Peugeot 405. Manual - part 5

0•16

Weekly Checks

Bulbs and fuses

4 Check all external lights and the horn.
Refer to the appropriate Sections of Chap-
ter 12 for details if any of the circuits are
found to be inoperative.

4 Visually check all accessible wiring
connectors, harnesses and retaining clips for
security, and for signs of chafing or damage.

If you need to check your
brake lights and indicators
unaided, back up to a wall or
garage door and operate the

lights. The reflected light should show
if they are working properly.

If a single indicator light, stop-light or
headlight has failed, it is likely that a bulb
has blown and will need to be replaced.

Refer to Chapter 12 for details. If both stop-
lights have failed, it is possible that the switch
has failed (see Chapter 9).

If more than one indicator light or tail light
has failed it is likely that either a fuse has
blown or that there is a fault in the circuit

(see Chapter 12). The fuses are located
behind a panel on the bottom of the driver’s
side lower facia panel.

To replace a blown fuse, simply pull it out
and fit a new fuse of the correct rating
(see wiring diagrams in Chapter 12). If the

fuse blows again, it is important that you find
out why - a complete checking procedure is
given in Chapter 12.

Battery

Caution: Before carrying out any work on the
vehicle battery, read the precautions given in
"Safety first" at the start of this manual.
4 Make sure that the battery tray is in good
condition, and that the clamp is tight.
Corrosion on the tray, retaining clamp and the
battery itself can be removed with a solution
of water and baking soda. Thoroughly rinse all
cleaned areas with water. Any metal parts
damaged by corrosion should be covered
with a zinc-based primer, then painted.
4 Periodically (approximately every three
months), check the charge condition of the
battery as described in Chapter 5A.
4 If the battery is flat, and you need to jump
start your vehicle, see Roadside Repairs.

The battery is located on the left-hand
side of the engine compartment. The
exterior of the battery should be

inspected periodically for damage such as a
cracked case or cover.

Check the tightness of the battery cable
clamps (A) to ensure good electrical
connections. You should not be able to

move them. Also check each cable (B) for
cracks and frayed conductors.

Battery corrosion can be kept to a
minimum by applying a layer of
petroleum jelly to the clamps and
terminals after they are reconnected.

If corrosion (white fluffy deposits) is
evident, remove the cables from the
battery terminals, clean them with a small

wire brush, then refit them. Tools for cleaning
the battery post and terminals are available.

Note that the battery negative terminal
stud can be removed for cleaning or

renewal. Unscrew the lead clamp, then pull off
the plastic insulator, and lever off the stud and
cover.

Lubricants and fluids

Lubricants, fluids and tyre pressures

0•17

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multigrade engine oil, viscosity SAE 10W/40 to

20W/50, to API SG/CD or better

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ethylene glycol based antifreeze

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . .

Gear oil, viscosity 75W/80W, to API GL5

Automatic transmission . . . . . . . . . . . . . . . . . . . . . .

Dexron II type ATF

Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic fluid to SAE J1703F or DOT 4

Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dexron II type ATF

Tyre pressures

Saloon models

Front

Rear

165/70 R 14 T tyres . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

175/70 R 14 T tyres:

Manual gearbox models . . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

Automatic transmission models . . . . . . . . . . . . . .

2.2 bars (32 psi)

185/65 R 14 H tyres

Manual gearbox models . . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

Automatic transmission models . . . . . . . . . . . . . .

2.2 bars (32 psi)

195/55 R 15 V tyres . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 bars (32 psi)

Estate models

175/70 R 14 T tyres:

Normal load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

2.3 bars (33 psi)

Full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

2.8 bars (41 psi)

185/65 R 14 H tyres:

Normal load:

Manual gearbox models . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

2.2 bars (32 psi)

Automatic transmission models . . . . . . . . . . . . .

2.2 bars (32 psi)

2.3 bars (33 psi)

Full load:

Manual gearbox models . . . . . . . . . . . . . . . . . . .

2.1 bars (30 psi)

2.8 bars (41 psi)

Automatic transmission models . . . . . . . . . . . . .

2.2 bars (32 psi)

2.8 bars (41 psi)

Note: Refer to the tyre pressure data label at the bottom of the rear edge of the driver’s door (visible when
the door is open) for the correct tyre pressures for your particular vehicle. Pressures apply only to original-
equipment tyres, and may vary if any other make or type is fitted; check with the tyre manufacturer or
supplier for correct pressures if necessary.

Chapter 1
Routine maintenance and servicing

Accelerator cable check and adjustment  . . . . . . . . . . . . . . . . . . . . . . .9
Air conditioning refrigerant check . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Air filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Automatic transmission fluid level check  . . . . . . . . . . . . . . . . . . . . . . .4
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .23
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . . . . . . . . . . . .5
Body drain channel check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Brake fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Clutch adjustment check and control mechanism lubrication  . . . . . .12
Coolant renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Driveshaft gaiter check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Emissions control systems check  . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Engine breather hose check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine oil and filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Front and rear disc pad check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Fuel filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Handbrake check and adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Hinge and lock lubrication  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hose and fluid leak check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Idle speed and mixture check and adjustment  . . . . . . . . . . . . . . . . .10
Ignition system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Intensive maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Manual transmission oil level check  . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pollen filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Rear brake shoe check - models with rear drum brakes  . . . . . . . . . .27
Road test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Spark plug renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Steering and suspension check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

1•1

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert
DIY or professional

Degrees of difficulty

Contents

Lubricants and fluids

Refer to the end of “Weekly checks”

Capacities

Engine oil

TU engine - with filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 litres

TU engine - without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 litres

XU engine (8-valve) - with filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.0 litres

XU engine (8-valve) - without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 litres

XU engine (16-valve) - with filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 litres

XU engine (16-valve) - without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.0 litres

Cooling system (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 litres

Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 litres

Automatic transmission:

Drain and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 litres

After overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 litres

Power steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.7 litres

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 litres

Engine

Oil filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion F104

Cooling system

Antifreeze mixture:

28% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection down to -15°C(-5°F)

50% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection down to -30°C(-22°F)

Fuel system

Idle speed:

TU carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 ± 50 rpm

XU carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 ± 50 rpm

XU5 and TU3 single-point injection (not adjustable) . . . . . . . . . . . . .

850 ± 50 rpm

Bosch L3.1 multi-point injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

925 ± 25 rpm

Other multi-point injection systems (not adjustable) . . . . . . . . . . . . .

850 ± 50 rpm

Idle mixture CO content:

TU carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8%

XU carburettor engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5%

XU5 and TU3 single-point injection (not adjustable) . . . . . . . . . . . . .

Less than 0.5 %

XU5, XU7, XU9, XU10 multi-point injection (not adjustable) . . . . . . .

Less than 1.0 %

Air filter element:

TU engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion V401

XU engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion U543

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L101, L206, L132 or L135

Ignition system

Spark plugs:

TU and XU carburettor engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C9YCC

XU injection 8-valve engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C7YCC

XU injection16-valve engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC7BMC

Spark plug electrode gap*:

8-valve engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

16-valve engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 mm

Ignition HT lead resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approximately 600 ohms per 100 mm length

*The spark plug gap quoted is that recommended by Champion for their specified plugs listed above.

Brakes

Front/rear brake pad friction material minimum thickness . . . . . . . . . . .

2.0 mm

Rear brake shoe friction material minimum thickness . . . . . . . . . . . . . .

1.0 mm

Tyre pressures

See end of “Weekly Checks”.

Torque wrench settings

lbf ft

Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual gearbox drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roadwheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1•2

Servicing Specifications

содержание .. 3 4 5 6 ..