🏷️ Basic Information

Make:

Peugeot

Model:

405

Year:

1996

Platform Code:

Type 4D (derived from PSA Group's Type 4 platform)

👋 Introduction

Positioning:

A family car that offered good ride comfort, practical space, and distinctive styling, competing in the C-segment.

Competitors:

Ford Sierra, Opel Vectra/Vauxhall Cavalier, Volkswagen Passat, Renault Laguna, Citroën Xantia.

Design:

Distinctive Pininfarina-styled body, known for its aerodynamic shape and spacious interior for its class.

Ride Handling:

Renowned for its excellent ride quality and handling, often praised for its 'active suspension' feel and comfortable highway cruising.

Target Audience:

Professional technicians and knowledgeable DIY mechanics.

Value Proposition:

Provides factory-level repair and maintenance information, enabling owners to perform tasks typically reserved for authorized service centers.

📋 Manual Details

Engine Coverage:

Petrol (XU series: XU7, XU9, XU10, DW8 diesel variants may be covered depending on specific edition, though emphasis is petrol)

Transmission Coverage:

Manual and Automatic transmissions

Chassis Coverage:

Front-wheel drive (FWD)

Estimated Page Count:

Variable, typically 300-700+ pages for a comprehensive factory-style manual

Type:

Service and Repair Manual (Workshop Manual)

Language:

English

File Format:

PDF

Delivery Method:

Instant Digital Download

Compatibility:

Windows and Mac OS

Requirements:

Adobe PDF Reader, WinZip (or equivalent decompression software)

📖 Manual Coverage

Engine:

Engine Mechanical (assembly, disassembly, overhaul), Engine Management (fuel injection, ignition, emissions), Cooling System, Lubrication System

Transmission:

Manual Gearbox (clutch, gearbox overhaul, selector mechanism), Automatic Gearbox (operation, overhaul, fluid service), Driveshafts and Differentials

Brakes:

Hydraulic System (master cylinder, lines, calipers, wheel cylinders), ABS System (if equipped), Parking Brake

Suspension:

Front Suspension (struts, control arms, ball joints), Rear Suspension (torsion beams, shock absorbers, bushings), Wheel Alignment specifications

Steering:

Steering Gear (rack and pinion), Power Steering System (pump, hoses, fluid)

Electrical:

Wiring Diagrams, Fuses and Relays, Battery, Charging System (alternator), Starting System (starter motor), Ignition System, Lighting System, Instrument Panel and Gauges, Power Accessories (windows, locks)

Body:

Body and Frame, Doors, Hood, Trunk, Bumpers, Interior Trim, Glass and Seals, HVAC System (heating, ventilation, air conditioning)

Maintenance:

Scheduled Maintenance (oil changes, filter replacements, fluid checks), Inspection Procedures, Lubrication Points

Repair:

Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair

Diagnostics:

Troubleshooting Guides, Fault Code Interpretation (OBD-I or specific Peugeot diagnostics if applicable), Diagnostic Procedures for Major Systems

Disassembly Assembly:

Step-by-step procedures for removal, disassembly, cleaning, inspection, reassembly, and installation of all major components.

Depth:

Comprehensive, covering from basic maintenance to in-depth component overhaul and diagnostic troubleshooting.

📊 Manual Specifications

Print Quality:

Full Printable (High Resolution for clear text and diagrams)

Zoom Functionality:

YES (Allows zooming in for detailed inspection of diagrams and text)

Digital Binding:

N/A (Digital File)

Digital Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Engine Code Examples:

XU7 JP4 (1.8L), XU9 (1.9L), XU10J2 (2.0L)

Horsepower Range:

Approximately 90 hp to 125 hp depending on engine variant.

Torque Range:

Approximately 140 Nm to 180 Nm depending on engine variant.

Injection Type:

Multi-point fuel injection (MPI) common on petrol engines.

Ignition System:

Electronic Ignition (Distributorless Ignition System - DIS - on some later models or specific engines).

Configuration:

Inline 4-cylinder, transverse mounting.

Timing Drive:

Timing Belt (requiring periodic replacement, a critical maintenance item).

🔧 Transmission

Type:

5-speed Manual Transmission

Type:

4-speed Automatic Transmission (AL4 or similar PSA unit)

Manual Fluid Type:

Refer to manual for specific API GL-4 or GL-5 gear oil, viscosity grade (e.g., 75W-90 or 80W-90).

Automatic Fluid Type:

Refer to manual for specific ATF specification (e.g., Dexron III equivalent or proprietary Peugeot fluid).

📐 Dimensions

Length:

Approx. 4400 mm (173.2 in) for Sedan, slightly longer for Estate (Break).

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1420 mm (55.9 in) for Sedan.

Curb Weight:

Approx. 1100-1250 kg (2425-2755 lbs) depending on engine and trim.

🛡️ Safety Features

Euro Ncap:

Euro NCAP ratings for this era are not directly comparable to modern standards. However, earlier 405 models typically performed moderately in front impact tests.

ABS:

Available on higher trims or as an option on certain models.

Airbags:

Driver airbag standard on many 1996 models; passenger airbag optional or standard on top trims.

Seatbelts:

Pre-tensioning seatbelts at the front.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player, often with basic speaker systems. CD players were optional or aftermarket additions.

Cruise Control:

Available as an option on higher trim levels, particularly with petrol engines.

Exterior Lighting:

Halogen headlights. Fog lights were common options. Wiring for accessory lights is usually covered in diagrams.

🔧 Maintenance

Engine Oil Change:

Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first. Refer to manual for specific interval based on driving conditions.

Timing Belt Replacement:

Critical interval, typically 60,000-80,000 km (36,000-50,000 miles) or 4-5 years. Failure can cause severe engine damage.

Coolant Type:

Ethylene Glycol based coolant, typically a long-life OAT (Organic Acid Technology) type or a traditional G11/G12 specification. Check manual for exact Peugeot spec.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Always use fresh fluid and follow bleeding procedures carefully.

Power Steering Fluid:

Specific hydraulic fluid, often a PSF type. Refer to manual for exact specification to avoid damage.

Electrical:

Intermittent electrical issues, particularly related to dashboard lights, central locking, or window mechanisms. Wire harness degradation in some areas can occur.

Suspension Wear:

Wear in suspension bushings and ball joints, leading to knocking noises or imprecise handling. Rear torsion bar mounts can corrode and wear.

Engine Management:

Fuel injector issues, lambda sensor failures, and occasional ignition coil problems can affect performance and emissions.

Bodywork:

Corrosion, especially on wheel arches, sills, and around the rear suspension mounts, can be an issue depending on climate and care.

📚 Vehicle History

Heritage:

Peugeot has a long history of producing popular family cars, building on a reputation for comfort and engineering.

Generation:

The 1996 model falls within the first generation (1987-1996 in Europe, continuing longer in other markets). It received a facelift in 1992, incorporating minor styling updates and interior improvements.

Manufacturing Locations:

Primarily manufactured in France, with production also occurring in other countries through licensing or assembly plants.

Sales Performance:

The Peugeot 405 was a very successful model for Peugeot, selling millions of units worldwide and renowned for its robustness and refinement.

🏆 Awards & Recognition

Car Of The Year:

While not winning 'Car of the Year' in major European markets, it was highly regarded and often placed highly in comparisons for its class and segment.

Consumer Reports:

Contemporary reviews and consumer reports often highlighted its comfort and build quality for the era.