Peugeot 405 Workshop Manual 1987–1997

Description

Factory Peugeot 405 Workshop Manual (1987–1997)

This is the same OEM dealer software used by authorized Peugeot service centers to diagnose and repair the 405 — covering every US-exported and international variant built across the full production run, from Phase 1 through the Phase 2 facelift.

Powertrain & Drive Coverage

Component	Variants Covered
Petrol	1.4L XU3, 1.6L XU5, 1.8L XU7, 1.9L XU9, 2.0L XU10
Diesel	1.8L XUD7 TE (turbodiesel), 1.9L XUD9, 1.9L XUD9 TE (turbodiesel)
Transmissions	5-speed manual (BE1, BE3), 4-speed automatic (ZF 4HP14)
Drive	FWD
Model Years	1987–1997
Badge Twins	Citroën ZX (shared XU engine/platform components); Peugeot 405 Mi16, T16 performance variants

Common 405 Repairs Covered

System	Procedures
XUD Diesel Head Gasket	Cylinder head removal, torque sequence, coolant system bleed on 1.9L XUD9 — a known failure point on high-mileage units
Fuel Injection (Bosch/Lucas)	Injector testing, fuel pressure regulation, and throttle body cleaning for XU-series petrol engines
Front Suspension	MacPherson strut replacement, lower arm bushings, and wheel bearing service with factory torque specs
BE3 Gearbox	Selector shaft seal replacement and synchromesh rebuild procedures addressing common 2nd-gear wear issues

Format & Delivery

Dealer software (Peugeot ServiceBox, VMware Virtual Machine — NOT a PDF). Compatible with Windows 11/10/8/7/Vista/XP, Mac, and Linux. Instant download; lifetime re-downloads.

Frequently Asked Questions

Is the XUD9 turbodiesel head gasket procedure included?

Yes. The 1.9L XUD9 and XUD9 TE turbodiesel head gasket is a well-documented failure on high-mileage 405s. The software includes the full cylinder head removal sequence, retorque specifications, and coolant system purge procedure specific to these engines.

Which 405 body styles and trim levels are supported?

All production variants are covered: the 4-door saloon and 5-door estate (Break), spanning trims from GL and GR through SR, SRi, Mi16, and the T16 performance model. Both Phase 1 (1987–1992) and Phase 2 facelift (1992–1997) generations are fully included.

Are interactive wiring diagrams included for the ABS and fuel injection systems?

Yes. The ServiceBox software provides color-coded, clickable wiring diagrams covering engine management, ABS, Bosch/Lucas fuel injection, climate control, lighting circuits, and central locking — with connector pinout data accessible directly within the interface.

What format is the manual?

This is not a PDF — it is the genuine Peugeot ServiceBox dealer software delivered as a VMware Player Virtual Machine image. It runs on Windows, Mac, and Linux and replicates the exact diagnostic and repair environment used at authorized Peugeot dealerships.