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.
Strengths:
Comfortable ride, refined styling, good handling, spacious interior, wide range of engine options including efficient diesel variants.
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.
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.
Estimated Page Count:
Likely exceeds 1000 pages in printed equivalent, given the comprehensive nature described.
Type:
Digital Workshop Repair Manual
Purpose:
Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration.
Format:
Digital (likely PDF or similar format for viewing and printing)
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).
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.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Includes detailed specifications, torque values, and diagnostic procedures for professional technicians.
File Types:
Likely PDF, possibly with separate image files or a proprietary viewer format.
Image Quality:
High Quality Photos, Illustrations And Diagrams - implies clear, detailed visuals suitable for reproduction.
Binding:
Not applicable for digital format; implies printable pages.
Paper Quality:
Not applicable for digital format; implies suitability for standard printing.
Text Search:
Likely searchable text if in PDF format, allowing quick access to specific topics.
Operating Systems:
Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, VISTA, Windows 7, and all Mac computers.
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.
Gti Performance (Example):
Peugeot 405 Mi16 (2.0L 16v) offered around 160 PS.
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.
Euro Ncap Rating:
Not available for this era model; Euro NCAP testing began later.
ABS:
Optional on many models, standard on higher trims (e.g., Mi16, later models).
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.
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.
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).
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.
Peugeot Legacy:
Peugeot has a long history of producing robust and driver-focused vehicles, with the 40x series representing their mainstream family car offerings.
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 Years:
1987-1997 (Europe), production continued in other regions for longer.
Manufacturing Locations:
Primarily France (Sochaux) and the UK (Ryton).
