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Peugeot 405 Service & Repair Manual 1987-1997

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Generation Production Years: 1987-1997 Codes Platform Code: Type 155 👋 Introduction Market Position Target Audience: DIY mechanics, amateur restorers, professional technicians working on Peugeot 405 vehicles. Competitive Analysis Value Proposition: Provides dealer-level repair and maintenance information at a fraction of the cost, enabling owners to perform their own servicing and repairs. Key Features Documentation Style: Features detailed sub-steps, notes, cautions, warnings, numbered instructions, and bold figure numbers for clarity. Visual Aids: Includes hundreds of detailed illustrations, drawings, and photos, with enlarged inset views for detailed part examination. Navigability: Features a numbered table of contents for quick information retrieval. Diagnostic Aid: Combines troubleshooting and electrical service procedures with wiring diagrams for efficient problem diagnosis. Availability Delivery: Instant digital download, ensuring immediate access to repair information. 📋 Manual Details Coverage Areas Models Covered: Saloon and Estate models Engine Variants Covered: 4-cylinder SOHC and DOHC petrol engines (1.4L, 1.6L, 1.8L, 1.9L, 2.0L), including Mi-16 and special/limited editions Page Count Total Pages: Over 300 Manual Type Type: Workshop Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine mechanical systems (cylinder head, cylinder block, pistons, crankshaft, camshafts, timing belts/chains) Engine Control System: Engine control systems (fuel injection, ignition, sensors, ECUs) Cooling System: Cooling system (radiator, water pump, thermostat, cooling fan, hoses) Lubrication System: Lubrication system (oil pump, oil filter, oil pressure) Fuel System: Fuel system (fuel tank, fuel pump, fuel filter, fuel injectors) Exhaust System: Exhaust system (manifold, catalytic converter, muffler) Emission Control Systems: Emission control systems (charcoal canister, EGR) Transmission Manual: Manual transaxle systems (clutch, gearbox, differential) Transmission Automatic: Automatic transmission systems (if applicable to covered variants, detailed torque converter clutch operation) Drive Shaft: Drive shaft and axle components Suspension Front: Front suspension system (struts, control arms, ball joints) Suspension Rear: Rear suspension system (shock absorbers, springs, trailing arms) Steering System: Steering system (rack and pinion, steering column, power steering) Brake System: Brake system (master cylinder, brake booster, calipers, rotors, pads, brake fluid, parking brake) Wheel And Tire System: Wheel and tire system (tire pressure, wheel alignment, hub assembly) Electrical System Charging: Charging system (alternator, battery, voltage regulator) Electrical System Starting: Starting system (starter motor, starter switch) Electrical System Ignition: Ignition system (spark plugs, ignition coils, distributor) Lighting System: Lighting system (headlights, taillights, interior lights, combination meter) Wiper And Washer System: Wiper and washer system (motors, blades, nozzles) Power Window Control System: Power window control system Power Door Lock Control System: Power door lock control system Sun Roof System: Sun roof system (if equipped) Supplemental Restraint System: Supplemental Restraint System (SRS) - Airbag system components and sensors Body Repair: Body repair procedures, panel replacement, alignment Interior Trim: Interior trim and component removal/installation Heating And Air Conditioning: HVAC system (heater radiator, blower motor, controls) Procedures Included Maintenance: Scheduled maintenance, routine checks, fluid changes Troubleshooting: Diagnostic procedures for common problems, fault finding Repair: Step-by-step repair procedures for all major systems Disassembly Assembly: Complete disassembly and reassembly instructions for components Electrical Diagnostics: Electrical system diagnosis and troubleshooting with detailed wiring diagrams Wiring Diagrams: Comprehensive wiring diagrams for all electrical circuits Component Replacement: Detailed instructions for replacing individual parts and assemblies Specifications Data: Torque specifications, clearances, fluid capacities, and other technical data Technical Depth Depth: Comprehensive, suitable for both DIY enthusiasts and professional mechanics, covering everything from basic maintenance to complete engine rebuilds. 📊 Manual Specifications File Format Format: PDF Compatibility: Windows, Mac, Linux Print Quality Printability: Fully printable without restrictions Image Quality: High-quality scanned pages with clear illustrations and text Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type Equivalent: High-quality, durable paper (if printed) ⚙️ Engine Specifications Primary Engine Engine Codes Common: XU5, XU7, XU9 (various variants including Mi-16), XU10 Performance Displacement Range: 1360cc to 1998cc Power Output Range: Approximately 70 hp (1.4L) to 160 hp (Mi-16) Torque Output Range: Approximately 110 Nm to 180 Nm Fuel System Fuel Delivery: Carbureted (early models) and Fuel Injection (multi-point injection, throttle body control) Fuel Type: Unleaded Petrol (Octane rating typically 95 RON) Mechanical Cylinder Head Design: SOHC (Single Overhead Camshaft) and DOHC (Double Overhead Camshaft) configurations Valve Gear: Belt-driven camshaft(s) or chain-driven (less common on later models) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transaxle Optional Transmission Type Optional: 4-speed Automatic Transmission Features Transmission Fluid Type: Refer to specific manual section for exact type (e.g., API GL-4 for manual, ATF for automatic) Clutch Type: Hydraulically operated single dry plate clutch 📐 Dimensions Exterior Body Styles: Saloon (4-door), Estate (5-door) Weights Curb Weight Range: Approx. 1100 - 1300 kg (depending on engine and body style) 🛡️ Safety Features Ratings Crash Test History: Peugeot 405 models from this era generally had moderate safety ratings by modern standards; specific ratings for individual markets are not detailed in product description but...
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Peugeot 405 Service & Repair Manual 1987-1997
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
405
Generation
Production Years:
1987-1997
Codes
Platform Code:
Type 155
👋 Introduction
Market Position
Target Audience:
DIY mechanics, amateur restorers, professional technicians working on Peugeot 405 vehicles.
Competitive Analysis
Value Proposition:
Provides dealer-level repair and maintenance information at a fraction of the cost, enabling owners to perform their own servicing and repairs.
Key Features
Documentation Style:
Features detailed sub-steps, notes, cautions, warnings, numbered instructions, and bold figure numbers for clarity.
Visual Aids:
Includes hundreds of detailed illustrations, drawings, and photos, with enlarged inset views for detailed part examination.
Navigability:
Features a numbered table of contents for quick information retrieval.
Diagnostic Aid:
Combines troubleshooting and electrical service procedures with wiring diagrams for efficient problem diagnosis.
Availability
Delivery:
Instant digital download, ensuring immediate access to repair information.
📋 Manual Details
Coverage Areas
Models Covered:
Saloon and Estate models
Engine Variants Covered:
4-cylinder SOHC and DOHC petrol engines (1.4L, 1.6L, 1.8L, 1.9L, 2.0L), including Mi-16 and special/limited editions
Page Count
Total Pages:
Over 300
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine mechanical systems (cylinder head, cylinder block, pistons, crankshaft, camshafts, timing belts/chains)
Engine Control System:
Engine control systems (fuel injection, ignition, sensors, ECUs)
Cooling System:
Cooling system (radiator, water pump, thermostat, cooling fan, hoses)
Lubrication System:
Lubrication system (oil pump, oil filter, oil pressure)
Fuel System:
Fuel system (fuel tank, fuel pump, fuel filter, fuel injectors)
Exhaust System:
Exhaust system (manifold, catalytic converter, muffler)
Emission Control Systems:
Emission control systems (charcoal canister, EGR)
Transmission Manual:
Manual transaxle systems (clutch, gearbox, differential)
Transmission Automatic:
Automatic transmission systems (if applicable to covered variants, detailed torque converter clutch operation)
Drive Shaft:
Drive shaft and axle components
Suspension Front:
Front suspension system (struts, control arms, ball joints)
Suspension Rear:
Rear suspension system (shock absorbers, springs, trailing arms)
Steering System:
Steering system (rack and pinion, steering column, power steering)
Brake System:
Brake system (master cylinder, brake booster, calipers, rotors, pads, brake fluid, parking brake)
Wheel And Tire System:
Wheel and tire system (tire pressure, wheel alignment, hub assembly)
Electrical System Charging:
Charging system (alternator, battery, voltage regulator)
Electrical System Starting:
Starting system (starter motor, starter switch)
Electrical System Ignition:
Ignition system (spark plugs, ignition coils, distributor)
Lighting System:
Lighting system (headlights, taillights, interior lights, combination meter)
Wiper And Washer System:
Wiper and washer system (motors, blades, nozzles)
Power Window Control System:
Power window control system
Power Door Lock Control System:
Power door lock control system
Sun Roof System:
Sun roof system (if equipped)
Supplemental Restraint System:
Supplemental Restraint System (SRS) - Airbag system components and sensors
Body Repair:
Body repair procedures, panel replacement, alignment
Interior Trim:
Interior trim and component removal/installation
Heating And Air Conditioning:
HVAC system (heater radiator, blower motor, controls)
Procedures Included
Maintenance:
Scheduled maintenance, routine checks, fluid changes
Troubleshooting:
Diagnostic procedures for common problems, fault finding
Repair:
Step-by-step repair procedures for all major systems
Disassembly Assembly:
Complete disassembly and reassembly instructions for components
Electrical Diagnostics:
Electrical system diagnosis and troubleshooting with detailed wiring diagrams
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical circuits
Component Replacement:
Detailed instructions for replacing individual parts and assemblies
Specifications Data:
Torque specifications, clearances, fluid capacities, and other technical data
Technical Depth
Depth:
Comprehensive, suitable for both DIY enthusiasts and professional mechanics, covering everything from basic maintenance to complete engine rebuilds.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows, Mac, Linux
Print Quality
Printability:
Fully printable without restrictions
Image Quality:
High-quality scanned pages with clear illustrations and text
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type Equivalent:
High-quality, durable paper (if printed)
⚙️ Engine Specifications
Primary Engine
Engine Codes Common:
XU5, XU7, XU9 (various variants including Mi-16), XU10
Performance
Displacement Range:
1360cc to 1998cc
Power Output Range:
Approximately 70 hp (1.4L) to 160 hp (Mi-16)
Torque Output Range:
Approximately 110 Nm to 180 Nm
Fuel System
Fuel Delivery:
Carbureted (early models) and Fuel Injection (multi-point injection, throttle body control)
Fuel Type:
Unleaded Petrol (Octane rating typically 95 RON)
Mechanical
Cylinder Head Design:
SOHC (Single Overhead Camshaft) and DOHC (Double Overhead Camshaft) configurations
Valve Gear:
Belt-driven camshaft(s) or chain-driven (less common on later models)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transaxle
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Transmission Fluid Type:
Refer to specific manual section for exact type (e.g., API GL-4 for manual, ATF for automatic)
Clutch Type:
Hydraulically operated single dry plate clutch
📐 Dimensions
Exterior
Body Styles:
Saloon (4-door), Estate (5-door)
Weights
Curb Weight Range:
Approx. 1100 - 1300 kg (depending on engine and body style)
🛡️ Safety Features
Ratings
Crash Test History:
Peugeot 405 models from this era generally had moderate safety ratings by modern standards; specific ratings for individual markets are not detailed in product description but manual covers SRS components.
Active Features
Braking Assistance:
Optional ABS (Anti-lock Braking System) on some higher-specification models.
Passive Features
Restraint Systems:
Seat belts (front and rear), optional driver and passenger airbags (later models/specific markets), Supplemental Restraint System (SRS).
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, with potential for aftermarket upgrades.
Driver Assistance
ABS:
Available on higher trims or as an option; manual covers ABS system diagnosis.
Connectivity
Interior Controls:
Basic analogue dashboard instrumentation, manual climate controls, central locking, power windows.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000-10,000 miles (10,000-15,000 km) or 12 months, depending on driving conditions and oil type. Manual provides specific recommendations.
Timing Belt Replacement:
Crucial for SOHC/DOHC engines. Interval typically 40,000-60,000 miles (60,000-100,000 km) or 5-6 years. Manual will specify exact interval and procedure.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grades (e.g., 10W-40, 15W-40, 5W-40 for synthetic) and API service classifications.
Coolant Type:
Ethylene glycol-based antifreeze (typically a 50/50 mix with distilled water). Manual specifies correct type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual specifies the required standard.
Known Issues
Common Wear Items:
Clutch wear, suspension bushes, exhaust system corrosion, potential for coolant leaks from plastic components, and electrical gremlins (common for vehicles of this age).
Engine Specific Issues:
Mi-16 models may experience head gasket issues if not maintained properly. Early SOHC engines might require more frequent ignition system maintenance.
📚 Vehicle History
Brand Heritage
Peugeot Heritage:
Peugeot has a long history of producing well-regarded family cars, with the 400 series representing a significant segment of their European market presence.
Model Evolution
Design Influence:
Designed by Pininfarina, the 405 is known for its aerodynamic styling and comfortable ride, often compared to contemporary rivals like the Ford Sierra and Opel/Vauxhall Cavalier.
Performance Variants:
The Mi-16 variant, with its 16-valve DOHC engine, offered significantly enhanced performance and handling, becoming a sought-after model.
Production
Manufacturing Locations:
Primarily manufactured in France (Sochaux) and other Peugeot facilities across Europe. Also produced under license in other countries.
🏆 Awards & Recognition
Recognitions
Industry Awards:
The Peugeot 405 received numerous accolades during its production run, including 'European Car of the Year' in 1988 and 'Car of the Year' in various other countries.
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