🏷️ Basic Information

Make:

Peugeot

Model:

405

Body Styles:

Saloon (Sedan), Estate (Station Wagon)

Powertrain Variants Covered:

Petrol (SOHC, DOHC, Mi 16, 1.4 litre variants)

Generations Covered:

First Generation (Type 15B, 1987-1996)

👋 Introduction

Market Segment:

Family car, executive car

Key Competitors:

Ford Sierra, Volkswagen Passat (B2/B3), Renault 21, Opel/Vauxhall Vectra (later models), Fiat Croma

Design Philosophy:

Designed by Giugiaro, emphasizing aerodynamic styling and spacious, comfortable interiors for its era.

Manual Advantage:

Provides factory-level diagnostic and repair procedures, including torque specifications and OEM data crucial for accurate servicing.

📋 Manual Details

Languages:

English

Regions Of Operation:

Global (primarily European markets reflected in factory specifications)

Technical Focus:

Repair and Maintenance

Specific Engines Covered In Detail:

1.4L (1360cc), 1.6L (1580cc), 1.8L (1769cc), 2.0L (1905cc) petrol engines including the Mi 16 variant.

Estimated Pages:

Variable (Digital PDF, often extensive, exceeding 1000 pages for full factory coverage)

Type:

Factory/Official Service Repair Workshop Manual

File Format:

PDF (Digital Download)

Delivery Method:

Instant Download

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing systems (SOHC/DOHC belt/chain), valve train

Engine Performance:

Fuel system (injection and carburetion depending on variant), ignition system, cooling system, lubrication system, exhaust system, emissions control

Transmission Drivetrain:

Manual and Automatic transmissions, clutch, drive axles, differentials

Chassis Suspension:

Suspension components (shocks, struts, springs, bushings), steering system (rack and pinion), wheels, tires

Brakes:

Brake system diagnosis, repair, hydraulic components (master cylinder, calipers, lines), parking brake

Electrical Electronics:

Wiring diagrams, starter, alternator, battery, lighting, instruments, fuses, relays, ECUs (Engine Control Units)

Body Interior:

Body panel repair, doors, windows, seats, interior trim, HVAC (Heating, Ventilation, and Air Conditioning)

Maintenance:

Routine service, oil changes, filter replacements, fluid checks, tune-ups, lubrication

Repair Rebuild:

Engine rebuilds, transmission overhauls, component replacement (alternator, starter, fuel pump, etc.)

Diagnostics Troubleshooting:

Step-by-step diagnostic procedures, fault code interpretation (where applicable), common issues and solutions

Inspection:

Pre-purchase inspections, regular safety checks, component wear analysis

Fuel System Diagnosis:

Includes fuel pump testing, injector diagnosis (for MPI), fuel pressure regulator checks, and carburetor adjustment/rebuild (for carbureted models).

Depth:

Comprehensive: from basic fluid changes to major component rebuilds and complex electrical diagnostics

Diagrams Illustrations:

Detailed exploded diagrams, electrical schematics, component illustrations, step-by-step repair sequences

Oem Specifications:

Torque specifications, fuel pressure charts, electrical connector data, compression ranges, valve clearances, timing specifications, wheel alignment data, and more are included.

📊 Manual Specifications

Searchability:

Searchable PDF text (typically)

Printability:

Printable pages for workshop use

Format Type:

Digital Download (PDF) - No physical binding

Physical Format:

N/A (Digital)

⚙️ Engine Specifications

Engine Types:

XU series inline-4 petrol engines

1.4 Litre:

Commonly found in earlier models, typically 8-valve SOHC. Power output around 70-75 hp.

Sohc Variants:

Includes 1.6 litre (approx. 88-90 hp) and 1.8 litre (approx. 95-100 hp) engines, known for reliability and decent fuel economy.

DOHc Variants:

Often found in higher trim levels, offering improved performance and breathing. Typically 16-valve configurations.

Mi 16:

Performance variant, typically 2.0 litre 16-valve DOHC engine producing around 145-160 hp. Known for its sporty character and multi-point fuel injection.

Mi 16 Engine Details:

The 2.0L (XU10J4) 16-valve engine produced approximately 150-160 PS. It featured Bosch Motronic fuel injection and ignition. Manual provides detailed ignition timing and fuel mixture adjustments.

Compression Ratios:

Varies by engine; typical for 1.4/1.6 SOHC around 9.2-9.5:1, Mi16 around 10.0-10.5:1. Manual will detail specific values.

Fuel Delivery:

Carbureted (e.g., Solex, Weber) on lower-end models, Bosch L-Jetronic or similar multi-point fuel injection (MPI) on higher-end and performance variants (e.g., Mi 16).

Fuel Pressure:

Specific values for EFI systems will be detailed in the manual, critical for proper mixture and performance.

🔧 Transmission

Manual Gearbox:

Typically 5-speed manual transmissions (e.g., BE1, BE3) across most variants. Information on clutch operation, replacement, and gearbox oil is included.

Automatic Gearbox:

Optional 3-speed or 4-speed automatic transmissions available on certain models. Manual covers maintenance, fluid changes, and basic troubleshooting.

Drive Chain Sprockets:

The manual includes detailed information on timing belt replacement intervals, tensioning, and related components (pulleys, tensioners) for SOHC and DOHC engines.

📐 Dimensions

Length:

Saloon: Approx. 4405 mm; Estate: Approx. 4445 mm

Width:

Approx. 1700 mm

Height:

Saloon: Approx. 1410 mm; Estate: Approx. 1460 mm

Curb Weight:

Varies by engine and equipment, generally between 1050 kg and 1300 kg.

🛡️ Safety Features

Crash Test Results:

Euro NCAP ratings were not established for this generation of the 405 as Euro NCAP testing began later. However, its safety features were competitive for its time. Manual will detail structural repair aspects.

Braking System:

Front ventilated discs, rear drums standard. Higher-performance models (Mi 16) often featured four-wheel disc brakes. ABS was an option on later models.

Seatbelts:

Front and rear seatbelts, pre-tensioners on some later models. Manual covers seatbelt mechanism servicing.

Airbags:

Driver's airbag became an option on later models; not standard across all variants. Manual would cover electrical checks related to airbag systems if equipped.

💡 Technology Features

Audio System:

Factory fitted radios/cassette players. Manual covers speaker replacement and basic wiring for aftermarket upgrades.

ABS:

Anti-lock Braking System was an optional feature on higher-spec models. Manual details ABS sensor testing, hydraulic modulator, and ECU diagnostics.

Central Locking:

Available on higher trims, often vacuum operated. Manual covers troubleshooting of vacuum lines and actuators.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-15,000 km) or annually, depending on driving conditions. Manual will specify exact intervals based on engine variant and oil type.

Timing Belt Replacement:

Crucial: typically every 60,000-80,000 miles (96,000-128,000 km) or 5 years. Failure can cause catastrophic engine damage. Manual details procedures and torque settings for tensioners.

Engine Oil:

Typically API SF/SG or higher specification. Viscosity grades like 10W-40 or 5W-40 are common, depending on climate. Manual will provide OEM specifications (e.g., PSA E Series).

Coolant:

Ethylene glycol-based antifreeze/coolant. Manual will specify type (e.g., OAT or HOAT) and correct dilution ratio with distilled water.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil. Specific SAE viscosity grade (e.g., 75W-90) will be provided in the manual.

Transmission Fluid Automatic:

Dexron II or equivalent automatic transmission fluid. Capacity and change intervals will be detailed.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify type and bleeding procedures.

Power Steering Fluid:

Specific hydraulic fluid type (often ATF or a dedicated PSA fluid) will be listed in the manual for power steering systems.

Electrical Gremlins:

Aging wiring looms, corroded connectors, and failing relays can cause intermittent electrical issues. Manual's wiring diagrams are invaluable here.

Cooling System:

Plastic coolant expansion tanks can become brittle and crack. Thermostat housings and water pumps are also common wear items.

Suspension Wear:

Control arm bushings, ball joints, and tie rod ends can wear out, leading to clunking noises and imprecise steering. Manual details replacement procedures.

Exhaust System:

Rust on exhaust components is common due to age and climate. Manual helps in diagnosing and replacing exhaust sections.

📚 Vehicle History

Peugeot Legacy:

Peugeot has a long history of producing well-engineered and comfortable family cars, building on the success of models like the 504 and 305.

405 Launch:

Launched in 1987 as a replacement for the Peugeot 305, it was a significant step forward in styling and technology. The Estate version followed shortly after.

Facelift Updates:

Received a facelift in 1992, with updated styling (e.g., clearer indicators, revised grille) and improved interior trim. The manual likely covers both pre- and post-facelift variations.

Production Period:

1987-1996 (Europe)

Manufacturing Locations:

Primarily France (Mulhouse), with production also in other PSA Peugeot Citroën facilities and licensed assembly in countries like Iran.

🏆 Awards & Recognition

European Car Of The Year:

While not a winner, the Peugeot 405 was a strong contender and nominated for European Car of the Year 1988, finishing second.