Peugeot 405 Workshop Service and Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 405 Generation Production Years: 1987-1997 (Europe), 1988-2012 (Iran & Egypt) Codes Chassis Codes: Type 155 👋 Introduction Market Position Segment: Family car, mid-size...

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Generation

Production Years:

1987-1997 (Europe), 1988-2012 (Iran & Egypt)

Codes

Chassis Codes:

Type 155

👋 Introduction

Market Position

Segment:

Family car, mid-size sedan/hatchback.

Competitive Analysis

Competitors:

Ford Sierra, Opel Vectra, Volkswagen Passat, Renault 21, Fiat Croma.

Key Features

Design Philosophy:

Value Proposition:

Offers a blend of performance, comfort, and durability, making it a popular choice in its segment.

Value Proposition

Manual Benefit:

Provides factory-level repair information, saving significant costs compared to dealer service or purchasing official CD-ROMs.

📋 Manual Details

Coverage Areas

Manual Coverage:

Comprehensive workshop service and repair information for the Peugeot 405.

Page Count

Estimated Page Count:

Varies by specific engine/body configuration, but typically extensive for a full workshop manual.

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English (based on product description, typical for international manuals)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

All aspects of engine operation, maintenance, repair, and overhaul (petrol and diesel).

Fuel System:

Fuel injection, carburetion (if applicable), fuel pump, lines, and tank.

Cooling System:

Radiator, thermostat, water pump, hoses, and coolant specifications.

Lubrication And Maintenance:

Oil change intervals, fluid specifications, filter replacements, lubrication points.

Exhaust System:

Muffler, catalytic converter, pipes, and emissions control integration.

Transmission:

Manual and automatic transmission overhaul, repair, clutch, and drive shafts.

Brakes:

Hydraulic system, disc/drum brakes, ABS (if equipped), fluid types, and service procedures.

Suspension:

Front and rear suspension components, alignment, shock absorbers, and bushings.

Steering:

Power steering system, steering rack, linkages, and wheel alignment.

Electrical System:

Battery, charging system, starter, ignition, lighting, and accessory circuits.

Wiring Diagrams:

Detailed electrical wiring schematics for all vehicle systems.

Body:

Body panel repair, door mechanisms, interior trim, glass replacement, and chassis.

Heating And Air Conditioning:

HVAC system operation, components, refrigerant, and service.

Emission Control Systems:

Catalytic converter, EGR (if applicable), and emissions-related component testing.

Procedures Included

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major components.

Maintenance Procedures:

Regular service tasks, fluid changes, filter replacements, and inspection points.

Troubleshooting:

Diagnostic procedures for common problems and fault finding.

Diagnostics:

Guidance on identifying and resolving mechanical and electrical issues.

Technical Depth

Depth:

Full workshop level, covering everything from basic maintenance to complete engine/transmission rebuilds.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all PC-based Windows operating systems and Mac.

Print Quality

Print Capability:

Fully printable; users can print all, specific sections, or individual pages.

Binding Type

Binding:

N/A (Digital PDF Format)

Paper Type

Paper Type:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Primary Engine

Petrol Engines:

1.6L (XU5), 1.8L (XU7), 2.0L (XU9/XU10) variants, including fuel-injected versions (e.g., Mi16 2.0L 16v).

Diesel Engines:

1.9L (XUD7) Naturally Aspirated Diesel, 1.9L (XUD9) Turbocharged Diesel.

Performance

Typical Horsepower Range:

60 hp (1.6D) to 160 hp (2.0 Mi16).

Engine Code Examples:

XU5M, XU7JP, XU9J2, XU10J4, XUD7TE, XUD9TE.

Fuel System

Injection Systems:

Bosch L-Jetronic, Motronic, K-Jetronic (early models).

Carburetors:

Solex, Weber (on some lower-spec variants).

🔧 Transmission

Standard

Manual Gearboxes:

5-speed manual (e.g., BE1, MA5).

Optional

Automatic Gearboxes:

4-speed automatic (e.g., ZF 4HP18).

Features

Drive Type:

Front-wheel drive (FWD).

All Wheel Drive:

Limited availability on specific performance variants (e.g., 405 T16).

📐 Dimensions

Exterior

Length:

Approx. 4400 mm (173.2 in)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1400 mm (55.1 in)

Weights

Curb Weight Range:

Approx. 1050 kg to 1300 kg depending on engine and trim.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not applicable for early production years (pre-Euro NCAP standards). Later models would conform to evolving European safety standards.

Active Features

Optional on many models, standard on higher trims and performance variants.

Passive Features

Airbags:

Driver airbag optional or standard on later models; passenger airbag less common.

Seatbelts:

Pre-tensioned front seatbelts.

💡 Technology Features

Infotainment

Audio Systems:

Basic AM/FM radio with cassette player, optional CD player on later models. Factory speaker systems.

Driver Assistance

Cruise Control:

Available as an option on higher trim levels and larger engine variants.

Connectivity

Connectivity Features:

Limited by era; typically basic power windows, central locking on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 - 15,000 km (4,500 - 9,000 miles) or 12 months, depending on engine and oil type (refer to manual for specific engine).

Timing Belt Replacement:

Crucial for non-interference engines; typically every 60,000 - 120,000 km (37,000 - 75,000 miles) depending on engine and belt type (check manual).

Fluid Specifications

Engine Oil Grade:

API SG/SH, ACEA A2/A3. Viscosity typically 10W-40 or 5W-40 for petrol, 15W-40 or 10W-40 for diesel. Specifics vary by engine.

Coolant Type:

Ethylene glycol-based antifreeze. Peugeot recommends specific coolants (e.g., Glycol 301).

Brake Fluid:

DOT 3 or DOT 4.

Transmission Fluid Manual:

API GL-4 SAE 75W-80 or 75W-90 gear oil.

Transmission Fluid Automatic:

ATF Dextron II/III (ZF spec may vary, check manual).

Known Issues

Common Problems:

Rear axle beam wear (requiring rebuild), electrical gremlins (especially in older wiring), radiator leaks, fuel pump issues, heater control valve failure.

Performance Variant Specific:

Mi16 models can suffer from piston ring wear and oil consumption; timing chain guides can be a wear item.

📚 Vehicle History

Brand Heritage

Peugeot History:

Peugeot, a French automotive manufacturer, has a long history dating back to 1810 (initially producing tools and bicycles).

Model Evolution

Predecessor:

Peugeot 305.

Successor:

Peugeot 406.

Production

Manufacturing Locations:

France (Sochaux), Italy (limited production), Iran (Iran Khodro), Egypt.

Rally Heritage:

The 405 achieved significant success in motorsport, particularly in the World Rally Championship (405 T16).

🏆 Awards & Recognition

Recognitions

European Car Of The Year:

Nominated for European Car of the Year 1988 (finished second).