🏷️ Basic Information

Make:

Peugeot

Model:

405

Product Name:

PEUGEOT 405 14 16 18 19 2 Petrol Service Repair Manual 1991-1996

Engine Codes Covered:

Likely XU7JP, XU9J1/Z, XU10J2/Z (Petrol variants)

Generation Covered:

Second Generation (1991-1996 facelift/late models)

👋 Introduction

Historical Segment:

Compact executive/family car, competing in a segment dominated by European and Japanese manufacturers.

Key Competitors:

Volkswagen Passat, Ford Mondeo, Opel/Vauxhall Vectra, Renault Laguna, Fiat Croma, Honda Accord, Toyota Avensis.

Design Philosophy:

Designed by Giugiaro, the 405 was known for its aerodynamic styling, spacious interior, and comfortable ride, particularly the 'Traction Avant' models which offered excellent handling for their era.

Safety Focus:

The 405 series was generally well-regarded for its safety features, with some models offering ABS and improved body structures.

📋 Manual Details

Vehicle Years:

1991, 1992, 1993, 1994, 1995, 1996

Engine Variants:

1.4L (1360cc) Petrol, 1.6L (1580cc) Petrol, 1.8L (1761cc) Petrol, 1.9L (1905cc) Petrol, 2.0L (1998cc) Petrol

Body Styles Covered:

Likely Sedan (Berline), Estate/Wagon (Break)

Estimated Page Count:

Hundreds (Exact count not specified, but typical for comprehensive manuals)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, component identification, cylinder head, block, pistons, crankshaft, camshaft, timing systems, lubrication, cooling.

Fuel System:

Fuel delivery, injection systems (likely Bosch Motronic, Lucas L-Jetronic), carburetion (for earlier/smaller engines), fuel pump, injectors, pressure regulator, fuel tank.

Ignition System:

Distributor, ignition coils, spark plugs, timing, electronic ignition control.

Transmission Manual:

Clutch system, gearbox overhaul, gear selection, driveshafts, internal components.

Transmission Automatic:

Likely covers ZF 4HP18 or similar automatic transmissions (if applicable to petrol variants of this period), torque converter, valve body, hydraulic control.

Brakes:

Hydraulic system, ABS (if equipped), front and rear brake assemblies (discs/drums), master cylinder, brake booster, calipers, pads, shoes, fluid specifications.

Suspension:

Front suspension (McPherson struts), rear suspension (torsion beam, trailing arms), shock absorbers, springs, bushings, wheel alignment specifications.

Steering:

Power steering system, steering rack, pump, fluid specifications, steering column.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, switches, instrument cluster, central locking, power windows.

Climate Control:

HVAC system, blower motor, evaporator, heater core, refrigerant type, system charging procedures.

Body And Interior:

Body panel removal and installation, doors, hood, trunk, bumpers, seats, dashboard, trim panels.

Maintenance Scheduled:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and changes (coolant, brake, power steering, transmission), belt replacements.

Troubleshooting:

Diagnostic procedures for common issues, fault finding trees, symptoms and causes.

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Component Replacement:

Specific guidance for replacing wear items and major components like clutch, brakes, suspension parts, engine mounts.

Diagnostics Scans:

Information on engine management systems, sensor testing, and potentially OBD-I (On-Board Diagnostics) codes for applicable models.

Wiring Diagrams:

Comprehensive electrical schematics for various systems, aiding in troubleshooting and repairs.

Depth Of Coverage:

Comprehensive, suitable for both DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to full engine and transmission overhauls.

Diagnostic Capabilities:

Detailed diagnostic procedures, including testing of sensors, actuators, and electrical circuits.

Torque Specifications:

Includes crucial torque values for fasteners across all major mechanical systems.

Special Tools:

Mentions any specific tools required for certain procedures, enhancing accuracy and efficiency.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for printing individual pages or the entire document.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

Searchable Text:

Yes (Typically, PDF manuals are text-searchable for quick information retrieval).

⚙️ Engine Specifications

Engine Range Petrol:

1.4L (1360cc), 1.6L (1580cc), 1.8L (1761cc), 1.9L (1905cc), 2.0L (1998cc) XU series petrol engines.

Power Output Range:

Approximately 70 hp (1.4) to 123 hp (2.0i) depending on specific engine variant and tuning.

Torque Output Range:

Varies by engine, e.g., 1.9L engines typically produced around 150-160 Nm.

Injection Systems:

Carburetion (early 1.4/1.6) and multi-point fuel injection (MPI) for later and larger engines (e.g., Bosch Motronic).

Engine Layout:

Inline-4, front-mounted, transverse.

Engine Block Material:

Likely cast iron block with aluminum cylinder head.

Valvetrain:

SOHC (Single Overhead Camshaft) for 8-valve engines, DOHC (Double Overhead Camshaft) for 16-valve variants (e.g., XU10J4).

🔧 Transmission

Standard Transmission:

5-speed manual transmission.

Optional Transmission:

4-speed automatic transmission (likely ZF sourced).

Transmission Fluid:

Specific ATF (Automatic Transmission Fluid) required for automatics, and gear oil for manuals. Manuals typically use API GL-4 or GL-5 compliant gear oil.

📐 Dimensions

Length:

Approx. 4400-4430 mm (Sedan), 4470-4500 mm (Estate)

Width:

Approx. 1700-1730 mm

Height:

Approx. 1400-1420 mm (Sedan), 1450-1460 mm (Estate)

Curb Weight:

Varies by engine and trim, typically 1050-1250 kg.

Wheelbase:

Approx. 2620 mm

Wheel Bolt Pattern:

Likely 4x108

🛡️ Safety Features

Euro Ncap Rating:

Not directly tested under modern Euro NCAP protocols, but generally considered safe for its era. Later models had improved structures.

ABS:

Available on higher trims and later models.

Traction Control:

Rare, but potentially available on top-tier performance variants (e.g., 405 Mi16).

Airbags:

Driver's side airbag became increasingly common from the mid-90s, passenger airbag less common.

Seatbelts:

Three-point inertia-reel seatbelts front and rear.

Body Structure:

Reinforced safety cage, energy-absorbing crumple zones.

💡 Technology Features

Audio System:

Factory-fitted radio/cassette players, often with basic FM/AM reception and speaker configurations. Upgrade options likely available.

Cruise Control:

Available on higher trim levels and as an option for some engine variants.

Connectivity Features:

Limited by era; primarily focused on the vehicle's internal systems. No advanced Bluetooth or smartphone integration as standard.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 km or 12 months, whichever comes first (or as specified by manufacturer). Check manual for exact interval based on driving conditions.

Timing Belt Interval:

Crucial interval, often around 80,000 - 120,000 km or 5-6 years, depending on engine. Belt failure can cause catastrophic engine damage.

Spark Plug Replacement:

Varies by spark plug type; typically 30,000 - 60,000 km for standard copper plugs, longer for platinum/iridium.

Engine Oil Spec:

Likely API SG/SH or ACEA A2/A3 specification. Viscosity grades like 10W-40 or 5W-40 depending on climate. Check manual for exact viscosity.

Coolant Spec:

Ethylene glycol-based antifreeze/coolant, often requiring a specific mix (e.g., 50/50 with distilled water). Typically blue or green coloured.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid is standard for this era.

Power Steering Fluid:

Specific hydraulic fluid; often Dexron II/III ATF or a dedicated PSA fluid.

Electrical Gremlins:

Common issues can include intermittent electrical faults, particularly with window regulators, central locking, and dashboard warning lights due to age and wiring loom degradation.

Suspension Wear:

Worn suspension bushings, ball joints, and wheel bearings are common wear items leading to knocking noises and poor handling.

Engine Management:

Fuel injection system issues, idle speed control problems, and sensor failures (e.g., TPS, MAP sensor) can occur.

Cooling System:

Radiator leaks, failing water pumps, and thermostat issues can lead to overheating if not addressed.

Exhaust System:

Corrosion of the exhaust system, catalytic converter failure, and lambda sensor issues are common with age.

📚 Vehicle History

Peugeot Legacy:

Peugeot has a long history of producing well-engineered and comfortable family cars, often with a focus on driving dynamics. The 405 followed in the footsteps of the successful 505 and 305 models.

Introduction Year:

First generation introduced in 1987.

Facelift Impact:

The 1991 facelift brought styling updates (grille, bumpers, lights) and interior improvements, including better materials and ergonomics, which this manual covers.

Performance Variants:

Notable performance variants like the 405 Mi16 and T16 (turbocharged, all-wheel-drive) were produced, known for their rally-inspired engineering.

Production Period:

1987-1996 (in Europe)

Manufacturing Locations:

Primarily France (Sochaux), also Iran (IKCO), Egypt, and other licensed production.

🏆 Awards & Recognition

Car Of The Year:

The Peugeot 405 was voted 'European Car of the Year' in 1988.

Sales Success:

Achieved significant sales success across Europe and globally, praised for its combination of comfort, practicality, and value.