The 1987-1997 Peugeot 405 service repair manual is comprehensive coverage of all saloon and estate variants including the legendary Mi-16 16-valve. Engine rebuilds for XU series, timing belt service, fuel injection diagnostics, ABS troubleshooting, suspension refresh, wiring diagrams, and troubleshooting for all Peugeot 405 models from the European Car of the Year winner.
1987-1997 Peugeot 405 Service Repair Workshop Manual
VEHICLE/EQUIPMENT INTRODUCTION:
The Peugeot 405 was a landmark model for the French manufacturer, designed by the legendary Pininfarina studio and launched in 1987 to critical acclaim that included the European Car of the Year award for 1988. It was Peugeot flagship in the large family car segment, replacing the aging 505, and it combined sophisticated aerodynamic styling with sophisticated chassis dynamics that earned Peugeot its reputation for producing the best-handling family sedans in Europe. Under the skin, the 405 featured an advanced torsion beam rear suspension and MacPherson strut front geometry tuned by Peugeot chassis engineers to deliver exceptional composure on winding roads.
The 405 range was offered with an impressive selection of engines across its production run. Entry-level buyers could choose the 1.4-liter XU3J or 1.6-liter XU5J SOHC petrol engines, while the heart of the lineup was the versatile 1.9-liter XU9J SOHC. Performance variants featured the legendary 2.0-liter XU10J DOHC engine, most famously in the 16-valve Mi-16 variant jointly developed with Cosworth, producing 158 horsepower and making the 405 a genuine performance sedan. The turbocharged Mi-16 T16 variant took output to 196 horsepower with all-wheel drive. Diesel options included the rugged 1.9-liter XUD9 indirect injection engine. The estate (break) variant provided practical family transport while the saloon carried Pininfarina signature elegant proportions.
SERVICE & REPAIR SCOPE:
- XU series engine overhaul including XU5, XU9, XU10 8V and 16V variants
- Timing belt replacement, hydraulic lifter inspection, head gasket replacement
- Mi-16 16-valve engine valve timing with Cosworth-designed head
- Manual gearbox Peugeot BA and BE series bearing and syncromesh service
- Automatic transmission ZF 4HP18 overhaul
- Torsion beam rear suspension trailing arm bearing and seal replacement
- Front MacPherson strut cartridge replacement and top bearing renewal
- Power steering rack rebuild and pump overhaul
- Bendix ABS Teves hydraulic unit diagnostic and repair
- Complete fuel injection systems including Bosch Motronic and Magneti Marelli
- Electric window motor and regulator replacement
- Central locking pump and door actuator troubleshooting
- Air conditioning system compressor, condenser, and blower motor service
- Full wiring harness diagrams for all equipment levels
TECHNICAL SPECIFICATIONS:
- 1.4 XU3J SOHC: 1360cc, 75 HP, 111 Nm
- 1.6 XU5J SOHC: 1580cc, 88-102 HP, 134 Nm
- 1.8 XN/Diesel variants available
- 1.9 XU9J SOHC: 1905cc, 105-125 HP, 160-170 Nm
- 2.0 XU10J DOHC 16V (Mi-16): 1998cc, 158 HP, 185 Nm
- 2.0 Turbo (T16 4WD): 1998cc, 196 HP, 288 Nm
- 1.9 XUD9 diesel: 1905cc, 68-90 HP
- Transmissions: 5-speed manual Peugeot BA/BE, ZF 4HP18 auto
- Front suspension: MacPherson strut with coil springs
- Rear suspension: Trailing arm torsion beam with coil springs
- Front brakes: Ventilated disc, Rear: disc (drum on base models)
- Wheelbase: 2670mm
DIAGNOSTIC INFORMATION:
- Timing belt maintenance: replace every 60,000 km, inspect tensioner bearing, align camshaft timing marks precisely to avoid valve contact on interference engines
- Head gasket failure on XU9: monitor coolant level, pressure test combustion chambers, inspect head surface flatness, use OEM gasket
- Mi-16 rough idle: clean throttle body, test idle air control valve, check coolant temperature sensor resistance, verify fuel pressure at rail
- Window not operating: test motor with 12V direct, inspect switch contacts, check wiring in door hinge boot for fatigue breaks
- Overheating at idle: check electric cooling fan operation, test fan relay and thermal switch, inspect water pump for impeller slippage
- Power steering whine: check fluid level, bleed air from system, inspect pump belt tension, test rack internal bypass
- ABS warning light: read fault codes via diagnostic connector, check wheel speed sensor air gap, inspect hydraulic modulator for leaks
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- XU engine family exploded views with timing belt routing and tensioner detail
- Mi-16 16-valve head with camshaft timing reference marks
- Manual gearbox cross-section with bearing preload settings
- Rear torsion beam suspension with trailing arm bearing detail
- Bendix Teves ABS hydraulic schematic with component locations
- Complete vehicle wiring diagrams by electrical system
- Bosch Motronic fuel injection system with sensor locations
- HVAC heater matrix removal from instrument panel
- Power steering rack exploded view with seal kit contents
COMPATIBILITY:
- Models: Peugeot 405 Saloon and Estate 1987-1997
- Engines: 1.4, 1.6, 1.8, 1.9, 2.0 SOHC and DOHC petrol plus diesel
- Includes Mi-16 and limited edition variants
- File format: Searchable PDF document
- Compatible with Windows, macOS, Linux, tablets, and smartphones
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
1987-1997 Peugeot 405 Service Repair Workshop Manual
VEHICLE/EQUIPMENT INTRODUCTION:
The Peugeot 405 was a landmark model for the French manufacturer, designed by the legendary Pininfarina studio and launched in 1987 to critical acclaim that included the European Car of the Year award for 1988. It was Peugeot flagship in the large family car segment, replacing the aging 505, and it combined sophisticated aerodynamic styling with sophisticated chassis dynamics that earned Peugeot its reputation for producing the best-handling family sedans in Europe. Under the skin, the 405 featured an advanced torsion beam rear suspension and MacPherson strut front geometry tuned by Peugeot chassis engineers to deliver exceptional composure on winding roads.
The 405 range was offered with an impressive selection of engines across its production run. Entry-level buyers could choose the 1.4-liter XU3J or 1.6-liter XU5J SOHC petrol engines, while the heart of the lineup was the versatile 1.9-liter XU9J SOHC. Performance variants featured the legendary 2.0-liter XU10J DOHC engine, most famously in the 16-valve Mi-16 variant jointly developed with Cosworth, producing 158 horsepower and making the 405 a genuine performance sedan. The turbocharged Mi-16 T16 variant took output to 196 horsepower with all-wheel drive. Diesel options included the rugged 1.9-liter XUD9 indirect injection engine. The estate (break) variant provided practical family transport while the saloon carried Pininfarina signature elegant proportions.
SERVICE & REPAIR SCOPE:
- XU series engine overhaul including XU5, XU9, XU10 8V and 16V variants
- Timing belt replacement, hydraulic lifter inspection, head gasket replacement
- Mi-16 16-valve engine valve timing with Cosworth-designed head
- Manual gearbox Peugeot BA and BE series bearing and syncromesh service
- Automatic transmission ZF 4HP18 overhaul
- Torsion beam rear suspension trailing arm bearing and seal replacement
- Front MacPherson strut cartridge replacement and top bearing renewal
- Power steering rack rebuild and pump overhaul
- Bendix ABS Teves hydraulic unit diagnostic and repair
- Complete fuel injection systems including Bosch Motronic and Magneti Marelli
- Electric window motor and regulator replacement
- Central locking pump and door actuator troubleshooting
- Air conditioning system compressor, condenser, and blower motor service
- Full wiring harness diagrams for all equipment levels
TECHNICAL SPECIFICATIONS:
- 1.4 XU3J SOHC: 1360cc, 75 HP, 111 Nm
- 1.6 XU5J SOHC: 1580cc, 88-102 HP, 134 Nm
- 1.8 XN/Diesel variants available
- 1.9 XU9J SOHC: 1905cc, 105-125 HP, 160-170 Nm
- 2.0 XU10J DOHC 16V (Mi-16): 1998cc, 158 HP, 185 Nm
- 2.0 Turbo (T16 4WD): 1998cc, 196 HP, 288 Nm
- 1.9 XUD9 diesel: 1905cc, 68-90 HP
- Transmissions: 5-speed manual Peugeot BA/BE, ZF 4HP18 auto
- Front suspension: MacPherson strut with coil springs
- Rear suspension: Trailing arm torsion beam with coil springs
- Front brakes: Ventilated disc, Rear: disc (drum on base models)
- Wheelbase: 2670mm
DIAGNOSTIC INFORMATION:
- Timing belt maintenance: replace every 60,000 km, inspect tensioner bearing, align camshaft timing marks precisely to avoid valve contact on interference engines
- Head gasket failure on XU9: monitor coolant level, pressure test combustion chambers, inspect head surface flatness, use OEM gasket
- Mi-16 rough idle: clean throttle body, test idle air control valve, check coolant temperature sensor resistance, verify fuel pressure at rail
- Window not operating: test motor with 12V direct, inspect switch contacts, check wiring in door hinge boot for fatigue breaks
- Overheating at idle: check electric cooling fan operation, test fan relay and thermal switch, inspect water pump for impeller slippage
- Power steering whine: check fluid level, bleed air from system, inspect pump belt tension, test rack internal bypass
- ABS warning light: read fault codes via diagnostic connector, check wheel speed sensor air gap, inspect hydraulic modulator for leaks
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- XU engine family exploded views with timing belt routing and tensioner detail
- Mi-16 16-valve head with camshaft timing reference marks
- Manual gearbox cross-section with bearing preload settings
- Rear torsion beam suspension with trailing arm bearing detail
- Bendix Teves ABS hydraulic schematic with component locations
- Complete vehicle wiring diagrams by electrical system
- Bosch Motronic fuel injection system with sensor locations
- HVAC heater matrix removal from instrument panel
- Power steering rack exploded view with seal kit contents
COMPATIBILITY:
- Models: Peugeot 405 Saloon and Estate 1987-1997
- Engines: 1.4, 1.6, 1.8, 1.9, 2.0 SOHC and DOHC petrol plus diesel
- Includes Mi-16 and limited edition variants
- File format: Searchable PDF document
- Compatible with Windows, macOS, Linux, tablets, and smartphones
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
