Target Audience:
Peugeot 405 owners, DIY mechanics, professional repair shops
Segment:
Family Car / Compact Executive Car
Manual Source:
Original manufacturer manual, same as used in professional shops.
Competitors:
Ford Sierra, Opel/Vauxhall Vectra/Cavalier, Volkswagen Passat, Renault 21, Citroën BX
Completeness:
Complete and intact, no missing or corrupt parts/pages.
Usability:
Easy to use with numbered table of contents, bold figure numbers, and detailed illustrations.
Digital Advantage:
No risk of oil/dirt damage, printable sections for direct use during repairs.
Covered Years:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Covered Models:
All Models, All Trim Levels
Covered Engines:
All Engines
Covered Transmissions:
All Transmission Types
Estimated Page Count:
Hundreds of pages (specific count not provided, but indicated as comprehensive)
Type:
Workshop Service Repair Manual
Format:
PDF (Downloadable)
Engine:
Service, Repair, Fuel Injection/Fuel System, Cooling System, Emission System, Engine Control System
Transmission:
Service, Repair, Differential/Drive, Axle
Electrical:
Electrical System, Wiring Diagrams, Engine Control System
Suspension Steering:
Suspension, Steering
Chassis Body:
Chassis/Body
Interior Safety:
Heater/Air Conditioner, Restraint System, Interior
Maintenance:
General Maintenance, Periodic Lubrication
Repair:
Detailed substeps, numbered instructions, step-by-step repair procedures, disassembly, assembly, cleaning, reinstalling procedures
Troubleshooting:
Troubleshooting and electrical service procedures
Engine Overhaul:
Detailed procedures for engine disassembly, component inspection, machining specifications (e.g., cylinder bore, piston ring gap, bearing clearance), and reassembly are included.
Fuel System Diagnosis:
Includes diagnostic steps for fuel pump operation, injector testing, fuel pressure regulation, and troubleshooting of emission control systems.
Brake System Repair:
Covers brake pad/shoe replacement, caliper/wheel cylinder servicing, brake line inspection and replacement, brake fluid bleeding procedures, and ABS component troubleshooting.
Suspension Component Replacement:
Detailed instructions for replacing struts, shock absorbers, control arms, ball joints, tie rod ends, and wheel bearings, along with alignment specifications.
Electrical Component Testing:
Guidance on testing alternators, starters, ignition coils, sensors (e.g., Crankshaft Position Sensor, Throttle Position Sensor), relays, and switches, supported by detailed wiring diagrams.
Body Panel Repair:
Information on adjusting doors, hoods, and trunk lids, as well as basic bodywork repair and alignment specifications.
HVAC System Service:
Covers refrigerant system diagnosis, component replacement (compressor, condenser, evaporator), blower motor repair, and dashboard ventilation system servicing.
Troubleshooting Electrical Faults:
Combines troubleshooting guides with specific wiring diagrams to aid in diagnosing intermittent electrical issues, short circuits, and open circuits.
Depth:
Professional-level diagnostics, repair, and maintenance as used by local service/repair shops. Includes critical specifications, diagrams, and detailed information.
Torque Specifications:
Includes precise torque values for critical fasteners throughout the vehicle, essential for proper assembly and safety.
Diagnostic Charts:
Provides symptom-based diagnostic flowcharts to help identify the root cause of common problems.
Illustrations Diagrams:
Hundreds of detailed illustrations, drawings, and photos, with enlarged insets for clear identification of parts and procedures.
Wiring Diagrams:
Comprehensive and accurate wiring diagrams for all electrical systems, crucial for troubleshooting and repairs.
Engine Types Covered:
The manual covers all engine variants for the Peugeot 405 from 1988-1997. This would typically include XU series naturally aspirated and turbocharged diesel engines (e.g., XUD7, XUD9), and various petrol engines (e.g., Douvrin/PRV variants, later XU series like XU5, XU7, XU9, XU10). Specific engine codes and displacements are detailed within the manual.
Diesel Engine Variants:
Notably, the XUD series diesel engines (XUD7 1.8L, XUD9 1.9L) were highly regarded for their durability and fuel efficiency. Turbocharged versions (XUD9TE) offered improved performance.
Performance Data:
The manual provides specifications for horsepower, torque, and other performance metrics for each engine variant. Specific values (e.g., 1.6L petrol: ~80-90 hp, 1.9L TD: ~90 hp) would be found within the relevant engine chapters.
Fuel System Details:
Comprehensive coverage of fuel injection systems (Bosch, Lucas) for petrol engines and injection pumps (Bosch VE) for diesel engines. Includes fuel delivery, pressure, and component testing procedures.
Petrol Injection Systems:
Covered systems include single-point injection (SPI) on earlier 1.6L models and multi-point injection (MPI) on later 1.8L and 2.0L variants.
Standard Transmission Type:
Manual transmissions (e.g., 5-speed, possibly 4-speed on early models) were common. Specific gear ratios and models (e.g., AL4, BVM) are detailed.
Optional Transmission Type:
Automatic transmissions (e.g., ZF 4HP18) were also available on certain models. The manual covers their service and repair.
Transmission Fluid Specifications:
The manual specifies the correct Automatic Transmission Fluid (ATF) for automatic gearboxes (e.g., Dexron II/III equivalent) and gear oil specifications for manual gearboxes (e.g., SAE 75W-90 GL-5).
Recommended Intervals:
The manual details recommended service intervals for oil changes, filter replacements, timing belt replacement (critical for interference engines), and other maintenance tasks. Typical oil change intervals are around 10,000-15,000 km or 12 months, with timing belt replacement every 60,000-80,000 km or 4-5 years, depending on engine type.
Engine Oil Specifications:
The manual specifies appropriate engine oil viscosity grades (e.g., 10W-40, 15W-40 for diesel, 5W-40 for modern synthetic) and API/ACEA service classifications based on engine and climate. Oil capacity also varies by engine.
Common Wear Items:
The manual provides guidance on common wear items such as suspension bushings, wheel bearings, exhaust components, clutch assembly, and glow plugs (for diesel). It also covers diagnosis and repair for issues like oil leaks and coolant system faults.
Common Faults:
The manual addresses common issues such as EGR valve problems (diesel), viscous coupling failure on AWD variants (4TC), and potential electrical gremlins associated with aging wiring.
Filter Part Numbers:
While specific OEM part numbers are usually proprietary, the manual guides users on identifying correct filter specifications (e.g., oil filter, air filter, fuel filter) and often cross-references to common aftermarket equivalents or types.
Peugeot Heritage:
Peugeot has a long history of producing family-oriented vehicles known for their comfortable ride, good handling, and practical design. The 405 followed this tradition, succeeding the Peugeot 305.
405 Evolution:
Launched in 1987, the 405 was designed by Pininfarina. It was available as a sedan and an estate (Break). An facelift (Phase 2) occurred in 1992, introducing minor styling changes and updated interiors. The manual covers both phases.
Styling Influence:
Designed by Pininfarina, known for its clean lines and aerodynamic profile, which contributed to its positive market reception.
Production Locations:
Primarily manufactured in France (Sochaux), but also produced under license in other countries including Iran (Khodro) and Egypt.
