🏷️ Basic Information

Make:

Peugeot

Model:

405

Year:

1996

Chassis Code Range:

15B6, 15D6, 15E6, 15F6 (depending on engine and body style)

👋 Introduction

Segment:

Compact Executive / Large Family Car

Target Audience:

Independent repair shops, DIY enthusiasts, owners seeking to perform their own maintenance and repairs.

Competitors:

Ford Sierra, Volkswagen Passat, Vauxhall Cavalier/Opel Vectra, Renault Laguna, Fiat Croma.

Unique Selling Points:

Comprehensive coverage for a specific model year, detailed step-by-step instructions, clear diagrams, electrical schematics, torque settings, fluid capacities, spare parts illustrations.

Ease Of Use:

Designed to be user-friendly for varying skill levels, with clear, concise language and step-by-step instructions.

📋 Manual Details

Primary Coverage:

Peugeot 405 (1996 Model Year)

Regional Variants:

Likely covers European market variants, potentially global depending on the source of the original manual.

Estimated Page Count:

800-1200 (typical for comprehensive workshop manuals of this era)

Type:

Workshop Manual / Service and Repair Manual

Language:

English

Format:

PDF

Searchability:

PDF format allows for text searching of specific terms, procedures, or part numbers.

📖 Manual Coverage

Engine Systems:

Engine mechanical (assembly, disassembly, inspection), Engine management (injection, ignition), Cooling system, Lubrication system.

Drivetrain Systems:

Clutch (operation, inspection, replacement), Gearbox (manual and automatic transmission repair, overhaul), Drive shafts, Differentials.

Chassis Systems:

Suspension (front and rear suspension components, geometry, adjustment), Steering system, Braking system (disc and drum brakes, ABS if applicable), Wheels and tires.

Electrical Systems:

Wiring diagrams, Lighting system, Starting and charging system, Ignition system, Fuel injection system, Instrumentation, Accessories, Body electrical components.

Body Systems:

Bodywork repair, Interior trim, Doors, Windows, Seats, HVAC (Air Temperature Control System).

Maintenance:

Scheduled maintenance, Oil changes, Filter replacements, Spark plug replacement, Fluid checks and top-ups.

Diagnostics Troubleshooting:

Component testing, Fault finding for mechanical and electrical issues, Diagnostic codes (OBD I/II if applicable).

Repair Overhaul:

Engine rebuild, Transmission overhaul, Suspension component replacement, Brake caliper repair, Electrical component replacement.

Special Procedures:

Timing belt replacement, Fuel system bleeding, Air conditioning system servicing (if detailed).

Engine Repair:

Detailed procedures for engine disassembly, inspection of bearings, pistons, rings, cylinder heads, valve timing, lubrication system, cooling system, and reassembly.

Injection Ignition Repair:

Troubleshooting and repair of fuel injection systems (including injector testing, fuel pump checks, ECU diagnostics), ignition system components (coil, distributor, plugs, leads), and emission control systems.

Suspension Steering Repair:

Procedures for replacing shock absorbers, springs, control arms, ball joints, tie rod ends, wheel bearings, steering rack overhaul, and alignment specifications.

Braking System Repair:

Detailed instructions for servicing brake discs and pads, brake calipers, wheel cylinders, brake shoes, drum servicing, brake line replacement, master cylinder overhaul, and ABS system diagnostics/repair.

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic information and electrical schematics.

Diagrams Illustrations:

Includes detailed exploded view diagrams for all major components, step-by-step repair illustrations, and comprehensive wiring schematics for the entire vehicle.

📊 Manual Specifications

File Type:

PDF

Printability:

All pages are printable.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Options 1996:

Likely includes the XU series engines. Common variants for 1996 would be 1.8i (XU7 JP), 2.0i (XU10 JP, XU10 J2), and potentially the 1.9 TD (XUD9 TE). Specific engine codes would be detailed within the manual.

Horsepower Range:

Approximately 90-130 PS (66-96 kW) for naturally aspirated petrol, and around 90 PS (66 kW) for the turbodiesel, depending on the specific engine variant.

Torque Range:

Torque figures vary significantly by engine, with petrol engines ranging from approximately 140-180 Nm and turbodiesels around 180-200 Nm.

Injection System:

Bosch Motronic, Lucas/Delco-Remy, or Magneti Marelli electronic fuel injection (EFI) systems, depending on engine variant and market. Diesel variants would use mechanical injection pumps (e.g., Lucas/Cav or Bosch).

Ignition Type:

Electronic ignition with distributor or distributorless ignition systems (DIS) depending on the engine and model year update.

🔧 Transmission

Transmission Type:

5-speed Manual Transmission (often the BE series gearbox).

Transmission Type:

4-speed Automatic Transmission (e.g., ZF 4HP18 or similar).

Clutch Type:

Hydraulically operated dry single-plate clutch.

📐 Dimensions

Length:

Approximately 4514 mm (Saloon) / 4534 mm (Estate)

Width:

Approximately 1720 mm

Height:

Approximately 1420 mm (Saloon) / 1480 mm (Estate)

Curb Weight:

Approximately 1150-1350 kg, depending on engine and body style.

Gross Vehicle Weight:

Typically around 1700-1900 kg.

🛡️ Safety Features

Euro Ncap Rating:

The 405 was tested under older, less stringent Euro NCAP protocols or equivalent national safety schemes of its launch era. Detailed specific ratings for the 1996 model may be difficult to find, but it offered frontal airbags and seatbelt pre-tensioners as optional or standard on higher trims.

ABS:

Anti-lock Braking System (ABS) was often an optional feature, particularly on higher-specification models.

Airbags:

Driver's airbag typically standard on later models, passenger airbag optional.

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners for front occupants.

💡 Technology Features

Audio System:

Factory fitted radio cassette player or radio CD player, often with optional amplifiers and speaker upgrades. Manual will cover basic wiring and component location.

Cruise Control:

Optional on higher specification models.

Central Locking:

Standard on most models, often with remote operation on higher trims.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 km or 12 months, whichever comes first, depending on driving conditions and oil specification. Manual will provide precise intervals.

Timing Belt Interval:

Crucial maintenance item. For XU engines, typically 80,000-120,000 km or 5-6 years. Replacement is critical to avoid catastrophic engine damage.

Engine Oil:

Depends on engine type and climate. Common specifications include API SG/SH or ACEA A2-96/A3-96. Viscosities commonly 10W-40 or 5W-40. Manual will specify exact grades and capacities.

Coolant:

Ethylene glycol-based coolant with anti-corrosion inhibitors. Typically a 50/50 mix with distilled water. Manual will specify type and capacity.

Brake Fluid:

DOT 4 brake fluid is common. Manual will specify type and change interval.

Transmission Fluid:

Manual gearbox: API GL-4 SAE 75W-80 or 75W-90. Automatic transmission: Specific ATF fluid type (e.g., Dexron II/III or equivalent). Manual will provide precise specifications and capacities.

Common Problems:

Head gasket failure (especially on some petrol variants), radiator leaks, electrical gremlins (e.g., dashboard lights, central locking), rust in common areas (wheel arches, sills), suspension wear (e.g., wishbone bushes, ball joints), exhaust system corrosion, clutch wear. Diesel variants can suffer from injector pump issues or glow plug failure.

📚 Vehicle History

Peugeot History:

Peugeot, founded in 1810, has a long and distinguished history in automotive manufacturing, known for its engineering, comfort, and distinctive styling. The 405 continued Peugeot's tradition of well-engineered front-wheel-drive sedans and estates.

Peugeot 405 Lineage:

The 405 was launched in 1987, succeeding the Peugeot 405. It was praised for its Pininfarina-designed styling, comfortable ride, and good handling. The 1996 model year represents a later stage in the 405's lifecycle, likely with minor updates to trim, features, and potentially emissions controls.

Production Period:

1987-1997 (Europe), extended production in other markets (e.g., Iran).

Manufacturing Locations:

Primary production in France (Sochaux), also assembled in other countries like the UK, Finland, Egypt, and Iran.

🏆 Awards & Recognition

European Car Of The Year:

While not a direct award for the 1996 model, the Peugeot 405 was awarded the 'European Car of the Year' in 1988.