax incentive) |
---|---|
legislation type | XFX |
number of cylinders | 6 |
bore x stroke (mm) | 87 x 82.6 |
capacity (cm3) | 2946 |
compression ratio | 10.9/1 |
maximum power : EU standards (KW) | 152 |
maximum power : standard DIN (HP) | 210 |
engine speed at max. power (r.p.m.) | 6000 |
maximum torque : EU standards (da.Nm) | 28.5 |
engine speed at max. torque (r.p.m.) | 3750 |
injection system | one-touch |
make | BOSCH |
type | ME7.4.6 |
catalytic converter | yes |
7 - ENGINE DW12TED4
Introduction of the DW12TED4 engine with particulate emission filter .
7 - 1 - IDENTIFICATION
Engine type reference plate including :
7 - 2 - DATA
engine type | DW12TED4 |
---|---|
legislation type | 4HX |
number of cylinders | 4 |
bore x stroke (mm) | 85 x 96 |
capacity (cm3) | 2179 |
compression ratio | 18/1 |
maximum power : EU standards (KW) | 5200 |
maximum power : standard DIN (HP) | 98 |
engine speed at max. power (r.p.m.) | 136 |
maximum torque : EU standards (da.Nm) | 4000 |
engine speed at max. torque (r.p.m.) | 31.5 |
injection system | HDI |
make | BOSCH |
type | EDC15C2 |
catalytic converter | yes |
7 - 3 - ACCESSORIES
Only one ancillary drive system version is available with the following options :
(10) Automatic roller tensioner .
(11) Fixed idler roller .
(12) Alternator pulley with free wheel .
7 - 4 - PARTICLE FILTER
The particulate emission filter positioned after the catalytic converter traps the particles of carbon which are then burned during the regeneration phases .
The additive added to the fuel automatically every time the tank is filled permits lowering of the soot combustion temperature ; The additive reservoir is taken from the 607 (capacity 5 litres) .
The particulate emission filter is controlled by the engine management ecu and by the diesel additive ecu; its operation is identical to 607 .
The 4 point clamp between the catalytic converter and the particulate emission filter is specific; the particulate emission filter 406 is shorter than the particulate emission filter 607 (length 9 inches) .
(13) Upstream pressure sensor .
(14) Downstream pressure sensor .
(15) Downstream temperature sensor .
(16) Upstream temperature sensor .
Measuring the upstream/downstream pressure difference permits calculation of the particulate emission filter's soot load .
Measuring the temperatures permits checking of the operation during the regeneration phase .
Regular maintenance must be carried out every 80000 miles kilometres) or at the request of the engine management ecu :
It is possible to force regeneration using the diagnostic equipment DIAG 2000 .
WARNING : during regeneration, the temperatures at the exhaust line are very high ; the working area must be clear ; do not connect the exhaust gas extraction take-off .
8 - ENGINE DW10
8 - 1 - PLASTIC WATER OUTLET HOUSING
The aluminium water outlet housing has been replaced with a plastic water outlet housing on DW10TD - DW10ATED engines .
Modified parts :
The water pipes are only modified at the engine end .
Old assembly/new assembly mixtures are not permitted .
Parts division will continue to supply the old parts .
8 - 2 - ELECTRIC DIESEL HEATER
The diesel heating system previously incorporated in the aluminium water outlet housing has been replaced with an electric diesel heater positioned on top of the engine .
9 - FUEL TANK
New fuel circuit: the tank and the filler spout have been modified to meet the requirements of evaporation standard EURO 3 and to permit the installation of the additive reservoir (versions with particulate emission filter) .
Addition of a switch positioned in the tank pipe transmitting tank cap presence information to an instrument panel warning light .
Petrol tank (EW10 , ES9J4S) .
Petrol tank (XU7JP , Overseas export) .
Diesel tank (DW10) without particulate emission filter .
Diesel tank (DW12) with particulate emission filter .
(17) Filler spout .
(18) Reservoir .
(19) New pump gauge module with incorporated filter .
(20) Pump gauge module .
(21) Petrol filter .
(22) Diesel additive reservoir incorporating the pump and additive low gauge functions .
(23) Additive reservoir breather .
(24) Additive injector .
10 - GEARBOX
10 - 1 - AUTOMATIC GEARBOX
The AL4 - 4HP20 automatic gearboxes have been modified :
10 - 2 - BE4 GEARBOX
engine type | EW10D/L4 | EW7J4/IFL5 (tax incentive) |
---|---|---|
unit reference | 20DL46 | 20DL43 |
type of gearbox | BE4/5J | BE4/5V |
1st gear | 11 x 38 | 11 x 38 |
2nd gear | 23 x 43 | 23 x 43 |
3rd gear | 25 x 32 | 25 x 34 |
gear no. 4 | 41 x 39 | 39 x 41 |
gear no. 5 | 44 x 35 | 44 x 35 |
reverse | 12 x 31 x 40 | 12 x 31 x 40 |
final drive gears | 19 x 77 | 19 x 79 |
speedometer drive gear | 22 x 18 | 22 x 18 |
oil capacity (litre(s)) | 1.9 | 1.9 |
At EW10J4/IFL5 (Tax incentive) :
10 - 3 - ML5T GEARBOX
engine type | EW12J4/L4 | DW12TED4/L4 |
---|---|---|
unit reference | 20LE92 | 20LE75 |
type of gearbox | ML5T/G | ML5T/I |
1st gear | 12 x 39 | 12 x 41 |
2nd gear | 23 x 41 | 23 x 41 |
3rd gear | 31 x 37 | 33 x 37 |
gear no. 4 | 41 x 37 | 44 x 35 |
gear no. 5 | 45 x 33 | 51 x 31 |
reverse | 13 x 26 x 41 | 13 x 26 x 41 |
final drive gears | 16 x 69 | 17 x 67 |
speedometer drive gear | 25 x 20 | 25 x 20 |
oil capacity (litre(s)) | 1.85 | 1.85 |
11 - WHEELS
Aluminium wheels are receiving mixed mounting bolts .
12 - BRAKES
12 - 1 - BRAKE VACUUM CIRCUIT
The engine brake vacuum circuit EW10D is specific .
(25) Inlet manifold .
(26) Pipes .
(27) Brake servo .
(28) Vacuum valve .
(29) Vacuum sensor .
(30) Interface accommodating the vacuum sensor and the vacuum valve .
(31) Retaining of the vacuum sensor on the interface by bolting .
(D) Black section towards the source of the vacuum .
(E) White section towards the servo .
EW10D engine operation in lean mixture mode (throttle open) does not permit creation of the vacuum necessary for servo-assisted braking .
The vacuum level in the servo is monitored by the engine management ecu via a vacuum sensor (23) .
When the vacuum level in the servo is too low, the engine management ecu closes the throttle (operation in uniform mixture mode) until the vacuum level in the brake servo is sufficient .
If the vacuum circuit fails, the engine management ecu positions the throttle to guarantee a sufficient vacuum level .
This fault is stored by the engine management ecu but the driver is not informed .
12 - 2 - ADAM EMERGENCY BRAKING ASSISTANCE SYSTEM
Introduction of the adam CONTINENTAL TEVES emergency braking assistance system as standard on all engines .
Adam: advanced dynamic aid mechanism .
The brake servo (32) is fitted with a device permitting reduction of the braking distance in the event of emergency braking .
It is a mechanical system permitting 2 operating modes :
The system is triggered when the power of the pedal (force x speed) exceeds a threshold; this threshold is set at the factory .
The master cylinder remains a conventional system (Tandem master cylinder) .
This system does not require any modification to the brake circuit bleed procedure .
Data :
12 - 3 - DISC BRAKES
The 406 vehicle is fitted with 4 disc brakes as standard on all models .
Reminder :
13 - EQUIPMENT
13 - 1 - DYNAMIC STABILITY CONTROL
Vehicles fitted with the ES9J4S engine are fitted with esp dynamic stability control as standard .
The purpose of the esp dynamic stability control system is to improve active safety in extreme driving conditions (slippery road surface, avoidance manoeuvre...) .
The esp dynamic stability control ecu controls the following functions :
To determine the trajectories, the ecu checks the following information and compares it with models :
The trajectory is modified by action on :
The asr traction control and esp dynamic stability control functions can be switched off partially by means of a switch to increase the traction of the front wheels .
Once they have been switched off by the driver, these functions remain off irrespective of the vehicle speed .
3 warning lights indicate the appearance of a fault in the system .
Description of the ESP pre-charge pump hydraulic circuit :
It is essential to bleed the esp hydraulic circuit in the following cases :
Bleeding requires the use of the diagnostic equipment DIAG 2000; the procedure is described in the DIAG 2000 .
13 - 2 - AMVAR AUTOMATICALLY ADJUSTED SUSPENSION
The amvar suspension option (ES9J4S engine) has been discontinued .
13 - 3 - AUDIO SYSTEMS
New RM2 model radio, made by CLARION with cassette player in the front panel .
New RD2 model radio, made by CLARION with CD player in the front panel .
This audio equipment is fitted with the automatic speed-related volume adjustment function .
These audios are able to run a cd player .
In service, the audio equipment and the multifunction display (B or C) must be configured using the DIAG 2000 (This function will become available during the course of the year) .
The amplifier JBL is available as an option on estate versions .
The role of the audio system amplifier is to give better reception and sound quality .
The amplifier JBL is secured to the satellite navigation system ecu support .
13 - 4 - TRIP COMPUTER
The trip computer is standard on level 1 saloons and estates .
13 - 5 - POWER STEERING
Vehicles fitted with the DW10TD engine are fitted with falling output power steering as standard .
13 - 6 - INSTRUMENT PANEL
Modification to the instrument panel graphics .
Addition of the following warning lights :
13 - 7 - ANTI-LOCK BRAKES
The anti-lock brake system is standard on all models .
14 - ELECTRONIC STRUCTURE
New electronic structure and new bsi incorporating the can gateway .
The bsi 406 controls the comfort van network (42) :
Introduction of the can network (G) including :
Introduction of the body van network (H) (for DW12TED4 versions with particulate emission filter) including :
For vehicles equipped with esp, the vehicle speed information is transmitted to the bsi by the esp ecu .
For vehicles fitted with abs, the abs ecu (54) transmits the vehicle speed information to the engine management ecu (49) which distributes it on the can network .
15 - ELECTRICAL EQUIPMENT
15 - 1 - HARNESS MODIFICATIONS
Modification to the electrical harnesses .
Front panel harness integrated in main panel .
15 - 2 - CONNECTIONS
Front door locks with connector SICMA 2 .
16 - COOLANT
From spare parts organisation number 08576 : The cooling circuits are filled with long-life coolant REVKOGEL 2000 or Glysantin G33 .