Market Position:
The Peugeot 405 was a popular family car that competed in the C-segment, aiming for comfort, driving dynamics, and practicality. It was designed to be a mainstream competitor against vehicles like the Ford Sierra, Volkswagen Passat, and Opel Vectra.
Competitive Analysis:
Praised for its Pininfarina-designed styling, comfortable ride, and engaging handling, the 405 offered a compelling alternative to its German and British rivals, often at a more accessible price point. Its availability in various body styles (saloon and estate) and with a range of engine options further broadened its appeal.
Key Features:
Stylish Italian design, refined interior, sophisticated suspension for its class, wide range of engine options including petrol and diesel, front-wheel drive platform, and later, the availability of all-wheel drive on some performance variants (like the Mi-16x4).
Systems Covered:
Engine (all variants), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Driveshafts, Suspension (Front & Rear), Steering System, Braking System (Front & Rear Discs/Drums, ABS where applicable), Electrical System (Wiring Diagrams, Lighting, Accessories), Bodywork (Interior & Exterior Trim, Doors, Windows, Seats), HVAC System, Wheels and Tires, Diagnosis and Troubleshooting.
Engine Management:
Detailed coverage of engine control units (ECUs), sensors, actuators, fuel injection systems, and ignition timing for various engine variants.
Body And Chassis:
Includes procedures for body panel alignment, rust repair, glass replacement, interior trim removal and installation, and chassis component checks.
Procedures Included:
Routine Maintenance, Adjustments, Component Removal and Installation, Disassembly and Assembly, Troubleshooting, Diagnostics, Repair Procedures, Specifcations, Torque Values, Wear Limits, Wiring Diagrams, Exploded Views, Pictorial Diagrams, Special Tool References.
Engine Rebuild:
Complete procedures for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves), cylinder head service, and reassembly, including torque specifications and critical clearances.
Electrical Diagnostics:
Extensive wiring diagrams for all electrical systems, including lighting, ignition, starting, charging, instruments, wipers, washers, and accessories. Troubleshooting guides for common electrical faults.
Technical Depth:
Comprehensive, covering everything from basic maintenance tasks and fluid changes to in-depth engine rebuilding, transmission overhauls, suspension component replacement, and detailed electrical system diagnostics. Suitable for both experienced mechanics and DIY enthusiasts.
Diagnostic Procedures:
Includes methods for diagnosing common and uncommon faults, fault codes (where applicable), testing electrical components, and interpreting diagnostic data.
Specifications And Tolerances:
Provides critical specifications such as engine bearing clearances, valve lash adjustments, brake component wear limits, suspension alignment angles, and tightening torques for hundreds of fasteners.
Engine Options General:
The Peugeot 405 offered a variety of gasoline and diesel engines throughout its production run. Common gasoline engines included the XU series (e.g., XU5, XU7, XU9, XU10) and the older Douvrin 'Suitcase' engine (PRV V6 for the sportier variants). Diesel engines were primarily from the XUD series.
Engine Displacement Range:
1.4L (1360cc) to 2.0L (1998cc) for gasoline; 1.8L (1769cc) to 1.9L (1905cc) for diesel. Performance models like the Mi-16 used the XU9J4 engine (1.9L) or XU10J4 (2.0L).
Engine Code Examples:
XU5J (1.6L), XU7JP (1.8L MPI), XU10J2 (2.0L SPI), XU10J4 (1.9L 16V - Mi16), XUD7 (1.8D), XUD9 (1.9D), XUD9TE (1.9D Turbo). The manual will cover the specifics for each code.
Typical Hp Range:
Power outputs generally ranged from approximately 60 hp (naturally aspirated diesel) to over 150 hp (turbocharged or multi-valve gasoline variants like the Mi-16). Specific figures varied significantly by engine and market.
Specific Engine Example Mi16:
Peugeot 405 Mi-16 (XU9J4): 1.9L DOHC 16-valve engine, producing approximately 160 hp (119 kW) at 6,500 rpm and 177 Nm (131 lb-ft) of torque at 5,000 rpm.
Fuel System Types:
Carbureted (early models, lower trims), Fuel Injection (Bosch LE-Jetronic, Motronic, etc. for higher trims and later models), Diesel Injection (indirect injection, often with turbocharging on later XUD variants).
Diesel Variants:
Common diesel engines include the XUD7 (1.8L naturally aspirated) and XUD9 (1.9L naturally aspirated or turbocharged). These are known for their durability and fuel efficiency. Turbocharged variants (XUD9TE) offered improved performance.
Standard Transmission:
Typically a 5-speed manual transmission.
Manual Gear Ratios:
Specific gear ratios for each transmission variant are detailed in the manual, crucial for performance calculations and diagnostics.
Optional Transmission:
Optional 3-speed or 4-speed automatic transmission was available on many models.
Automatic Transmission Type:
Typically ZF or Peugeot's own Aisin-Warner sourced automatics. Coverage includes service, fluid changes, and troubleshooting.
Transmission Features:
Front-wheel drive (FWD) was standard. Some high-performance variants, such as the 405 Mi-16x4, featured all-wheel drive (AWD).
Overall Length:
Approx. 4,360 mm (171.7 in) for saloon; Approx. 4,370 mm (172.0 in) for estate. (Exact dimensions may vary slightly by body style).
Interior Volume:
Refer to specific model variants within the manual for detailed interior measurements. Known for a spacious cabin relative to its class.
Cargo Volume Estate:
Generous cargo capacity in the estate variant, a key selling point for practicality.
Curb Weight:
Curb weight varied significantly by engine and specification, typically ranging from 1,100 kg to 1,400 kg (2,425 lbs to 3,086 lbs).
Gross Vehicle Weight Rating:
GVWR information will be specific to each model variant and available in the manual's specification tables.
Crash Test Ratings:
Euro NCAP ratings were not consistently applied to vehicles of this era in the same way as modern standards. However, the 405 was designed with contemporary safety considerations. The manual will detail passive safety features and any available active safety systems.
Active Safety Features:
Optional Anti-lock Braking System (ABS) was available on higher trims and later models. Power-assisted steering contributed to vehicle control.
Brake System Details:
Front ventilated discs and rear drums or discs depending on model. ABS system specifics, hydraulic circuits, master cylinder specifications, and brake fluid type (DOT 3 or DOT 4).
Passive Safety Features:
Crumple zones, reinforced passenger cell, seat belts (pre-tensioners may be present on later models), and child safety locks. Side impact beams were incorporated into the door structures.
Infotainment Features:
Basic for its era. Primarily featured analog radio, cassette players, and a simple speaker system. Higher trims might have featured more advanced radio units with preset channels.
Driver Assistance Systems:
Limited by modern standards. Power steering was common. ABS was an option. Cruise control was available on some higher-spec models.
Connectivity Features:
None in the modern sense. Connectivity was limited to the car's internal systems and analog audio.
Typical Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first, for conventional mineral oil. Synthetic oil may allow for extended intervals as specified in the manual.
Timing Belt Replacement:
Crucial maintenance item. Recommended replacement interval is typically around 60,000-80,000 km (37,000-50,000 miles) or 5 years. Failure can cause catastrophic engine damage, especially on interference engines.
Engine Oil Type:
Refer to manual for specific viscosity grades (e.g., 10W-40, 15W-40 for gasoline; 10W-40, 15W-40 for diesel, depending on temperature and engine type). Manual will specify API or ACEA service classifications. Examples might include API SF/SG or CD/CE for diesel.
Coolant Type:
Antifreeze/coolant mixture, typically a 50/50 blend of ethylene glycol and distilled water. Manual will specify type and capacity.
Transmission Fluid Type:
Manual transmission oil (GL-4 specification often recommended, specific viscosity varies). Automatic transmission fluid (ATF) type will be specific to the transmission model, often a Dexron-II or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on vehicle specification and presence of ABS.
Common Issues:
Head gasket failure (especially on higher mileage engines), suspension component wear (bushings, ball joints), electrical gremlins (e.g., faulty switches, dashboard lights), aging rubber hoses and seals, and rust in common areas for vehicles in damp climates. Diesel engines (XUD) are generally robust but can suffer from glow plug issues or injector pump wear.
Cooling System Issues:
Radiator leaks, thermostat failures, and degradation of coolant hoses are common on older vehicles. The manual provides testing and replacement procedures.
Brand Heritage:
Peugeot, a French automobile manufacturer with a history dating back to 1810, is known for its diverse range of vehicles, from small city cars to larger executive models and performance vehicles. The '40' series historically represented Peugeot's mid-size offerings, with models like the 404 and 405 being significant in their respective eras.
Model Evolution:
Launched in 1987 as the successor to the Peugeot 305, the 405 was a significant step forward in design and technology for Peugeot. It shared its platform with the Citroën BX. It received a facelift in 1992, introducing updated styling, improved interiors, and some mechanical revisions.
Performance Variants:
The 405 range included sporty models like the 405 S, SRi, Mi-16, and the rally-bred 405 T16 (though the T16 falls outside the 1987-1997 scope for most markets, its development is linked). The Mi-16 was a significant performance variant with a powerful 16-valve engine and improved suspension.
Production Period:
1987-1997 (Europe). Production also occurred in other regions through licensed assembly. The 405 was succeeded by the Peugeot 406.
Industry Awards:
The Peugeot 405 was awarded 'European Car of the Year' in 1988. It also received numerous other accolades from automotive publications and industry bodies across Europe.
Reliability Ratings:
While generally considered reliable, specific reliability varied by engine and maintenance. Known for its good ride and handling, which often scored well in contemporary reviews. The manual's detailed procedures are key to maintaining its original performance.
Certifications:
The manual itself adheres to industry standards for technical documentation, ensuring clarity and accuracy in repair procedures. This ensures that maintenance and repairs meet manufacturer specifications.
