Target Audience:
Professional technicians, experienced DIY mechanics, and owners seeking in-depth knowledge of their Peugeot 405.
Value Proposition:
Provides factory-level information for comprehensive vehicle maintenance and repair, often surpassing owner's manuals and generic guides.
Accessibility:
Instant PDF download for immediate use.
Content Depth:
Step-by-step procedures, critical specifications, illustrations, and diagnostic information.
Coverage:
Comprehensive service, repair, and maintenance for the Peugeot 405 1990 model year.
Estimated Page Count:
Varies by specific factory manual, but digital versions aim for comprehensive coverage comparable to factory equivalents.
Manual Type:
Service and Repair Manual
Engine:
Detailed diagnosis, repair, and overhaul for various engine options (e.g., XU petrol, XUD diesel).
Transmission:
Repair and maintenance of manual and automatic transmissions.
Suspension Steering:
Inspection, repair, and alignment procedures for front and rear suspension, steering rack, and associated components.
Brakes:
Servicing and repair of hydraulic brake systems, including discs, drums, master cylinder, and ABS (if equipped).
Electrical System:
Wiring diagrams, component testing, diagnosis of lighting, ignition, charging, starting, and accessory systems.
Fuel System:
Diagnosis and repair of fuel injection systems (Bosch LE2-Jetronic, K-Jetronic on some variants), carburettor systems, and diesel fuel injection pumps.
Cooling Heating Ac:
Service procedures for the cooling system, heater core, and air conditioning system (if fitted).
Body Chassis:
Body panel repair, door mechanisms, interior trim, and chassis component servicing.
Exhaust System:
Inspection, diagnosis, and replacement of exhaust components.
Climate Control:
Service for heating system and optional air conditioning.
Routine Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, belt adjustments.
Troubleshooting:
Diagnostic flowcharts and common problem identification.
Disassembly Assembly:
Step-by-step instructions for removing and refitting major components.
Engine Rebuild:
Detailed instructions for engine overhaul, including torque specifications and clearances.
Transmission Overhaul:
Procedures for rebuilding manual and automatic gearboxes.
Electrical Diagnostics:
Testing of sensors, actuators, ECUs, and wiring harness integrity.
Body And Trim Repair:
Instructions for interior and exterior trim removal and installation, minor bodywork.
Wheel Alignment Specifications:
Detailed front and rear wheel alignment settings.
Depth:
Covers everything from basic owner maintenance to advanced engine and transmission rebuilds, suitable for professional technicians and experienced DIY enthusiasts.
Common Petrol Engine Codes:
XU5, XU7, XU9 (various displacements like 1.6L, 1.8L, 1.9L)
Common Diesel Engine Codes:
XUD7, XUD9 (1.8L, 1.9L naturally aspirated and turbocharged)
Horsepower Range:
Approximately 70-125 hp depending on engine variant.
Torque Range:
Approximately 130-180 Nm depending on engine variant.
Petrol Injection Systems:
Bosch LE2-Jetronic, Weber/Solex carburettors (early models), Bosch K-Jetronic (some performance variants).
Diesel Injection Systems:
Bosch inline and rotary fuel injection pumps.
Manual Transmission Options:
5-speed manual (e.g., BA7, ML5 transmission types).
Automatic Transmission Options:
3-speed or 4-speed automatic transmissions (e.g., ZF 4HP18).
Clutch Type:
Hydraulically operated single dry plate clutch.
Euroncap Rating Era:
While Euro NCAP was in its infancy and not as comprehensive in 1990, the 405 was considered a safe vehicle for its time, with a focus on structural integrity.
ABS:
Available as an option on some higher trim levels and engine variants.
Seatbelts:
Front and rear seat belts, with pre-tensioners on front belts on later models.
Airbags:
Driver airbag became available as an option in the later part of the 405's lifecycle, but not standard on the 1990 model.
Oil Change Interval:
Typically every 7,500 to 10,000 miles or 12 months, depending on driving conditions and oil type.
Timing Belt Replacement:
Critical interval for XU engines, typically 60,000 miles or 5 years. Failure can cause catastrophic engine damage.
Engine Oil Viscosity:
API SG or SH, SAE 10W-40 or 5W-40 depending on climate (refer to manual for exact specs).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Peugeot recommends specific types (e.g., Autocool).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Type Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Type Automatic:
Dexron III or equivalent ATF fluid.
Electrical Gremlins:
Common for older European cars; faulty earth points, aging wiring loom insulation can cause intermittent issues.
Suspension Wear:
Worn ball joints, tie rod ends, and rear axle pivot bearings are common wear items.
Diesel Glow Plugs:
Failure of glow plugs or their control unit can lead to difficult cold starting in XUD diesel engines.
Rust:
Corrosion can be an issue in certain areas, particularly around wheel arches, sills, and the rear axle.
Peugeot Legacy:
Peugeot has a long history of producing well-engineered and comfortable family cars, building on success with models like the 205 and 309.
405 Design Era:
Designed by Pininfarina, the 405 was launched in 1987 and represented a modern, aerodynamic design for its era.
405 Body Styles:
Offered as a 4-door saloon and a 5-door estate (Break).
Production Period:
1987-1996 (Europe), with continued production under license in other regions.
