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Table Of Contents

   Also See for PEUGEOT 405

   Summary of Contents for PEUGEOT 405

  • Page 2

    Peugeot 405 (petrol) Service and Repair Manual Steve Rendle and A K Legg LAE MIMI Models covered (1559-336) 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)

  • Page 3: Table Of Contents

    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...

  • Page 4: Wiring Diagrams

    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...

  • Page 5

    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 We hope the book will help you to get the maximum a Peugeot GTX Saloon.

  • Page 6

    Safety First! 0•5 Working on your car can be dangerous. • Mains voltage is also dangerous. Make Special hazards This page shows just some of the potential sure that any mains-operated equipment is risks and hazards, with the aim of creating a correctly earthed.

  • Page 7

    Roadside Repairs 0•6 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 If your car won’t start and the starter motor even though the starter...

  • Page 8: Jump Starting

    Roadside Repairs 0•7 Jump starting Jump starting will get you out of trouble, but you must correct whatever made the battery go When jump-starting a car using a Make sure that the booster battery is flat in the first place. There are booster battery, observe the following the same voltage as the discharged three possibilities:...

  • Page 9: Wheel Changing

    Roadside Repairs 0•8 Wheel changing Some of the details shown here will vary 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 lay-by or a gateway. Be wary of according to model.

  • Page 10: Gearbox Oil, Power Steering Fluid, Brake Fluid, Identifying Leaks

    Roadside Repairs 0•9 Identifying leaks Puddles on the garage floor or drive, or Warning: Most automotive oils The smell of a fluid leaking obvious wetness under the bonnet or and fluids are poisonous. Wash from the car may provide a underneath the car, suggest a leak that needs them off skin, and change out of clue to what’s leaking.

  • Page 11: Underbonnet Check Points

    Weekly Checks 0•10 Introduction There are some very simple checks which Keeping an eye on tyre condition and If your car develops a brake fluid leak, the need only take a few minutes to carry out, but pressures, will not only help to stop them first time you might know about it is when which could save you a lot of inconvenience wearing out prematurely, but could also save...

  • Page 12

    Weekly Checks 0•11 1.9 litre Engine oil level dipstick Engine oil filler cap Coolant filler cap Brake fluid reservoir Power steering fluid reservoir Screen washer fluid reservoir 2.0 litre Engine oil level dipstick Engine oil filler cap Coolant filler cap Brake fluid reservoir Power steering fluid reservoir Screen washer fluid reservoir...

  • Page 13: Engine Oil Level, Coolant Level

    Weekly Checks 0•12 Engine oil level Before you start 4 Make sure your car is on level ground. 4 Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some of the oil will...

  • Page 14: Brake Fluid Level, Safety First, Power Steering Fluid Level

    Weekly Checks 0•13 Brake fluid level Warning: Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. Warning: Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness.

  • Page 15: Tyre Condition And Pressure

    Weekly Checks 0•14 Tyre condition and pressure It is very important that tyres are in good the tyre has been punctured, refit the nail so New tyres should be balanced when they are condition, and at the correct pressure - having that its point of penetration is marked.

  • Page 16: Wiper Blades, Screen Washer Fluid Level

    Weekly Checks 0•15 Screen washer fluid level Screenwash additives not only keep the weather - which is when you are likely to need freeze during cold weather. On no account winscreen clean during foul weather, they also it most. Don’t top up using plain water as the use coolant antifreeze in the washer system prevent the washer system freezing in cold screenwash will become too diluted, and will...

  • Page 17: Bulbs And Fuses

    Weekly Checks 0•16 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.

  • Page 18: Tyre Pressures, Lubricants, Fluids And Tyre Pressures

    Lubricants, fluids and tyre pressures 0•17 Lubricants and fluids Engine ........Multigrade engine oil, viscosity SAE 10W/40 to 20W/50, to API SG/CD or better Cooling system .

  • Page 19: Table Of Contents

    1•1 Chapter 1 Routine maintenance and servicing Contents Accelerator cable check and adjustment ..... . .9 Fuel filter renewal .........8 Air conditioning refrigerant check .

  • Page 20: Servicing Specifications

    Servicing Specifications 1•2 Lubricants and fluids Refer to the end of “Weekly checks” Capacities Engine oil TU engine - with filter ........3.5 litres TU engine - without filter .

  • Page 21: Maintenance Schedule - Models Up To

    Maintenance schedule - models up to 1993 1•3 The maintenance intervals in this manual wish to perform some of these procedures speeds (idling in traffic) or on short journeys, are provided with the assumption that you will more often. encourage frequent more frequent maintenance intervals are be carrying out the work yourself.

  • Page 22: Maintenance Schedule - Models From

    In addition to all the items listed above, carry out the following: Renew the timing belt (Section 25) - this is the Check the air conditioning system refrigerant interval recommended by Peugeot, but we (Section 19) recommend that the belt is changed more Renew the spark plugs (Section 11) frequently, at 36 000 miles - see above.

  • Page 23

    Maintenance & Servicing 1•5 Underbonnet view of a 1580 cc carburettor engine 1 Left-hand suspension strut top mounting 2 Battery 3 Air filter housing 4 Cold air inlet duct 5 Bonnet lock 6 Bonnet release latch 7 Engine oil filler cap/tube 8 Carburettor air inlet duct (carburettor below) 9 Radiator (coolant filler) cap...

  • Page 24

    Maintenance & Servicing 1•6 Underbonnet view of a 1905 cc engine 1 Left-hand strut top mounting 2 Battery 3 Fuel damper 4 Power steering fluid reservoir 5 Air filter cover 6 Fuel injection control unit 7 Thermostat housing 8 Cold air inlet 9 Throttle housing 10 Brake servo vacuum hose 11 Bonnet lock...

  • Page 25

    Maintenance & Servicing 1•7 Front underbody view of a 1905 cc engine model 1 Fuel lines 2 Front exhaust silencer 3 Brake lines 4 Front subframe rear mounting 5 Steering rack mountings 6 Exhaust downpipe 7 Steering tack rod 8 Lower suspension arm 9 Radiator lower hose 10 Engine oil sump 11 Rear engine mounting...

  • Page 26: Maintenance Procedures

    Access to the underside of the Peugeot dealer. vehicle will be greatly improved if it can be 1 Frequent oil and filter changes are the most...

  • Page 27

    2 With the engine idling and the selector lever 18 000 miles (30 000 km). in the “P” (Park) position, withdraw the Note: Peugeot specify the use of a special dipstick from the tube, and wipe all the fluid electronic tool (SEEM C.TRONIC type 105 belt from its end with a clean rag or paper towel.

  • Page 28

    6000 Mile / 6 Month Service 1•10 checked using the special electronic tool at the earliest opportunity. 1 Except for XU9J4 16-valve engines, all models are fitted with one auxiliary drivebelt driven from the crankshaft pulley on the right- hand side of the engine. On non-air conditioning models the belt drives the alternator and power steering pump and its tension is adjusted manually.

  • Page 29: Hose And Fluid Leak Check, Engine Breather Hose Check

    35 Loosen the pump mounting bolts and system leaks. If the original Peugeot crimped- deterioration. remove the drivebelt. type hose clips are used, it may be a good...

  • Page 30

    If this is not (Sections 7 and 29). filter. Bearing in mind the information given in available, the car must be taken to a Peugeot e) Check that the air cleaner filter element is the relevant Part of Chapter 4 on depres- dealer for the work to be carried out.

  • Page 31

    If this is not available, required, it is made via mixture adjustment the screw, use a sharp instrument to hook out the car must be taken to a Peugeot dealer for screw located on the airflow meter (see the plug.

  • Page 32: Spark Plug Renewal

    (carbon build-up, bore the car must be taken to a Peugeot dealer for Chapter). If this type is used, and the engine is wear etc) or after a major overhaul, the the work to be carried out.

  • Page 33: Driveshaft Gaiter Check

    12 000 Mile / 12 Month Service 1•15 11.5 Pulling the HT leads 11.7 Tools required for spark plug 11.12 Measuring the spark plug gap with a from the spark plugs removal, gap adjustment and refitting feeler blade 6 It is advisable to remove the dirt from the 10 If the insulator nose is covered with light 2 The clutch itself should function correctly, spark plug recesses, using a clean brush,...

  • Page 34

    12 000 Mile / 12 Month Service 1•16 the wheel. Repeat this check by holding the 2 Inspect the balljoint dust covers and the inner joint and attempting to rotate the steering rack-and-pinion gaiters for splits, driveshaft. Any obvious movement indicates chafing or deterioration.

  • Page 35: Hinge And Lock Lubrication, Coolant Renewal

    No fluid flow - have the system checked tailgate securely when raised. for leaks by a Peugeot dealer or air conditioning specialist. 19 Air conditioning refrigerant c) Continuous stream of clear air bubbles in...

  • Page 36

    “header tank” when refilling the cooling system, to reduce the possibility of air being trapped in the system. Although Peugeot dealers use a special header tank, the same effect can be achieved by using a suitable bottle, with a seal between the bottle and the expansion tank (see illustration and Haynes Hint).

  • Page 37: Air Filter Renewal

    (see illustration). Where the crimped-type become progressively less effective. the retaining clips (where fitted). Peugeot hose clips are fitted, cut the clips and 32 Always use an ethylene-glycol based discard them; use standard worm-drive hose antifreeze which is suitable for use in mixed- XU models clips on refitting.

  • Page 38: Ignition System Check

    24 000 Mile / 2 Year Service 1•20 21.9 Removing the air filter element 21.13 Disconnect the intake duct from the 21.14a . . . then slacken the retaining front of the cylinder head cover . . . screws (arrowed) . . . 21.14b .

  • Page 39: Brake Fluid Renewal

    24 000 Mile / 2 Year Service 1•21 24 Brake fluid renewal Note: On models from 1994, the maker’s specified interval for this procedure is every 2 years, regardless of mileage. Warning: Brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it.

  • Page 40: Timing Belt Renewal, Pollen Filter Renewal, Road Test

    Peugeot dealer. 5 Filling the transmission with oil is an 9000 miles (15 000 km) or 12 months. Haynes Hint: It may be possible to use the extremely awkward operation;...

  • Page 41

    If any problems are found, they engine. As the engine starts, there should be a should be referred to a Peugeot dealer. Drivetrain noticeable “give” in the brake pedal as 12 Listen for a metallic clicking sound from 6 Check the performance of the engine, clutch vacuum builds up.

  • Page 42

    2A•1 Chapter 2 Part A: TU petrol engine in-car repair procedures Contents Camshaft and rocker arms - removal, inspection and refitting ..10 Engine/transmission mountings - inspection and renewal ..16 Camshaft oil seal - renewal .

  • Page 43

    The 405 range is fitted with the 1360 cc carried out on the TU series engine while it 10 The camshaft is driven by a toothed version of the engine;...

  • Page 44

    Refer to a inspection and refitting.* sprocket bolt, noting that it should always be Peugeot dealer or other specialist if in doubt h) Cylinder head - removal and refitting. rotated in a clockwise direction (viewed from as to whether a particular pressure reading is i) Cylinder head and pistons - decarbonising.

  • Page 45

    (see illustration). negative lead. Where the original crimped-type Peugeot hose clip is still fitted, cut it off and discard it. 5 Timing belt covers - removal Use a standard worm-drive clip on refitting.

  • Page 46

    8 If the timing belt is to be re-used, use white retaining bolts. to be correct. Refer to a Peugeot dealer for paint or similar to mark the direction of Centre cover advice.

  • Page 47

    Note: If this method is used, ensure that the 1 Disconnect the battery negative terminal. or 15, then tighten the tensioner pulley nut to belt tension is checked by a Peugeot dealer at 2 Position the engine assembly/valve timing the specified torque.

  • Page 48

    In the absence of the special 7.10 Use the fabricated tool shown to lock 7.11a Remove the crankshaft sprocket Peugeot tool, an acceptable substitute can be flywheel ring gear and prevent the retaining bolt . . . fabricated as follows. Use two lengths of steel...

  • Page 49

    2A•8 TU engine in-car repair procedures flanged spacer, aligning its slot with the seats on its locating shoulder. Use a suitable screw as necessary. Once the correct Woodruff key. tubular drift, such as a socket, which bears clearance is obtained, hold the adjusting 25 Align the crankshaft sprocket slot with the only on the hard outer edge of the seal.

  • Page 50

    TU engine in-car repair procedures 2A•9 10.5a To remove the left-hand pedestal, 10.5b . . . then remove the grub screw 10.8 Undo the retaining bolt, and remove lock two nuts together the camshaft thrust fork (arrowed) . . . and unscrew the stud .

  • Page 51

    In the removed as an assembly. from the throttle body/fuel rail (plug all absence of the special Peugeot liner All models openings, to prevent loss of fuel and entry clamps, the liners can be clamped in 17 Slacken and remove the bolt securing the of dirt into the fuel system).

  • Page 52

    Molykote G Rapid Plus grease models only one thickness of gasket is position, whereas on the thicker “repair” (available from your Peugeot dealer - a sachet available, so this is not a problem. However, gasket there will be a single cut-out (see on all other models, there are two different is supplied with the top-end gasket set);...

  • Page 53

    2A•12 TU engine in-car repair procedures 11.37a Cylinder head bolt tightening 11.37b Working in the sequence shown, 11.38 . . . then through the angle sequence tighten the head bolts first to the specified for stage 2 stage 1 torque setting . . . that an angle-measuring gauge is used during 47 Reconnect the coolant hoses to the 2 Drain the engine oil, then clean and refit the...

  • Page 54

    However, it may be possible to have it the strainer cover. Remove the relief valve the crankcase. surface-ground; seek the advice of a Peugeot piston and spring (and guide pin - cast-iron 6 Wash off any traces of oil, then refit the dealer or engine reconditioning specialist.

  • Page 55

    2A•14 TU engine in-car repair procedures 8 If the new flywheel retaining bolts are not Renewal 18 Check carefully for signs of wear or supplied with their threads already pre- damage on all components, and renew them Right-hand mounting coated, apply a suitable thread-locking where necessary.

  • Page 56: Specifications

    2B•1 Chapter 2 Part B: XU petrol engine in-car repair procedures Contents Camshaft and followers - removal, inspection and refitting ..10 Engine/transmission mountings - inspection and renewal ..18 Camshaft oil seal(s) - renewal .

  • Page 57

    *The engine code is either stamped on a plate attached to the front left-hand end of the cylinder block on 1761 cc engines and stamped directly onto the front face of the cylinder block (just to the left of the oil filter) on 1998 cc engines. This is the code most often used by Peugeot. The code given in brackets is the factory identification number, and is not often referred to by Peugeot or this manual.

  • Page 58

    XU engine in-car repair procedures 2B•3 Camshaft (continued) Cylinder head bearing journal diameter (inside diameter): 1580 cc and 1905 cc models: No 1 ..........27.000 to 27.033 mm No 2 .

  • Page 59

    The clutch and transmission are attached to This Part of Chapter 2 describes those 16-valve), the engine is of the conventional its left-hand end. The 405 range is available repair procedures that can reasonably be “dry-liner” type. The cylinder block is cast in...

  • Page 60

    The oil cooler is supplied with coolant from camshaft sprocket(s) and crankshaft pulley. Note that the special Peugeot locking pins are the engine cooling system. The holes are used to align the crankshaft and...

  • Page 61

    2B•6 XU engine in-car repair procedures 7 Lift off the cylinder head cover, and remove 15 Pull each ignition HT coil off its spark it along with its rubber seal. Examine the seal plug. Trace the coil wiring back to its for signs of damage and deterioration, and if connector on the left-hand end of the cylinder necessary, renew it.

  • Page 62

    XU engine in-car repair procedures 2B•7 4.29 On 1761 cc and 1998 cc 8-valve 4.32 Fitting a spark plug hole oil seal 4.40a Spark plug hole oil seal (2). models tighten the cylinder cover retaining Apply silicon sealant to the areas nuts in the sequence shown arrowed (3) - XU9J4 engine 31 Reconnect the breather hoses, inlet duct...

  • Page 63

    Move the cover upwards to free it bolts, then remove the lower timing belt cover known to be correct. Refer to a Peugeot dealer from the two locating pins situated at the base from the engine.

  • Page 64

    5 Belt tension measuring area Remove the single nut securing the bracket to 20 Align the engine assembly/valve timing the mounting rubber, and lift off the bracket. (using Peugeot special tool) holes as described in Section 3, and lock the...

  • Page 65

    If this method is refitting it. Fit the belt over the crankshaft and to be correct. Refer to a Peugeot dealer for used, however, the tension must be checked camshaft sprockets. Ensure that the belt advice.

  • Page 66

    65 If the special measuring tool is being equipment is available, it should be fitted to Woodruff key slot. Peugeot state that the use the “front run” of the timing belt, between the used, the final belt tension on the “front run”...

  • Page 67

    In the absence of the special the camshaft, remove it and store it with the and tighten its retaining bolt to the specified Peugeot tool, an acceptable substitute can be sprocket for safe-keeping. Examine the fabricated from two lengths of steel strip (one camshaft oil seal for signs of oil leakage and, torque.

  • Page 68

    XU engine in-car repair procedures 2B•13 50 With the timing belt correctly engaged on the sprockets, tension the belt as described in Section 7. 51 Once the belt is correctly tensioned, refit the timing belt covers (see Section 6). Camshaft sprocket(s) - 1905 cc and 1998 cc 16-valve models 52 Refit the Woodruff key to its slot in the camshaft end.

  • Page 69

    2B•14 XU engine in-car repair procedures 66 Slide on the crankshaft sprocket, aligning 82 Once the belt is correctly tensioned, refit 2 Remove the cylinder head cover and gasket its slot with the Woodruff key. the timing belt covers as described in as described in Section 4.

  • Page 70

    (where the necessary specifica- remove it. Note the O-ring seals fitted to each shown in illustration 10.54, evenly and tions have been quoted by Peugeot), noting of the pipe unions on later models. progressively slacken the camshaft bearing that No 1 journal is at the transmission end of cap retaining screws by one turn at a time.

  • Page 71

    2B•16 XU engine in-car repair procedures 54 Working sequence shown, progressively tighten the camshaft bearing cap bolts by one turn at a time, until the caps touch the cylinder head evenly. Go round again, working in the same sequence, and tighten all the bolts to the specified torque setting (see illustration).

  • Page 72

    XU engine in-car repair procedures 2B•17 10.64 Early supply pipe (A) without seals 11.7 Example of valve shim thickness 11.9 Measuring a valve clearance and later pipe (B) with seals calculation using a feeler blade I Inlet unmarked, and free from oil. Refit the bearing fully closed, with the tip of the cam facing E Exhaust caps, using the identification marks noted on...

  • Page 73

    2B•18 XU engine in-car repair procedures 11 Jack up the front of the car and support on axle stands (see “Jacking and Vehicle Support”). 12 Unscrew and remove the horizontal bolt from the engine rear mounting link beneath the rear of the engine. 13 Place a jack beneath the engine, with a block of wood on the jack head.

  • Page 74

    In the absence of the special 36 With all the cylinder head bolts removed, clean before refitting the head. Use a hard Peugeot liner clamps, the liners can be the joint between the cylinder head and plastic or wooden scraper to remove all traces clamped in position as follows.

  • Page 75

    12.55 Cylinder head bolt tightening reconnected to the correct components. take the old gasket along to your Peugeot sequence b) Ensure that the coolant hoses are dealer, and have the dealer confirm the gasket correctly reconnected, and that their type.

  • Page 76

    XU engine in-car repair procedures 2B•21 69 Refit the right-hand engine mounting and tighten the bolts to the specified torque. The jack can then be removed from under the engine. 70 The remaining procedure is a reversal of removal noting the following points. a) Ensure that all wiring is correctly routed, and that all connectors are securely reconnected to the correct components.

  • Page 77

    2B•22 XU engine in-car repair procedures 14.5a Remove the oil pump cover 14.5b . . . then lift off the cover and 14.5c . . . and relief valve piston, noting retaining bolts . . . remove the spring . . . which way round it is fitted sprocket, fitted to the crankshaft, be renewed Refitting...

  • Page 78

    15 Locate the driveplate on its locating preferable. Seek the advice of a Peugeot 10 Lubricate the lips of the new seal with dowel. dealer or engine reconditioning specialist to...

  • Page 79

    2B•24 XU engine in-car repair procedures 2 Check the mounting rubber to see if it is bracket to the side of the cylinder head, and 23 Refit the rubber damper to the top of the cracked, hardened or separated from the securely tighten its retaining bolts.

  • Page 80

    Specifications Note: At the time of writing, many specifications for the 1761 cc and 1998 cc (16-valve) engines were not available. Where the relevant specifica- tions are not given here, refer to your Peugeot dealer for further information. Cylinder head Maximum gasket face distortion .

  • Page 81: Cylinder Block

    2C•2 Engine removal and overhaul Valves (continued) Valve stem diameter: Inlet: 1360 cc engines ........6.84 to 6.99 mm 1580 cc and 1905 cc (8-valve) engines .

  • Page 82

    *On 1360 cc models, the main bearing shells were modified in February 1992, resulting in a reduction in the specified running clearance - see text for further information. **These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot. Piston rings Note: The following are suggested figures - no exact values are stated by Peugeot.

  • Page 83

    2C•4 Engine removal and overhaul noise, and high fuel consumption may also 8 As a final note, to ensure maximum life and 1 General information point to the need for an overhaul, especially if minimum trouble from a reconditioned engine, they are all present at the same time.

  • Page 84

    Do not engine/transmission. Note: Peugeot recommend that 8-valve XU disconnect the refrigerant lines from the 16 From underneath the vehicle, slacken and engines are removed by lowering from the...

  • Page 85

    Molykote BR2 plus - available from your tightening them lightly only. models equipped with anti-lock brakes, great Peugeot dealer) to the splines of the 47 From underneath the vehicle, refit the rear mounting link and install both its bolts. care must be taken to ensure that the anti- transmission input shaft.

  • Page 86

    Molykote G1 grease (available from your 1 Remove the cylinder head as described in Peugeot dealer) to the torque converter removed first, to be transferred to the Part A or B of this Chapter (as applicable).

  • Page 87

    2C•8 Engine removal and overhaul 7.4a Compress the valve spring using a 7.4b . . . then extract the collets and 7.4c Remove the spring retainer . . . spring compressor . . . release the spring compressor 7.4d . . . followed by the valve spring . . . 7.4e .

  • Page 88

    Peugeot dealer on the best course of action. 5 With all the valves installed, place the sunk into the cylinder head.

  • Page 89

    2C•10 Engine removal and overhaul 10.3 Connecting rod and big-end bearing 10.5 Removing a big-end bearing cap 10.6 To protect the crankshaft journals, cap marked for identification and shell tape over the connecting rod stud threads (No 3 cylinder shown) prior to removal by a turn at a time.

  • Page 90

    Engine removal and overhaul 2C•11 11.15 Removing the oil seal carrier from 11.16a Remove the oil pump 11.16b . . . then slide off the the front of the cylinder block - XU engine drive chain . . . drive sprocket . . . 11.16c .

  • Page 91

    Specifications. Where no tioning specialist. restore damaged threads (see illustration). If figures are stated by Peugeot, if there is any 24 If renewal is necessary, new liners, possible, use compressed air to clear the doubt about the condition of the cylinder complete with pistons and piston rings, can holes of debris produced by this operation.

  • Page 92

    O-rings. Clean the liners and carried out by a Peugeot dealer or engine wipe dry, then fit a new O-ring to the base of each liner. To aid installation, apply a smear of...

  • Page 93

    The result can 18 Examine all components, and obtain any be able to determine whether or not the be compared with the specified amount, and new parts from your Peugeot dealer. If new journal out-of-round. Take...

  • Page 94

    Consult your Peugeot dealer or engine specialist for further 1 Before reassembly begins, ensure that all information on parts availability. new parts have been obtained, and that all necessary tools are available.

  • Page 95

    Undersize (see illustration). Where no figures are given, 17.10 Piston ring fitting diagram (typical) Blue (class A) 1.844 1.994 seek the advice of a Peugeot dealer or engine Black (class B) 1.858 2.008 1 Oil control ring reconditioning specialist. Green (class C) 1.869...

  • Page 96

    Bearing colour Thickness (mm) 16 Seek the advice of your Peugeot dealer side, trace a vertical line down from the code Standard Undersize...

  • Page 97

    Blue (Class A) lower bearing shells should the grooved bearing shells, both upper and Plastigauge or rotate the crankshaft. be fitted. Refer to your Peugeot dealer for lower, are fitted to Nos 2 and 4 main bearings 27 Compare the width of the crushed further information.

  • Page 98

    Section 13. preferable to use a new set, since the results 38 Note that Peugeot do not specify a main 43 Thoroughly degrease the mating surfaces obtained will be more conclusive.

  • Page 99

    2C•20 Engine removal and overhaul that an angle-measuring gauge is used during this stage of the tightening, to ensure accuracy. If a gauge is not available, use a dab of white paint to make alignment marks between the bolt head and casting prior to tightening;...

  • Page 100

    72 Locate the tab of each sealing strip over 78 Refit the Woodruff key, then slide on the 2 Consult your Peugeot dealer for the latest the pins on the base of No 1 bearing cap, and oil pump drive sprocket and spacer (where information on parts availability.

  • Page 101

    (see illustration). levels. Make a final check that everything has 13 Note that Peugeot do not specify a 20 Ensure that the bearing shell is still been reconnected, and that there are no tools recommended big-end bearing running correctly installed.

  • Page 102

    Engine removal and overhaul 2C•23 disconnecting the ignition HT coil lead from little longer than usual, due to the fuel system speed settings, then switch the engine off. the distributor cap, and earthing it on the components having been disturbed. 8 After a few minutes, recheck the oil and cylinder block.

  • Page 103

    3•1 Chapter 3 Cooling, heating and ventilation systems Contents Air conditioning system - general information and precautions ..10 Cooling system - flushing ......See Chapter 1 Air conditioning system components - removal and refitting .

  • Page 104

    3•2 Cooling, heating and ventilation systems the hose with a blunt instrument (such as a Cover the cap with a thick layer of cloth, 1 General information and flat-bladed screwdriver), but do not apply too to avoid scalding, and slowly unscrew the precautions much force, and take care not to damage the filler cap until a hissing sound is heard.

  • Page 105

    Cooling, heating and ventilation systems 3•3 clip, and release the air inlet tube from the brush. Be careful, as the fins are sharp, and body front panel, above the radiator (see easily damaged. illustrations). 13 If necessary, a radiator specialist can 6 Where applicable, disconnect the wiring perform a “flow test”...

  • Page 106

    3•4 Cooling, heating and ventilation systems 4.4a Thermostat housing cover retaining 4.4b Thermostat housing cover (arrowed) 4.5 Removing the sealing ring from the bolts (arrowed) - 1.4 litre engine - 2.0 litre engine thermostat flange also improved if the air cleaner ducting is engine until normal operating temperature is Refitting reached, then allow it to idle.

  • Page 107

    Peugeot dealer 16 If the gauge needle remains at the “hot” controlled by a switch mounted in the should be sought. The sensor itself can only end of the scale when the engine is cold,...

  • Page 108

    3•6 Cooling, heating and ventilation systems 7.6a Withdraw the coolant pump . . . 7.6b . . . and recover the O-ring - 7.6c Removing the coolant pump (1.6 litre 1.4 litre engine shown engine) - shown with engine removed 10 Refit the pump using a new gasket or are contained in the air distribution housing, control stalk switch (left-hand-drive models),...

  • Page 109

    Cooling, heating and ventilation systems 3•7 9.11 Heater control cables reconnection 9.22 Remove the heater control unit 9.24 Disconnect the control cables from sequence - models up to 1992 securing screws - models from 1993 the heater control unit - models from 1993 Heater/ventilation control unit - 22 Remove the two securing screws located Refitting...

  • Page 110

    3•8 Cooling, heating and ventilation systems 9.36a Remove the two 9.36b . . . then withdraw the 9.36c . . . and recover the O-rings from the securing screws . . . heater matrix . . . pipe connections 36 To remove the matrix from the heater screws, and remove the plastic shields from b) Ensure that the wiring harnesses are assembly, unscrew the two securing screws,...

  • Page 111

    Cooling, heating and ventilation systems 3•9 9.59 Disconnect the blower motor 9.60 Withdrawing the heater blower motor 9.64 Pull the rubber grommet from the wiring plug motor casing for access to the wiring 9.65a Remove the securing screws . . . 9.65b .

  • Page 112

    - removal and evaporator. The refrigerant returns to the entrust this task to your Peugeot dealer or a refitting compressor, and the cycle begins again. refrigeration engineer.

  • Page 113

    All other models with a catalytic converter ..... 95 RON unleaded or 98 RON (super) unleaded *On some early models the ignition timing must be retarded by 3° in order to use 95 RON unleaded fuel - check with your Peugeot dealer. Torque wrench settings lbf ft Fuel pump retaining bolts .

  • Page 114

    (see illustration). lower housing. supply of fuel to the carburettor is kept at a Where the crimped-type Peugeot hose clips 9 Release the lower housing from the constant pressure, and is free of air bubbles. are fitted, cut the clips and discard them; use...

  • Page 115

    Fuel/exhaust systems - carburettor models 4A•3 inlet until, when the engine is fully warmed-up 8 Hot air is drawn from the collector plate to normal operating temperature, only cold air over the exhaust manifold. These two ducts from the front of the car is entering the air join together at the air inlet mixer housing cleaner.

  • Page 116

    (see illustration). Where crimped-type Peugeot hose clips are fitted, cut the clips and discard them; use standard worm-drive hose clips on refitting. Place wads of rag beneath the hose unions to catch any spilled fuel, then 5.3 Remove the plastic access cover .

  • Page 117

    Where the crimped-type adjust the handbrake (see Chapter 9). before proceeding. Peugeot hose clips are fitted, cut the clips and d) On completion, refill the tank with a small Removal discard them; use standard worm-drive hose amount of fuel, and check for signs of clips on refitting.

  • Page 118

    Where the crimped-type Removal through the bulkhead. Once the cable end is Peugeot hose clip is still fitted, cut the clip visible, untie the string, then clip the outer 1 Release the choke inner cable from the and discard it;...

  • Page 119

    Where original crimped- instrument. The throttle linkages are arranged valve wiring (see illustration). type Peugeot hose clips are still fitted, the so that the secondary throttle valve will not 8 Disconnect the fuel inlet pipe either at the clips should be cut and discarded;...

  • Page 120

    A heating element repair kit carburettor retaining nuts. solenoid valve must be renewed. is available from your Peugeot dealer. To b) Use the notes made on dismantling to 6 Remove the five screws and lift off the...

  • Page 121

    Fuel/exhaust systems - carburettor models 4A•9 14 Inlet manifold - removal and refitting Note: Refer to the warning note in Section 1 before proceeding. Removal 1 Remove the carburettor as described in Section 12. 2 On TU engines, drain the cooling system as described in Chapter 1, and disconnect the coolant hose from the base of the manifold.

  • Page 122

    4A•10 Fuel/exhaust systems - carburettor models 15.1 Remove the hot-air intake hose . . . 15.2 . . . then undo the three retaining 15.5 Power-assisted steering and coolant screws (arrowed) and remove the exhaust pipe clamps (arrowed) manifold shroud (TU engine) (XU injection engine shown) procedure, noting the following points: one part of the system needs attention, it is...

  • Page 123

    Fuel/exhaust systems - carburettor models 4A•11 11 Unhook the centre silencer from its been removed from the flanges and mounting rubber and remove it from renew all necessary gaskets. underneath the vehicle. b) Inspect the rubber mountings for signs of damage or deterioration, and renew as Tailpipe and silencer necessary.

  • Page 124

    4B•1 Chapter 4 Part B: Fuel/exhaust systems - single-point fuel injection models Contents Accelerator cable - removal, refitting and adjusting ....4 Fuel gauge sender unit - removal and refitting ....10 Accelerator pedal - removal and refitting .

  • Page 125

    4B•2 Fuel/exhaust systems - single-point fuel injection models The fuel recommended by Peugeot is given 1 General information and 4 Accelerator cable - removal, in the Specifications Section of this Chapter, precautions refitting and adjustment followed by the equivalent petrol currently on sale in the UK.

  • Page 126

    ECU, to provide the best settings for cranking, should be taken to a Peugeot dealer at the standards. The system operates as follows. earliest opportunity. A complete test of the...

  • Page 127

    Where the crimped-type fuel line. Plug the pipe ends, to minimise fuel Peugeot hose clips are fitted, cut the clips and 19 Ensure that the fuel pump pick-up filter is loss and prevent the entry of dirt into the fuel clean and free of debris.

  • Page 128

    If the original crimped-type Peugeot clips are still fitted, cut the clips and discard them; use standard worm-drive hose clips on refitting (see illustration).

  • Page 129

    22 Refitting is a reversal of removal. the problem, the vehicle should be taken to a injector. Peugeot dealer for testing. A wiring block 9 Recover and discard the injector sealing Manifold absolute pressure rings (check to ensure that new sealing rings...

  • Page 130

    At the time of writing, the fuel pressure regulator assembly was not available separately from the throttle body assembly. Refer to a Peugeot dealer for the latest information. Although the unit can be dismantled for cleaning, if required, it should 15.6 Fuel pressure regulator...

  • Page 131

    If this fails, the vehicle described earlier in this Section. which is mounted onto the rear of the battery should be taken to a Peugeot dealer for 10 Refitting is a reverse of the removal mounting tray. testing using the appropriate specialist...

  • Page 132

    Fuel/exhaust systems - single-point fuel injection models 4B•9 Throttle body heating element sealing compound to the manifold mating surface. Refit the manifold and tighten its 29 The throttle body heating element is retaining nuts to the specified torque. situated in the front of the throttle body. b) Ensure that all relevant hoses are 30 To remove the element, first disconnect reconnected to their original positions and...

  • Page 133

    All other engines ......... 95 RON unleaded (UK unleaded premium). Leaded fuel must not be used on models with a catalytic converter *It may be possible to use unleaded if the ignition is retarded by 3° - check with your Peugeot dealer.

  • Page 134

    4C•2 Fuel/exhaust systems - multi-point fuel injection models Torque wrench settings lbf ft Inlet manifold: TU engine ..........XU engine .

  • Page 135

    Peugeot dealer. If travelling abroad, the operation of the injectors. speed control valve. No supplementary air consult one of the motoring organisations (or a 3 The electronic control unit (ECU) and device is fitted.

  • Page 136

    19 If the warning light comes on, the vehicle removal and refitting d) Throttle switch correctly adjusted. should be taken to a Peugeot dealer at the e) Engine must be hot, the cooling fan earliest opportunity. A complete test of the...

  • Page 137

    Fuel/exhaust systems - multi-point fuel injection models 4C•5 speed. However, if these are found to be in need of adjustment, the car must be taken to a suitably-equipped Peugeot dealer for further testing. Neither the mixture adjustment (exhaust gas CO level) nor the idle speed are...

  • Page 138

    4C•6 Fuel/exhaust systems - multi-point fuel injection models Magneti Marelli 8P system located behind the engine compartment bulkhead on the left-hand side. On the L3.1 18 Remove cleaner-to-throttle system it is located on the air cleaner cover housing duct as described in Section 2. and is removed by removing the cover as 19 As applicable,...

  • Page 139

    Fuel/exhaust systems - multi-point fuel injection models 4C•7 14.6a Secondary throttle adjusting screw 14.6b . . . and viewed from underneath 14.13 Throttle switch unit mounting bolts (arrowed) . . . (A) and plug terminal numbers 5 Remove the feeler blade then turn the Fuel rail and injectors the fuel rail and pull out the injectors.

  • Page 140

    46 Tilt the water housing to gain access to been tampered with. Adjustment should be obtained, renew the switch. the air device securing bolts and remove the entrusted to a Peugeot dealer. 17 Reconnect the switch wiring plug on bolts and air device. completion.

  • Page 141

    Where the original crimped- 18 Depress the retaining clip and disconnect fuel return hose from the bottom of the type Peugeot hose clips are still fitted, cut the wiring connector from the air valve. pressure regulator. Be prepared for fuel them and discard;...

  • Page 142

    Where the and remove it from the throttle housing. whenever they are disturbed. original crimped-type Peugeot hose clips are Examine the sensor O-ring for signs of 7 On refitting the injectors, fit new O-rings to still fitted, cut them off and discard them;...

  • Page 143

    Fuel/exhaust systems - multi-point fuel injection models 4C•11 42 Refitting is a reversal of the removal then undo the two retaining screws and 69 Trace the wiring back from the sensor to procedure, noting the following points: remove the throttle potentiometer from the its wiring connector, and disconnect it from base of the housing.

  • Page 144

    Where the and/or starter bracket. speed power) which is 370 mm long, diameter original crimped-type Peugeot hose clips are c) Ensure that any disturbed gaskets are 45 mm. still fitted, cut them off and discard them; use renewed.

  • Page 145

    Fuel/exhaust systems - multi-point fuel injection models 4C•13 20 Exhaust manifold - removal and refitting Removal 1 Refer to Chapter 4A, Section 15, noting that where applicable the lambda (oxygen) sensor wiring connectors should be disconnected. Alternatively, care must be taken to support the front pipe, to avoid any strain being placed sensor...

  • Page 146

    If the inlet air/fuel mixture is is retarded by 3° - check with your Peugeot The canister stores them until they can be too rich, the exhaust gases are low in oxygen, dealer.

  • Page 147

    14 If the CO level at the tailpipe is too high, Testing drive the car at all (or at least as little as the vehicle should be taken to a Peugeot 2 If the system is thought to be faulty, possible) until the fault is cured.

  • Page 148

    5A•1 Chapter 5 Part A: Starting and charging systems Contents Alternator drivebelt - removal, refitting and tensioning ... .6 General information and precautions ......1 Alternator - removal and refitting .

  • Page 149

    (condition reading less than of the battery or remove the radio/cassette described later in this Section. If the indicator 12.2 volts), have it recharged by your Peugeot unit from the vehicle. If a Peugeot shows clear/yellow, then the electrolyte level...

  • Page 150

    Starting and charging systems 5A•3 7.2 Connections on the rear of the 7.4a Slacken and remove the alternator 7.4b . . . and lower bolt (arrowed) alternator upper mounting bolt . . . 3 Unscrew the nuts and remove the battery should be approximately 12 to 13 volts, and electricians will be able to supply and fit clamp.

  • Page 151

    5A•4 Starting and charging systems 10.2 Unscrew the two nuts (arrowed) and 10.3 Starter support bracket bolts 10.5 Unscrew the starter motor disconnect the wiring from the rear of the (arrowed) on an early model securing bolts (1). Note the location starter motor of the bracket (2) voltage is available at the battery positive lead...

  • Page 152

    Starting and charging systems 5A•5 then refit the drain plug and tighten it to the 15 Oil temperature sensor - specified torque setting (see Chapter 1). removal and refitting 4 Disconnect the wiring connector then unscrew the sensor from the sump, and remove it from underneath the vehicle along with its sealing washer.

  • Page 153

    All other fuel injection models ....... ECU controlled (non-adjustable) *Note: If unleaded fuel is used in the following engines, the ignition timing must be retarded by 3° - check with your Peugeot dealer. a) TU3 (K1A)

  • Page 154

    1 The components of electronic ignition Peugeot dealer. On some models a knock sensor is systems are normally very reliable; most faults Engine misfires incorporated into the ignition system.

  • Page 155

    3.3 On breakerless ignition models, suitably equipped Peugeot dealer for testing. it from the engine. Release the inlet duct disconnect the capacitor wiring connector, and release the TDC sensor connector .

  • Page 156

    15 If the coil is thought to be faulty, have your described in Section 3 and the inlet duct as of the HT leads then disconnect them from findings confirmed by a Peugeot dealer before described in the relevant Part of Chapter 4. the coil terminals.

  • Page 157

    Ignition system 5B•5 Tighten the centre screw. Refit the rotor and tighten the Torx-headed screws. 15 On 8-valve engines lubricate the new O- ring with a smear of engine oil and fit it to the groove in the distributor body. Examine the distributor cap seal for wear or damage and renew if necessary.

  • Page 158

    6 Ignition timing - the transmission housing aperture. The check must be left to a Peugeot dealer. checking and adjustment flywheel timing mark should be aligned with 9 When the ignition timing is correct, stop the the appropriate notch on the timing plate engine and disconnect the timing light.

  • Page 159

    9•1 Chapter 9 Braking system Contents Anti-lock Braking System (ABS) - general information ... .23 Hydraulic system - bleeding ....... . .2 Anti-lock Braking System (ABS) components - Master cylinder - removal, overhaul and refitting .

  • Page 160

    Special equipment is required, and the most other models (refer to Section 23 for Always renew components (in axle sets, where task must be referred to a Peugeot dealer. further information on ABS operation). applicable) if in doubt about their condition,...

  • Page 161

    Braking system 9•3 other end of the tube in the jar, and pour in sufficient fluid to cover the end of the tube. 13 Ensure that the master cylinder reservoir fluid level is maintained at least above the “MIN” level line throughout the procedure. 14 Have the assistant fully depress the brake pedal several times to build up pressure, then maintain it on the final downstroke.

  • Page 162

    Peugeot procedure may be due to worn master dealers. All that is then necessary is to bend it cylinder seals. to shape, following the line of the original, 30 On models with ABS, reconnect the wiring before fitting it to the car.

  • Page 163

    13 Slide the retaining plate into place, and that when the pads are installed in the caliper, kits are available from Peugeot dealers. install the new small spring clip at its inner the spring end will be located at the opposite 8 If the brake pads are still serviceable, end.

  • Page 164

    New brake pads are available pivot the caliper upwards, away from the front brake caliper. from Peugeot dealers. brake pads and mounting bracket, taking care 27 Refit the roadwheels, then lower the 7 If the brake pads are still serviceable,...

  • Page 165

    Braking system 9•7 fluid leaks, corrosion or damage. If attention 14 Depress the brake pedal repeatedly until 1 Remove the brake drum (see Section 9). is necessary, see Section 11. the pads are pressed into firm contact with 2 Working carefully, and taking the necessary 9 If new brake pads are to be fitted, the the brake disc, and normal (non-assisted) precautions, remove all traces of brake dust...

  • Page 166

    19 Manoeuvre the shoe and strut assembly 11 If genuine Peugeot brake shoes are being the other end of the spring, and lever the into position on the vehicle, and engage the...

  • Page 167

    44 Repeat the above procedure on the remaining rear brake. 32 If genuine Peugeot brake shoes are being 45 Once both sets of rear shoes have been installed, it will be necessary to remove the renewed, adjust the lining-to-drum clearance adjusting lever from the original leading shoe, and install it on the new shoe.

  • Page 168

    9•10 Braking system 7.4 Checking disc run-out 7.7 Removing a Girling caliper 7.8 Disc securing screws (arrowed) using a dial gauge mounting bracket bolt worn at any point to the specified minimum d) On models with Girling calipers, refit the d) Refit the brake pads as described in thickness or less, the disc must be renewed.

  • Page 169

    Peugeot dealer. Ensure that the correct repair 11 Depress the footbrake several times to 4 Working carefully, remove all traces of kit is obtained for the caliper being worked on.

  • Page 170

    9•12 Braking system 10.6 Components of Bendix front caliper 1 Guide bolt 2 Caliper body 3 Pad retaining plate kit 4 Bleed screw 5 Mounting plate 6 Guide pin assembly 7 Repair kit 10.13 Removing a Girling caliper upper guide pin bolt Refitting 7 Screw the caliper fully onto the flexible hose union, then position the caliper over the brake...

  • Page 171

    Braking system 9•13 Peugeot dealer. Ensure that the correct repair kit is obtained for the caliper being worked on. Note the locations of all components to ensure correct refitting, and lubricate the new seals using clean brake fluid. Follow the assembly instructions supplied with the repair kit (see illustration).

  • Page 172

    Peugeot dealer. Ensure that the correct repair cylinder reservoir (as applicable). kit is obtained for the wheel cylinder being 12 Ensure that the brake shoes are correctly 12 Rear wheel cylinder - worked on.

  • Page 173

    Overhaul 9 No spare parts are available from Peugeot Testing for the master cylinder, and if faulty the complete unit must be renewed. 1 To test the operation of the servo unit,...

  • Page 174

    9•16 Braking system 15.14 Unscrew the nuts (arrowed) 15.15 Removing the vacuum servo/pedal 15.16 Unscrew the nuts (arrowed) securing the servo to the scuttle bracket assembly securing the servo to the pedal bracket 11 Where applicable, depress the retaining damage, and renew if necessary. The valve the rear, where applicable, remove the rear body undershield for access to the handbrake clip and detach the end of the clutch cable...

  • Page 175

    Braking system 9•17 17.14 Adjust the clearance between the 18.5 Three of the handbrake lever cable end fitting (A) and the handbrake securing nuts (arrowed) operating lever (B) at the caliper of approximately 15.0 mm between the rear mounting plate to the floor (clean the face of the adjuster nut and the end of the mating faces of the mounting plate and threaded adjuster rod.

  • Page 176

    On these models, the task should 8 Reconnect the wiring plug, then reconnect mechanism and back off the adjuster nut. be entrusted to a Peugeot dealer - see the battery negative lead. 24 If the left-hand cable is being removed, Section 23.

  • Page 177

    4 Release the sensor wiring from any Peugeot dealer. Failure to heed this General securing clips and, where applicable, push warning may result in personal injury, or...

  • Page 178

    Bendix “integral” connectors, bleed the complete hydraulic 21 Open the bonnet, and unclip the cover ABS - refer the operation to a Peugeot dealer. system as described in Section 2. from the top of the scuttle to expose the Modulator assembly - control unit.

  • Page 179

    10•1 Chapter 10 Suspension and steering Contents Front hub bearings - renewal ....... .3 Power steering system - bleeding .

  • Page 180

    10•2 Suspension and steering Torque wrench settings lbf ft Front suspension (continued) Subframe rear securing bolts: M12 bolts ..........M14 bolts .

  • Page 181

    Suspension and steering 10•3 2.3 Withdraw the R-clip from the 2.11 Release the lower balljoint using a 2.12 Hub carrier-to-suspension strut driveshaft nut locking cap balljoint separator tool clamp nut (arrowed) a socket and extension bar, slacken and 10 Slacken and partially unscrew the track Refitting remove driveshaft...

  • Page 182

    10•4 Suspension and steering 20 Align the balljoint with the lower arm, then Press the bearing onto the hub, using a fit the balljoint nut, and tighten to the specified tubular spacer which bears only on the inner torque. race of the hub bearing, until it seats against 21 Engage the track rod balljoint in the hub the hub shoulder.

  • Page 183

    Suspension and steering 10•5 accordance with manufacturer’s 12 Refit the bolt securing the anti-roll bar 2 If not already done, fit coil spring instructions, lightly tighten drop link to the strut. compressors accordance with compressors. Note that the strut can be 13 Tighten the two strut top mounting nuts to manufacturer’s instructions, and compress removed without using spring compressors, but...

  • Page 184

    10•6 Suspension and steering 5.10f . . . fit the upper spring seat, 5.10g . . . the lower . . . 5.10h . . . and upper dished plates . . . followed by . . . 5.10i . . . the rubber buffer . . . 5.10j .

  • Page 185

    Peugeot dealer. Do not attempt 9 Examine the shank of the pivot bolt for 2 Remove the bolts securing the anti-roll bar the work using an improvised tool.

  • Page 186

    On completion, have the anti-roll bar locking compound (this is only effective once). introduced. The later bolts incorporate a adjustment checked by a Peugeot dealer 1 Apply the handbrake, then jack up the front captive washer in place of the Bellville washer at the earliest opportunity.

  • Page 187

    Use only the specified parts, available from a Peugeot dealer. 10.6b Removing the inner bearing race . . . 10.6c . . . and the oil seal support cup 16 Further refitting is a reversal of removal, bearing in mind the following points.

  • Page 188

    DIY work, and should be then apply the handbrake and chock the front new hub cap into place in the centre of the entrusted to a Peugeot dealer. wheels. Do not support the vehicle with the hub (see illustrations).

  • Page 189

    The operation should be entrusted to a both the shock absorber mounting bolts. the opens ends of the pipes and the valve. Peugeot dealer, as it not possible to carry out 9 Manoeuvre the shock absorber into 12 Where applicable, remove the rear ABS...

  • Page 190

    Do not attempt to dismantle the steering wheel. c) Do not attempt to fit a steering wheel from another model of vehicle (even a different model of Peugeot 405), as the air bag control module is calibrated for each particular model. Removal Note: A new securing nut and washer must be 17.11 Lower steering column securing...

  • Page 191

    Suspension and steering 10•13 Inspection 14 The steering column incorporates a telescopic safety feature. In the event of a front-end crash, the shaft collapses and prevents the steering wheel injuring the driver. Before refitting the steering column, examine the column and mountings for signs of damage and deformation, and renew as necessary.

  • Page 192

    Peugeot retaining clips. fluid reservoir, topping-up if necessary (refer dealer. The only components which can be...

  • Page 193

    Suspension and steering 10•15 22.3 Counterhold the pump spindle and 22.9a Unscrew the securing bolts . . . 22.9b . . . and remove the pump - XU5 and slacken the pulley bolts XU9 engines (engine removed for clarity) d) On completion, refill and bleed the 20 Apply the handbrake, then jack up the 22 Power steering pump - hydraulic system as described in...

  • Page 194

    10•16 Suspension and steering that the same number of exposed threads are visible, as were noted prior to removal. 9 Screw the track rod end onto the track rod by the number of turns noted on removal. This should bring the locknut to within a quarter of a turn of the end face of the track rod, with the alignment marks that were made on removal (if applicable) lined up.

  • Page 195

    8 If adjustment is necessary, apply the track rods. If they are not the same, then the to a Peugeot dealer or similar expert. Note handbrake, then jack up the front of the adjustment has not been made equally, and that most tyre-fitting shops now possess vehicle and support it securely on axle stands.

  • Page 196

    11•1 Chapter 11 Bodywork and fittings Contents Body exterior fittings - removal and refitting ....25 Front bumper - removal and refitting ......6 Body front panel assembly - removal and refitting .

  • Page 197

    11•2 Bodywork and fittings avoid damage to the finish. Always check that is required. Remove any loose rust from the Repairs of rust holes the door and ventilator opening drain holes bottom of the scratch with a penknife, then or gashes in bodywork and pipes are completely clear, so that water apply rust-inhibiting paint, to prevent the Remove all paint from the affected area,...

  • Page 198

    With the use of more and more plastic body At this stage, the “dent” should be only be carried out accurately by a Peugeot components by the vehicle manufacturers (eg surrounded by a ring of bare metal, which in dealer using special jigs.

  • Page 199

    11•4 Bodywork and fittings 10 On models with rear underbody shields fitted under the sides of the bumper, release the exhaust system from its rear mounting (loosen the clamp if necessary), then lower the rear of the system for access to the left-hand rear underbody shield.

  • Page 200

    Bodywork and fittings 11•5 the lock can be improved by removing the front grille panel (see Section 25). Refitting 19 Refitting is a reversal of removal. 10 Bonnet lock - removal and refitting Removal 1 Open the bonnet. 2 Unscrew the two securing bolts, then 9.3 Bonnet release lever 9.5 Disconnecting the bonnet release withdraw the lock and disconnect the end of...

  • Page 201

    11•6 Bodywork and fittings 11.7a Disconnecting the front light wiring 11.7b Disconnect the front light wiring 11.7c . . . and disconnect the plug from the connectors - models up to 1992 connectors (arrowed) . . . terminal block - models from 1993 11.8 Unbolt the earth leads from the 11.12 Removing a body front panel 11.14 Unscrew the body front panel...

  • Page 202

    Bodywork and fittings 11•7 shims fitted between the hinge and the door. 8 Prise the mirror trim plate from the front To add or remove shims, loosen the bolts corner of the door (see illustration). Where securing the hinge to the door (the door inner applicable, loosen the clamp screw, and release the mirror adjuster knob from the trim trim panel must be removed for access to the...

  • Page 203

    11•8 Bodywork and fittings Refitting 4 Refitting is a reversal of removal, ensuring the link rod is correctly reconnected. Where applicable, fit a new sealing sheet if the sheet was damaged during removal, and refit the door trim panel with reference to Section 13. Exterior door handle Removal 5 Remove the door inner trim panel as...

  • Page 204

    8 On models up to 1992, this is a difficult operation, as the lugs on the clip must be released from behind the glass. Peugeot tool (-)7.1309 is available for this purpose, but the tool can be improvised by drilling a hole of suitable diameter in a small block of wood or 14.10b Using the improvised tools to...

  • Page 205

    11•10 Bodywork and fittings 2 Have an assistant hold the boot lid open then, using a pair of pliers, disconnect the spring assisters from the brackets on the body - take care, as the springs are under tension. Note which bracket slots the ends of the springs are positioned in, to ensure correct refitting (see illustration).

  • Page 206

    Bodywork and fittings 11•11 tailgate wiper motor and the central locking motor wiring plugs. 7 Disconnect the washer fluid hose from the washer nozzle. 8 Release the wiring harnesses and the washer fluid hose from any clips inside the tailgate. 9 Pull the wiring grommets from the top corners of the tailgate.

  • Page 207

    11•12 Bodywork and fittings 20 Central locking components - removal and refitting Note: Before attempting work on any of the central locking system components, disconnect battery negative lead. Reconnect the lead on completion of work. Electronic control unit Removal 1 Remove the glovebox as described in 19.2 Withdraw the plastic trim panel 19.3 .

  • Page 208

    Bodywork and fittings 11•13 22 Working inside the luggage compartment, open the cover flap to expose the rear washer fluid reservoir. 23 Remove the two securing screws, then lift out the reservoir to expose the lock motor. Note that there is no need to disconnect the washer fluid tubing.

  • Page 209

    11•14 Bodywork and fittings 2 The control unit is clipped to a bracket on the to the mirror wiring connector(s). Disconnect the rear of the door trim panel (see illustration). wiring connectors (see illustration). 3 Unclip the control unit and withdraw it from 4 If not already done, prise the mirror trim the panel.

  • Page 210

    Therefore, any problems with this type of sunroof should be referred to a Peugeot dealer. 3 Removal and refitting of the sunroof motor is described in the following paragraphs.

  • Page 211

    Chapter 12. 6 Recover the washers, where applicable, should be entrusted to a Peugeot dealer. 8 Disconnect the washer fluid hose from the then lift the seat from the vehicle. T-piece at the right-hand side of the scuttle 7 Where applicable, recover the plastic plates (see illustration).

  • Page 212

    Bodywork and fittings 11•17 26.12a Remove the securing screw . . . 26.12b . . . and withdraw the armrest trim 26.15 Rear seat cushion hinge securing panel - Saloon model nut (arrowed) - Estate model 13 Pull each side of the seat back upwards to 3 Prise off the trim plate, and unscrew the disengage it from the securing lugs, then seat belt upper anchor bolt (see illustration).

  • Page 213

    Removal incorporates the pre-tensioner assembly. 18 Unbolt the lower seat belt anchor from the Refer the operation to a Peugeot dealer. body. Door trim panels Removal 19 Fold the rear seat back forwards. 1 Refer to Section 13.

  • Page 214

    Bodywork and fittings 11•19 29 Centre console - removal and refitting “Highline” console - models up to 1992 Removal 1 Disconnect the battery negative lead. 2 Move the seats fully rearwards. 3 Where applicable, remove the securing screws, then prise the side panels from the 28.4a Remove the securing screws .

  • Page 215

    11•20 Bodywork and fittings 11 Lift the console slightly, then disconnect all relevant wiring, and release the wiring harnesses from any clips under the console. 12 Withdraw the console over the gear lever and the handbrake lever. Refitting 13 Refitting is a reversal of removal. “Lowline”...

  • Page 216

    Bodywork and fittings 11•21 30.9a Remove the two bolts (arrowed) 30.9b . . . and the single bolt (arrowed) 30.12 Two of the heater control panel from the ashtray recess . . . from the radio/cassette player recess securing screws 30.16 Disconnect the two main feed 30.18 Unbolt the earth lead (arrowed) 30.19 Remove the bolt securing the relay...

  • Page 217

    11•22 Bodywork and fittings 30.34 Unscrew the two screws below the 30.36a Remove screws from top of radio/ 30.36b . . . then withdraw the housing ashtray housing cassette player/oddments housing . . . 30.37 Prise out the blanking plate to 30.38a Remove the two screws from the 30.38b .

  • Page 218

    Bodywork and fittings 11•23 30.41a Remove the carpet trim panel . . . 30.41b . . . then disconnect the three 30.42a Remove the securing screw . . . wiring connectors (arrowed) 44 Where applicable (if the earth cable connects to the facia wiring harness), unbolt the earth cable from the footwell, then release the wiring harness from the clips under the facia.

  • Page 219

    11•24 Bodywork and fittings 30.53 Remove the screw and withdraw the 30.56 Remove the securing screws and 30.60 Unplug the main wiring harness bonnet release lever withdraw connector/control unit brackets connectors 30.62a Pull the relay out of 30.62b . . . then pull the connector from 30.64a Remove the securing clip .

  • Page 220

    Bodywork and fittings 11•25 68 Unscrew the centre facia upper securing bolt, located above the heater control unit (see illustration). 69 Unscrew the two rear centre facia securing bolts, securing the facia brackets to the heater assembly (see illustration). 70 Working in the engine compartment, unscrew the three facia securing nuts located in the scuttle (see illustration).

  • Page 221

    12•1 Chapter 12 Body electrical system Contents Air bag system - general information, precautions and system Instrument panel - removal and refitting ..... . .9 de-activation .

  • Page 222

    12•2 Body electrical system conjunction with any of the tests described in connected to “earth” - the metal of the 2 Electrical fault finding - the following sub-Sections. engine/transmission and the car body - and general information 6 Apart from problems poor most systems are wired so that they only...

  • Page 223

    Body electrical system 12•3 3.3a Release the securing clips 3.3b . . . and lower the fusebox panel - 3.3c Removing the fusebox cover - (arrowed) . . . early models later models c) Slide the fusebox to the left, and then pull the assembly out from the facia (see illustration).

  • Page 224

    12•4 Body electrical system 3.14b Unscrewing a relay bracket 3.14c Main relay box located behind 3.14d Relays in engine compartment securing screw from under the steering fusebox at rear of facia - models from 1993 relay box - models up to 1992 column - models from 1993 (viewed with (viewed with facia removed and inverted) steering column shrouds removed)

  • Page 225

    Body electrical system 12•5 4.19 Prise the trim panel from the bottom 4.20 . . . then prise off the switch 4.21 . . . and remove the switch of the oddments tray . . . trim panel . . . Tape the wiring to the door pillar, to prevent it falling back into the door pillar.

  • Page 226

    12•6 Body electrical system 4.42 Luggage compartment courtesy light 4.46 Prise out the blanking plate . . . 4.47 . . . then prise out the sunroof switch switch screw (arrowed) - Estate model 42 Remove the screw securing the switch to 3 Disconnect the wiring plug from the rear of 9 Working in the engine compartment, the headlight bulb.

  • Page 227

    Body electrical system 12•7 behind the spoiler and disconnect the wiring from the light. Prise the rubber cover from the light, then release the spring clip and withdraw the bulb. 26 On models where the rear of the light unit is covered by the spoiler, remove the two securing screws from the front of the light unit and withdraw the reflector/lens assembly.

  • Page 228

    12•8 Body electrical system 5.36a Removing a rear wing-mounted light 5.36b Removing a tailgate-mounted light 5.39 Prise the lens from the bumper . . . bulbholder - Estate model bulbholder - Estate model 5.40 . . . and withdraw the number plate 5.42 Prise out the number plate 5.43 .

  • Page 229

    Body electrical system 12•9 Facia switch illumination bulbs 25 The bulbs are integral with the switches, and cannot be renewed independently. Instrument panel illumination and warning light bulbs 26 Remove instrument panel described in Section 9. 27 Twist the relevant bulbholder anti- clockwise to remove it from the rear of the panel (see illustration).

  • Page 230

    12•10 Body electrical system 7.8 Outer headlight securing bolts 7.9 Removing a headlight lens 7.16 Remove the front driving light/ (arrowed) securing clip foglight cowl securing screws 8 Unscrew the two outer headlight securing 16 Remove the two screws securing the light 24 Squeeze the two retaining clips, and cowl to the spoiler, then withdraw the withdraw the bulbholder from the rear of the...

  • Page 231

    (balljoints) in the rear carried out by a Peugeot dealer or suitably- facia. On models with adjusters mounted on of the headlights.

  • Page 232

    12•12 Body electrical system 9 Tilt the instrument panel forwards, and the lower trim panel from the driver’s footwell. Tie a length of string to the disconnect the speedometer cable from the 15 Where applicable, move the steering end of the adjuster cable rear of the panel.

  • Page 233

    Body electrical system 12•13 9.19 Prise the trim panel from the facia 9.21 Unscrew the lower instrument panel 9.22 Lever the upper securing securing screws clip down . . . Gauges - models from 1993 10 Instrument panel 5 Working at the rear of the panel, remove the components - lens securing screws from around the edge of removal and refitting...

  • Page 234

    12•14 Body electrical system 10.10 Remove the gauge 10.11a . . . then withdraw the gauge . . . 10.11b . . . and recover the spacers from securing screws . . . the studs 11 Carefully withdraw the gauge from the Refitting the two securing screws, then withdraw the front of the instrument panel, taking care not to...

  • Page 235

    Body electrical system 12•15 be obtained from the driver’s footwell after unclipping the carpet trim panel from the lower facia. 6 Untie the string from the end of the cable, and leave the string in position to aid refitting. Refitting 7 Refitting is a reversal of removal, but use the string to pull the cable into position, and make sure that the cable ball is correctly...

  • Page 236

    12•16 Body electrical system 2 Disconnect the battery negative lead. Refitting 3 Remove the scuttle grille panel as 10 Refitting is a reversal of removal. described in Chapter 11. 4 Where applicable, unscrew the securing bolts, and withdraw the cover from the motor. 18 Tailgate wiper motor - 5 Disconnect the motor wiring connector.

  • Page 237

    (see illustrations). Radio/cassette player Removal 9 If the reservoir still contains fluid, empty out with “Peugeot” fixings the contents into a container, then disconnect 1 Disconnect the battery negative lead. Removal the wiring plug and the fluid hose from the 2 Carefully prise out and remove the small pump, and withdraw the reservoir.

  • Page 238

    12•18 Body electrical system 6 Carefully prise the loudspeaker cover panel from the top of the facia (see illustration). 7 Remove the two securing screws, then withdraw the loudspeaker from the facia, and disconnect the wiring (see illustration). Facia-mounted loudspeakers - models from 1993 8 Disconnect the battery negative lead.

  • Page 239

    Note: This information is applicable only to the lower fixing bolt. 2 Disconnect the battery negative lead. anti-theft alarm system fitted by Peugeot as 15 Working at the top of the aerial, unscrew 3 Unclip the sun visors from the roof console.

  • Page 240

    5 Should the alarm system become faulty, the beeps. The red light should go out, and the described in the following sub-Section. vehicle should be taken to a Peugeot dealer engine can them be started. c) Do not attempt to test any of the air bag for examination.

  • Page 241

    2 Any suspected faults with the air bag bag system as described in Section 24. steering wheel and the front faces of the system should be referred to a Peugeot dealer steering column shrouds is 8.0 mm. If the Air bag rotary connector...

  • Page 242

    12•22 Wiring diagrams...

  • Page 243

    Wiring diagrams 12•23...

  • Page 244

    12•24 Wiring diagrams...

  • Page 245

    Wiring diagrams 12•25...

  • Page 262

    Notes 11 12 Wire identification is not by colour, but by letters or numbers appearing on the wire at each end. Wires may interconnect between diagrams 18 19 21 22 and are located by using a grid reference e.g. 2/A1 denotes a position on diagram 2 grid location A1.

  • Page 263

    Starting and charging system - automatic Starting and transmission petrol models charging system - manual transmission petrol models Connector colours BA White BG Beige E040 GR Grey JN Yellow BB10 MR Brown RG Red BB10 BE Blue OR Orange 5 4 3 4/K6 RS Pink Mauve...

  • Page 264

    BB15 E040 M115 BB10 1394 M11A/M120 M11A/M120 C120 E005 D428 4B 2B E020 C120 C120 1070 1070 1070 E000 BB15 Starting,charging and preheating system - turbo diesel Twin cooling fans Key to items B41/B410 Battery 16 Post heat thermal switch Battery +ve control unit 17 Post heat relay M15D...

  • Page 265

    Engine systems - carburettor Key to items models without submerged pump Connector colours Battery BA White BG Beige Battery +ve control unit GR Grey JN Yellow Fusebox MR Brown RG Red MPR1 Ignition switch BE Blue OR Orange Instrument cluster CC21 BB10 RS Pink...

  • Page 266

    Connector colours C120 BA White BG Beige GR Grey JN Yellow MR Brown RG Red BE Blue OR Orange RS Pink Mauve VE Green NR Black BB10 7 10 9 4/L8 8/H2 E002 M120 E050 E000 BA 2 1 3 4 5 C123 E020 C121...

  • Page 267

    Digital clock/outside Analogue clock Horns air temp. display 3 4 5 6 7 BB10 E000 E020 6A 5B A283 B251 E020 E001 E002 E000 E000 Side, tail and number plate lights (saloon) MMC1 M26A V092 Key to items E001 Battery 56 RH rear light cluster (saloon) Battery +ve control unit a = direction indicator...

  • Page 268

    Tail and number M26A plate lights (estate) E054 BB10 VO9D M26A VO9G E020 E052 VO94 E000 M268B E053 E000 BB19 Key to items Main Battery 64 Dim-dip relay B PR10 PR10 Battery +ve control unit 65 Driving light relay MMC2 Fusebox 66 Dim-dip relay A Ignition switch...

  • Page 269

    Connector colours M26A BA White BG Beige M26A GR Grey JN Yellow E054 MR Brown RG Red BE Blue OR Orange RS Pink Mauve VE Green NR Black Interior lighting feed E050 V193 5/E3 E000 V193/V197 V197 M26B V19D V19F M200 C127 E052...

  • Page 270

    Direction indicators 2 3 1 2 3 1 M23A E020 B15A M319 B153 B154 B15B A306 A306 E020 M319 MV19 E000 V19C 2340/2343 E050 2330/2333 Typical interior light M26A 2343 (Estate only) 234/2344 E000 Key to items E054 M26A 233/2334 Battery 74 LH rear light cluster (estate) 2343...

  • Page 271

    Interior lighting and cigar lighter Map reading light and Connector colours glovebox illumination BA White BG Beige GR Grey JN Yellow MR Brown RG Red E020 BE Blue OR Orange RS Pink Mauve BB10 BB10 VE Green NR Black MVR4 M311 M306 F16A...

  • Page 272

    M530 E054 BB11 BB10 Front wash/wipe BB15 2B 1A A241 M521 5A 1A Connector colours 5A 7A BA White BG Beige GR Grey JN Yellow E053 MR Brown RG Red E000 E000 BE Blue OR Orange RS Pink Mauve Rear wash/wipe (estate) A241 A241 VE Green...

  • Page 273

    Electric mirrors Radio/cassette (NR) M841 8431 8441 V199 E020 B520 BB10 8/C3 V193 BB10 B15C M840 7B 2A E050 B520 M640 E000 B154 E000 6401 6401 6411 6411 Lights on buzzer M813 M814 1 2 3 4 5 BB10 E020 Key to items Battery 113 Electric aerial...

  • Page 274

    Central locking Electric windows 6041 6042 M600 B152 6001 M623 6052 BB10 6005 6051 6052 7A 7B 6051 M603 A301 A301 6040 6040 B151 6050 6050 6252 6231 6251 E000 M623 2A 4B A302 E000 E020 A282 B155 Connector colours B156 BA White BG Beige...

  • Page 275: Dimensions And Weights

    Reference REF•1 Dimensions and Weights ....REF•1 Radio/cassette unit Anti-theft System ..REF•5 Conversion Factors ..... . . REF•2 Tools and Working Facilities .

  • Page 276: Fuel Consumption

    Conversion Factors REF•2 Length (distance) Inches (in) 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) 0.305 = Metres (m) x 3.281 = Feet (ft) Miles 1.609 = Kilometres (km) x 0.621 = Miles Volume (capacity) Cubic inches (cu in; in x 16.387 = Cubic centimetres (cc;...

  • Page 277: Vehicle Identification Numbers

    Buying Spare Parts REF•3 Spare parts are available from many sources, Accessory shops members of a local or national chain. They including maker’s appointed garages, accessory frequently offer competitive prices when These are good places to buy materials and shops, and motor factors. To be sure of compared with a main dealer or local garage, components needed for the maintenance of obtaining the correct parts, it may sometimes be...

  • Page 278

    General Repair Procedures REF•4 Whenever servicing, repair or overhaul work unshouldered, the seal should be fitted with effectiveness after long periods of use, and is carried out on the car or its components, it its face flush with the housing top face (unless should be renewed as a matter of course.

  • Page 279

    The radio/cassette unit fitted to later the battery negative lead, or remove the displayed for 2 minutes. After 2 minutes, it will models as standard equipment by Peugeot is radio/cassette unit from the vehicle. be possible to enter a code again. If 3 wrong...

  • Page 280: Tools And Working Facilities

    Tools and Working Facilities REF•6 Introduction Maintenance Repair and overhaul tool kit and minor repair tool kit A selection of good tools is a fundamental These tools are virtually essential for requirement for anyone contemplating the The tools given in this list should be anyone undertaking any major repairs to a maintenance and repair of a motor vehicle.

  • Page 281

    Tools and Working Facilities REF•7 Special tools Buying tools Working facilities Not to be forgotten when discussing tools The tools in this list are those which are not Reputable motor accessory shops and is the workshop itself. If anything more than used regularly, are expensive to buy, or which superstores often offer excellent quality tools routine maintenance is to be carried out, a...

  • Page 282

    MOT Test Checks REF•8 This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test.

  • Page 283

    MOT Test Checks REF•9 Electrical equipment Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the Switch on the ignition and check the steering from lock to lock, and ensure that the operation of the horn. hoses do not contact the wheel, tyre, or any Check the windscreen washers and wipers, part of the steering or suspension mechanism.

  • Page 284

    MOT Test Checks REF•10 Exhaust system Front and rear suspension and The same general checks apply to vehicles wheel bearings fitted with other suspension types, such as Start the engine. With your assistant torsion bars, hydraulic displacer units, etc. holding a rag over the tailpipe, check the Starting at the front right-hand side, grasp Ensure that all mountings and attachments are entire system for leaks.

  • Page 285

    MOT Test Checks REF•11 for smoke emissions from the exhaust tailpipe. If the idle speed is obviously much too high, or if dense blue or clearly-visible black smoke comes from the tailpipe for more than 5 seconds, the vehicle will fail. As a rule of thumb, blue smoke signifies oil being burnt (engine wear) while black smoke signifies unburnt fuel (dirty air cleaner element, or other...

  • Page 286: Fault Finding, Automatic Transmission

    Fault Finding REF•12 Engine ......1 Automatic transmission ....6 Fluid leakage Engine fails to rotate when attempting to start Transmission fluid brown, or has burned smell...

  • Page 287

    Fault Finding REF•13 The pages which follow provide an easy-reference guide to the indicated, look for loose or broken wires before digging out the test gear. more common problems which may occur during the operation of the Cure the disease, not the symptom. Substituting a flat battery with vehicle.

  • Page 288

    Fault Finding REF•14 1 Engine (continued) Engine hesitates on acceleration Oil pressure warning light illuminated with engine running Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). Vacuum leak at the carburettor, throttle body, inlet manifold or Low oil level, or incorrect oil grade (Chapter 1). associated hoses (Chapter 4A, 4B or 4C).

  • Page 289: Cooling System

    Fault Finding REF•15 2 Cooling system Overheating External coolant leakage Insufficient coolant in system (“Weekly checks”). Deteriorated or damaged hoses or hose clips (Chapter 1). Thermostat faulty (Chapter 3). Radiator core or heater matrix leaking (Chapter 3). Radiator core blocked, or grille restricted (Chapter 3). Pressure cap faulty (Chapter 3).

  • Page 290: Manual Transmission

    Fault Finding REF•16 5 Manual transmission Noisy in neutral with engine running Jumps out of gear Primary gears and bearings worn (noise apparent with clutch Worn or damaged gear linkage (Chapter 7A). pedal released, but not when depressed) (Chapter 7A).* Incorrectly-adjusted gear linkage (Chapter 7A).

  • Page 291: Braking System, Suspension And Steering

    Fault Finding REF•17 8 Braking system Note: Before assuming that a brake problem exists, make sure that Brake pedal feels spongy when depressed the tyres are in good condition and correctly inflated, that the front Air in hydraulic system (Chapter 9). wheel alignment is correct, and that the vehicle is not loaded with Deteriorated flexible rubber brake hoses (Chapters 1 and 9).

  • Page 292: Electrical System

    Fault Finding REF•18 9 Suspension and steering (continued) Tyre wear excessive Tyres worn in centre of tread Tyres over-inflated (“Weekly checks”). Tyres worn on inside or outside edges Tyres worn on inside and outside edges Tyres under-inflated (wear on both edges) (“Weekly checks”). Tyres under-inflated (“Weekly checks”).

  • Page 293

    Fault Finding REF•19 Windscreen/tailgate washers inoperative, Window glass fails to move or unsatisfactory in operation Blown fuse (Chapter 12). Faulty relay (Chapter 12). One or more washer jets inoperative Broken or disconnected wiring or connections (Chapter 12). Blocked washer jet (Chapter 1). Faulty motor (Chapter 11).

  • Page 294

    Glossary of Technical Terms REF•20 would tend to clog the radiator and coolant Bearing The curved surface on a shaft or in a passages and reduce cooling efficiency. bore, or the part assembled into either, that ABS (Anti-lock brake system) A system, Anti-seize compound A coating that...

  • Page 295

    Glossary of Technical Terms REF•21 Camshaft A rotating shaft on which a series Catalytic converter A silencer-like device in Crocodile clip See Alligator clip of cam lobes operate the valve mechanisms. the exhaust system which converts certain The camshaft may be driven by gears, by pollutants in the exhaust gases into less harmful substances.

  • Page 296

    Glossary of Technical Terms REF•22 Feeler blade A thin strip or blade of hardened electrode in a spark plug. Also refers to the steel, ground to an exact thickness, used to spacing between the points in a contact EGR valve A valve used to introduce exhaust check or measure clearances between parts.

  • Page 297

    Glossary of Technical Terms REF•23 Overhead cam (ohc) engine An engine with the ozone in the upper atmosphere. the camshaft(s) located on top of the cylinder Rocker arm A lever arm that rocks on a shaft Jump start Starting the engine of a vehicle head(s).

  • Page 298

    Glossary of Technical Terms REF•24 automatic transmission, switch that front wheel drive vehicles, a slight amount of obstructs one or more ports or passageways. prevents starting if the vehicle is not in Neutral toe-out is usually specified. A valve is also the movable part of such a or Park.

  • Page 299

    Index REF•25 Note: References throughout this index are in the form - “Chapter number” • “page number” Braking system - 9•1 et seq Coil spring - 10•5 ABS - 9•19 Compression test - 2A•3 bleeding the brakes - 9•2 Connecting rods - 2C•10, 2C•13, brake pedal - 9•15 2C•21, 2C•22 ABS system - 9•19...

  • Page 300

    - 2A•10, 2B•18, 2C•7, 2C•9 Interior trim panel - 11•7, 11•18 fuel pump - 4A•4, 4B•4 fault finding - REF•13 Introduction to the Peugeot 405 - 0•4 fuel tank - 4A•5, 4B•5, 4C•4 flywheel - 2A•13, 2B•23 inlet manifold -4A•9, 4B•9, 4C•11 main and big-end bearings - 2C•15,...

  • Page 301

    Index REF•27 Oil pressure warning light switch - 5A•4 Seat belts - 11•17 Oil pump - 2A•12, 2B•21 Seats - 11•16 Oil seals - 7A•4, 7B•4, REF•4 Selector cable (automatic transmission) - Tailgate - 11•11 camshaft - 2A•8, 2B•14 7B•2 lock - 11•12 crankshaft - 2A•13, 2B•22 Selector lever assembly - 7B•3...

  • Page 302

    Preserving Our Motoring Heritage < The Model J Duesenberg Derham Tourster. Only eight of these magnificent cars were ever built – this is the only example to be found outside the United States of America Almost every car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum.

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405 petrol

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  • #unknown Jul 03, 2015 01:50:
    I have been ripped off 3 times.
    Whe​re are chapters 6, 7, and 8 from the Haynes manual on Peugeot 405???????​????????
    H​ow can I get them??????​?????