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PEUGEOT 405 Service Repair Manual 87-97

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Year Range: 1987-1997 Codes Chassis Codes: Type 155 (sedan/saloon), Type 805 (estate/break) 👋 Introduction Market Position Segment: Family car, upper-medium segment Market...
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UGS: 209907
PEUGEOT 405 Service Repair Manual 87-97PEUGEOT 405 Service Repair Manual 87-97PEUGEOT 405 Service Repair Manual 87-97PEUGEOT 405 Service Repair Manual 87-97
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
405
Year Range:
1987-1997
Codes
Chassis Codes:
Type 155 (sedan/saloon), Type 805 (estate/break)
👋 Introduction
Market Position
Segment:
Family car, upper-medium segment
Market Appeal:
Known for its comfort, driving dynamics, and spaciousness, particularly the estate variant
Competitive Analysis
Key Competitors:
Ford Sierra, Volkswagen Passat, Opel Vectra, Fiat Croma, Renault 25
Key Features
Design Inspiration:
Pininfarina styling contributed to its distinctive and elegant design
Driving Dynamics:
Renowned for its sophisticated and compliant suspension tuning, offering excellent ride comfort and handling
Body Styles:
Available as a 4-door sedan (saloon) and a 5-door estate (break/wagon)
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily European specifications)
Page Count
Estimated Pages:
Hundreds (exact number not specified, but described as 'Hundreds of Pages')
Manual Type
Type:
Service and Repair Manual
Language
Language:
English (presumed based on product description phrasing)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection, ignition, cooling, exhaust, lubrication
Transmission Systems:
Manual and automatic transmission overhaul, clutch, driveshafts
Braking Systems:
Front and rear brakes (discs/drums), ABS (if equipped), hydraulic systems
Electrical Systems:
Wiring diagrams, lighting, starting and charging systems, instruments, power accessories
Suspension Steering:
Front and rear suspension, steering gear, power steering
Body Chassis:
Body repair, interior trim, doors, windows, bumpers, chassis structural components
Climate Control:
HVAC system, heating, ventilation, air conditioning (if equipped)
Procedures Included
Maintenance:
Routine servicing, oil changes, filter replacements, spark plugs, timing belts
Repair Overhaul:
Engine rebuilding, transmission repair, brake system overhauls, component replacement
Troubleshooting:
Diagnostic procedures, common fault finding, fault codes (if applicable)
Diagnosis:
System-specific diagnostic steps and symptom analysis
Refurbishment Restoration:
Detailed guidance for restoring various vehicle components and systems
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full rebuilds
Diagnostics:
Detailed diagnostic information and flowcharts
Torque Specifications:
Specific torque values for all critical fasteners
Alignment Specs:
Wheel alignment angles and specifications
Wiring Diagrams:
Detailed, system-specific electrical wiring schematics
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Readability:
High-resolution, designed for clear viewing and printing
Binding Type
Binding:
N/A (PDF Format)
Paper Type
Paper Quality:
N/A (PDF Format)
Features
Searchable Text:
Likely searchable text within PDF, enhancing usability
Illustrations Diagrams:
Includes detailed illustrations, diagrams, and schematics
Table Of Contents:
Comprehensive and well-organized Table of Contents for easy navigation
⚙️ Engine Specifications
Primary Engine
Engine Family:
PSA XU/XUD series, Simca/Talbot/PSA EW series (later models)
Common Petrol Engines:
1.6L (XU5), 1.8L (XU7), 2.0L (XU9/XU10 - including fuel-injected versions like GTI)
Common Diesel Engines:
1.9L (XUD7), 1.9L Turbo Diesel (XUD7TE, XUD9TE)
Performance
Power Output Range:
Approximately 70 hp (diesel) to 150 hp (2.0 GTI) depending on engine variant
Torque Range:
Approx. 130 Nm (diesel) to 187 Nm (2.0 GTI)
Fuel System
Petrol Fuel Delivery:
Carburetor (early 1.6L) or Multi-Point Fuel Injection (MPI)
Diesel Fuel Delivery:
Indirect injection (IDI) rotary or inline injection pumps (Bosch)
Technical Details
Engine Orientation:
Transverse
Cylinder Layout:
Inline 4-cylinder
Valve Train:
SOHC (Single Overhead Camshaft)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed manual transmission
Optional
Transmission Type Optional:
4-speed automatic transmission (ZF-based)
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Final Drive:
Front-wheel drive with final drive integrated into transmission casing
📐 Dimensions
Exterior
Length Sedan:
Approx. 4,420 mm (174.0 in)
Length Estate:
Approx. 4,500 mm (177.2 in)
Width:
Approx. 1,700 mm (66.9 in)
Height Sedan:
Approx. 1,420 mm (55.9 in)
Height Estate:
Approx. 1,460 mm (57.5 in)
Wheelbase:
Approx. 2,670 mm (105.1 in)
Weights
Curb Weight Range:
Approx. 1,100 kg to 1,300 kg (depending on body style and engine)
Gross Vehicle Weight:
Varies by model, typically around 1,700-1,850 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not tested under current Euro NCAP protocols; older PSA vehicles generally received moderate ratings for their time.
Active Features
Braking System:
Front ventilated discs, rear discs or drums. Optional ABS on higher trims and later models.
Traction Control:
Rarely fitted, not a common feature on most 405 models.
Passive Features
Airbags:
Driver's airbag became available on later models and higher trims, not standard across all variants.
Seatbelts:
Pre-tensioned front seatbelts on many models.
Body Structure:
Designed with crumple zones for improved crash safety
💡 Technology Features
Infotainment
Radio System:
Factory fitted radio cassette players were common, often with basic digital tuning and 4-6 speakers
Navigation:
Not available on standard models; aftermarket units were rare during the production run.
Driver Assistance
ABS:
Optional on many models, standard on some higher-performance variants
Connectivity
Bluetooth:
Not available from the factory
Other Features
Power Windows:
Available on higher trims, often front power windows, rear manual
Central Locking:
Available on many models, often vacuum operated
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 15,000 km (4,500 - 9,000 miles) or 12 months, depending on oil type and driving conditions
Timing Belt Replacement:
Crucial: 60,000 - 90,000 km (36,000 - 54,000 miles) or 4-5 years for XU engines. Failure can cause catastrophic engine damage.
Spark Plug Replacement:
Refer to manual, typically 30,000 - 60,000 km depending on type
Fluid Specifications
Engine Oil Type:
API SG/SH or ACEA A2/A3, viscosity grades like 10W-40 or 5W-40 (check manual for specific engine and climate)
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., PSA B71 2000 standard)
Brake Fluid Type:
DOT 3 or DOT 4
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90
Transmission Fluid Automatic:
Dexron II or equivalent (check manual for exact specification)
Known Issues
Electrical Gremlins:
Can suffer from minor electrical issues, particularly aging wiring and connectors
Suspension Wear:
Worn suspension components (bushings, ball joints, shock absorbers) are common with age and mileage
Radiator Fan Control:
Problems with the radiator fan control module or resistor can occur
Fuel Pump Reliability:
Fuel pumps can become a point of failure over time
Rust Prone Areas:
Wheel arches, sills, and boot floors can be susceptible to rust, especially in regions with road salt
Diesel Glow Plugs:
Glow plugs and their associated relay can fail on diesel models, affecting cold starting
📚 Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot has a long history of producing comfortable and dynamically competent family cars
Model Evolution
Predecessor:
Peugeot 305
Successor:
Peugeot 406
Introduction Year:
1987
Production
Production Period:
1987-1997 (Europe), extended production in other regions
Manufacturing Locations:
France (Mulhouse), UK (Ryton), Finland (Uusikaupunki), Iran (IKCO)
Total Production Units:
Over 2.3 million units globally
🏆 Awards & Recognition
Recognitions
European Car Of The Year Nomination:
Runner-up for European Car of the Year in 1988
What Car Reader Satisfaction:
Generally well-regarded by owners for its comfort and reliability in its class and era.
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