Haynes Peugeot 405 Service And Repair Manual(1).pdf

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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
© Haynes Publishing 1996
Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,
Somerset BA22 7JJ
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted
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
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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
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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
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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.
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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
• 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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