Peugeot 405 1987-1997 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Peugeot Model: 405 Generation Generation Designation: First Generation Codes Chassis Code: Type 155 (sedan/saloon), Type 156 (estate/break) 👋 Introduction Market Position Positioning: The Peugeot 405 was a popular mid-size family car in Europe, known for its comfortable ride, attractive styling (by Pininfarina), and capable handling. It competed with vehicles like the Ford Sierra, Opel/Vauxhall Vectra, and Volkswagen Passat. Competitive Analysis Strengths: Comfort, handling, Pininfarina design, wide range of engine options, practicality (especially the estate version). Offered a good balance of refinement and driving engagement for its class. Key Features Highlights: Pininfarina styling, independent front and rear suspension, front-wheel drive (with option of 4WD on some variants), wide range of petrol and diesel engines, comfortable and spacious interior. 📋 Manual Details Coverage Areas Years Covered: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Page Count Estimated Page Count: Extensive (typical workshop manuals of this era exceed 500 pages) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Digital) Delivery Method Delivery: Fast and free electronic delivery via Email. 📖 Manual Coverage Systems Covered Engine And Drivetrain: Engine overhaul, fuel system, ignition system, lubrication system, cooling system, exhaust system, engine management, transmission (manual and automatic), clutch, drivetrain components. Chassis And Body: Suspension (front and rear), steering system, braking system, wheels and tires, body panels, interior trim, exterior trim, chassis components. Electrical And Electronics: Electrical system schematics, lighting, ignition, starting and charging system, instrument cluster, body electronics, engine control unit (ECU) diagnostics and wiring. Comfort And Convenience: Climate control (heating and ventilation), interior trim, seats, doors, windows, mirrors, exterior lighting, wipers, and washers. Bodywork And Chassis: Structural repair, welding procedures, body panel replacement, rust prevention, and chassis component alignment. Procedures Included Maintenance And Servicing: Routine maintenance schedules, fluid checks and changes, filter replacements, spark plug replacement, tune-ups, brake pad replacement. Diagnostics And Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues, troubleshooting charts, fault code interpretation (if applicable). Repair And Overhaul: Detailed instructions for component removal, installation, repair, and overhaul, including engine rebuilds, transmission overhauls, suspension repairs, brake system repairs. Wheel And Tire Service: Wheel alignment, tire rotation, balancing, and replacement. Includes specifications for wheel torque and tire pressures. Safety System Service: Procedures for servicing and repairing braking systems, including ABS components, as well as seatbelt mechanisms and airbag systems (where applicable). Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission rebuilds, including proprietary component information. Diagnostic Tools: Reference to special Peugeot tools required for specific adjustments or repairs, often with part numbers and illustrations. Schematics And Diagrams: Detailed wiring diagrams, vacuum diagrams, and exploded view diagrams for component identification and assembly/disassembly guidance. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable. High-resolution digital format allowing for clear printing of all diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) File Content Content Accuracy: Ensured accuracy with information reflecting product specifications at the time of writing, incorporating proprietary component manufacturer instructions. ⚙️ Engine Specifications Primary Engine Common Petrol Engine 1.9I: Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 9.5:1, Fuel Injection: Bosch LE2-Jetronic (early models) or Motronic (later models), Power: Approx. 110 PS (108 hp; 81 kW) at 5800 rpm, Torque: Approx. 168 Nm (124 lb-ft) at 3200 rpm. Common Diesel Engine 1.9D: Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 22:1, Fuel System: Indirect injection (Bosch VE rotary pump), Power: Approx. 71 PS (70 hp; 52 kW) at 4600 rpm, Torque: Approx. 121 Nm (89 lb-ft) at 2000 rpm. Performance Top Speed 1.9I: Approx. 190 km/h (118 mph) Acceleration 0 100Kmh 1.9I: Approx. 10.3 seconds Fuel System Fuel Type: Unleaded gasoline (for petrol engines), Diesel (for diesel engines). Injection System: Mechanical fuel injection (Bosch K-Jetronic, L-Jetronic) or electronic fuel injection (Motronic) depending on engine and year. Diesel engines use Bosch VE rotary injection pumps. 🔧 Transmission Standard Gearbox Type: 5-speed manual transaxle Optional Gearbox Type Automatic: 3-speed or 4-speed automatic transaxle (e.g., ZF 4HP14 or AL4 for later models) Features Clutch Type: Dry single plate, hydraulically operated (for manual transmissions) 📐 Dimensions Exterior Length Sedan: Approx. 4,400 mm (173.2 in) Width Sedan: Approx. 1,700 mm (66.9 in) Height Sedan: Approx. 1,410 mm (55.5 in) Cargo Trunk Volume Sedan: Approx. 500 liters (17.7 cu ft) Weights Curb Weight Typical: Approx. 1100-1300 kg (2425-2866 lbs) depending on engine and specification. 🛡️ Safety Features Ratings Euro Ncap Rating: Not directly available for the early model years. Later models may have been tested, but data is scarce for this specific generation. Active Features Braking System: Front: Ventilated discs. Rear: Drums or discs (depending on engine/trim). ABS was available as an option on higher trims....
The Peugeot 405 was a popular mid-size family car in Europe, known for its comfortable ride, attractive styling (by Pininfarina), and capable handling. It competed with vehicles like the Ford Sierra, Opel/Vauxhall Vectra, and Volkswagen Passat.
Competitive Analysis
Strengths:
Comfort, handling, Pininfarina design, wide range of engine options, practicality (especially the estate version). Offered a good balance of refinement and driving engagement for its class.
Key Features
Highlights:
Pininfarina styling, independent front and rear suspension, front-wheel drive (with option of 4WD on some variants), wide range of petrol and diesel engines, comfortable and spacious interior.
Suspension (front and rear), steering system, braking system, wheels and tires, body panels, interior trim, exterior trim, chassis components.
Electrical And Electronics:
Electrical system schematics, lighting, ignition, starting and charging system, instrument cluster, body electronics, engine control unit (ECU) diagnostics and wiring.
Comfort And Convenience:
Climate control (heating and ventilation), interior trim, seats, doors, windows, mirrors, exterior lighting, wipers, and washers.
Bodywork And Chassis:
Structural repair, welding procedures, body panel replacement, rust prevention, and chassis component alignment.
Procedures Included
Maintenance And Servicing:
Routine maintenance schedules, fluid checks and changes, filter replacements, spark plug replacement, tune-ups, brake pad replacement.
Diagnostics And Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, troubleshooting charts, fault code interpretation (if applicable).
Repair And Overhaul:
Detailed instructions for component removal, installation, repair, and overhaul, including engine rebuilds, transmission overhauls, suspension repairs, brake system repairs.
Wheel And Tire Service:
Wheel alignment, tire rotation, balancing, and replacement. Includes specifications for wheel torque and tire pressures.
Safety System Service:
Procedures for servicing and repairing braking systems, including ABS components, as well as seatbelt mechanisms and airbag systems (where applicable).
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission rebuilds, including proprietary component information.
Diagnostic Tools:
Reference to special Peugeot tools required for specific adjustments or repairs, often with part numbers and illustrations.
Schematics And Diagrams:
Detailed wiring diagrams, vacuum diagrams, and exploded view diagrams for component identification and assembly/disassembly guidance.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable. High-resolution digital format allowing for clear printing of all diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
File Content
Content Accuracy:
Ensured accuracy with information reflecting product specifications at the time of writing, incorporating proprietary component manufacturer instructions.
⚙️ Engine Specifications
Primary Engine
Common Petrol Engine 1.9I:
Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 9.5:1, Fuel Injection: Bosch LE2-Jetronic (early models) or Motronic (later models), Power: Approx. 110 PS (108 hp; 81 kW) at 5800 rpm, Torque: Approx. 168 Nm (124 lb-ft) at 3200 rpm.
Common Diesel Engine 1.9D:
Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 22:1, Fuel System: Indirect injection (Bosch VE rotary pump), Power: Approx. 71 PS (70 hp; 52 kW) at 4600 rpm, Torque: Approx. 121 Nm (89 lb-ft) at 2000 rpm.
Performance
Top Speed 1.9I:
Approx. 190 km/h (118 mph)
Acceleration 0 100Kmh 1.9I:
Approx. 10.3 seconds
Fuel System
Fuel Type:
Unleaded gasoline (for petrol engines), Diesel (for diesel engines).
Injection System:
Mechanical fuel injection (Bosch K-Jetronic, L-Jetronic) or electronic fuel injection (Motronic) depending on engine and year. Diesel engines use Bosch VE rotary injection pumps.
🔧 Transmission
Standard
Gearbox Type:
5-speed manual transaxle
Optional
Gearbox Type Automatic:
3-speed or 4-speed automatic transaxle (e.g., ZF 4HP14 or AL4 for later models)
Features
Clutch Type:
Dry single plate, hydraulically operated (for manual transmissions)
📐 Dimensions
Exterior
Length Sedan:
Approx. 4,400 mm (173.2 in)
Width Sedan:
Approx. 1,700 mm (66.9 in)
Height Sedan:
Approx. 1,410 mm (55.5 in)
Cargo
Trunk Volume Sedan:
Approx. 500 liters (17.7 cu ft)
Weights
Curb Weight Typical:
Approx. 1100-1300 kg (2425-2866 lbs) depending on engine and specification.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not directly available for the early model years. Later models may have been tested, but data is scarce for this specific generation.
Active Features
Braking System:
Front: Ventilated discs. Rear: Drums or discs (depending on engine/trim). ABS was available as an option on higher trims.
Passive Features
Airbags:
Driver airbag became increasingly common in later years, but was not standard on all models.
Seatbelts:
Front seatbelt pre-tensioners were available on some models.
💡 Technology Features
Infotainment
Radio System:
Factory-fitted radio/cassette players were common. Some higher trims offered more advanced systems with more speakers.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was available as an optional extra on many models, particularly in later production years.
Connectivity
Connectivity Features:
Limited by modern standards. Primarily focused on basic audio playback and communication (if a factory telephone was optioned, which was rare).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-15,000 km) or 12 months, whichever comes first, depending on driving conditions and oil type.
Timing Belt Replacement:
Crucial for petrol engines. Typically every 60,000-80,000 miles (96,000-128,000 km) or 5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Grade Petrol:
API SF/SG or ACEA A2/A3. Viscosity grades such as 10W-40 or 15W-50 are common, depending on climate. Consult manual for specific recommendation.
Engine Oil Grade Diesel:
API CD/CE or ACEA B2/B3. Viscosity grades like 10W-40 or 15W-40 are typical.
Coolant Type:
Ethylene glycol based antifreeze, typically a pink or red OAT (Organic Acid Technology) or HOAT (Hybrid Organic Acid Technology) type. Ensure correct concentration for freeze protection.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Must be replaced periodically (e.g., every 2 years) due to moisture absorption.
Transmission Fluid Manual:
API GL-4 hypoid gear oil, typically SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
ATF (Automatic Transmission Fluid) meeting specific Peugeot specifications (e.g., LT 71141 or similar). Consult manual for exact type and change interval.
Power Steering Fluid:
Hydraulic fluid meeting PSA specifications. Typically a mineral oil based fluid, not ATF or brake fluid.
Known Issues
Suspension Wear:
Front suspension components (ball joints, wishbone bushings) can wear over time, leading to knocking noises and alignment issues. Rear suspension torsion bars can also require adjustment or replacement.
Cooling System:
Radiator hoses, thermostat, and water pump can degrade with age. Overheating can occur if these components fail. Heater matrix leaks are also a known issue.
Electrical Gremlins:
Older wiring harnesses and connections can be prone to corrosion or degradation, leading to intermittent electrical faults. Check grounds and connectors.
Rust Corrosion:
As with many cars of this era, rust can affect wheel arches, sills, and floor pans, particularly in areas exposed to salt.
Engine Mounts:
Engine and transmission mounts can degrade, leading to increased vibration and harshness felt in the cabin.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Peugeot is a French automotive manufacturer with a long history dating back to 1810. Known for producing robust, comfortable, and driver-focused vehicles.
Model Evolution
405 Introduction:
The Peugeot 405 was introduced in 1987 as a replacement for the Peugeot 305 and to bridge the gap between the 205 and the larger 505. Designed by Pininfarina, it was praised for its modern styling and dynamic capabilities.
405 Variants:
Available as a 4-door saloon/sedan and a 5-door estate/break. Performance variants like the 405 Mi16 and T16 (turbocharged) were also produced, offering significant power and rallying heritage.
Production
Production Years:
1987-1997 (in Europe). Production continued in other markets like Iran (Peugeot Pars) for many years.
Manufacturing Locations:
Primarily France (Sochaux), but also manufactured in other European countries and later under license in Iran and Egypt.
🏆 Awards & Recognition
Recognitions
European Car Of The Year:
The Peugeot 405 was a finalist for European Car of the Year in 1988, finishing second to the Ford Sierra.
Rally Success:
The 405 Mi16 and T16 variants achieved significant success in motorsport, particularly in the Pikes Peak International Hill Climb and the World Rally Championship (Group A).