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Discussion Starter #1 (Edited)
TECHNICAL HELP ON PEUGEOT (for 406 but applies to all other models)
Fault: Erratic (weird) idle speed

Cause(s):1) Malfunction of Stepper Motor OR
2) Malfunction of TPS or (Throttle Position Sensor or potentiometer).

Remedy: 1)Take of Take off throttle inlet assembly, remove stepper motor and clean it off its carbon deposits or replace..
Remedy: 2) Remove Throttle Position Potentiometer and spray lubricant into its center or replace.
Fault: Illumination of the brake pad wear warning lamp in damp or salty conditions

Cause: The warning lamp circuit is easily influenced

Remedy: Detach the battery earth lead and make sure that the accidental reconnection is not possible -Take off the instrumental panel
Detach the 180 multi-pin plug and recognize the wires connected to pin 4 and pin 5 - Cut wire 210C, take off the black insulation 15mm, join them together and solder to the resistor
Perform the same process for wire 444
Perform insulation of the joints and tape the resistor to the harness
Now reconnect the battery earth lead
Make sure that brake pad wear warning lamp goes off when the brake pedal is pressed down
Now connect brake pad wear sensor wire to earth and press down the brake pedal and make sure that the brake pad wear warning lamp gets illuminated
Fault: Illumination of SRS (Airbag) warning lamp

Cause: It is caused due to bad connection of pyrotechnic pretensioner multi-plugs under front seat(s).

Remedy: Take off the pyrotechnic pretensioner multi-plugs under front seat.
Make the system disarm (unconnect battery)
Change the pyrotechnic pretensioner "multi-plugs", cut it and solder the wires (cover connections with heat shrink sleeves) reconnect battery.
Fault: Irregular power loss on accelerating
The speed of the engine is limited till 2500rpm
Frequent loss of crankshaft position sensor signal

Cause: It is caused due to leaking from thermostat housing into crankshaft position sensor harness multi-plug

Remedy: Perform trouble checking and clean the crankshaft position sensor harness multi-plug contacts
Rectify the engine coolant leak from the thermostat housing
Take a note of the engine coolant level
Fault: Engine starting is poor even when it is hot
Stalling of engine
Discrepant idle
Irregular engine function
Misfiring of engine

Cause: It is caused due to transmission of false signal by the engine engine coolant temperature sensor

Use new engine engine coolant temperature sensor
Fault: Engine fails to start even when it cranks
Starting from cold is not good
Misfiring of engine

Cause: Damaged hydraulic tappets

Remedy: Perform the compression test
Use new hydraulic tappets if required
Fault: Illumination of the engine coolant temperature warning lamp but the engine temperature gauge reads normally
The function of the engine coolant temperature warning lamp is affected when the air-conditioning system is switched on

Cause: It is caused due to defective engine coolant blower motor relays

Remedy: Use 3 new relays
Fault: All the bulbs are blown off
Too many error codes stored
The instrument panel gauge is not steady
Illumination of the instrument panel warning lamps at random

Cause: It is caused due to high alternator voltage output

Remedy: Use new alternator
Fault: Illumination of the engine stop warning lamp
Non- stop functioning of the engine coolant blower motor
Even though the engine coolant temperature gauge reading is high, the engine is not overheated

Cause: It is caused due to leak in the crankcase breather hose thereby causing oil and dirt to move into engine coolant temperature sensor harness multi-plug. The safety clip is not holding the crankcase breather properly

Remedy: Clean the engine coolant temperature sensor harness multi-plug contacts. Make sure that the safety clips holding the crankcase breather is properly tighten
Fault: Discharge from the battery

Cause: It is caused due to entry of water into the engine control module thereby making it non functional

Remedy: Use new engine wiring harness
Detach the yellow 2 pin engine coolant temperature switch connector
Use new engine control module.
Process of Rebooting BSI in Peugeot:
Method for starting the BSI:
The very first step is to unplug the diagnostic tool from the vehicle.
Make sure all the gadgets are switched off, the driver’s window lowered down and open the bonnet.
Then close all the doors and take off the key from ignition.
After a 3 minute interval, unplug the vehicle’s battery terminals and wait for a further 15 seconds.
Attach back the battery terminals and give a 10 second pause making sure the doors are closed.
Turn the side lights on.
Now turn the engine on and inspect the system functioning.
Press and hold down the lock button on the key for 10 seconds.
Check the central locking system by unlocking and locking the door consecutively.
Turn the engine on again and finish inspecting the system.

Following any other procedure could cause malfunctioning of different units which depend on BSI.

Method for unplugging the battery:
Before unplugging the battery, turn off all gadgets and lights, closing all the doors and unplugging any kind of diagnostic tool.
The drivers side window has to be kept open for any kind of requirement.
Turn off the ignition and take out the key following which unplug the battery after an interval of 3 minutes.
The BSI needs to be taken to Sleep mode or Active Economy mode, during which nothing in the vehicle should be operating.
Even the bonnet should not be opened that time as it can ‘wake up’ the BSI if the vehicle has got an alarm installed.
For batteries under the bonnet, the bonnet should be opened and left up before allowing the BSI to go to Sleep Mode.
During this 3 minute interval, use of any remote control central locking gadgets for other vehicles should be avoided in the vicinity of the concerned vehicle.

Method for connecting the battery:
The following procedure is for reinstalling the battery connection unless told otherwise by Peugeot or Product service.
Failure to follow this procedure may result in damage to the BSI’s embedded software during reconnection.

All the doors have to be closed with the ignition key turned off and the key taken out.
Now without opening the doors, replug the battery and wait for 10 seconds.
Turn on the headlights, turn on the engine and inspect the system’s functioning.
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