PEUGEOT 405 Digital Workshop Repair Manual 1987-1997

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Product Name: PEUGEOT 405 Digital Workshop Repair Manual 1987-1997 Generation Generation Covered: First Generation (15B) Codes Chassis Codes: 15B Engine Codes: XU5 (1.6L), XU7 (1.8L), XU9 (1.9L), XU10 (2.0L), XUD7 (1.8L Diesel), XUD9 (1.9L Diesel), XUD9TE (1.9L Turbo Diesel) 👋 Introduction Market Position Positioning: The Peugeot 405 was a popular family car positioned in the mid-size segment, known for its comfortable ride, distinctive styling (especially the aerodynamic design by Pininfarina), and engaging handling. It competed with vehicles like the Ford Sierra, Opel/Vauxhall Vectra, and Volkswagen Passat. Competitive Analysis Strengths: Comfortable ride, refined styling, good handling, spacious interior, wide range of engine options including efficient diesel variants. Key Features Design Heritage: Designed by Pininfarina, contributing to its aerodynamic and elegant appearance. Driving Dynamics: Often praised for its balanced chassis and responsive steering, offering a good driving experience for its class. Engine Range: Offered a diverse range of gasoline (petrol) and diesel engines, catering to various performance and economy needs. 📋 Manual Details Coverage Areas Models Covered: All Peugeot 405 models manufactured between 1987 and 1997, including Saloon (sedan) and Estate (wagon) variants. Regions Covered: Global specifications and procedures, primarily focusing on European market configurations. Page Count Estimated Page Count: Likely exceeds 1000 pages in printed equivalent, given the comprehensive nature described. Manual Type Type: Digital Workshop Repair Manual Purpose: Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration. Language Language: English Format Format: Digital (likely PDF or similar format for viewing and printing) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel system (injection, carburetion, pumps, injectors), ignition system, cooling system, exhaust system, engine management systems (ECU, sensors). Transmission: Manual transmission (gearbox, clutch, driveshafts), Automatic transmission (gearbox, torque converter, valve body, solenoids), shift linkages. Chassis: Suspension (front MacPherson struts, rear torsion beam/independent), steering (rack and pinion, power steering system), brakes (front discs, rear drums/discs, ABS system), wheels and tires. Electrical: Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), wipers and washers, horn, fuse box, relays, wiring diagrams for all major circuits. Bodywork: Body panel removal and installation, doors, windows, sunroof, seats, interior trim, bumpers, paint and corrosion protection details. Comfort And Convenience: HVAC system (air conditioning, heating, ventilation), power windows, power door locks, central locking, alarm systems (if equipped). Procedures Included Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, belt inspections and replacements, lubrication points. Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation (if applicable to the era), component testing procedures. Repair Rebuild: Engine overhaul, transmission rebuild, brake caliper overhaul, suspension component replacement, steering rack replacement, starter motor/alternator replacement, fuel injector cleaning/replacement. Installation Adjustment: Installation of accessories, timing belt adjustment, brake pad replacement, clutch adjustment, door alignment. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Includes detailed specifications, torque values, and diagnostic procedures for professional technicians. 📊 Manual Specifications File Format File Types: Likely PDF, possibly with separate image files or a proprietary viewer format. Print Quality Image Quality: High Quality Photos, Illustrations And Diagrams - implies clear, detailed visuals suitable for reproduction. Binding Type Binding: Not applicable for digital format; implies printable pages. Paper Type Paper Quality: Not applicable for digital format; implies suitability for standard printing. Searchability Text Search: Likely searchable text if in PDF format, allowing quick access to specific topics. Compatibility Operating Systems: Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, VISTA, Windows 7, and all Mac computers. ⚙️ Engine Specifications Primary Engine Engine Family: PSA XU engine family 1.6L Gasoline (Xu5M): Displacement: 1580 cc, Bore x Stroke: 83 x 73 mm, Compression Ratio: 9.2:1, Power: Approx. 89-90 PS (65-66 kW), Torque: Approx. 130-135 Nm. 1.9L Gasoline (Xu9J2/J3Z): Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 9.3:1, Power: Approx. 108-110 PS (79-81 kW) (single point injection), Approx. 125-130 PS (92-96 kW) (multi-point injection - GTI models). 2.0L Gasoline (Xu10J2/J4R): Displacement: 1998 cc, Bore x Stroke: 86 x 86 mm, Compression Ratio: 9.5:1, Power: Approx. 115-120 PS (85-88 kW) (multi-point injection). 1.8L Diesel (Xud7): Displacement: 1769 cc, Bore x Stroke: 80 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 60 PS (44 kW), Torque: Approx. 110 Nm. 1.9L Diesel (Xud9): Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 71 PS (52 kW), Torque: Approx. 120 Nm. 1.9L Turbo Diesel (Xud9Te): Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 90-92 PS (66-68 kW), Torque: Approx. 180-190 Nm. Performance Gti Performance (Example): Peugeot 405 Mi16 (2.0L 16v) offered around 160 PS. Fuel System Gasoline Injection: Bosch LE2-Jetronic (single-point), Bosch Motronic (multi-point), or Solex/Weber carburettors on lower trims. Diesel Injection: Lucas/CAV or Bosch rotary injection pumps. 🔧 Transmission Standard Manual Transmission: 5-speed...

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Tags: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 405 Car Cars Peugeot

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Product Name:

PEUGEOT 405 Digital Workshop Repair Manual 1987-1997

Generation

Generation Covered:

First Generation (15B)

Codes

Chassis Codes:

Engine Codes:

XU5 (1.6L), XU7 (1.8L), XU9 (1.9L), XU10 (2.0L), XUD7 (1.8L Diesel), XUD9 (1.9L Diesel), XUD9TE (1.9L Turbo Diesel)

👋 Introduction

Market Position

Positioning:

The Peugeot 405 was a popular family car positioned in the mid-size segment, known for its comfortable ride, distinctive styling (especially the aerodynamic design by Pininfarina), and engaging handling. It competed with vehicles like the Ford Sierra, Opel/Vauxhall Vectra, and Volkswagen Passat.

Competitive Analysis

Strengths:

Comfortable ride, refined styling, good handling, spacious interior, wide range of engine options including efficient diesel variants.

Key Features

Design Heritage:

Driving Dynamics:

Often praised for its balanced chassis and responsive steering, offering a good driving experience for its class.

Engine Range:

Offered a diverse range of gasoline (petrol) and diesel engines, catering to various performance and economy needs.

📋 Manual Details

Coverage Areas

Models Covered:

All Peugeot 405 models manufactured between 1987 and 1997, including Saloon (sedan) and Estate (wagon) variants.

Regions Covered:

Global specifications and procedures, primarily focusing on European market configurations.

Page Count

Estimated Page Count:

Likely exceeds 1000 pages in printed equivalent, given the comprehensive nature described.

Manual Type

Type:

Digital Workshop Repair Manual

Purpose:

Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration.

Language

Language:

English

Format

Format:

Digital (likely PDF or similar format for viewing and printing)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel system (injection, carburetion, pumps, injectors), ignition system, cooling system, exhaust system, engine management systems (ECU, sensors).

Transmission:

Manual transmission (gearbox, clutch, driveshafts), Automatic transmission (gearbox, torque converter, valve body, solenoids), shift linkages.

Chassis:

Suspension (front MacPherson struts, rear torsion beam/independent), steering (rack and pinion, power steering system), brakes (front discs, rear drums/discs, ABS system), wheels and tires.

Electrical:

Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), wipers and washers, horn, fuse box, relays, wiring diagrams for all major circuits.

Bodywork:

Body panel removal and installation, doors, windows, sunroof, seats, interior trim, bumpers, paint and corrosion protection details.

Comfort And Convenience:

HVAC system (air conditioning, heating, ventilation), power windows, power door locks, central locking, alarm systems (if equipped).

Procedures Included

Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, belt inspections and replacements, lubrication points.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation (if applicable to the era), component testing procedures.

Repair Rebuild:

Engine overhaul, transmission rebuild, brake caliper overhaul, suspension component replacement, steering rack replacement, starter motor/alternator replacement, fuel injector cleaning/replacement.

Installation Adjustment:

Installation of accessories, timing belt adjustment, brake pad replacement, clutch adjustment, door alignment.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Includes detailed specifications, torque values, and diagnostic procedures for professional technicians.

📊 Manual Specifications

File Format

File Types:

Likely PDF, possibly with separate image files or a proprietary viewer format.

Print Quality

Image Quality:

High Quality Photos, Illustrations And Diagrams - implies clear, detailed visuals suitable for reproduction.

Binding Type

Binding:

Not applicable for digital format; implies printable pages.

Paper Type

Paper Quality:

Not applicable for digital format; implies suitability for standard printing.

Searchability

Text Search:

Likely searchable text if in PDF format, allowing quick access to specific topics.

Compatibility

Operating Systems:

Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, VISTA, Windows 7, and all Mac computers.

⚙️ Engine Specifications

Primary Engine

Engine Family:

PSA XU engine family

1.6L Gasoline (Xu5M):

Displacement: 1580 cc, Bore x Stroke: 83 x 73 mm, Compression Ratio: 9.2:1, Power: Approx. 89-90 PS (65-66 kW), Torque: Approx. 130-135 Nm.

1.9L Gasoline (Xu9J2/J3Z):

Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 9.3:1, Power: Approx. 108-110 PS (79-81 kW) (single point injection), Approx. 125-130 PS (92-96 kW) (multi-point injection - GTI models).

2.0L Gasoline (Xu10J2/J4R):

Displacement: 1998 cc, Bore x Stroke: 86 x 86 mm, Compression Ratio: 9.5:1, Power: Approx. 115-120 PS (85-88 kW) (multi-point injection).

1.8L Diesel (Xud7):

Displacement: 1769 cc, Bore x Stroke: 80 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 60 PS (44 kW), Torque: Approx. 110 Nm.

1.9L Diesel (Xud9):

Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 71 PS (52 kW), Torque: Approx. 120 Nm.

1.9L Turbo Diesel (Xud9Te):

Displacement: 1905 cc, Bore x Stroke: 83 x 88 mm, Compression Ratio: 23.0:1, Power: Approx. 90-92 PS (66-68 kW), Torque: Approx. 180-190 Nm.

Performance

Gti Performance (Example):

Peugeot 405 Mi16 (2.0L 16v) offered around 160 PS.

Fuel System

Gasoline Injection:

Bosch LE2-Jetronic (single-point), Bosch Motronic (multi-point), or Solex/Weber carburettors on lower trims.

Diesel Injection:

Lucas/CAV or Bosch rotary injection pumps.

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (e.g., BE1, MA5 gearboxes depending on engine and market).

Optional

Automatic Transmission:

4-speed ZF automatic transmission, often found on higher-spec models.

Features

Clutch:

Hydraulically operated single dry plate clutch.

📐 Dimensions

Exterior

Length:

Approx. 4405 mm (Saloon), 4465 mm (Estate)

Width:

Approx. 1700 mm

Height:

Approx. 1420 mm (Saloon), 1460 mm (Estate)

Wheelbase:

Approx. 2600 mm

Cargo

Luggage Capacity:

Approx. 500-530 liters (Saloon), significantly more with rear seats folded in Estate.

Weights

Curb Weight:

Ranging from approximately 1050 kg (1.6L) to 1300 kg (2.0L Turbo Diesel / higher trims).

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not available for this era model; Euro NCAP testing began later.

Active Features

Optional on many models, standard on higher trims (e.g., Mi16, later models).

Passive Features

Airbags:

Driver's airbag became available later in the production run, optional on most models.

Seatbelts:

Pre-tensioned front seatbelts on later models; all seats equipped with inertia reel belts.

Chassis Safety:

Reinforced safety cell construction, energy-absorbing crumple zones front and rear.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio-cassette players were common, often with 4 or 6 speakers. Upgrades to more modern head units are straightforward.

Driver Assistance

Cruise Control:

Available as an option on higher-spec models.

Connectivity

Remote Locking:

Central locking was standard on most trims, with remote operation available on higher specifications.

🔧 Maintenance

Service Intervals

Oil Change:

Every 10,000 km or 6 months (whichever comes first) for gasoline, 15,000 km or 12 months for diesel, subject to severe driving conditions.

Timing Belt:

Every 80,000 km or 5 years for gasoline engines (XU family). Critical to follow; failure can cause catastrophic engine damage.

Air Filter:

Inspect every 20,000 km, replace as needed or every 40,000 km.

Fuel Filter:

Replace every 40,000 km for gasoline, 60,000 km for diesel.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 10W-40 or 15W-50 depending on climate. Consult manual for specific viscosity grades and API specifications for each engine variant. Capacity: Approx. 3.5-4.5 liters.

Coolant:

50/50 mix of ethylene glycol antifreeze and distilled water. Peugeot recommends specific types (e.g., Type D). Capacity: Approx. 6-7 liters.

Brake Fluid:

DOT 3 or DOT 4 (check manual for specific recommendation). Replace every 2 years due to hygroscopic nature. Capacity: Approx. 0.75 liters.

Transmission Fluid:

Manual: SAE 75W-80 GL-4. Automatic: ATF Dexron II or III equivalent. Capacity: Manual: Approx. 2 liters. Automatic: Approx. 3-4 liters (check dipstick).

Known Issues

Engine Cooling:

Thermostat failure, radiator leaks, or fan motor issues can lead to overheating. Plastic coolant expansion tanks can become brittle.

Suspension:

Worn front wishbone bushes, rear torsion bar bearings, and shock absorbers are common wear items affecting ride and handling.

Electrical:

Corroded earth points, faulty door lock actuators, and intermittent dashboard warning lights can occur over time.

Exhaust:

Rust can affect exhaust system components, particularly the rear silencer and catalytic converter (if fitted).

Diesel Engines:

Glow plug issues, injector pump leaks, and head gasket failures can be encountered on older diesel units.

📚 Vehicle History

Brand Heritage

Peugeot Legacy:

Peugeot has a long history of producing robust and driver-focused vehicles, with the 40x series representing their mainstream family car offerings.

Model Evolution

Introduction:

The Peugeot 405 was launched in 1987 as the successor to the Peugeot 305, aiming to compete in the increasingly important mid-size car segment.

Facelift:

A minor facelift occurred in 1992, featuring revised front and rear styling (clearer indicator lenses, updated grille, improved interior trim).

Performance Variants:

Iconic performance versions included the 405 Mi16 (16-valve engine, often with 4WD) and the turbocharged 405 T16 (rally-inspired).

Production

Production Years:

1987-1997 (Europe), production continued in other regions for longer.

Manufacturing Locations:

Primarily France (Sochaux) and the UK (Ryton).

🏆 Awards & Recognition

Recognitions

European Car Of The Year:

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

Other Awards:

Received numerous accolades for styling and driving dynamics from automotive publications worldwide during its production run.