Segment:
Compact/Small Family Car
Positioning:
Known for its Pininfarina-designed elegant styling, comfortable ride, and practical interior. Competed in a crowded European segment.
Key Competitors:
Ford Sierra, Opel/Vauxhall Vectra, Volkswagen Passat, Renault 21, Fiat Croma.
Design:
Aerodynamic styling by Pininfarina, excellent road holding, and a spacious cabin for its class.
Driving Dynamics:
Renowned for its sophisticated suspension setup, offering a balance of comfort and engaging handling.
Primary Coverage:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Peugeot 405 models
Engine Coverage:
1.4L (8v/16v gasoline), 1.6L (8v gasoline), 1.8L (8v gasoline), 1.9L (8v/16v gasoline), 2.0L (8v gasoline)
Body Style Coverage:
All models and body styles, including saloon/sedan and estate/wagon variants
Estimated Page Count:
Comprehensive coverage suggesting a substantial page count, typically 500-1500 pages for such a detailed manual.
Type:
Service and Repair Workshop Manual
Engine Mechanical:
Detailed procedures for engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing, lubrication, and cooling systems.
Fuel And Exhaust:
Fuel injection systems (Bosch LE-Jetronic, Motronic, etc.), carburetor systems (if applicable), fuel pumps, filters, lines, and exhaust system diagnostics and repair.
Emission Control:
Diagnosis and repair of emission control systems, including catalytic converters, EGR valves, and secondary air injection where applicable.
Starting And Charging:
Maintenance and repair of the starter motor, alternator, battery, and charging system circuits.
Ignition System:
Ignition coil, spark plugs, distributor (if applicable), ignition control module, and timing adjustments.
Cooling Heating Ac:
Radiator, water pump, thermostat, cooling fan, heater core, blower motor, and air conditioning system servicing and refrigerant handling (where applicable).
Braking System:
Disc and drum brake systems, ABS (Anti-lock Braking System) diagnosis and repair, brake lines, master cylinder, calipers, pads, and rotors.
Bodywork Fittings:
Front and rear bumper replacement, door panel removal, interior trim, glass replacement, seals, and body panel adjustments.
Body Electrical:
Headlights, taillights, interior lighting, power windows, central locking, wipers, horn, and dashboard instrument cluster diagnostics.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, belt tensioning, spark plug replacement.
Diagnosis:
Troubleshooting common problems, diagnostic flowcharts, fault code interpretation (OBD-I era where applicable), and symptom-based diagnostics.
Repair:
Step-by-step repair instructions for all covered systems, including component removal, overhaul, and reinstallation.
Disassembly Assembly:
Detailed instructions for disassembling and reassembling major vehicle components and sub-systems.
Depth Of Coverage:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and bodywork repairs.
Diagrams Illustrations:
Highly detailed exploded pictures and diagrams to guide repair procedures accurately.
1.4L Gasoline:
TU3 series (e.g., TU3M). Power output typically around 75-80 PS (55-60 kW). Known for good fuel economy.
1.6L Gasoline:
XU5 series (e.g., XU5M). Power output typically around 90 PS (66 kW). A common and reliable engine option.
1.8L Gasoline:
XU7 series (e.g., XU7JP). Power output typically around 100-105 PS (74-77 kW). Offered a good balance of performance and economy.
1.9L Gasoline:
XU9 series (e.g., XU9J1, XU9JA). Power outputs varied from 105 PS (77 kW) for the 8v to 125-130 PS (92-96 kW) for the 16v (Mi16 models).
2.0L Gasoline:
XU10 series (e.g., XU10J2). Power output typically around 110-120 PS (81-88 kW). Offered stronger performance in later models.
Peak Horsepower Range:
Approximately 75 PS (1.4L) to 130 PS (1.9L 16v Mi16).
Injection Systems:
Bosch LE-Jetronic, Bosch Motronic ML4.1, Bosch Motronic M2.1, or single-point injection depending on engine and market. Carburetor variants were less common in later years.
Transmission Type:
5-speed manual transmission (e.g., BE1, MA5) was standard on most models.
Transmission Type:
4-speed automatic transmission (e.g., ZF 4HP18) was available as an option on select gasoline engines.
Gear Ratios:
Specific gear ratios for each engine and transmission combination are detailed within the manual.
Clutch Type:
Hydraulically operated single dry plate clutch.
Length:
Approx. 4,230-4,450 mm (saloon/estate), varying slightly by model year and body style.
Height:
Approx. 1,400-1,450 mm.
Wheelbase:
Approx. 2,600 mm.
Curb Weight:
Typically ranging from 1,050 kg to 1,300 kg depending on engine, transmission, and equipment.
Gross Vehicle Weight:
Specific GVW ratings available in the manual for load capacity.
Crash Test Results:
Euro NCAP ratings were not standard for this era. Early models had basic safety features. Later models saw improvements.
Braking:
Front ventilated discs, rear drums. Optional ABS on higher trims and later models.
Steering:
Power assisted steering was available on most models.
Airbags:
Driver airbag was optional on early models and became more common in later years, especially on higher trims. Passenger airbags were rare.
Seatbelts:
Front seatbelt pre-tensioners were introduced on some later models.
Audio System:
Basic factory fitted radios with cassette players were standard. CD players were optional or aftermarket additions.
Instrument Cluster:
Features typical analog gauges for speedometer, tachometer, fuel, and temperature, along with various warning lights.
ABS:
Anti-lock Braking System (ABS) was an optional feature, becoming more widespread on higher trim levels and later production years.
Connectivity Features:
Limited by era; primarily basic connectivity for audio systems. No Bluetooth or USB natively.
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, depending on oil type and driving conditions. Check manual for exact recommendations.
Timing Belt Replacement:
Crucial: XU and TU engines typically require timing belt replacement every 80,000-120,000 km or 5-7 years. Failure can cause catastrophic engine damage.
Spark Plug Replacement:
Recommended every 40,000-60,000 km, depending on plug type (standard vs. platinum).
Engine Oil Type:
API SG or SH, SAE 10W-40 or 5W-40. Specific viscosity depends on climate. Refer to manual for exact specifications and capacities (approx. 3.5-4.5 liters).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water. Capacity approx. 7-8 liters.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Capacity approx. 0.5-1 liter.
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90 hypoid gear oil. Capacity approx. 2.0-2.5 liters.
Transmission Fluid Automatic:
Specific ATF fluid for ZF 4HP18 (e.g., Dexron II or equivalent). Refer to manual for precise type and capacity.
Engine:
Head gasket leaks, oil seal leaks (crankshaft, camshaft), timing belt tensioner failure, minor electrical gremlins (especially with age).
Suspension Steering:
Worn front suspension bushes, ball joints, and tie rod ends are common wear items. Power steering pump leaks can occur.
Electrical:
Failing central locking motors, dashboard warning light issues, alternator and starter motor wear are typical for vehicles of this age.
Bodywork:
Rust can be an issue, particularly on wheel arches, sills, and around the boot lid. Door seals can degrade, leading to water ingress.
Peugeot History:
Peugeot, a historic French automobile manufacturer, has a long legacy of producing reliable and innovative vehicles, with a strong emphasis on driving dynamics and comfort.
405 Introduction:
Launched in 1987, the Peugeot 405 replaced the aging Peugeot 305 and quickly gained acclaim for its design and driving characteristics. It was designed by Pininfarina.
405 Variants:
Key variants included the sporty 405 Mi16 (16-valve engine) and the powerful 405 T16 (turbocharged, rally-inspired, AWD). Estate versions (Break) were also popular.
Manufacturing Locations:
Primarily manufactured in France (Sochaux), but also produced under license in various countries, including Iran (as the Pars) and Egypt.
Production End Europe:
Production in Europe ceased around 1997, though models like the Peugeot Pars continued in other markets.
