Peugeot 405 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Year: 1991 Variant: All Variants (implied by comprehensive coverage) 👋 Introduction Market Position Target Audience: Professional Technicians, DIY Mechanics with basic electrical...

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Taper: Car

Distributeur:

UGS: 213123

Mots clés: 1991 405 Car Cars Peugeot

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Year:

Variant:

All Variants (implied by comprehensive coverage)

👋 Introduction

Market Position

Target Audience:

Professional Technicians, DIY Mechanics with basic electrical and mechanical knowledge

Segment:

Family car, mid-size sedan/estate.

Competitive Analysis

Value Proposition:

Provides factory-level information for maintenance and repair, enabling informed decision-making and cost-effective servicing.

Contemporaries:

Competed with vehicles like the Ford Sierra, Opel Vectra/Vauxhall Cavalier, Volkswagen Passat, and Renault 21.

Key Features

Learning Curve:

Designed to teach factory-trained technician knowledge through step-by-step guidance.

Delivery Method:

Instant Download

Completeness:

Covers topics typically found in both factory service manuals and owner's manuals, providing a holistic view of vehicle care.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Maintenance, Troubleshooting

Page Count

Estimated Page Count:

Extensive (typical for factory service manuals, often 1000+ pages)

Manual Type

Manual Type:

Service Repair Manual / Workshop Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emissions control

Transmission:

Manual transmission, Automatic transmission (likely, depending on specific 405 models covered)

Drivetrain:

Front-wheel drive system, CV joints, driveshafts

Suspension:

Front suspension (MacPherson struts, control arms), Rear suspension (torsion beam, trailing arms), shock absorbers, springs

Steering:

Steering system components, power steering system (if applicable), steering column

Brakes:

Front disc brakes, Rear drum brakes (common), ABS system (if equipped), brake hydraulics, parking brake

Electrical System:

Battery, charging system, starter, lighting system, ignition system, gauges, horns, wipers, power accessories

Body And Chassis:

Body panels, doors, windows, interior trim, seats, bumpers, chassis components

HVAC:

Heating, ventilation, and air conditioning system (if equipped)

Fuel System Details:

Fuel pump, fuel filter, fuel injectors (for injection models), carburetor settings and overhaul (for carbureted models), fuel tank and lines.

Cooling System Details:

Radiator, water pump, thermostat, cooling fan (mechanical or electric), hoses, coolant types, and bleeding procedures.

Ignition System Details:

Spark plugs, ignition coils, distributor (if applicable), ignition timing, electronic ignition control module (if applicable).

Exhaust System:

Catalytic converter (if equipped), exhaust manifolds, pipes, mufflers, and mounting hardware.

Fuel Tank And Lines:

Removal, installation, and leak detection for the fuel tank and associated lines.

Wheel And Tire:

Wheel torque specifications, tire pressure recommendations, wheel bearing service.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tune-ups

Repair:

Engine component repair/replacement, transmission overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and repair

Disassembly Assembly:

Detailed step-by-step instructions for component removal and reinstallation

Troubleshooting:

Diagnostic procedures for common problems, fault codes (if applicable), symptom-based troubleshooting guides

Diagnostics:

Procedures for diagnosing electrical and mechanical issues

Engine Rebuild:

Detailed procedures for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), cylinder head overhaul, and reassembly with torque specifications.

Transmission Repair:

Detailed procedures for manual and automatic transmission repair, including clutch replacement, gear synchromesh repair, and hydraulic system servicing for automatics.

Electrical Troubleshooting Charts:

Likely includes wiring diagrams and troubleshooting charts based on symptoms.

Body Repair:

Information on door adjustments, window regulator repair, and potentially basic body panel alignment.

Lubrication Points:

Identification and types of lubricants for various chassis and suspension components.

Air Conditioning Service:

Procedures for charging refrigerant, leak testing, and component replacement for the A/C system (if equipped).

Body And Paint:

May include basic guidance on rustproofing or minor bodywork procedures.

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for professional technicians and advanced DIYers, covering fundamentals to complex repairs

Diagnostic Tools:

Likely mentions necessary specialized tools for certain procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

PDF format generally allows for text searching (if text is not an image), aiding quick access to information.

Print Quality

Printable:

Full Printable

Zoom Functionality:

YES (Zoom IN/OUT)

Binding Type

Binding:

Digital (Downloadable PDF)

Paper Type

Paper Type:

N/A (Digital)

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility:

All Versions of Windows & Mac

Delivery

Delivery Speed:

Instant Download

⚙️ Engine Specifications

Primary Engine

Engine Options 1991 405:

Likely includes various gasoline engines: e.g., 1.4L, 1.6L, 1.8L, 1.9L (XU series), and potentially a 2.0L or turbo-diesel variants (XUD series). Manual will cover specifics for each.

Performance

Horsepower Range:

Varies by engine, typically from ~70 HP to ~130 HP for gasoline models, and ~60-80 HP for diesel models.

Fuel System

Fuel Delivery:

Carbureted or Fuel Injection (MPI) depending on engine variant. Manual will detail specific fuel system types.

Engine Codes

Common Engine Codes:

Likely includes XU series engines (e.g., XU5, XU7, XU9, XU10 for petrol) and XUD series diesel engines (e.g., XUD7, XUD9). Manual will detail specific engine codes and their differences.

🔧 Transmission

Standard

Standard Transmission:

Likely a 5-speed manual transmission for most models.

Optional

Optional Transmission:

Likely a 3-speed or 4-speed automatic transmission depending on market and engine.

Features

Transmission Fluid Type:

Specific to manual or automatic transmission type, manual will specify exact fluid and capacity (e.g., GL-4 for manual, ATF type for automatic).

📐 Dimensions

Exterior

Body Styles:

Saloon (Sedan), Estate (Wagon)

Weights

Curb Weight:

Varies by body style and engine, typically 1000-1300 kg.

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with European safety standards of the era. Manual will detail specific safety features and testing if available.

Active Features

Braking System:

Power-assisted front discs and rear drums, optional ABS on higher trims.

Passive Features

Seatbelts:

Front and rear seatbelts, with pre-tensioners on some models.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, potentially optional CD player. Manual will cover head unit operation and fuse locations.

Driver Assistance

Optional Anti-lock Braking System (ABS) on higher trim levels and specific engine variants. Manual will detail system operation and diagnostics.

Connectivity

Central Locking:

Available on some models, manual will cover its electrical system and potential troubleshooting.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles or 12 months, depending on driving conditions and oil type. Manual will provide precise intervals.

Timing Belt Replacement:

Crucial for XU engines. Typically every 60,000 miles or 5 years. Manual will specify the exact interval and procedure, including tensioner and water pump recommendations.

Fluid Specifications

Engine Oil:

Likely 10W-40 or 5W-40 synthetic/semi-synthetic oil, with specific API/ACEA ratings detailed in the manual. Capacity around 4-5 liters depending on engine.

Coolant:

Ethylene glycol based coolant with appropriate antifreeze protection. Manual will specify type and mixture ratio (typically 50/50).

Brake Fluid:

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

Power Steering Fluid:

Specific hydraulic fluid for power steering system if equipped. Manual will specify type and capacity.

Gearbox Oil:

API GL-4 or GL-5 rated gear oil for manual transmissions. Manual will specify viscosity grade (e.g., 75W-90, 80W-90) and capacity.

Known Issues

Common Faults:

Radiator fan issues, ignition coil failures, suspension wear (bushings), gearbox synchromesh wear (manual transmissions), potential for head gasket issues on some engine variants if overheated.

Body Corrosion:

Can be susceptible to rust in certain areas, especially wheel arches and sills, depending on climate and maintenance. Manual might offer basic advice on care.

Electrical Connectors:

Corrosion on electrical connectors, especially in damp climates, can lead to intermittent faults. Manual would be essential for diagnosing these.

📚 Vehicle History

Brand Heritage

Peugeot Legacy:

Peugeot has a long history of producing robust and comfortable family cars, known for their ride quality and handling.

Model Evolution

405 Development:

The Peugeot 405 was developed in collaboration with Chrysler Europe and designed by Pininfarina. It was a successor to the Peugeot 405 and a contemporary of the Citroën BX.

Production

Production Period:

1987–1996 (Europe), with production continuing in other markets longer.

🏆 Awards & Recognition

Recognitions

European Car Of The Year:

The Peugeot 405 was awarded 'European Car of the Year' in 1988, a testament to its design, engineering, and market appeal.