Peugeot 405 Petrol Service and Repair Manual 1987-1997 (Searchable iPad-ready)
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🏷️ Basic Information Identification Make: Peugeot Model: 405 Body Styles Covered: All styles (sedan, coupe, convertible, sport utility vehicle (SUV) implied by context, though primarily sedan/coupe in this era for 405) Codes Production Years Covered: 1987-1997 Engine Types Covered: Petrol (Gasoline) 👋 Introduction Market Position Target Audience: Do-it-yourself enthusiasts and experienced mechanics Value Proposition: Inexpensive way to keep vehicle working properly, dealer-level repair information Competitive Analysis Availability: Instant download, responsible seller Key Features Content Completeness: 100% Complete and Intact Navigation: Numbered table of contents for fast access 📋 Manual Details Coverage Areas Manual Type: Complete Digital Workshop Service and Repair Manual Language: English Page Count Total Pages: >301 Format File Format: PDF Compatibility: Windows, Mac, Linux Features: Searchable, Printable, iPad-ready 📖 Manual Coverage Systems Covered Engine: Mechanical, Control System, Coolant, Charging System, Ignition System, Lubrication System Drivetrain: Transmission (Manual Transaxle System/Oil/Assy), Drive Shaft, Differential Case Assy, Output Shaft Assy, Input Shaft Assy Chassis: Brake System (Master Cylinder, Fluid, Booster, Actuator, Pedal), Steering System (Column, Sensor), Suspension (Front, Rear, Coil Spring, Shock Absorber), Wheel And Tire System, Rear Axle Beam, Rear Axle Hub Electrical: Wiring Diagrams, Wire Harness Repair, Combination Meter, Instrument Panel, Lighting System, Starting System (Starter Assy/Switch), Power Window Control System, Power Mirror Control System, Power Door Lock Control System Body: Body Repair, Interior Components (Roof Headlining, Seat, Seat Belt, Instrument Panel, Combination Meter), Exterior Components (Bumpers, Mirrors, Lights, Glass, Mouldings) Comfort And Climate: Cooling System, Cooling Fan System, Heater Radiator Assy, Sun Roof System Safety Systems: Supplemental Restraint System (SRS), Air Bag Systems (Curtain Shield, Center Air Bag Sensor, Side Air Bag Sensor, Passenger Air Bag), Seat Belt Warning System, Shift Lock System Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes (Oil, Coolant, Brake Fluid, Transmission Oil), Filter Replacements (Oil Filter) Repair And Overhaul: Engine Mechanical (Cylinder Head, Cylinder Block), Transmission, Brakes, Steering, Suspension, Electrical Components, Body Panels Troubleshooting: Diagnosis of problems, specific troubleshooting sections for electrical systems Diagnostics: Detailed diagnostic procedures, including electrical system diagnostics Technical Depth Depth Of Information: Comprehensive; covers complete disassembly and reassembly procedures Illustrations: Hundreds of detailed illustrations, drawings, and photos Instruction Style: Step-by-step numbered instructions, detailed sub-steps, highlighted figure numbers Critical Information: Notes, cautions, and warnings throughout each chapter 📊 Manual Specifications File Format Digital Quality: High quality, complete and intact, no missing/corrupt pages Print Quality Printability: All pages printable Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) Protection Digital Rights Management: DRM-free; without any restriction ⚙️ Engine Specifications Primary Engine Engine Family: TU series, XU series (common for Peugeot 405 petrol models) Performance Horsepower Range: Variable (e.g., 1.4L ~65-70hp, 1.6L ~80-90hp, 1.8L ~100hp, 1.9L ~110-120hp, 2.0L ~110-130hp, Mi16 variants significantly higher) Torque Range: Variable based on engine displacement and tuning. Fuel System Fuel Delivery: Carburetor or Multi-Point Fuel Injection (MPI) depending on engine and market Components Cylinder Head: Cylinder Head Assy detailed procedures Cylinder Block: Cylinder Block Assy detailed procedures Camshaft: Camshaft procedures, Camshaft Position Sensor Engine Control: Engine Control System, SFI System (Sequential Fuel Injection) Ignition: Ignition System components and procedures Knock Control: Knock Sensor procedures Thermostat: Thermostat replacement and function Oil System: Oil Pump, Oil Filter, Lubrication System Throttle Body: Throttle Body Assy procedures Emission Control: Emission Control Systems, Charcoal Canister 🔧 Transmission Standard Type: Manual Transaxle Optional Type: Automatic Transmission (Coverage not explicitly stated, but likely included for all models/engines) Features Clutch: Clutch Unit, Clutch System, Clutch Pedal Sub-Assy, Clutch Master Cylinder Assy, Clutch Release Cylinder Assy, Clutch Start Switch Assy Maintenance Fluid: Manual Transaxle Oil specifications (covered in manual) 📐 Dimensions Exterior Length: Approx. 4220-4400 mm (depending on variant) Width: Approx. 1700-1720 mm Height: Approx. 1400-1450 mm Weights Curb Weight: Approx. 1050-1300 kg (depending on engine and equipment) 🛡️ Safety Features Passive Features Airbags: Supplemental Restraint System (SRS) coverage, Passenger Air Bag Assy, Side Air Bag Sensor Assy, Center Air Bag Sensor Assy, Curtain Shield Air Bag Assy Seatbelts: Seat Belt, Seat Belt Warning System, Rear Seat Belt Active Features Brakes: Brake System, Brake Master Cylinder, Brake Booster, Brake Actuator (ABS may be covered depending on option) Traction Control: Possibly covered for specific models/options (e.g., Skid Control Sensor) 💡 Technology Features Infotainment Audio System: Radio Receiver Assy, Speaker Assy (details on repair/replacement of these components are likely covered). Driver Assistance Sensors: Camshaft Position Sensor, Yaw Rate Sensor, Speed Sensor Front, Skid Control Sensor, Steering Sensor. Connectivity Lighting Control: Lighting System components, Combination Meter, Instrument Panel illumination. 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific intervals based on driving conditions (typically 5,000-10,000 km or 6-12 months) Timing Belt: Crucial replacement interval (e.g., 60,000-90,000 km or 4-5 years, depending on engine and belt type) - critical for engine health. Fluid Specifications Engine Oil: Refer to manual for specific viscosity grades (e.g., 10W-40, 15W-40, synthetic options may be recommended) and API/ACEA...
Brake System (Master Cylinder, Fluid, Booster, Actuator, Pedal), Steering System (Column, Sensor), Suspension (Front, Rear, Coil Spring, Shock Absorber), Wheel And Tire System, Rear Axle Beam, Rear Axle Hub
Electrical:
Wiring Diagrams, Wire Harness Repair, Combination Meter, Instrument Panel, Lighting System, Starting System (Starter Assy/Switch), Power Window Control System, Power Mirror Control System, Power Door Lock Control System
Cooling System, Cooling Fan System, Heater Radiator Assy, Sun Roof System
Safety Systems:
Supplemental Restraint System (SRS), Air Bag Systems (Curtain Shield, Center Air Bag Sensor, Side Air Bag Sensor, Passenger Air Bag), Seat Belt Warning System, Shift Lock System
Manual Transaxle Oil specifications (covered in manual)
📐 Dimensions
Exterior
Length:
Approx. 4220-4400 mm (depending on variant)
Width:
Approx. 1700-1720 mm
Height:
Approx. 1400-1450 mm
Weights
Curb Weight:
Approx. 1050-1300 kg (depending on engine and equipment)
🛡️ Safety Features
Passive Features
Airbags:
Supplemental Restraint System (SRS) coverage, Passenger Air Bag Assy, Side Air Bag Sensor Assy, Center Air Bag Sensor Assy, Curtain Shield Air Bag Assy
Seatbelts:
Seat Belt, Seat Belt Warning System, Rear Seat Belt
Active Features
Brakes:
Brake System, Brake Master Cylinder, Brake Booster, Brake Actuator (ABS may be covered depending on option)
Traction Control:
Possibly covered for specific models/options (e.g., Skid Control Sensor)
💡 Technology Features
Infotainment
Audio System:
Radio Receiver Assy, Speaker Assy (details on repair/replacement of these components are likely covered).
Driver Assistance
Sensors:
Camshaft Position Sensor, Yaw Rate Sensor, Speed Sensor Front, Skid Control Sensor, Steering Sensor.
Connectivity
Lighting Control:
Lighting System components, Combination Meter, Instrument Panel illumination.
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual for specific intervals based on driving conditions (typically 5,000-10,000 km or 6-12 months)
Timing Belt:
Crucial replacement interval (e.g., 60,000-90,000 km or 4-5 years, depending on engine and belt type) - critical for engine health.
Fluid Specifications
Engine Oil:
Refer to manual for specific viscosity grades (e.g., 10W-40, 15W-40, synthetic options may be recommended) and API/ACEA specifications.
Coolant:
Antifreeze/coolant specifications (e.g., ethylene glycol based, specific Peugeot recommendations).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).
Transmission Fluid:
Specific manual transmission oil (API GL-4 or GL-5, viscosity depends on temperature). Automatic transmission fluid (ATF) for automatic variants.
Known Issues
Engine:
Head gasket failure, timing belt failure (if not replaced on schedule), carburetor/fuel injection issues, oil leaks.