Haynes Peugeot 405 Diesel 88-96.pdf

Peugeot 405 (petrol)

Service and Repair Manual

Steve Rendle and A K Legg LAE MIMI

Models covered

Saloon and Estate models with 4-cylinder SOHC and DOHC petrol engines,

including Mi-16 and special/limited editions;

1.4 (1360 cc), 1.6 (1580 cc), 1.8 (1761 cc), 1.9 (1905 cc) and 2.0 (1998 cc)

(1559-336)

For Diesel engine models, see OWM 3198

Does not cover four-wheel-drive models

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,

Somerset BA22 7JJ

A book in the Haynes Service and Repair Manual Series

in any form or by any means, electronic or mechanical, including

photocopying, recording or by any information storage or retrieval system,

without permission in writing from the copyright holder.

Haynes Publishing

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

ISBN 1 85960 174 X

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library.

Editions Haynes S.A.

147/149, rue Saint Honoré, 75001 PARIS, France

Contents

LIVING WITH YOUR PEUGEOT 405

Introduction to the Peugeot 405

Page 0•4

Safety first!

Page 0•5

Roadside Repairs

If your car won’t start

Page 0•6

Jump starting

Page 0•7

Wheel changing

Page 0•8

Identifying leaks

Page 0•9

Towing

Page 0•9

Weekly Checks

Introduction

Page 0•10

Underbonnet check points

Page 0•10

Engine oil level

Page 0•12

Coolant level

Page 0•12

Brake fluid level

Page 0•13

Power steering fluid level

Page 0•13

Tyre condition and pressure

Page 0•14

Screen washer fluid level

Page 0•15

Wiper blades

Page 0•15

Battery

Page 0•16

Bulbs and fuses

Page 0•16

Lubricants, fluids and tyre pressures

Page 0•17

MAINTENANCE

Routine Maintenance and Servicing

Peugeot 405 petrol models

Page 1•1

Maintenance schedule - models up to 1993

Page 1•3

Maintenance schedule - models from 1994

Page 1•4

Maintenance procedures

Page 1•8

Contents

REPAIRS AND OVERHAUL

Engine and Associated Systems

TU petrol engine in-car repair procedures

Page 2A•1

XU petrol engine in-car repair procedures

Page 2B•1

Engine removal and overhaul procedures

Page 2C•1

Cooling, heating and ventilation systems

Page 3•1

Fuel/exhaust systems - carburettor models

Page 4A•1

Fuel/exhaust systems - single-point fuel injection models

Page 4B•1

Fuel/exhaust systems - multi-point fuel injection models

Page 4C•1

Emission control systems

Page 4D•1

Starting and charging systems

Page 5A•1

Ignition system

Page 5B•1

Transmission

Clutch

Page 6•1

Manual transmission

Page 7A•1

Automatic transmission

Page 7B•1

Driveshafts

Page 8•1

Brakes and Suspension

Braking system

Page 9•1

Suspension and steering

Page 10•1

Body equipment

Bodywork and fittings

Page 11•1

Body electrical systems

Page 12•1

Wiring Diagrams

Page 12•22

REFERENCE

Dimensions and weights

Page REF•1

Conversion factors

Page REF•2

Buying spare parts and vehicle identification

Page REF•3

General repair procedures

Page REF•4

Jacking and vehicle support

Page REF•5

Radio/cassette unit anti-theft system - precaution

Page REF•5

Tools and working facilities

Page REF•6

MOT test checks

Page REF•8

Fault finding

Page REF•12

Glossary of technical terms

Page REF•20

Index

Page REF•25

0•4 Introduction

The Peugeot 405 model range was introduced into the UK in

January 1988 in Saloon form only.

Available with 1.6, 1.8, 1.9 and 2.0 engines, all models have front-

wheel-drive with all round independent suspension.

Automatic transmission models were introduced in April 1988.

In July 1988 came the sporty Mi 16 version with its 1.9 litre double

overhead cam, 16-valve engine, uprated gearbox, suspension and an

ABS braking system to match its power.

Estate car versions were introduced in October 1988.

From 1991, engines equipped with catalytic converters were

progressively introduced, to meet the more stringent exhaust gas

emission regulations.

Since its introduction, the 405 range has continually been

developed. All models have a high trim level, which is very

comprehensive in the upper model range.

For the home mechanic, the Peugeot 405 is a straightforward

vehicle to maintain and repair since design features have been

incorporated to reduce the actual cost of ownership to a minimum, and

most of the items requiring frequent attention are easily accessible.

Your Peugeot 405 Manual

The aim of this manual is to help you get the best value from your

vehicle. It can do so in several ways. It can help you decide what work

must be done (even should you choose to get it done by a garage),

provide information on routine maintenance and servicing, and give a

logical course of action and diagnosis when random faults occur.

However, it is hoped that you will use the manual by tackling the work

yourself. On simpler jobs, it may even be quicker than booking the car

into a garage and going there twice, to leave and collect it. Perhaps

most important, a lot of money can be saved by avoiding the costs a

garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of

the various components, so that their layout can be understood. Then

the tasks are described and photographed in a clear step-by-step

sequence.

Peugeot 405 SRi Saloon

Peugeot 405 GL Estate

The Peugeot 405 Team

Acknowledgements

Haynes manuals are produced by dedicated and

enthusiastic people working in close co-operation. The

team responsible for the creation of this book included:

Thanks are due to Champion Spark Plug who supplied the

illustrations showing spark plug conditions. Certain other illustrations

are the copyright of the Peugeot Talbot Motor Company Limited, and

are used with their permission. Special thanks to Gliddons of Taunton

who provided several of the project vehicles used in the origination of

this manual. Thanks are also due to Sykes-Pickavant Limited, who

provided some of the workshop tools, and to all those people at

Sparkford who helped in the production of this manual.

We take great pride in the accuracy of information given in this

manual, but vehicle manufacturers make alterations and design

changes during the production run of a particular vehicle of which

they do not inform us. No liability can be accepted by the authors

or publishers for loss, damage or injury caused by any errors in, or

omissions from, the information given.

Project vehicles

The vehicles used in the preparation of this manual, and which

appear in many of the photographic sequences, were a Peugeot 405

GL Saloon, a Peugeot 405 GTX Estate, a Peugeot 405 GR Saloon, and

a Peugeot GTX Saloon.

Authors

Steve Rendle

Andy Legg

Sub-editor

Carole Turk

Editor & Page Make-up

Bob Jex

Workshop manager

Paul Buckland

Photo Scans

John Martin

Paul Tanswell

Cover illustration & Line Art

Roger Healing

Wiring diagrams

Matthew Marke

We hope the book will help you to get the maximum

enjoyment from your car. By carrying out routine

maintenance as described you will ensure your car’s

reliability and preserve its resale value.

Safety First! 0•5

Working on your car can be dangerous.

This page shows just some of the potential

risks and hazards, with the aim of creating a

safety-conscious attitude.

General hazards

Scalding

• Don’t remove the radiator or expansion

tank cap while the engine is hot.

• Engine oil, automatic transmission fluid or

power steering fluid may also be dangerously

hot if the engine has recently been running.

Burning

• Beware of burns from the exhaust system

and from any part of the engine. Brake discs

and drums can also be extremely hot

immediately after use.

Crushing

• When working under or near

a raised vehicle,

always

supplement the

jack with axle

stands, or use

drive-on

ramps.

Never

venture

under a car which

is only supported by a jack.

• Take care if loosening or tightening high-

torque nuts when the vehicle is on stands.

Initial loosening and final tightening should

be done with the wheels on the ground.

Fire

• Fuel is highly flammable; fuel vapour is

explosive.

• Don’t let fuel spill onto a hot engine.

• Do not smoke or allow naked lights

(including pilot lights) anywhere near a

vehicle being worked on. Also beware of

creating sparks

(electrically or by use of tools).

• Fuel vapour is heavier than air, so don’t

work on the fuel system with the vehicle over

an inspection pit.

• Another cause of fire is an electrical

overload or short-circuit. Take care when

repairing or modifying the vehicle wiring.

• Keep a fire extinguisher handy, of a type

suitable for use on fuel and electrical fires.

Electric shock

• Ignition HT

voltage can be

dangerous,

especially to

people with heart

problems or a

pacemaker. Don’t

work on or near the

ignition system with

the engine running or

the ignition switched on.

• Mains voltage is also dangerous. Make

sure that any mains-operated equipment is

correctly earthed. Mains power points should

be protected by a residual current device

(RCD) circuit breaker.

Fume or gas intoxication

• Exhaust fumes are

poisonous; they often

contain carbon

monoxide, which is

rapidly fatal if inhaled.

Never run the

engine in a

confined space

such as a garage

with the doors shut.

• Fuel vapour is also

poisonous, as are the vapours from some

cleaning solvents and paint thinners.

Poisonous or irritant substances

• Avoid skin contact with battery acid and

with any fuel, fluid or lubricant, especially

antifreeze, brake hydraulic fluid and Diesel

fuel. Don’t syphon them by mouth. If such a

substance is swallowed or gets into the eyes,

seek medical advice.

• Prolonged contact with used engine oil can

cause skin cancer. Wear gloves or use a

barrier cream if necessary. Change out of oil-

soaked clothes and do not keep oily rags in

your pocket.

• Air conditioning refrigerant forms a

poisonous gas if exposed to a naked flame

(including a cigarette). It can also cause skin

burns on contact.

Asbestos

• Asbestos dust can cause cancer if inhaled

or swallowed. Asbestos may be found in

gaskets and in brake and clutch linings.

When dealing with such components it is

safest to assume that they contain asbestos.

Special hazards

Hydrofluoric acid

• This extremely corrosive acid is formed

when certain types of synthetic rubber, found

in some O-rings, oil seals, fuel hoses etc, are

exposed to temperatures above 400 0 C. The

rubber changes into a charred or sticky

substance containing the acid. Once formed,

the acid remains dangerous for years. If it

gets onto the skin, it may be necessary to

amputate the limb concerned.

• When dealing with a vehicle which has

suffered a fire, or with components salvaged

from such a vehicle, wear protective gloves

and discard them after use.

The battery

• Batteries contain sulphuric acid, which

attacks clothing, eyes and skin. Take care

when topping-up or carrying the battery.

• The hydrogen gas given off by the battery

is highly explosive. Never cause a spark or

allow a naked light nearby. Be careful when

connecting and disconnecting battery

chargers or jump leads.

Air bags

• Air bags can cause injury if they go off

accidentally. Take care when removing the

steering wheel and/or facia. Special storage

instructions may apply.

Diesel injection equipment

• Diesel injection pumps supply fuel at very

high pressure. Take care when working on

the fuel injectors and fuel pipes.

Warning: Never expose the hands,

face or any other part of the body

to injector spray; the fuel can

penetrate the skin with potentially fatal

results.

Remember...

• Do use eye protection when using power

tools, and when working under the vehicle.

• Do wear gloves or use barrier cream to

protect your hands when necessary.

• Do get someone to check periodically

that all is well when working alone on the

vehicle.

• Do keep loose clothing and long hair well

out of the way of moving mechanical parts.

• Do remove rings, wristwatch etc, before

working on the vehicle – especially the

electrical system.

• Do ensure that any lifting or jacking

equipment has a safe working load rating

adequate for the job.

A few tips

DON’T

• Don’t attempt to lift a heavy component

which may be beyond your capability – get

assistance.

• Don’t rush to finish a job, or take

unverified short cuts.

• Don’t use ill-fitting tools which may slip

and cause injury.

• Don’t leave tools or parts lying around

where someone can trip over them. Mop

up oil and fuel spills at once.

• Don’t allow children or pets to play in or

near a vehicle being worked on.

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