1987-1997 Peugeot 405 (Diesel) Service & Repair Manual

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•11 Coolant level Page 0•11 Brake fluid level Page 0•12 Power steering fluid level Page 0•12 Screen washer fluid level Page 0•13 Wiper blades Page 0•13 Tyre condition and pressure Page 0•14 Battery Page 0•15 Bulbs and fuses Page 0•15 Lubricants, fluids and tyre pressures Page 0•16 MAINTENANCE Routine Maintenance and Servicing Peugeot 405 diesel models · Page 1•1 Maintenance schedule Maintenance procedures Page 1•6

.REPAIRS AND OVERHAUL Engine and Associated Systems Engine in-car repair procedures Engine removal and overhaul procedures Cooling, heating and ventilation systems Fuel, exhaust and emission control systems Starting and charging systems Preheating system Transmission Clutch Manual transmission Drives hafts Brakes and Suspension Braking system Suspension and steering Body equipment Body'!)(,(lf,k apci'fittings Body electrical systems Wiring Diagrams REFERENCE Dimensions and weights · Conversion factors . Buying spare parts and vehicle identification General repair procedures Jacking and vehicle support Radio/cassette unit anti-theft system - precaution Tools and working facilities MOT test checks Fault finding Glossary of technical terms Index Contents Page 2A•1 Page 2B•1 Page. 3•1 Page 4•1 Page 5A•1 Page 5B•1 Page 6•1 Page 9•1 Page 10.•1 Page 11•1 Page 12•1 Page 12•22 Page REF•1 Page REF•2 Page REF•3 Page REF•4 Page REF•5 Page REF•5 Page REF•6 Page REF•B Page REF•12 Page REF•19 Page REF•23

o•4 Introduction The Peugeot 405 diesel mod,el range was introduced into the UK in 1988 in Saloon and Estate forms, with 1.8 litre (1769 cc) Turbo and 1.9 litre (1905 cc) normally-aspirated engines. All engines are derived from the well-proven XUD series engines, which have appeared in many Peugeot and Citroen vehicles. The engine is of four-cylinder overhead camshaft design, mounted transversely and inclined to the rear, with the transmission mounted on the left-hand side. All models have five-speed manual transmissions. All models have front-wheel-drive with fully-independent front _suspension. The rear suspension is semi-independent with torsion bars and trailing arms. lri 1992, the modef range was revised, and the bodywork, suspension and interior were all subtly modified. At the same time, the 1.9 litre· (1905 cc) Turbo engine was introduced to replace the ageing 1.7 litre (1769 cc) Turbo version. 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. Central locking, electric windows, an electric sunroof and an air bag are all available.· Later models are fitted with air conditioning as standard equipment. ' For the home mechanic, the Peugeot 405 is a straightforward Peugeot 405 GLXd Saloon The Peugeot 405 Team Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The team responsible for the creation of this book included: Author Sub-editor Editor & Page Make-up Workshop manager Photo Scans Cover illustration & Line Art Wiring diagrams Steve Rendle Carole Turk Bob Jex Paul Buckland John Martin Paul Tanswell Roger Healing 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. vehicle to mafHtain. and rep·air 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 fai..Jlts 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 la6our and overheads. The manual has drawings and de~criptions 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 ~tep-by-step sequence. References to the "left" or "right" of the vehicle are in the sense of a person in the driving seat, facing forwards. Peugeot 405 GTDT Estate Acknowledgements 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 Draper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We would also like to thank Mr Tony Brookes for information on heater matrix removal. 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 405 GLX TD Saloon, a 405 GLD Estate, and a 405 GLX TD Estate.

Working on your car can be di:tngerous. 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 ls 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 ar:iy part of the engine. 'Brake discs and drums can also be extremely hot immediately after use. Crushing 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 sh~rt-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. l;lectric shock -,, • Ignition HT . ,.,;:;;;::::v:;;:;:.;;:~ voltage can be dangerous, especially to ,- people with heart )- problems or a pacemaker. Don't work on or near the ignition system with f ; -...,. the engine running or ) J \ ! \ ' the ignition switched on. .• Mains voltage is also dangerous. Make sure that any mains-operated equipment is cofrectly earthed. Mains power points should be:protected bY a residua! current device (RCD) circuit breaker. · Fume or gas intoxication • Ekhaust fumes are poisonous; they often contain carbon monoxide, :ivhich is rapidly fatal if inhaled. Neiver 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 antifre·eze, brake hydraulic fluid and Diesel fuet 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 o'r 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 f!ame (including a cigarette). lt 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. Safety First! o·s Special hazards Hydrofluoric acid • This extremely corrosive acid is formed when certain types of synthetic r.ubber, found in some 0-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°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 instructib.ns m_ay 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.

0°6 Roadside Repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won't start and the starter motor doesn't turn 0 Open the bonnet and make sure that the battery terminals are clean and tight. 0 Switch on the headlights and try to start the engine. If the . headlights go very .dim when you're trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend's car. If your car won't start even though the starter motor turns as normal O Is there fuel in the tank? 0 Does the glow plug warning light come on and then go out when the ignition is switched on? If the light does not come on, check the wiring to the glow plugs and the fuel injection pump stop solenoid.- If there is moisture:on the wiring, spray a water-repellent aerosol product {such as-W0-40 or equivalent) on the wiring terminals shown in the photos. D Is there Bir in the fuel system? This is only likely if work has recently-been done on the fuel system components (such as fitting a new fuel filter). Bleed the fuel system as described in Chapter 4, This win get rid of any air, which may have got into the. system. " A .C:hSck. the condition and secudty of the battery connections, B The stop so!e.noid wiring terminal may cause problems If not connected . securely. C Check the preheating control unit wiring for security. Check that electrical connections· are secure (with. the 'ignition. switched off) and spray them with a water dispersant spray like WD40 i.f you suspect a problem due to damp . D Check the wiring to the glow plugs. E If there is air in the fuel system, the system can be bled as described in Chapter 4.

Roadside Repairs o•7 Connect one end of the red jump'leadJo the positive (+) term.inal of the flat l)attery ---------- ... I I I W.hen jump-starting a car using a booster battery, observe the following precautions: t/ Before connecting the booster battery, make sure that the ignition is switched off. t/ Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. t/ Take note of any special precautions printed on the battery case. Connect the other end of the red lead to the positive(+) terminal of the booster battery. r---- 1 r·· I I I I I I I I I I I I I .. ------------------------------~ - . Jump starting t/ Make sure that the booster battery is the same voltage as the discnarged one in the vehicle. t/ If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. t/ Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). Connect. one end of the black jump lead to the negative(-) terminal of the booster battery Co~i)~C.t:J~.~!ie!.~' ,'/·',;p;>:•'f·.·.·.-'.'', .<·· ·,,,,:¢kJLI.rTIP lead to .~:.:1?:0,lt:gr:l:).~~F~.Ef~:'()P. tti~. ·~ngine block, we.u.:,;:1.~ay,.fr9~;,:·the· battery i· on the vehicle to be started; .. . ···1·· . .. M ... ake •.". re tha .. tthe ju. mp leads wil.l . .not come into contact with the fan, drive- , --_ belts or other moving -parts of the engine. I Start the engine using the booster _battery and run it at idle speed. Switch _ o'n, the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc.

o•a Roadside Repairs Wheel changing Sorile of th.e· details shown here will vary according to mOdel. For instance, the location of the spare wheel and ja6k is not the same on all cars. However, the basic principles apply to all vehicles. Preparation D When a puncture occurs, stop as soon as it is safe to do so. D Park on firm level ground, if possible, · and well out of the way of other trciffic. 0 Use hazard warning lights. if necessary, Changing the wheel 1 In ·the boot, use th·e whee1 bf-ace to Jodsen the spare whSel cradle b6!t 7 Remove the bolts and 'lift the wheel ciear, then fit the spare whee'!. Refit the Wheel bolts and tighten modercitely. With·. the wheel brace. Warning: Do not change a wheel in a situation Where you risk being hit by other traffic. On busy roads,· .try to stop in a Jay-by or a gateway. Be waty of passing traffic while changing the wheel·- it is easy to become distracted by the job .in hand. D If you. ·have one, use a warning triangle to alert.other drivers of your presence. D Apply the handbrake and engage first or reverse gear. O Chock the wheel diagonally opposite the 2 ·Re'move the spare wheel from the· ·cradle. 5 Locate the jack head in the jacking point and use the brace to raiSe the car until the wheel .is clear of the ground. 8 Lower the car to the ground, then finally tighten the wheel bolts In a diagonal sequence. Fit the whee'l trim and secure the damaged wheel in the spare wheel cradle. one being removed - a couple of large stones will do for this. D If the ground is soft, use a flat piece of wood to spread .the load under the foot of the jack. 3 6 Use the wheel brac'e to remove the wheel trim. "For safety iti thei event of the jack slipping, position the spare whee! under the sm, close to the jacking point. Finally ..• D Remove the wheel chocks. D Stow the jack and tools ir'l the correct locations in the car. D Make sure that the spare wheel cradle is properly secured, or: it could drop onto the road while driving. D Check the tyre pressure on the wheel just fitted. If it is low, or if you don't have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to the right pressure. D Have the damaged tyre or wheel repaired as soon as possible.

Puddles on the garage floor or drive, or obvious wetness · under the bonnet or underneath the car, suggest aJeak.that needs investigating. It can sometimes .be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem Hes. Sump oil Engine oil may leak from the drain plug.,, Antifreeze Leaking antifreeze often leaves ·a crystalline deposit llke this. When all else fails, you may find yourself having to get a tow home - or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: D Use a proper tow-rope - they are not expensive. ·The vehicle being towed must display an 'ON TOW' sign in its rear window. D Always turn the ignition key to the 'on', position when the vehicle is being towed, so Roadside Repairs o•9 Warning: Most auto.motive oils and fluids are poisonous. Wash them off skin, and change out of contaminated clothing. without delay. Oil .from filter ... orJrOITrthe b8.se of the Oil filter. Brake fluid A 1eak oct:urring·at a wheel ·is almost certainly brakeJJuid. . that the steering lock is released, and that the direction indi.cator and br.ake. lights Will work. D Only atta.ch the tow-rope to . .the towing. eye.s prOyided'. D BBfore beirig·towed, release the.handbia1s:e· and select neutral on the transm.ission. D Note that . greater-than-usual. ..~:~~~I pressure will be required t.o opeJa.te_'::;,t_he brakes,. since the vacuum servo ·unit is. on.ly operational with the engine running, D On models with poWer steerin"g; ·greater- than-usua! steering effort will a!sQ .be requtred. Identifying leaks Gearbox oil Gearbox oil can leak from the· seals at the inboard ends of the driveshafts, Power steering fluid PoWer.steering'fluid m·ay leak frPrrtthS.pipe connectors on · ''/:> Towing [].The·: ddver '.Of the. c·a:r. be.i·ng towed must l<;~.ep the to.w-rope taut at all times to avoid _s.n13,t¢hing .. Er .fy't.a.ke·su.re that both drivers know the route - 0.efbre setting off. D .Ohly driv·e· at mo.derate speeds aiid keep the· ·distanc·e towed ·to a minimum. Drive srrioothly"Cl.nd :a11ow plenty of time for slowing dO.wn at junctions.

0°10 Weekly Checks Introduction There· are som.e very simple checks which heed .only .take a few minutes to carry _out, but whic.h c?uld __ save· you a lot of.iriconVenience and expense. These "Weel<ly.checks» req~ire no great. skill or. special tools, and tt)e small .amount of time they take to perform could prove to be very well sp.en't. D Keeping an eye on tyre condition and . pressures, will not only .help to stop them wearing out prematurely, but could also Save your life. ' D Many breakdowns are caused by electrical problems. Battery-related faults are particularly common, and a quick check on a regular basis will often prevent the majority of these. Underbonnet check points D If your car develops a brake fluid leak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem. D If the oil or coolant levels run low, the cost of repairing any engine damage will be far greater than fixing the leak, for example. .,. Non-turbo models A Engine oil level dipstick B Engine oil filler cap C Cooiant expansion tank D Brake fluid reservoir E Power steering fluid reservoir f Screen washer fluid reservoir G Battery <II Turbo models A Engine oil /eve! dipstick B Engiiie oil filler cap' C Coolant expansion tank D Brake fluid reservoir E Power steering fluid reservoir F Screen washer fluid _reservoir G Battery

Engine oil level Before you start t/ Make sure your car is on level ground. t/ Check the oil level before the car ls driven, or at least 5 minutes after the .engine has been switched off. The correct oil Modern engines place great demands on their oil. It is very important that the correct. pi/, for your car is used (See ''.Lubricants, fluids and tyre pressures'?. Car Care • If you have to add oil fre·quentty, you should check whether you have any oil leaks. PlaCe some clean paper under thei car overnight, and check for stains in the morning. If there are no leaks, the engine may. be burning oil (see "Fault Finding"). 8 Always maintain the level between the upper and lower dipstick marks (see photo 3). If the level is too low severe engine damage may occur .. Oi! seal fai,IUre may result if the engine is overfilled by adding too muC:h oil. Coolant level Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a vel)f great risk of scalding. Do not leave open Containers of coolant about, as it is poisonous. 1 The coolant' level varies···with: en·gi.rte temperat[Jre .. When cold, the:coo!ant level should be on the "MAXI" mark (arrowed). When hot, the level may riSe slightly above the "MAXI" mark. A· warning light will come on if the level falls dangerously low. Weekly Checks 0°11 1 .The dipstick is iii a plastic housing· at the front of the engine (see jJ.Underbonnet Check·Points" on page 0•10 for exac.t ·location). Withdraw the dipstick. 3 Note the Oil level on. the· end ··of the dipstick,· which should be between the upper ("MAX") mark aod lower ("MIN") mark. Approximately 1.5 litres of oil wm raise . the level from the lower mark to the upper mark. Car Care e With a· sealed-type cooling system, adding coolant should not be necessary. on a regular' basis. !f frequent t.oppi.ng-up is required,· it is !ikety there is·.a leak. Ch.eek 'the radiator, all hoses and joint faces for signs of staining or wetriess, and rectify as necessary. 2 To top up the system th~ expa·nsioR.t8hk·.·. cap must: be remov.Sd. Wait, until the, engine is cold. Turn . the cap anti- clockwise until it reaches the first stop. Once any pressure is released, push the cap down, turn lt to the second stop, and lift off. ·2 Using a clean. rag or paper towel remove · all ·oil from the dipstick. Insert the clean diPs.tick into the tube as far as it will go, then withdraw it again. 4 Oil.is added through the filler cap. Where applicable, release the clips, then pull out the cap and. top-up the level. A funnel may help to reduce· spillage. Add the oil slowly, checking the level on the dipstick often. Don't ovetii!I. e It is important that antifreeze is used in the cooling system all year round, not just during the winter months. Don't top-up with water alone, as the antifreeze will become too diluted. 3 . ··Add·a mixture of wate·r and antifreeze ·through the e~pansion tank filler neck, until the coolant is up to the "MAXI" level mark: ·Refit the cap,·turning it .clockwise as far as it will go until it is secure.

1987-1997 Peugeot 405 (Diesel) Service & Repair Manual

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