🏷️ Basic Information

Make:

Peugeot

Model:

405

Model Years Covered:

1992-1997

Chassis Code Range:

Various, dependent on specific model variant and region (e.g., 15B, 15D for saloon, 6B, 6D for estate)

👋 Introduction

Market Position:

The Peugeot 405 was a significant model for Peugeot during its production run, competing in the family car segment against rivals like the Ford Sierra, Volkswagen Passat, and Opel Vectra. It was known for its comfortable ride, distinctive styling (especially the Giugiaro-designed notchback saloon), and a range of efficient engines.

Competitive Analysis:

The 405 offered a blend of European refinement and practicality. Its strengths lay in its chassis dynamics, particularly the independent rear suspension (on most models), and its comfortable interior. The manual covers a broad spectrum of these characteristics, enabling owners to maintain and repair them effectively.

Key Features:

Key features of the 405 included its aerodynamic styling, spacious interior, and the availability of advanced features for its time, such as ABS and later, fuel injection. The manual's comprehensive nature ensures owners can address all these aspects.

Design Philosophy:

The 405 embodied Peugeot's commitment to driving dynamics and comfort, often contrasted with more utilitarian competitors of its time. Its design aimed for aerodynamic efficiency and a pleasing aesthetic.

📋 Manual Details

Coverage Areas:

All mechanical and electrical systems, bodywork, maintenance, troubleshooting, and repair for the Peugeot 405 (1992-1997 models).

Page Count:

Hundreds of pages (specific count not provided but implied by description of 'Highly Detailed' and 'Hundreds Of Pages')

Manual Type:

Service Repair Manual

Language:

English (assumed based on product description)

Format:

PDF

📖 Manual Coverage

Engine:

Detailed coverage of all engine variants, including DOHC, SOHC, naturally aspirated, and turbocharged gasoline (e.g., XU7, XU9, XU10 series) and diesel (e.g., XUD7, XUD9, XUD11 series) engines. Includes engine assembly, disassembly, component testing, overhaul procedures, cooling system, lubrication system, fuel system (injection and carburetor), ignition system, and emissions control.

Transmission:

Comprehensive coverage of manual transmissions (e.g., BE series) and automatic transmissions (e.g., AL4). Includes transmission removal and installation, internal component repair, clutch service, torque converter overhaul, and transmission fluid specifications.

Brakes:

In-depth coverage of hydraulic brake systems, including disc and drum brake service, ABS (Anti-lock Braking System) operation and diagnosis, brake fluid specifications, bleeding procedures, parking brake adjustments, and caliper/master cylinder overhaul.

Suspension Steering:

Detailed information on front and rear suspension systems (e.g., MacPherson struts, torsion beam), shock absorber replacement, spring service, wheel alignment procedures, steering rack overhaul, power steering system service, and wheel bearing replacement.

Electrical Electronics:

Extensive coverage of the vehicle's electrical system, including wiring diagrams, fuse box layouts, lighting systems, starter and alternator service, battery maintenance, instrument cluster diagnosis, power windows and locks, and onboard diagnostics (OBD) if applicable to the era.

Body Chassis:

Covers body panel removal and installation, door mechanisms, window regulators, convertible top operation (if applicable), rust repair, welding procedures, interior trim removal, and chassis component servicing.

Climate Control:

Coverage of heating systems, ventilation, and air conditioning (A/C) system components, refrigerant types, and troubleshooting for climate control issues.

Fuel Tank Exhaust:

Details on fuel tank removal and installation, fuel lines, fuel pump access, and exhaust system component replacement and repair.

Exhaust System:

Covers inspection, repair, and replacement of exhaust pipes, catalytic converter, muffler, and mounting hardware. Includes emissions control system information.

Cooling Fan Control:

Diagnostic procedures for electric cooling fan operation, including relays, temperature sensors, and fan motor testing.

Scheduled Maintenance:

Detailed maintenance schedules, including oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid changes, and timing belt/chain replacement intervals.

Troubleshooting:

Systematic troubleshooting guides for common and uncommon problems, including symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation (if applicable), and component testing procedures.

Rebuilding Overhaul:

Step-by-step instructions for complete engine rebuilds, transmission overhauls, brake system component replacement, and suspension system refurbishment.

Diagnostics:

Guidance on using diagnostic tools, interpreting sensor data, and performing electrical circuit testing to identify faults.

Specifications Data:

Includes torque specifications for all fasteners, fluid capacities, recommended lubricants and fluids, diagnostic specifications, and measurement data for critical components.

Engine Mounts:

Instructions for replacing engine and transmission mounts, crucial for reducing vibration and noise.

Body Panel Alignment:

Guidance on adjusting doors, hood, trunk lid, and fenders for proper fit and sealing.

Interior Trim Removal:

Step-by-step guides for removing and reinstalling interior panels, seats, and dashboard components for access to underlying systems.

Wheel Alignment:

Recommended alignment specifications for front and rear suspension, and procedures for adjustment.

Technical Depth:

Comprehensive, covering everything from basic routine maintenance and fluid checks to in-depth engine, transmission, and electrical system diagnostics and repair. Suitable for both DIY enthusiasts and professional mechanics.

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems, essential for diagnosing electrical faults.

Component Testing:

Detailed methods for testing individual components such as sensors, actuators, relays, and solenoids using multimeters and specialized equipment.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High resolution, suitable for printing individual pages or the entire manual. Assumed clarity of diagrams and text.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Searchable Text:

PDF format typically allows for searchable text, making it easy to find specific information quickly.

⚙️ Engine Specifications

Engine Variants:

The Peugeot 405 was offered with a wide range of engines, including: - 1.4L (1360cc) TU3 petrol - 1.6L (1580cc) XU5 petrol - 1.8L (1769cc) XU7 petrol - 2.0L (1998cc) XU10 petrol (including fuel-injected versions like the Mi-16 and SLE) - 1.8L (1769cc) XUD7 diesel - 1.9L (1905cc) XUD9 diesel (naturally aspirated and turbocharged) - 2.1L (2088cc) XUD11 diesel (turbocharged)

Performance General:

Performance varied significantly with engine choice, ranging from economical diesel outputs to spirited performance in the Mi-16 variants (e.g., ~160 hp).

Fuel System Options:

Carbureted (early models, smaller engines), Bosch L-Jetronic or Motronic fuel injection (petrol), indirect injection (diesel), and turbo-diesel injection systems.

Cooling System:

Pressurized cooling system utilizing a radiator, thermostat, water pump, and coolant reservoir. The manual details flushing, filling, and component testing procedures.

Lubrication System:

Wet sump lubrication system with oil pump, oil filter, and oil cooler (on some variants). Manual covers oil change intervals, filter part numbers, and oil pressure testing.

🔧 Transmission

Standard Transmission:

5-speed manual transmission was common across most variants.

Optional Transmission:

4-speed automatic transmission was available on select models, often paired with larger petrol engines.

Transmission Features:

The manual will detail clutch operation, gear selection mechanisms, and torque converter lock-up (on automatics).

Clutch Service:

Details on clutch assembly, diaphragm pressure plate, clutch disc, release bearing, and hydraulic actuation system. Includes adjustment and replacement procedures.

📐 Dimensions

Exterior Dimensions:

Saloon and Estate (Break) body styles. Overall length typically around 4.4 meters, width around 1.7 meters, height around 1.4 meters. Specific dimensions vary by body style and trim.

Interior Dimensions:

Known for a well-appointed and spacious interior for its class, offering good headroom and legroom for front and rear occupants.

Cargo Dimensions:

The Estate version provided significantly more cargo volume than the saloon, with a flat load floor and folding rear seats.

Curb Weights:

Curb weights typically ranged from approximately 1050 kg for base models to over 1300 kg for diesel or higher-spec variants.

Wheelbase:

Approximately 2600 mm (102.4 inches) for saloon and estate models.

Track Width:

Front track: ~1460 mm, Rear track: ~1440 mm (varies slightly by model).

🛡️ Safety Features

Safety Ratings Era:

While formal Euro NCAP ratings as we know them today were not prevalent, the 405 was designed with safety in mind, featuring crumple zones and a robust passenger cell. Later models often included airbags and ABS.

Active Safety Features:

Optional ABS (Anti-lock Braking System), power steering, and effective disc/drum brake setup.

Passive Safety Features:

Seatbelts (often pre-tensioned), reinforced body structure, impact-absorbing dashboard materials, and optional driver/passenger airbags on later models.

💡 Technology Features

Infotainment Features:

Basic factory-fitted radios with cassette players were common. Higher trims might have had CD players. Coverage for repair and replacement of these units is likely included.

Driver Assistance Features:

ABS was an optional but increasingly common feature in this era. Power steering was standard on many models. The manual will cover the operational principles and diagnostic procedures for these systems.

Connectivity Features:

Limited by era; primarily focused on audio system connectivity (e.g., antenna input). The manual will not cover modern smartphone integration.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-15,000 km) or 12 months, depending on driving conditions and oil type. Manual will specify exact intervals.

Timing Belt Replacement:

For most petrol and diesel engines using a timing belt (e.g., XU series), replacement is recommended every 60,000-80,000 miles (100,000-120,000 km) or 5-6 years. This is a critical maintenance item to prevent catastrophic engine damage. Manual will specify exact interval and procedure.

Engine Oil Specification:

Various grades depending on engine and climate, commonly 10W-40, 15W-40 for diesel, and 5W-40 or 10W-40 for petrol. Manual will specify Peugeot approved grades (e.g., PSA B71 2290 for diesel, B71 2294 for petrol).

Coolant Specification:

Typically a long-life antifreeze/coolant concentrate (e.g., Type D or Type Y coolant, meeting PSA specifications) mixed with distilled water.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid. Manual will specify the exact type and change interval.

Transmission Fluid Specification:

Manual transmission fluid (e.g., 75W-80 GL-5) or automatic transmission fluid (e.g., LT 71141 for AL4 automatic) as specified by Peugeot. Manual will detail type and capacity.

Known Issues:

Common issues can include: electrical gremlins (especially related to body control modules and wiring harnesses), heater matrix leaks, suspension wear (ball joints, bushings), aging fuel pumps and injectors, and timing belt failure if not replaced at recommended intervals. Diesel engines (XUD) can be robust but may suffer from glow plug issues or turbo wear on turbocharged variants. The manual provides diagnostic procedures for these.

Brake Pad Replacement Procedure:

Detailed steps for front disc brake pad replacement, including caliper release, pad insertion, and reassembly. Similar procedures for rear drum brakes are also covered.

Spark Plug Specification:

Specific spark plug types (e.g., Bosch W8AC, Champion N9YC) and gap settings for each engine variant. Manual provides replacement intervals and torque specs.

📚 Vehicle History

Brand Heritage:

Peugeot, a French manufacturer, has a long history dating back to the late 19th century, known for producing reliable and stylish vehicles across various segments.

Model Evolution:

The 405 succeeded the 305 and was produced from 1987 to 1997 in Europe. It was lauded for its design and chassis, particularly the independent rear suspension and its rallying success (e.g., Dakar Rally).

Production Period:

1987-1997 (Europe). It was also produced in other regions, including Iran (as the Pars) and Egypt.

Model Variants:

Available in Saloon (sedan) and Estate (wagon/break) body styles. Performance variants like the 405 Mi-16 and T16 were notable. Trim levels varied by market (e.g., GL, GR, GTi, SRI, GTX, Estate LX/SR).

🏆 Awards & Recognition

Recognitions:

The Peugeot 405 was widely praised by automotive journalists upon its release, winning numerous 'Car of the Year' awards from various publications and organizations across Europe. It was notably named 'European Car of the Year' in 1988.