🏷️ Basic Information

Make:

Peugeot

Model:

405

Year:

1994

Chassis Code:

405

👋 Introduction

Target Audience:

Professional technicians, dealership service departments, and experienced DIY mechanics seeking detailed repair information for the Peugeot 405 (1994).

Segment:

Compact executive car (also known as the family car segment).

Manual Value Proposition:

Offers factory-level repair data and procedures in a digital format, providing immediate access and often covering information not readily available in retail stores. Emphasizes comprehensive coverage and step-by-step guidance.

Feature List:

Instant download, printable, zoomable, comprehensive system coverage, detailed diagrams/illustrations (implied), step-by-step procedures, critical specifications.

📋 Manual Details

Manual Scope:

Comprehensive service, repair, and maintenance for the Peugeot 405 (1994 model year).

Estimated Page Count:

Extensive (typical factory service manuals for this era exceed 800 pages, though exact count not specified).

Type:

Service Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed information on all engine variants, including disassembly, assembly, inspection, and repair of internal components, cylinder heads, crankshafts, pistons, connecting rods, timing systems.

Engine Management And Fuel:

Covers fuel injection systems (e.g., Bosch L-Jetronic/Motronic depending on engine), ignition systems, emission controls, fuel delivery, sensors, and diagnostic procedures.

Transmission Manual:

Repair and maintenance of manual transmissions, including clutch system, gearshift mechanisms, gearbox internals, and differential.

Transmission Automatic:

Details on automatic transmission operation, maintenance, fluid specifications, and common repair procedures (if applicable to the 1994 model range).

Brakes:

Front and rear brake system overhauls, including disc and drum brake components, hydraulic systems, ABS (if equipped), parking brake, and bleeding procedures.

Suspension And Steering:

Detailed procedures for front and rear suspension components (struts, shock absorbers, control arms, bushings), steering gear, power steering systems, and wheel alignment specifications.

Electrical System:

Comprehensive electrical schematics, wiring diagrams, battery, charging system (alternator), starting system, lighting, instruments, power windows, central locking, and accessory circuits.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, frame repair basics, and anti-corrosion measures.

Heating Ventilation And Air Conditioning:

HVAC system components, refrigerant handling (with safety precautions), blower motor, evaporator, condenser, and diagnostic tips.

Fuel Pump:

Detailed diagnostics and replacement procedures for fuel pumps, fuel filters, and fuel lines.

Cooling Fan:

Information on the electric cooling fan system, its operation, and troubleshooting.

Maintenance:

Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, and general inspection points.

Repair:

Step-by-step repair procedures for all major vehicle systems, including component removal, overhaul, reassembly, and adjustment.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common problems across all vehicle systems.

Disassembly Assembly:

Detailed instructions for taking apart and putting back together various components and systems.

Technical Specifications:

Inclusion of critical data such as torque specifications, clearances, fluid capacities, and electrical values.

Timing Belt Replacement:

Explicit step-by-step instructions for timing belt replacement, including critical alignment marks and tensioning procedures.

Engine Rebuild:

Comprehensive instructions for full engine disassembly, measurement of wear, part replacement, and reassembly, suitable for a complete engine rebuild.

Depth:

Designed for professional technicians but accessible to DIY mechanics with basic knowledge. Covers both routine maintenance and complex repairs, essentially mirroring factory service manual content.

Diagnostic Tools:

While primarily a repair manual, it will guide users on interpreting diagnostic codes and using basic diagnostic tools (multimeter, pressure gauges) where applicable.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely includes searchable text content within the PDF for efficient information retrieval.

Printability:

Full Printable

Zoom Functionality:

YES

Binding:

Digital Download (PDF) - effectively unlimited 'binding' via digital access.

Paper Type:

Not applicable to digital format; printable quality is dependent on user's printer.

Delivery Method:

Instant Download

Software Requirements:

Adobe PDF Reader, WinZip (or equivalent decompression software).

Operating Systems:

Compatible with all Versions of Windows & Mac

⚙️ Engine Specifications

Engine Options 1994:

Likely includes 1.8L and 2.0L inline-four gasoline engines (e.g., XU7JP, XU9J2/J4, XU10J2, XU10J4). Diesel options (e.g., XUD7, XUD9) were also prevalent in European markets.

Typical Performance 2.0L:

Approximately 110-120 hp and 170-180 Nm torque, depending on specific engine variant and tuning (e.g., Mi16 variants would be higher).

Fuel Delivery:

Multi-point fuel injection (MPI) for gasoline engines was common, though carbureted variants might exist in some markets. Diesel engines would feature indirect or direct injection systems.

Diesel Engine Options:

Likely includes 1.9L naturally aspirated diesel (XUD9A) and potentially a turbodiesel variant (XUD9TE).

🔧 Transmission

Manual Transmission:

5-speed manual transmission was standard on most variants.

Automatic Transmission:

A 4-speed automatic transmission was available as an option on certain engine configurations.

Clutch Type:

Hydraulically actuated single dry plate clutch.

📐 Dimensions

Body Styles:

Available as a 4-door sedan and a 5-door hatchback (often referred to as the 'Peugeot 405 Break' or 'Estate').

Curb Weight Range:

Approximately 1100-1300 kg, depending on body style, engine, and equipment.

🛡️ Safety Features

Crash Safety Notes:

No specific global rating agencies like NCAP were universally applied in the same way as today. However, the 405 was designed with European safety standards of the time in mind, likely featuring crumple zones and side impact beams.

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature on higher trim levels or specific engine variants.

Passive Safety Features:

Seat belts (likely with pre-tensioners on front seats), reinforced body structure, and impact-absorbing steering column.

💡 Technology Features

Audio System:

Base models typically featured basic radio/cassette players, with upgraded systems and CD players available on higher trims. Speaker count and quality varied.

Driver Aids:

Limited driver assistance technology by modern standards. ABS was available, but features like traction control or advanced stability systems were not common on this model.

Connectivity Features:

No integrated connectivity features like Bluetooth or USB ports were standard. Aftermarket solutions would be required for modern device integration.

🔧 Maintenance

Oil Change Interval:

Typically 10,000 km or 12 months, whichever comes first, using appropriate quality oil. Exact interval depends on driving conditions and oil specification.

Timing Belt Replacement:

Crucial: For most XU series engines, timing belt replacement is recommended every 80,000-120,000 km or 5-7 years. Failure can cause catastrophic engine damage.

Engine Oil Specification:

Commonly API SF/SG or ACEA A2-96/B2-96 specification. Viscosity grade typically 10W-40 or 5W-40, depending on climate. Consult manual for precise OEM recommendations.

Coolant Type:

Ethylene glycol-based coolant, typically mixed 50/50 with distilled water. Peugeot specific G11 type coolant is often recommended.

Brake Fluid Type:

DOT 4 brake fluid is standard.

Transmission Oil Manual:

API GL-4, SAE 75W-80 or 75W-90 gear oil.

Transmission Oil Automatic:

Specific ATF fluid (e.g., Dexron II or equivalent) as per Peugeot specification for the fitted gearbox.

Power Steering Fluid:

Specific hydraulic fluid (e.g., Citroën LHM or compatible equivalent, or proprietary Peugeot fluid, depending on system type).

Clutch Fluid:

Typically brake fluid (DOT 4).

Common Issues:

Common issues can include aging suspension bushings, wear in the steering rack, electrical gremlins (especially intermittent faults), cooling system component failures (radiator, hoses), and potential head gasket issues on high-mileage or poorly maintained engines. Rust can also be a factor in certain climates.

Engine Mounts:

Engine mounts (both hydraulic and standard rubber) are known to wear over time, leading to increased vibration and noise.

Exhaust System:

Corrosion of the exhaust system components is a common wear item.

📚 Vehicle History

Peugeot Brand Context:

Peugeot has a long history of producing family cars known for their ride comfort, handling, and distinct French design. The 405 followed the successful 305 and preceded the 406.

405 Generation:

The Peugeot 405 was launched in 1987 and represented a significant step up in design and technology for Peugeot's mid-size offering, sharing its platform with the Citroën BX. The 1994 model is part of the later production run, which received minor updates.

Production Period:

1987-1997 (Europe), with production continuing in some markets (like Iran) much longer.

Notable Variants:

The high-performance '405 Mi16' and '405 T16' (rally homologation) models are notable performance variants.

🏆 Awards & Recognition

Model Awards:

The Peugeot 405 was voted 'European Car of the Year' in 1988, recognizing its strong combination of design, engineering, and market appeal. It also received numerous other accolades in various European countries.