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Peugeot 405 1988-1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Model Years Covered: 1988-1997 Vin Decoder Information: Manual provides guidance on VIN decoding specific to the Peugeot 405 range. Generation Generation Designation: First Generation (Type 150) Codes Chassis Codes: Primarily Type 150 👋 Introduction Market Position Positioning: A highly regarded family car in its era, known for its comfortable ride, aerodynamic styling, and sophisticated handling, particularly the GTI and Mi16 variants. Competitive Analysis Key Competitors: Ford Sierra, Volkswagen Passat, Opel/Vauxhall Vectra, Renault 21, Citroën BX. Key Features Vehicle Aerodynamics: Extremely low drag coefficient (Cd) for its time, contributing to fuel efficiency and quietness. Ride Comfort: Renowned for excellent ride quality, absorbing bumps and imperfections effectively, often compared favorably to more premium vehicles. Key Features Manual Completeness: Offers 'A-Z' coverage for all models and all repairs, making it a truly comprehensive resource. Authenticity: Directly stated as the exact same manual used by dealership technicians, ensuring factory-level accuracy. Diy Focus: Designed to empower owners with DIY repair capabilities, saving costs and providing satisfaction. 📋 Manual Details Coverage Areas Regions Covered: Global, with emphasis on European specifications Page Count Estimated Page Count: Extensive (typically 1000+ pages for a complete factory service manual equivalent) Manual Type Type: Complete Official Full Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: All engine variants, including XU and PRV engines; cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling. Engine Management: Fuel injection systems (Bosch Motronic, K-Jetronic etc.), ignition systems, sensor diagnostics, ECU troubleshooting. Transmission Manual: Manual gearboxes: clutch, gearbox internal components, shift mechanisms, lubrication. Transmission Automatic: Automatic gearboxes (if applicable to specific models/years): operation, maintenance, troubleshooting. Drivetrain: Front-wheel drive components: driveshafts, CV joints, differentials, wheel bearings. Suspension: Front suspension (MacPherson struts), rear suspension (torsion beam or independent), shock absorbers, springs, bushings, alignment specifications. Steering: Steering rack, power steering system (if equipped), steering column, tie rods, alignment. Brakes: Front and rear brake systems: disc and drum brakes, hydraulic system, ABS (if equipped), bleeding procedures, component replacement. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, horns, wipers, washers, power windows, central locking. Wiring Schematics: Comprehensive wiring diagrams for all major electrical systems, including engine control, lighting, comfort features, and safety systems. Body And Chassis: Body panels, doors, hood, trunk, interior trim, structural components, corrosion protection. Climate Control: HVAC system: A/C operation, heating, ventilation, blower motor, refrigerant handling, heater core, evaporator. Safety Systems: Seat belts, airbag systems (if equipped), ABS operation and diagnostics. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement, brake pad inspection. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation. Repair Procedures: Step-by-step instructions for component removal, installation, and repair across all covered systems. Rebuilding: Detailed procedures for engine, transmission, and major component rebuilding. Diagnostics: Systematic diagnostic approaches, including the use of diagnostic tools and interpreting feedback. Specifications Settings: Torque values, alignment angles, engine timing, valve clearances, fluid capacities, and other critical settings. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full printable – users can print specific pages or the entire manual. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type Digital: N/A (Digital PDF, allows for high-resolution image viewing and printing on any paper type). Searchability Text Search: Searchable text allows for quick access to specific information. Zoom Capability Zoom: Yes, allows for zooming in on diagrams and images for clarity. Requirements Software Requirements: Adobe PDF Reader and WinZip (or equivalent decompression software). Compatibility Operating Systems: Compatible with all versions of Windows and Mac. ⚙️ Engine Specifications Primary Engine Common Engine Options: 1.6L (XU5), 1.8L (XU7), 2.0L (XU9, XU10), 1.9L Diesel (XUD7, XUD9), 2.0L V6 (PRV - in models like 405 Mi16 V6). Performance Gtx 2.0L Performance: Approx. 115-125 hp (depending on injection/carburetion). Mi16 2.0L Performance: Approx. 160 hp (16-valve DOHC). Fuel System Fuel Delivery: Carburetor (Solex, Weber) or Bosch L-Jetronic / Motronic fuel injection systems. Cooling System Coolant Capacity: Typically 6-7 liters, depending on engine and radiator size. Ignition System Ignition Type: Distributor-based ignition with electronic control or distributorless ignition systems (DIS) on later models. 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission. Optional Optional Transmission: 4-speed automatic transmission (AL4 or similar). Features Clutch Type: Hydraulically operated single dry plate clutch. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-80 or 75W-90 gear oil. Automatic Transmission Fluid: Typically ATF Dexron II or equivalent. 📐 Dimensions Exterior Length: Approximately 4400-4430 mm (depending on variant). Width: Approximately 1700-1720 mm. Height: Approximately 1400-1420 mm. Weights Curb Weight: Ranges from approximately 1050 kg to 1350 kg, depending on engine and equipment. Gross Vehicle Weight: Varies by model,...
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Peugeot 405 1988-1997 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
405
Model Years Covered:
1988-1997
Vin Decoder Information:
Manual provides guidance on VIN decoding specific to the Peugeot 405 range.
Generation
Generation Designation:
First Generation (Type 150)
Codes
Chassis Codes:
Primarily Type 150
👋 Introduction
Market Position
Positioning:
A highly regarded family car in its era, known for its comfortable ride, aerodynamic styling, and sophisticated handling, particularly the GTI and Mi16 variants.
Competitive Analysis
Key Competitors:
Ford Sierra, Volkswagen Passat, Opel/Vauxhall Vectra, Renault 21, Citroën BX.
Key Features Vehicle
Aerodynamics:
Extremely low drag coefficient (Cd) for its time, contributing to fuel efficiency and quietness.
Ride Comfort:
Renowned for excellent ride quality, absorbing bumps and imperfections effectively, often compared favorably to more premium vehicles.
Key Features Manual
Completeness:
Offers 'A-Z' coverage for all models and all repairs, making it a truly comprehensive resource.
Authenticity:
Directly stated as the exact same manual used by dealership technicians, ensuring factory-level accuracy.
Diy Focus:
Designed to empower owners with DIY repair capabilities, saving costs and providing satisfaction.
📋 Manual Details
Coverage Areas
Regions Covered:
Global, with emphasis on European specifications
Page Count
Estimated Page Count:
Extensive (typically 1000+ pages for a complete factory service manual equivalent)
Manual Type
Type:
Complete Official Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
All engine variants, including XU and PRV engines; cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling.
Engine Management:
Fuel injection systems (Bosch Motronic, K-Jetronic etc.), ignition systems, sensor diagnostics, ECU troubleshooting.
Transmission Manual:
Manual gearboxes: clutch, gearbox internal components, shift mechanisms, lubrication.
Transmission Automatic:
Automatic gearboxes (if applicable to specific models/years): operation, maintenance, troubleshooting.
Drivetrain:
Front-wheel drive components: driveshafts, CV joints, differentials, wheel bearings.
Suspension:
Front suspension (MacPherson struts), rear suspension (torsion beam or independent), shock absorbers, springs, bushings, alignment specifications.
Steering:
Steering rack, power steering system (if equipped), steering column, tie rods, alignment.
Brakes:
Front and rear brake systems: disc and drum brakes, hydraulic system, ABS (if equipped), bleeding procedures, component replacement.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, horns, wipers, washers, power windows, central locking.
Wiring Schematics:
Comprehensive wiring diagrams for all major electrical systems, including engine control, lighting, comfort features, and safety systems.
Body And Chassis:
Body panels, doors, hood, trunk, interior trim, structural components, corrosion protection.
Climate Control:
HVAC system: A/C operation, heating, ventilation, blower motor, refrigerant handling, heater core, evaporator.
Safety Systems:
Seat belts, airbag systems (if equipped), ABS operation and diagnostics.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection and replacement, brake pad inspection.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair across all covered systems.
Rebuilding:
Detailed procedures for engine, transmission, and major component rebuilding.
Diagnostics:
Systematic diagnostic approaches, including the use of diagnostic tools and interpreting feedback.
Specifications Settings:
Torque values, alignment angles, engine timing, valve clearances, fluid capacities, and other critical settings.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full printable – users can print specific pages or the entire manual.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type Digital:
N/A (Digital PDF, allows for high-resolution image viewing and printing on any paper type).
Searchability
Text Search:
Searchable text allows for quick access to specific information.
Zoom Capability
Zoom:
Yes, allows for zooming in on diagrams and images for clarity.
Requirements
Software Requirements:
Adobe PDF Reader and WinZip (or equivalent decompression software).
Compatibility
Operating Systems:
Compatible with all versions of Windows and Mac.
⚙️ Engine Specifications
Primary Engine
Common Engine Options:
1.6L (XU5), 1.8L (XU7), 2.0L (XU9, XU10), 1.9L Diesel (XUD7, XUD9), 2.0L V6 (PRV - in models like 405 Mi16 V6).
Performance
Gtx 2.0L Performance:
Approx. 115-125 hp (depending on injection/carburetion).
Mi16 2.0L Performance:
Approx. 160 hp (16-valve DOHC).
Fuel System
Fuel Delivery:
Carburetor (Solex, Weber) or Bosch L-Jetronic / Motronic fuel injection systems.
Cooling System
Coolant Capacity:
Typically 6-7 liters, depending on engine and radiator size.
Ignition System
Ignition Type:
Distributor-based ignition with electronic control or distributorless ignition systems (DIS) on later models.
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission.
Optional
Optional Transmission:
4-speed automatic transmission (AL4 or similar).
Features
Clutch Type:
Hydraulically operated single dry plate clutch.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-80 or 75W-90 gear oil.
Automatic Transmission Fluid:
Typically ATF Dexron II or equivalent.
📐 Dimensions
Exterior
Length:
Approximately 4400-4430 mm (depending on variant).
Width:
Approximately 1700-1720 mm.
Height:
Approximately 1400-1420 mm.
Weights
Curb Weight:
Ranges from approximately 1050 kg to 1350 kg, depending on engine and equipment.
Gross Vehicle Weight:
Varies by model, typically around 1600-1800 kg.
🛡️ Safety Features
Ratings
Crash Test Information:
Early models predated stringent modern crash testing standards, but generally performed well for their era in front and side impacts. Manual provides guidance on structural integrity and repair.
Active Features
ABS:
Anti-lock Braking System (ABS) was available as an option on many models, particularly higher trims and performance variants.
Passive Features
Seatbelts:
Front and rear seat belts are standard. Manual details pre-tensioner systems if equipped.
Airbags:
Driver's side airbag became available on later models. Manual covers airbag system operation and replacement procedures.
💡 Technology Features
Infotainment
Original Infotainment:
Basic radio/cassette players, often with manual antenna. Higher trims might have 4 speakers. Manual covers removal and installation of these units.
Driver Assistance
Cruise Control:
Available as an option on some models, particularly higher-spec versions. Manual details its operation and servicing.
Connectivity
Original Connectivity:
Limited to basic electrical systems. No contemporary digital connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, depending on oil used and driving conditions. Manual specifies precise intervals.
Timing Belt Replacement:
Crucial maintenance item. Varies by engine but generally around 80,000-120,000 km or 5-7 years. Manual provides exact intervals and procedures.
Spark Plug Replacement:
Intervals vary based on plug type (copper, platinum, iridium), typically 20,000-60,000 km. Manual details recommended types and intervals.
Fluid Specifications
Engine Oil Type:
API SJ/SL or ACEA A3/B3. Viscosity grades such as 5W-40, 10W-40, or 15W-40 depending on climate. Manual specifies exact types.
Coolant Type:
Ethylene glycol based coolant, typically orange or blue, meeting PSA specifications. Manual details correct type and mixture.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual specifies which is appropriate and replacement intervals.
Known Issues
Common Problems:
Electrical gremlins, starter motor issues, alternator problems, worn suspension bushings, heater matrix leaks, fuel pump failures, timing belt failure (if not replaced on schedule).
Rust Prone Areas:
Wheel arches, sills, rear shock absorber mounts, door bottoms, and boot lid edges can be susceptible to rust, especially in areas with harsh climates.
📚 Vehicle History
Brand Heritage
Peugeot Heritage:
Peugeot has a long history of producing well-engineered and driver-focused vehicles, with the 405 continuing this tradition following models like the 404 and 405.
Model Evolution
405 Evolution:
Introduced in 1987 as a replacement for the 305, it was designed by Pininfarina. Key variants included the 405 GR, SR, GTX, Mi16 (performance sedan), and the estate (Break). Facelifted in 1992 with revised styling and features.
Production
Production Locations:
Primarily France (Mulhouse), but also produced in other countries under license or via assembly plants.
Production Years:
1987-1997 (in Europe), with some markets continuing production longer.
🏆 Awards & Recognition
Recognitions
European Car Of The Year:
Named European Car of the Year for 1988, highlighting its significant impact and design.
Overall Reception:
Widely praised for its handling, comfort, and styling by automotive journalists and the public alike.
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