๐ท๏ธ Basic Information Identification Make: Peugeot Model: 405 Year: 1991 Variant: All Variants (implied by comprehensive coverage) ๐ Introduction Market Position Target Audience: Professional Technicians, DIY Mechanics with basic electrical and mechanical knowledge Segment: Family car, mid-size sedan/estate. Competitive Analysis Value Proposition: Provides factory-level information for maintenance and repair, enabling informed decision-making and cost-effective servicing. Contemporaries: Competed with vehicles like the Ford Sierra, Opel Vectra/Vauxhall Cavalier, Volkswagen Passat, and Renault 21. Key Features Learning Curve: Designed to teach factory-trained technician knowledge through step-by-step guidance. Delivery Method: Instant Download Completeness: Covers topics typically found in both factory service manuals and owner's manuals, providing a holistic view of vehicle care. ๐ Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Troubleshooting Page Count Estimated Page Count: Extensive (typical for factory service manuals, often 1000+ pages) Manual Type Manual Type: Service Repair Manual / Workshop Manual Language Language: English Format File Format: PDF ๐ Manual Coverage Systems Covered Engine: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emissions control Transmission: Manual transmission, Automatic transmission (likely, depending on specific 405 models covered) Drivetrain: Front-wheel drive system, CV joints, driveshafts Suspension: Front suspension (MacPherson struts, control arms), Rear suspension (torsion beam, trailing arms), shock absorbers, springs Steering: Steering system components, power steering system (if applicable), steering column Brakes: Front disc brakes, Rear drum brakes (common), ABS system (if equipped), brake hydraulics, parking brake Electrical System: Battery, charging system, starter, lighting system, ignition system, gauges, horns, wipers, power accessories Body And Chassis: Body panels, doors, windows, interior trim, seats, bumpers, chassis components HVAC: Heating, ventilation, and air conditioning system (if equipped) Fuel System Details: Fuel pump, fuel filter, fuel injectors (for injection models), carburetor settings and overhaul (for carbureted models), fuel tank and lines. Cooling System Details: Radiator, water pump, thermostat, cooling fan (mechanical or electric), hoses, coolant types, and bleeding procedures. Ignition System Details: Spark plugs, ignition coils, distributor (if applicable), ignition timing, electronic ignition control module (if applicable). Exhaust System: Catalytic converter (if equipped), exhaust manifolds, pipes, mufflers, and mounting hardware. Fuel Tank And Lines: Removal, installation, and leak detection for the fuel tank and associated lines. Wheel And Tire: Wheel torque specifications, tire pressure recommendations, wheel bearing service. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tune-ups Repair: Engine component repair/replacement, transmission overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and repair Disassembly Assembly: Detailed step-by-step instructions for component removal and reinstallation Troubleshooting: Diagnostic procedures for common problems, fault codes (if applicable), symptom-based troubleshooting guides Diagnostics: Procedures for diagnosing electrical and mechanical issues Engine Rebuild: Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), cylinder head overhaul, and reassembly with torque specifications. Transmission Repair: Detailed procedures for manual and automatic transmission repair, including clutch replacement, gear synchromesh repair, and hydraulic system servicing for automatics. Electrical Troubleshooting Charts: Likely includes wiring diagrams and troubleshooting charts based on symptoms. Body Repair: Information on door adjustments, window regulator repair, and potentially basic body panel alignment. Lubrication Points: Identification and types of lubricants for various chassis and suspension components. Air Conditioning Service: Procedures for charging refrigerant, leak testing, and component replacement for the A/C system (if equipped). Body And Paint: May include basic guidance on rustproofing or minor bodywork procedures. Technical Depth Depth Of Coverage: Comprehensive, suitable for professional technicians and advanced DIYers, covering fundamentals to complex repairs Diagnostic Tools: Likely mentions necessary specialized tools for certain procedures. ๐ Manual Specifications File Format File Type: PDF Searchability: PDF format generally allows for text searching (if text is not an image), aiding quick access to information. Print Quality Printable: Full Printable Zoom Functionality: YES (Zoom IN/OUT) Binding Type Binding: Digital (Downloadable PDF) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac Delivery Delivery Speed: Instant Download โ๏ธ Engine Specifications Primary Engine Engine Options 1991 405: Likely includes various gasoline engines: e.g., 1.4L, 1.6L, 1.8L, 1.9L (XU series), and potentially a 2.0L or turbo-diesel variants (XUD series). Manual will cover specifics for each. Performance Horsepower Range: Varies by engine, typically from ~70 HP to ~130 HP for gasoline models, and ~60-80 HP for diesel models. Fuel System Fuel Delivery: Carbureted or Fuel Injection (MPI) depending on engine variant. Manual will detail specific fuel system types. Engine Codes Common Engine Codes: Likely includes XU series engines (e.g., XU5, XU7, XU9, XU10 for petrol) and XUD series diesel engines (e.g., XUD7, XUD9). Manual will detail specific engine codes and their differences. ๐ง Transmission Standard Standard Transmission: Likely a 5-speed manual transmission for most models. Optional Optional Transmission: Likely a 3-speed or 4-speed automatic transmission depending on market and engine. Features Transmission Fluid Type: Specific to manual or automatic transmission type, manual will specify exact fluid and...
Engine component repair/replacement, transmission overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and repair
Disassembly Assembly:
Detailed step-by-step instructions for component removal and reinstallation
Troubleshooting:
Diagnostic procedures for common problems, fault codes (if applicable), symptom-based troubleshooting guides
Diagnostics:
Procedures for diagnosing electrical and mechanical issues
Engine Rebuild:
Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), cylinder head overhaul, and reassembly with torque specifications.
Transmission Repair:
Detailed procedures for manual and automatic transmission repair, including clutch replacement, gear synchromesh repair, and hydraulic system servicing for automatics.
Electrical Troubleshooting Charts:
Likely includes wiring diagrams and troubleshooting charts based on symptoms.
Body Repair:
Information on door adjustments, window regulator repair, and potentially basic body panel alignment.
Lubrication Points:
Identification and types of lubricants for various chassis and suspension components.
Air Conditioning Service:
Procedures for charging refrigerant, leak testing, and component replacement for the A/C system (if equipped).
Body And Paint:
May include basic guidance on rustproofing or minor bodywork procedures.
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for professional technicians and advanced DIYers, covering fundamentals to complex repairs
Diagnostic Tools:
Likely mentions necessary specialized tools for certain procedures.
๐ Manual Specifications
File Format
File Type:
PDF
Searchability:
PDF format generally allows for text searching (if text is not an image), aiding quick access to information.
Print Quality
Printable:
Full Printable
Zoom Functionality:
YES (Zoom IN/OUT)
Binding Type
Binding:
Digital (Downloadable PDF)
Paper Type
Paper Type:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
Delivery
Delivery Speed:
Instant Download
โ๏ธ Engine Specifications
Primary Engine
Engine Options 1991 405:
Likely includes various gasoline engines: e.g., 1.4L, 1.6L, 1.8L, 1.9L (XU series), and potentially a 2.0L or turbo-diesel variants (XUD series). Manual will cover specifics for each.
Performance
Horsepower Range:
Varies by engine, typically from ~70 HP to ~130 HP for gasoline models, and ~60-80 HP for diesel models.
Fuel System
Fuel Delivery:
Carbureted or Fuel Injection (MPI) depending on engine variant. Manual will detail specific fuel system types.
Engine Codes
Common Engine Codes:
Likely includes XU series engines (e.g., XU5, XU7, XU9, XU10 for petrol) and XUD series diesel engines (e.g., XUD7, XUD9). Manual will detail specific engine codes and their differences.
๐ง Transmission
Standard
Standard Transmission:
Likely a 5-speed manual transmission for most models.
Optional
Optional Transmission:
Likely a 3-speed or 4-speed automatic transmission depending on market and engine.
Features
Transmission Fluid Type:
Specific to manual or automatic transmission type, manual will specify exact fluid and capacity (e.g., GL-4 for manual, ATF type for automatic).
๐ Dimensions
Exterior
Body Styles:
Saloon (Sedan), Estate (Wagon)
Weights
Curb Weight:
Varies by body style and engine, typically 1000-1300 kg.
๐ก๏ธ Safety Features
Ratings
Safety Standards:
Compliant with European safety standards of the era. Manual will detail specific safety features and testing if available.
Active Features
Braking System:
Power-assisted front discs and rear drums, optional ABS on higher trims.
Passive Features
Seatbelts:
Front and rear seatbelts, with pre-tensioners on some models.
๐ก Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, potentially optional CD player. Manual will cover head unit operation and fuse locations.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) on higher trim levels and specific engine variants. Manual will detail system operation and diagnostics.
Connectivity
Central Locking:
Available on some models, manual will cover its electrical system and potential troubleshooting.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or 12 months, depending on driving conditions and oil type. Manual will provide precise intervals.
Timing Belt Replacement:
Crucial for XU engines. Typically every 60,000 miles or 5 years. Manual will specify the exact interval and procedure, including tensioner and water pump recommendations.
Fluid Specifications
Engine Oil:
Likely 10W-40 or 5W-40 synthetic/semi-synthetic oil, with specific API/ACEA ratings detailed in the manual. Capacity around 4-5 liters depending on engine.
Coolant:
Ethylene glycol based coolant with appropriate antifreeze protection. Manual will specify type and mixture ratio (typically 50/50).
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact type and replacement interval.
Power Steering Fluid:
Specific hydraulic fluid for power steering system if equipped. Manual will specify type and capacity.
Gearbox Oil:
API GL-4 or GL-5 rated gear oil for manual transmissions. Manual will specify viscosity grade (e.g., 75W-90, 80W-90) and capacity.
Known Issues
Common Faults:
Radiator fan issues, ignition coil failures, suspension wear (bushings), gearbox synchromesh wear (manual transmissions), potential for head gasket issues on some engine variants if overheated.
Body Corrosion:
Can be susceptible to rust in certain areas, especially wheel arches and sills, depending on climate and maintenance. Manual might offer basic advice on care.
Electrical Connectors:
Corrosion on electrical connectors, especially in damp climates, can lead to intermittent faults. Manual would be essential for diagnosing these.
๐ Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot has a long history of producing robust and comfortable family cars, known for their ride quality and handling.
Model Evolution
405 Development:
The Peugeot 405 was developed in collaboration with Chrysler Europe and designed by Pininfarina. It was a successor to the Peugeot 405 and a contemporary of the Citroรซn BX.
Production
Production Period:
1987โ1996 (Europe), with production continuing in other markets longer.
๐ Awards & Recognition
Recognitions
European Car Of The Year:
The Peugeot 405 was awarded 'European Car of the Year' in 1988, a testament to its design, engineering, and market appeal.