PEUGEOT 405 14 16 18 19 2 Petrol Service Repair Manual 1991-1996

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Product Name: PEUGEOT 405 14 16 18 19 2 Petrol Service Repair Manual 1991-1996 Codes Engine Codes Covered: Likely XU7JP, XU9J1/Z, XU10J2/Z (Petrol variants) Generation Generation Covered: Second Generation (1991-1996 facelift/late models) 👋 Introduction Market Position Historical Segment: Compact executive/family car, competing in a segment dominated by European and Japanese manufacturers. Competitive Analysis Key Competitors: Volkswagen Passat, Ford Mondeo, Opel/Vauxhall Vectra, Renault Laguna, Fiat Croma, Honda Accord, Toyota Avensis. Key Features Design Philosophy: Designed by Giugiaro, the 405 was known for its aerodynamic styling, spacious interior, and comfortable ride, particularly the 'Traction Avant' models which offered excellent handling for their era. Safety Focus: The 405 series was generally well-regarded for its safety features, with some models offering ABS and improved body structures. 📋 Manual Details Coverage Areas Vehicle Years: 1991, 1992, 1993, 1994, 1995, 1996 Engine Variants: 1.4L (1360cc) Petrol, 1.6L (1580cc) Petrol, 1.8L (1761cc) Petrol, 1.9L (1905cc) Petrol, 2.0L (1998cc) Petrol Body Styles Covered: Likely Sedan (Berline), Estate/Wagon (Break) Page Count Estimated Page Count: Hundreds (Exact count not specified, but typical for comprehensive manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, component identification, cylinder head, block, pistons, crankshaft, camshaft, timing systems, lubrication, cooling. Fuel System: Fuel delivery, injection systems (likely Bosch Motronic, Lucas L-Jetronic), carburetion (for earlier/smaller engines), fuel pump, injectors, pressure regulator, fuel tank. Ignition System: Distributor, ignition coils, spark plugs, timing, electronic ignition control. Transmission Manual: Clutch system, gearbox overhaul, gear selection, driveshafts, internal components. Transmission Automatic: Likely covers ZF 4HP18 or similar automatic transmissions (if applicable to petrol variants of this period), torque converter, valve body, hydraulic control. Brakes: Hydraulic system, ABS (if equipped), front and rear brake assemblies (discs/drums), master cylinder, brake booster, calipers, pads, shoes, fluid specifications. Suspension: Front suspension (McPherson struts), rear suspension (torsion beam, trailing arms), shock absorbers, springs, bushings, wheel alignment specifications. Steering: Power steering system, steering rack, pump, fluid specifications, steering column. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, switches, instrument cluster, central locking, power windows. Climate Control: HVAC system, blower motor, evaporator, heater core, refrigerant type, system charging procedures. Body And Interior: Body panel removal and installation, doors, hood, trunk, bumpers, seats, dashboard, trim panels. Procedures Included Maintenance Scheduled: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and changes (coolant, brake, power steering, transmission), belt replacements. Troubleshooting: Diagnostic procedures for common issues, fault finding trees, symptoms and causes. Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Component Replacement: Specific guidance for replacing wear items and major components like clutch, brakes, suspension parts, engine mounts. Diagnostics Scans: Information on engine management systems, sensor testing, and potentially OBD-I (On-Board Diagnostics) codes for applicable models. Wiring Diagrams: Comprehensive electrical schematics for various systems, aiding in troubleshooting and repairs. Technical Depth Depth Of Coverage: Comprehensive, suitable for both DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to full engine and transmission overhauls. Diagnostic Capabilities: Detailed diagnostic procedures, including testing of sensors, actuators, and electrical circuits. Torque Specifications: Includes crucial torque values for fasteners across all major mechanical systems. Special Tools: Mentions any specific tools required for certain procedures, enhancing accuracy and efficiency. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire document. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) Searchability Searchable Text: Yes (Typically, PDF manuals are text-searchable for quick information retrieval). ⚙️ Engine Specifications Primary Engine Engine Range Petrol: 1.4L (1360cc), 1.6L (1580cc), 1.8L (1761cc), 1.9L (1905cc), 2.0L (1998cc) XU series petrol engines. Performance Power Output Range: Approximately 70 hp (1.4) to 123 hp (2.0i) depending on specific engine variant and tuning. Torque Output Range: Varies by engine, e.g., 1.9L engines typically produced around 150-160 Nm. Fuel System Injection Systems: Carburetion (early 1.4/1.6) and multi-point fuel injection (MPI) for later and larger engines (e.g., Bosch Motronic). Engine Design Engine Layout: Inline-4, front-mounted, transverse. Engine Block Material: Likely cast iron block with aluminum cylinder head. Valvetrain: SOHC (Single Overhead Camshaft) for 8-valve engines, DOHC (Double Overhead Camshaft) for 16-valve variants (e.g., XU10J4). 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission. Optional Optional Transmission: 4-speed automatic transmission (likely ZF sourced). Features Transmission Fluid: Specific ATF (Automatic Transmission Fluid) required for automatics, and gear oil for manuals. Manuals typically use API GL-4 or GL-5 compliant gear oil. 📐 Dimensions Exterior Length: Approx. 4400-4430 mm (Sedan), 4470-4500 mm (Estate) Width: Approx. 1700-1730 mm Height: Approx. 1400-1420 mm (Sedan), 1450-1460 mm (Estate) Weights Curb Weight: Varies by engine and trim, typically 1050-1250 kg. Wheelbase: Approx. 2620 mm Wheel Bolt Pattern: Likely 4x108 🛡️ Safety Features...

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Sku: 210277

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Availability: In stock

Tags: 1991 1992 1993 1994 1995 1996 405 Car Cars Peugeot

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Product Name:

PEUGEOT 405 14 16 18 19 2 Petrol Service Repair Manual 1991-1996

Codes

Engine Codes Covered:

Likely XU7JP, XU9J1/Z, XU10J2/Z (Petrol variants)

Generation

Generation Covered:

Second Generation (1991-1996 facelift/late models)

👋 Introduction

Market Position

Historical Segment:

Compact executive/family car, competing in a segment dominated by European and Japanese manufacturers.

Competitive Analysis

Key Competitors:

Volkswagen Passat, Ford Mondeo, Opel/Vauxhall Vectra, Renault Laguna, Fiat Croma, Honda Accord, Toyota Avensis.

Key Features

Design Philosophy:

Designed by Giugiaro, the 405 was known for its aerodynamic styling, spacious interior, and comfortable ride, particularly the 'Traction Avant' models which offered excellent handling for their era.

Safety Focus:

The 405 series was generally well-regarded for its safety features, with some models offering ABS and improved body structures.

📋 Manual Details

Coverage Areas

Vehicle Years:

1991, 1992, 1993, 1994, 1995, 1996

Engine Variants:

1.4L (1360cc) Petrol, 1.6L (1580cc) Petrol, 1.8L (1761cc) Petrol, 1.9L (1905cc) Petrol, 2.0L (1998cc) Petrol

Body Styles Covered:

Likely Sedan (Berline), Estate/Wagon (Break)

Page Count

Estimated Page Count:

Hundreds (Exact count not specified, but typical for comprehensive manuals)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, component identification, cylinder head, block, pistons, crankshaft, camshaft, timing systems, lubrication, cooling.

Fuel System:

Fuel delivery, injection systems (likely Bosch Motronic, Lucas L-Jetronic), carburetion (for earlier/smaller engines), fuel pump, injectors, pressure regulator, fuel tank.

Ignition System:

Distributor, ignition coils, spark plugs, timing, electronic ignition control.

Transmission Manual:

Clutch system, gearbox overhaul, gear selection, driveshafts, internal components.

Transmission Automatic:

Likely covers ZF 4HP18 or similar automatic transmissions (if applicable to petrol variants of this period), torque converter, valve body, hydraulic control.

Brakes:

Hydraulic system, ABS (if equipped), front and rear brake assemblies (discs/drums), master cylinder, brake booster, calipers, pads, shoes, fluid specifications.

Suspension:

Front suspension (McPherson struts), rear suspension (torsion beam, trailing arms), shock absorbers, springs, bushings, wheel alignment specifications.

Steering:

Power steering system, steering rack, pump, fluid specifications, steering column.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, switches, instrument cluster, central locking, power windows.

Climate Control:

HVAC system, blower motor, evaporator, heater core, refrigerant type, system charging procedures.

Body And Interior:

Body panel removal and installation, doors, hood, trunk, bumpers, seats, dashboard, trim panels.

Procedures Included

Maintenance Scheduled:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and changes (coolant, brake, power steering, transmission), belt replacements.

Troubleshooting:

Diagnostic procedures for common issues, fault finding trees, symptoms and causes.

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Component Replacement:

Specific guidance for replacing wear items and major components like clutch, brakes, suspension parts, engine mounts.

Diagnostics Scans:

Information on engine management systems, sensor testing, and potentially OBD-I (On-Board Diagnostics) codes for applicable models.

Wiring Diagrams:

Comprehensive electrical schematics for various systems, aiding in troubleshooting and repairs.

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for both DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to full engine and transmission overhauls.

Diagnostic Capabilities:

Detailed diagnostic procedures, including testing of sensors, actuators, and electrical circuits.

Torque Specifications:

Includes crucial torque values for fasteners across all major mechanical systems.

Special Tools:

Mentions any specific tools required for certain procedures, enhancing accuracy and efficiency.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or the entire document.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Searchability

Searchable Text:

Yes (Typically, PDF manuals are text-searchable for quick information retrieval).

⚙️ Engine Specifications

Primary Engine

Engine Range Petrol:

1.4L (1360cc), 1.6L (1580cc), 1.8L (1761cc), 1.9L (1905cc), 2.0L (1998cc) XU series petrol engines.

Performance

Power Output Range:

Approximately 70 hp (1.4) to 123 hp (2.0i) depending on specific engine variant and tuning.

Torque Output Range:

Varies by engine, e.g., 1.9L engines typically produced around 150-160 Nm.

Fuel System

Injection Systems:

Carburetion (early 1.4/1.6) and multi-point fuel injection (MPI) for later and larger engines (e.g., Bosch Motronic).

Engine Design

Engine Layout:

Inline-4, front-mounted, transverse.

Engine Block Material:

Likely cast iron block with aluminum cylinder head.

Valvetrain:

SOHC (Single Overhead Camshaft) for 8-valve engines, DOHC (Double Overhead Camshaft) for 16-valve variants (e.g., XU10J4).

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed automatic transmission (likely ZF sourced).

Features

Transmission Fluid:

Specific ATF (Automatic Transmission Fluid) required for automatics, and gear oil for manuals. Manuals typically use API GL-4 or GL-5 compliant gear oil.

📐 Dimensions

Exterior

Length:

Approx. 4400-4430 mm (Sedan), 4470-4500 mm (Estate)

Width:

Approx. 1700-1730 mm

Height:

Approx. 1400-1420 mm (Sedan), 1450-1460 mm (Estate)

Weights

Curb Weight:

Varies by engine and trim, typically 1050-1250 kg.

Wheelbase:

Approx. 2620 mm

Wheel Bolt Pattern:

Likely 4x108

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not directly tested under modern Euro NCAP protocols, but generally considered safe for its era. Later models had improved structures.

Active Features

Available on higher trims and later models.

Traction Control:

Rare, but potentially available on top-tier performance variants (e.g., 405 Mi16).

Passive Features

Airbags:

Driver's side airbag became increasingly common from the mid-90s, passenger airbag less common.

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced safety cage, energy-absorbing crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory-fitted radio/cassette players, often with basic FM/AM reception and speaker configurations. Upgrade options likely available.

Driver Assistance

Cruise Control:

Available on higher trim levels and as an option for some engine variants.

Connectivity

Connectivity Features:

Limited by era; primarily focused on the vehicle's internal systems. No advanced Bluetooth or smartphone integration as standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 km or 12 months, whichever comes first (or as specified by manufacturer). Check manual for exact interval based on driving conditions.

Timing Belt Interval:

Crucial interval, often around 80,000 - 120,000 km or 5-6 years, depending on engine. Belt failure can cause catastrophic engine damage.

Spark Plug Replacement:

Varies by spark plug type; typically 30,000 - 60,000 km for standard copper plugs, longer for platinum/iridium.

Fluid Specifications

Engine Oil Spec:

Likely API SG/SH or ACEA A2/A3 specification. Viscosity grades like 10W-40 or 5W-40 depending on climate. Check manual for exact viscosity.

Coolant Spec:

Ethylene glycol-based antifreeze/coolant, often requiring a specific mix (e.g., 50/50 with distilled water). Typically blue or green coloured.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid is standard for this era.

Power Steering Fluid:

Specific hydraulic fluid; often Dexron II/III ATF or a dedicated PSA fluid.

Known Issues

Electrical Gremlins:

Common issues can include intermittent electrical faults, particularly with window regulators, central locking, and dashboard warning lights due to age and wiring loom degradation.

Suspension Wear:

Worn suspension bushings, ball joints, and wheel bearings are common wear items leading to knocking noises and poor handling.

Engine Management:

Fuel injection system issues, idle speed control problems, and sensor failures (e.g., TPS, MAP sensor) can occur.

Cooling System:

Radiator leaks, failing water pumps, and thermostat issues can lead to overheating if not addressed.

Exhaust System:

Corrosion of the exhaust system, catalytic converter failure, and lambda sensor issues are common with age.

📚 Vehicle History

Brand Heritage

Peugeot Legacy:

Peugeot has a long history of producing well-engineered and comfortable family cars, often with a focus on driving dynamics. The 405 followed in the footsteps of the successful 505 and 305 models.

Model Evolution

Introduction Year:

First generation introduced in 1987.

Facelift Impact:

The 1991 facelift brought styling updates (grille, bumpers, lights) and interior improvements, including better materials and ergonomics, which this manual covers.

Performance Variants:

Notable performance variants like the 405 Mi16 and T16 (turbocharged, all-wheel-drive) were produced, known for their rally-inspired engineering.

Production

Production Period:

1987-1996 (in Europe)

Manufacturing Locations:

Primarily France (Sochaux), also Iran (IKCO), Egypt, and other licensed production.

🏆 Awards & Recognition

Recognitions

Car Of The Year:

The Peugeot 405 was voted 'European Car of the Year' in 1988.

Sales Success:

Achieved significant sales success across Europe and globally, praised for its combination of comfort, practicality, and value.