Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Current generation
- Dashboard
- Driving assistance
- Electrical harnesses
- Engine
- Equipment
- Front anti -roll bar
- Front axle
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Glovebox
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Power unit
- Pre-heating
- Protections and doors
- Rear axle
- Rear parcel tray
- Rear section
- Rear shock absorbers
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot 405 I
Step-by-step instructions on "Engine" for Peugeot 405 I (1987–2014). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Check liner protrusion (XU7JP4, XU7JP)
- Removing - refitting: ancillary drive belt (without air conditioning and with power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and without power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and with power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (without power steering and without air conditioning) (TU5JP4)
- Removing - refitting: engine ring seals (TU5JP4)
- Removing - refitting: ancillary drive belt (TU5JP4)
- Modification: MATCHING OF THE CRANKSHAFT HALF BEARING SHELLS
- Assembling the connecting rods/pistons (XU7JP4, XU7JP)
- Modification: securing of timing gear on crankshaft and accessories control pulley (TUF engine from engine no. 256463) (1.4)
- Modification: securing of timing gear on crankshaft and accessories control pulley (TUF engine from engine number 256463) (1.4)
- Modification: reciprocating gear
- Data - identification pistons - piston rings (XU7JP4, XU7JP)
- Data - identification conrods (XU7JP4, XU7JP)
- Data - identification half shells (XU7JP4, XU7JP)
- Data - identification crankshaft (XU7JP4, XU7JP)
- Data - identification liners (XU7JP4, XU7JP)
- Check crankshaft pulley (XU7JP4, XU7JP)
- Reduction in bearing clearances: crankshaft
Lubrication
- Data - tightening torques: lubrication (engine)
- Data - identification: lubrication (XU10J4TE engine)
- Data - identification: lubrication (XU10J4TE engine) — variant 2
- Recommendations: lubricants
- Recommendations: lubricants — variant 2
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure
- Check: oil pressure — variant 2
- Check: oil pressure — variant 3
- Check: oil pressure — variant 4
- Removing - refitting: oil pressure sensor (TU5JP4)
- Removing - refitting: oil pump (TU5JP4)
- Replace: engine oil filter cartridge
- Assembly: new engine oil filter cartridge
- Data: cooling system
- Replace: engine oil filter cartridge — variant 2
- Replacement: engine oil filter cartridge
Engine block
Cylinder head
- Modification: cylinder head
- Identification - data: cylinder head gasket
- Modification - cylinder head bolts
- Modification: valve guides
- Identification, data, tightening torque(s): cylinder head
- Data - identification cylinder heads (XU7JP4, XU7JP)
- Data - identification valve seats (XU7JP, XU7JP4)
- Data - identification valves (XU7JP, XU7JP4)
- Data - identification cylinder head gasket (XU7JP4, XU7JP)
- Data - identification valve springs (XU7JP, XU7JP4)
- Data - identification cylinder head bolts (XU7JP4, XU7JP)
- Data - identification valve guides (XU7JP4, XU7JP)
- Identification: cylinder head bolt
- Identification: cylinder head bolts
- Identification: cylinder head bolt — variant 2
- Identification: cylinder head bolts — variant 2
- Identification: cylinder head bolts — variant 3
- Identification: cylinder head bolts — variant 4
- Identification: cylinder head bolts — variant 5
- Removing - refitting cylinder head
- Removing - refitting: cylinder head (on vehicle) (TU5JP4)
- Removing - refitting: cylinder head — variant 2
- Removal - refitting: cylinder head
- Removing - refitting: cylinder head (XU10J4TE engine)
- Removal - refitting: cylinder head (XU10J4TE engine)
- Removal - refitting: rockers
- Removing - refitting: valve rockers
- Removing - refitting cylinder head (XU7JP)
- Removing - refitting cylinder head (XU7JP4)
- Modification: XU5JP, XU7JP engines (XU5JP, XU7JP)
- Modification: XU5, XU7 engine (XU7JP, XU5JP)
- Data: timing gear
- Checks and adjustments valve rockers
- Checks and adjustments - valve clearances (XU7JP, XU7JP4)
Timing gear
- Removing - refitting: ancillary drive belt (power assisted steering - air conditioning) (XU7JP4, XU7JP)
- Removing - refitting: camshaft (TU5JP4)
- Reference: timing belt (engines: XU all types except XU10J4)
- Modification: timing belt tension
- Data - identification camshafts (XU7JP, XU7JP4)
- Check: setting the valve timing (TU5JP4)
- Standard replacement
- Removing - refitting: timing belt (TU5JP4)
- Removal - refitting: XU5-XU7-XU9 timing belt
- Removing - refitting camshaft
- Removing - refitting timing belt
- Removing - refitting: timing belt (XU10J4TE engine)
- Removal - refitting: timing belt (XU10J4TE engine)
- Removing - refitting: camshaft (XU10J4TE engine)
- Removal - refitting: camshaft (XU10J4TE engine)
- Removing - refitting: accessories belt dynamic tensioner
- Removing - refitting: XU5-XU7-XU9 timing belt
- Removing - refitting camshaft (XU7JP)
- Removing - refitting camshaft (XU7JP4)
- Removing - refitting: timing belt (XU7JP)
- Removing - refitting timing belt (XU7JP4)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (part number 9776.X9)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (Part No. 9776.X9)
Cooling system
- Data cooling system
- Data: cooling system — variant 2
- Data: cooling system — variant 3
- Data: cooling system — variant 4
- Data: cooling system — variant 5
- Identification: fan (XUD9 engine from 70 860 016)
- Identification: fan (XUD9 engine from 70 860 016) — variant 2
- Production modifications: Coolant
- Production modifications: coolant — variant 2
- Identification of cooling system caps: cooling system
- Identification: components
- Removing - refitting coolant pump
- Removing - refitting: coolant outlet housing
- Removing - refitting: Coolant pump (TU5JP4)
- Removing - refitting: coolant outlet housing — variant 2
- Removing - refitting: engine cooling radiator (TU5JP4)
- Removing - refitting: cooling fan (TU5JP4)
- Removing - refitting: engine cooling radiator (TU5JP4) — variant 2
- Removal - refitting: coolant pump
- Removing - refitting: coolant pump — variant 2
- Removing - refitting: radiator
- Removal - refitting: radiator
- Drain and refill - refilling - bleeding: cooling system
- Draining - filling - bleeding: cooling system (XU10J4TE engine)
- Application: tooling
- Schematic diagram: coolant thermostat
- Check: purge canister solenoid valve function
- Check: purge canister solenoid valve function — variant 2
- Drain and refill - refilling: refrigerant circuit
- Draining - refilling: refrigerant circuit
- Drain and refill - refilling: refrigerant circuit — variant 2
Air and fuel supply
- Data - identification - carburettor - SOLEX 32/34 Z2 carburettor
- Data - identification: carburettor
- Data - identification: carburettor — variant 2
- Production modifications: injection pump drive pulley (XUD engine)
- Production modifications: injection pump drive pulley (XUD engine) — variant 2
- Identification: induction circuit
- Identification: air inlet circuit
- Replace: inlet manifold (XU7JP engine) (XU7JP)
- Replacement: inlet manifold (XU7JP engine) (XU7JP)
- Positioning: fuel gauge (transmitter)
- Checks: idling - emission control
- Checks: idling - emission control — variant 2
- Checks: idling - emission control — variant 3
- Checks: idling - emission control — variant 4
- Checks: idling - emission control — variant 5
- Checks: idling - emission control — variant 6
- Checks: idling - emission control — variant 7
- Checks: idling - emission control — variant 8
- Checks: idling - emission control — variant 9
- Checks: idling - emission control — variant 10
- Checks and adjustments SOLEX 32-34 Z2 carburettor
- Checks and adjustments
- Checks and adjustments: SOLEX 34/34Z1 - 32/34Z2 carburettor reference
- Checks and adjustments: load lever switch
- Checks and adjustments: load lever switch — variant 2
- Removal - refitting: injectors
- Removing - refitting: motorised throttle housing (TU5JP4)
- Removing - refitting: air cleaner (TU5JP4)
- Removing - refitting: Fuel filter (TU5JP4)
- Removing - refitting: Fuel tank (TU5JP4)
- Removing - refitting: injectors
- Removing - refitting: fuel system click-on connectors
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump LUCAS)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump LUCAS)
- Removing - refitting: fuel filter (XU7JP4, XU7JP)
- Replacement: fuel filter
- Replacement: diesel fuel filter
- Check: ignition advance
- Check: ignition advance — variant 2
- Check: ignition advance — variant 3
- Check: ignition advance — variant 4
Emission control
Turbocharging
Exhaust
Ignition
- Identification: fuel system
- Identification: fuel system — variant 2
- Pressurising the fuel system
- Pressurising the fuel system — variant 2
- Injection-ignition: BOSCH MP7.0
- Injection-ignition: BOSCH MP7.0 — variant 2
- Help in diagnosis
- Help in diagnosis — variant 2
- Check: ignition advance
- Check: ignition advance — variant 2
- Check high voltage present
- Check high voltage present — variant 2
- Check high voltage present — variant 3
- Check high voltage present — variant 4
- Check high voltage present — variant 5
- Check high voltage present — variant 6
- Foot Off/Foot Down recognition
- Foot Off/Foot Down recognition — variant 2
- Checks and adjustments: ignition advance
- Checks and adjustments: ignition advance — variant 2
- Injection-ignition wiring diagram: injection ignition
- Injection-ignition wiring diagram: injection ignition — variant 2