Vehicle Segment:
Compact/Mid-size family car
Target Audience:
DIY mechanics, independent repair shops, Peugeot enthusiasts
Key Competitors Era:
Ford Sierra, Opel/Vauxhall Vectra, Volkswagen Passat, Renault 21, Fiat Croma
Design Influences:
Designed by Pininfarina, known for its aerodynamic and elegant styling.
Manual Utility:
Essential for accurate diagnostics, efficient repairs, and preserving the longevity of the Peugeot 405.
Engine Mechanical:
Full coverage of all engine variants, including disassembly, assembly, inspection, and repair of all internal components (pistons, rings, bearings, crankshaft, camshaft, valves, etc.)
Engine Management And Emissions:
Detailed diagnostics and repair procedures for fuel injection systems (Bosch Motronic, Magneti Marelli), ignition systems, sensor testing, and emission control systems (catalytic converter, EGR, EVAP).
Transmission Manual:
Complete overhaul and repair procedures for manual gearboxes, including clutch replacement, gear selection mechanisms, and internal component servicing.
Transmission Automatic:
Diagnostic and repair information for automatic transmissions, including fluid checks, hydraulic system diagnosis, and internal component repair where applicable.
Suspension And Steering:
Detailed procedures for front and rear suspension component replacement (struts, shocks, control arms, bushings), power steering system diagnosis and repair, and wheel alignment specifications.
Brakes:
Comprehensive coverage of hydraulic brake systems, including disc and drum brake servicing, ABS diagnostics and component testing, brake fluid specifications, and bleeding procedures.
Electrical System:
Extensive electrical schematics, wiring diagrams for all major systems, component testing procedures, fuse and relay identification, and troubleshooting for lighting, charging, starting, and accessory circuits.
Body And Chassis:
Information on body panel repair, door and window mechanisms, interior trim removal and installation, corrosion prevention, and chassis component identification.
Heating Ventilation And Air Conditioning (HVAC):
Diagnostic and repair procedures for the HVAC system, including refrigerant handling (where applicable), blower motor, A/C compressor, and climate control unit servicing.
Routine Maintenance:
Detailed step-by-step instructions for oil changes, filter replacements, spark plug service, coolant flushes, and general inspection points.
Troubleshooting Diagnostics:
Systematic diagnostic trees and symptom-based troubleshooting guides for common and uncommon issues across all vehicle systems.
Component Replacement:
Detailed instructions for replacing virtually every mechanical and electrical component on the vehicle.
Engine Rebuilds:
Complete instructions for engine disassembly, inspection, measurement of critical components, and reassembly with torque specifications.
Transmission Overhauls:
Guidance on the complete disassembly, cleaning, inspection, and reassembly of both manual and automatic transmissions.
Brake System Repair:
Procedures for replacing brake pads, rotors, calipers, brake lines, and ABS components.
Electrical Component Testing And Replacement:
Instructions on how to test and replace alternators, starters, sensors, relays, ECUs, and other electrical modules.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, including advanced electrical diagnostics.
Common Engine Variants:
1.6L (XU5), 1.8L (XU7), 2.0L (XU9/XU10 J4/J4R - including Mi16), 1.9L TD (XUD7TE), 1.9L D (XUD7)
Typical Horsepower Range:
60 hp (1.9D) to 160 hp (2.0 Mi16)
Typical Torque Range:
81 lb-ft (1.9D) to 133 lb-ft (2.0 Mi16)
Fuel Delivery Petrol:
Carbureted (early models) and Multi-point Fuel Injection (MPI) depending on engine and market.
Fuel Delivery Diesel:
Indirect injection, often with turbocharging (TD).
Oil Change Interval:
Typically every 7,500 - 10,000 miles (12,000 - 15,000 km) or 12 months, depending on driving conditions and oil type.
Timing Belt Replacement:
Critical. Typically every 60,000 miles (96,000 km) or 5 years for petrol engines. Diesel engines may have different intervals or chain-driven camshafts.
Coolant Specification:
Peugeot-approved coolant or OAT (Organic Acid Technology) coolant, typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF or specific PSA hydraulic fluid (e.g., LHM for certain hydraulic systems, though less common on the 405 than some other Peugeot models).
Common Faults:
Rear axle beam failures (common for independent rear suspension), electrical gremlins (e.g., dashboard faults, central locking issues), injector seal leaks on diesel engines, thermostat housing leaks, clutch slave cylinder failure.
Maintenance Tips:
Regularly check and replace the timing belt, inspect the rear suspension torsion bars and bearings for wear, and address any electrical issues promptly to prevent cascading failures.
Peugeot Heritage:
Peugeot has a long history of producing robust and comfortable family cars, with models like the 404 and 504 being iconic predecessors.
405 Introduction:
Launched in 1987 as a successor to the Peugeot 305 and 405 predecessor, sharing a platform with the Citroën BX.
1992 Update:
The 1992 model year represents the latter half of the 405's production run, often incorporating minor styling updates, improved safety features, and updated engine management systems.
Production Period:
1987 - 1997 (Europe), continued production in other regions (e.g., Iran) beyond this date.
