Target Audience:
Enthusiasts, DIY mechanics, independent repair shops, and owners seeking to understand and maintain their Peugeot 405.
Value Proposition:
Provides expert-level repair and maintenance information, empowering users to perform tasks typically requiring dealership-level resources, leading to significant cost savings.
Content Accuracy:
Based on manufacturer-provided data, ensuring accuracy and adherence to original specifications.
Instruction Clarity:
Features step-by-step instructions, diagrams, and illustrations for ease of understanding and execution.
Wiring Schematics:
Includes essential wiring diagrams for troubleshooting electrical systems.
Applicable Years:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
Coverage Areas:
General Information, Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch System, Manual Transaxle, Automatic Transaxle, Driveshaft and Axle, Suspension, Steering, Restraint System, Brake System, Body (Interior and Exterior), Body Electrical System, Heating, Ventilation, Air Conditioning (HVAC)
Manual Type:
Service and Repair Workshop Manual
Engine Mechanical:
Detailed repair and overhaul procedures for engine components including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing systems, lubrication, and cooling systems.
Engine Electrical:
Includes ignition system, starter, alternator, battery, engine control unit (ECU) diagnostics, and sensor information.
Fuel System:
Covers fuel injection systems (Bosch Motronic, Magneti Marelli), fuel pumps, injectors, fuel pressure regulators, and fuel tank servicing.
Transmission:
Detailed procedures for both manual (e.g., BE series) and automatic transmissions, including clutch, gear selection, differential, and overhaul.
Suspension Steering:
Covers front and rear suspension components (McPherson struts, trailing arms), steering rack, power steering system, wheel alignment specifications.
Brake System:
Repair and maintenance of hydraulic systems, disc and drum brakes, ABS (if equipped), parking brake, and brake fluid specifications.
Body Electrical:
Wiring diagrams for all electrical systems, including lighting, instrumentation, power windows, central locking, and exterior/interior accessories.
HVAC:
Service and repair of heating, ventilation, and air conditioning systems, including refrigerant handling and component replacement.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, spark plug changes, fluid checks, and lubrication.
Troubleshooting:
Diagnostic procedures for common problems, symptom analysis, and fault finding for various vehicle systems.
Repair:
Step-by-step instructions for component removal, repair, overhaul, and installation for virtually all mechanical and electrical systems.
Diagnostics:
Detailed diagnostic flowcharts and explanations for engine management, electrical faults, and system malfunctions.
Bodywork And Trim:
Instructions for removing and refitting interior and exterior trim panels, bumpers, doors, hood, and trunk lid.
Chassis And Underbody:
Covers subframe removal and installation, exhaust system servicing, and underbody protection.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid checks and minor repairs to major component overhauls and complex electrical diagnostics. Equivalent to manufacturer dealer workshop manuals.
Wiring Diagrams Detail:
Detailed schematics for engine management, lighting circuits, body electronics, and HVAC systems.
Engine Variants Covered:
Likely covers various gasoline and diesel engines offered in the 405 during this period, including XU and PRV series (e.g., XU5, XU7, XU9, XU10, PRV V6) depending on specific manual compilation.
Displacement And Power:
Details specifications for engine displacements such as 1.6L, 1.8L, 1.9L (naturally aspirated and turbo-diesel), 2.0L, and 2.8L V6, with corresponding horsepower and torque figures.
Fuel Delivery:
Covers both carbureted (early models) and fuel-injected (MPI, TBI) systems, including Bosch and Magneti Marelli ECUs.
Coolant Type:
Specifications for coolant mixtures, coolant capacity, and cooling fan operation.
Catalytic Converter:
Details on emission control systems, including catalytic converters, oxygen sensors, and EGR (Exhaust Gas Recirculation) systems, and their maintenance.
Manual Transmission Types:
Likely covers Peugeot's BE series transaxles (e.g., BE1, BE3) with various gear ratios depending on engine and model.
Automatic Transmission Types:
Details for ZF automatic transmissions commonly paired with Peugeot engines of this era.
Transmission Fluid Specifications:
Provides specific fluid types and capacities for both manual and automatic transmissions.
Body Styles:
Covers saloon (sedan), hatchback (5-door), and estate (break/SW) body styles.
Curb Weight:
Includes curb weight specifications for different engine and trim configurations.
Wheel Bolt Pattern:
Typically 4x108 mm for Peugeot vehicles of this period.
Tire Sizes:
Details recommended tire sizes for various models, e.g., 185/65R14, 195/60R15.
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-15,000 km) or 12 months, depending on engine and oil type. Manual will specify exact intervals.
Timing Belt Replacement:
Critical interval, typically every 40,000-60,000 miles (60,000-90,000 km) for gasoline engines. Failure can cause severe engine damage.
Engine Oil Specification:
Various grades like 10W-40 or 5W-40 API SG/SH or ACEA A2/A3, depending on engine and climate. Manual will list precise specifications (e.g., PSA S71 2294).
Coolant Specification:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Specific PSA approvals may be cited.
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Manual:
Gear oil specification for manual transmissions (e.g., SAE 75W-80 GL-4 or GL-5, specific PSA approvals).
Power Steering Fluid:
Specific hydraulic fluid required for the power steering system, often LHM or a specified ATF.
Electrical Gremlins:
Commonly reported issues include intermittent electrical faults, particularly with lighting, central locking, and window mechanisms, often due to aging wiring and grounds.
Suspension Wear:
Wear in front suspension components like ball joints, track rod ends, and strut mounts can lead to imprecise steering and knocking noises.
Engine Mounts:
Engine and transmission mounts can degrade over time, leading to increased vibration and noise transmitted into the cabin.
Rust:
While generally robust, areas prone to corrosion include wheel arches, sills, and suspension mounting points, especially in regions with harsh winters and road salt.
Peugeot Motorsport:
The 405 achieved significant success in motorsport, including winning the 1988 Pikes Peak International Hill Climb with Ari Vatanen and the 1993 Paris-Dakar Rally with the 405 Turbo 16, highlighting the robustness of its platform.
Design Influence:
Designed by Pininfarina, the 405 is renowned for its aerodynamic and elegant styling, a hallmark of Italian design influence on French automotive engineering.
Manufacturing Locations:
Primarily produced in France (Sochaux), with other manufacturing facilities and assembly plants in various countries for global markets.
