Peugeot 405 Manual

Heater/ventilation components - removal and refitting
Cooling, heating and ventilation systems / Heater/ventilation components - removal and refitting


Heater/ventilation control unit - models up to 1992
Removal
1 Disconnect the battery negative lead.

2 Where applicable, remove the radio/ cassette player as described in Chapter 12.

3 Move the steering column to its lowest position.

4 Remove the lighting control stalk switch (right-hand-drive models) or the wash/wipe control stalk switch (left-hand-drive models), as described in Chapter 12. Note that there is no need to disconnect the switch wiring, but the switch must be moved to allow clearance for removal of the centre facia panel.

5 Unclip the trim panel from the lower edge of the instrument panel to expose the upper centre facia panel securing screw. Remove the screw (see illustration).

9.5 Removing the upper centre facia panel securing screw - models up to 1992
9.5 Removing the upper centre facia panel securing screw - models up to 1992

6 Unclip the oddments tray from the front of the facia centre panel.

7 Unclip the ashtray and remove it from the facia.

8 Unscrew the five centre facia panel securing screws exposed by removal of the oddments tray and ashtray (see illustration).

9.8 Centre facia panel securing screws (arrowed) - models up to 1992
9.8 Centre facia panel securing screws (arrowed) - models up to 1992

9 Pull the centre facia panel forwards from the facia, then reach behind the panel and disconnect the wiring from the switches, clock, and cigarette lighter, as applicable.

Note the locations of the wiring connectors to ensure correct refitting, and remove the facia panel.

10 Unscrew the four heater control unit securing screws, then manipulate the unit from the facia, and disconnect the control cables and/or wiring plugs (see illustration).

9.10 Two heater control unit securing screws (arrowed) - models up to 1992
9.10 Two heater control unit securing screws (arrowed) - models up to 1992

The cables can be disconnected after releasing the metal spring clips securing the cable sheaths to the control unit.

Refitting
11 Refitting is a reversal of removal, but note that the control cables must be reconnected in the order shown (see illustration).

9.11 Heater control cables reconnection sequence - models up to 1992
9.11 Heater control cables reconnection sequence - models up to 1992

12 Refit the radio/cassette player with reference to Chapter 12.

Heater/ventilation control unit - models from 1993
Note: Refer to the facia removal procedure in Chapter 11 for relevant illustrations of facia housing removal.

Removal
13 Disconnect the battery negative lead.

14 Remove the centre console (Chapter 11).

15 Open the ashtray cover, and unscrew the two screws located at the bottom of the ashtray housing.

16 Where applicable, remove the radio/ cassette player with reference to Chapter 12.

On models not fitted with a radio/cassette player, prise out the oddments tray.

17 Remove the two securing screws from the top of the radio/cassette player/oddments tray housing, then withdraw the housing from the facia. Where applicable, disconnect the wiring plug(s) from the rear of the housing.

18 Prise the blanking plate from the top corner of the facia centre ventilation nozzle housing. Remove the now-exposed securing screw.

19 Remove the four housing securing screws located under the heater control panel. Two screws are accessible from the front of the housing, and two screws from underneath.

20 Carefully prise the switches from below the centre facia ventilation nozzles to reveal the remaining housing securing screw.

Remove the screw.

21 Pull the housing forwards, and disconnect the wiring from the clock, then withdraw the housing.

22 Remove the two securing screws located at the top of the heater control unit (see illustration).

9.22 Remove the heater control unit securing screws - models from 1993
9.22 Remove the heater control unit securing screws - models from 1993

23 Pull the control unit forwards from the facia.

24 Working at the top of the unit, disconnect the two control cables and the wiring plug.

The cables can be disconnected after releasing the metal spring clips securing the cable sheaths to the control unit (see illustration). Note the cable locations to ensure correct refitting.

9.24 Disconnect the control cables from the heater control unit - models from
9.24 Disconnect the control cables from the heater control unit - models from 1993

25 Working under the unit, disconnect the remaining control cable, then withdraw the unit.

Refitting
26 Refitting is a reversal of removal, ensuring that the cables are correctly routed and securely reconnected.

Heater/ventilation control cables Removal
27 Disconnect the cables from the heater control unit by removing the control unit as described previously in this Section.

28 With the heater control unit removed, access can be gained to the cable connections on the heater unit, behind the facia (see illustration).

9.28 Heater control cable metal spring clip (arrowed) at heater unit
9.28 Heater control cable metal spring clip (arrowed) at heater unit

Access may be
improved by removing surrounding panels with reference to Chapter 11.

29 Note the locations and routing of the cables to ensure correct refitting.

Refitting
30 Refitting is a reversal of removal, bearing in mind the following points.

a) The cables are of a preset length, and no adjustment is required; small adjustments can be made by repositioning the cable sheaths in the securing clips.

b) When reconnecting the air inlet flap cable, the cable must be routed around the air inlet duct, not behind it (see illustration).

9.30 Correct routing of heater air inlet flap control cable - models up to
9.30 Correct routing of heater air inlet flap control cable - models up to 1992

1 Incorrect routing 2 Correct routing

c) Refit the heater control unit as described previously in this Section.

Heater matrix
Removal
31 Remove the complete facia assembly as described in Chapter 11.

32 Drain the cooling system (Chapter 1).

33 Place a tray under the heater pipe connections in the passenger compartment, and place absorbent cloths on the carpet, in case of coolant spillage.

34 Where applicable, unscrew the bolt securing the heater pipes.

35 Unscrew the screw(s) securing the heater pipes to the connector on the heater matrix (see illustration).

9.35 Remove the screw securing the heater pipes to the matrix connector
9.35 Remove the screw securing the heater pipes to the matrix connector

36 To remove the matrix from the heater assembly, unscrew the two securing screws, then carefully withdraw the matrix from its housing in the heater assembly, moving the heater pipes aside as the matrix is withdrawn.

Recover the O-rings from the matrix pipe connections (see illustrations).

9.36a Remove the two securing screws . . .
9.36a Remove the two securing screws . . .

9.36b . . . then withdraw the heater matrix . . .
9.36b . . . then withdraw the heater matrix . . .

9.36c . . . and recover the O-rings from the pipe connections
9.36c . . . and recover the O-rings from the pipe connections

Refitting
37 Refitting is a reversal of removal, bearing in mind the following points.

a) Use new O-rings when reconnecting the heater matrix pipes to the connector on the heater matrix.

b) Refit the facia assembly (see Chapter 11).

c) On completion, refill (or top-up) the cooling system as described in Chapter 1.

Complete heater assembly - models without air conditioning Removal
38 Remove the complete facia assembly as described in Chapter 11.

39 Drain the cooling system (see Chapter 1).

40 Working in the engine compartment, disconnect the coolant hoses from the heater matrix (it may be necessary to remove surrounding components for access on some models).

41 Where applicable, remove the securing screws, and remove the plastic shields from the heater air inlet, and the windscreen wiper motor in the scuttle at the rear of the engine compartment. This will expose the heater securing bolts (see illustration).

9.41 Plastic shield securing screws (1) and heater securing bolt (2)
9.41 Plastic shield securing screws (1) and heater securing bolt (2)

42 Working in the scuttle, unscrew the heater securing bolts.

43 Unclip the air ducts connecting the heater assembly to the floor heating.

44 Place a tray under the heater pipe connections in the passenger compartment, and place absorbent cloths on the carpet, in case of coolant spillage.

45 Where applicable, unscrew the bolt securing the heater pipes.

46 Unscrew the screw(s) securing the heater pipes to the connector on the heater matrix.

47 Unscrew the bolt from the lower right-hand corner of the heater unit (see illustration).

9.47 Heater unit lower right-hand securing bolt (arrowed)
9.47 Heater unit lower right-hand securing bolt (arrowed)

48 Disconnect the wiring plugs from the heater assembly, and release the wiring harnesses from any clips. Note the routing of the wiring to ensure correct refitting.

49 Pull the heater assembly back from the bulkhead to disengage the matrix connector from the heater pipes. Withdraw the heater assembly from the vehicle (complete with the control unit), being prepared for coolant spillage. Recover the O-rings from the matrix pipe connections.

Refitting
50 Refitting is a reversal of removal, bearing in mind the following points.

a) Use new O-rings when reconnecting the heater matrix pipes to the connector on the heater matrix.

b) Ensure that the wiring harnesses are routed as noted before removal.

c) Refit the facia assembly as described in Chapter 11.

d) On completion, refill (or top-up) the cooling system as described in Chapter 1.

Complete heater assembly - models with air conditioning Warning: Do not attempt to remove the heater unit until the air conditioning refrigerant circuit has been discharged by a qualified expert.

Removal
51 Before carrying out any work, have the air conditioning refrigerant circuit discharged by a qualified air conditioning specialist.

52 Working in the engine compartment, unscrew the nuts securing the clamp to the evaporator refrigerant pipes at the engine compartment bulkhead.

53 Slide the clamp back along the pipes, away from the bulkhead.

54 Pull the two refrigerant pipes from the relief valve on the bulkhead.

55 Proceed as described in paragraphs 38 to 49 inclusive, but note that it will be necessary to disconnect the wiring plugs from the air conditioning electrical components mounted on the heater assembly. Note the locations of the connectors, and the routing of the wiring harnesses.

Refitting
56 Refitting is a reversal of removal, noting the following points.

a) Ensure that all wiring plugs are correctly reconnected, and that the wiring is routed as noted before removal.

b) Use new O-rings when reconnecting the heater matrix pipes to the connector on the heater matrix.

c) Use new O-rings when reconnecting the refrigerant pipes to the relief valve at the bulkhead.

d) On completion, refill (or top-up) the cooling system as described in Chapter 1, and have the refrigerant circuit recharged by a qualified air conditioning specialist.

Heater blower motor
Removal
57 Working under the passenger’s side of the facia, release the securing clips and withdraw the carpet trim panel from under the facia.

58 If desired, to improve access, remove the glovebox as described in Chapter 11.

59 Reach up under the facia and disconnect the blower motor wiring plug. Where applicable, release the wiring from the clip(s) on the motor casing (see illustration).

9.59 Disconnect the blower motor wiring plug
9.59 Disconnect the blower motor wiring plug

60 Unscrew the three securing screws from the bottom of the motor casing, and withdraw the motor assembly (see illustration).

9.60 Withdrawing the heater blower motor
9.60 Withdrawing the heater blower motor

Refitting
61 Refitting is a reversal of removal.

Heater blower control module Removal
62 The control module assembly is located in the motor casing.

63 Remove the blower motor as described previously in this Section.

64 Where applicable, pull the rubber grommet from the motor casing, and disconnect the wiring from the motor (see illustration). Note the wire locations to ensure correct refitting.

9.64 Pull the rubber grommet from the motor casing for access to the wiring
9.64 Pull the rubber grommet from the motor casing for access to the wiring

65 Working through the fan blades, remove the screws, and/or release the clips securing the motor assembly to the casing (release the clips using a pair of pliers or a screwdriver, depending on the type of clip encountered) (see illustrations).

9.65a Remove the securing screws . . .
9.65a Remove the securing screws . . .

9.65b . . . and release the clips . . .
9.65b . . . and release the clips . . .

66 Withdraw the motor/fan blade assembly from the casing (see illustration).

9.66 . . . then withdraw motor from casing
9.66 . . . then withdraw motor from casing

67 Disconnect the wiring plug from the rear of the control module (see illustration).

9.67 Disconnect the wiring plug . . .
9.67 Disconnect the wiring plug . . .

68 Remove the two securing screws, and withdraw the control module (see illustrations).

9.68a . . . then remove the securing screws . . .
9.68a . . . then remove the securing screws . . .

9.68b . . . and withdraw the control module
9.68b . . . and withdraw the control module

Refitting
69 Refitting is a reversal of removal.


© 2018 www.peugeot405.ru. All Rights Reserved.