Peugeot 405 Manual

Choke cable - removal, refitting and adjustment
Fuel/exhaust systems - carburettor models / Choke cable - removal, refitting and adjustment


Removal
1 Release the choke inner cable from the carburettor linkage.

2 Slacken and remove the retaining bolt and remove the outer cable retaining clamp.

3 Slacken the retaining clip securing the rubber collar to the outer cable, and slide the collar off the cable. Where the original crimped-type Peugeot hose clip is still fitted, cut the clip and discard it; use a standard worm-drive hose clip on refitting.

4 Working back along the length of the cable, free it from any retaining clips or ties, noting its correct routing. Tie a length of string to the end of the choke inner cable.

5 Working from inside the vehicle, pull the choke lever fully out, to gain access to the retaining screw. Unclip the choke lever from the facia and withdraw the lever and cable assembly from the facia, disconnecting the wiring from the lever switch (where fitted) as it becomes accessible. Once the end of the cable appears through the lever aperture, untie the string and leave it in position in the vehicle - it can then be used to draw the cable back into position on refitting.

Refitting
6 Tie the string to the end of the choke cable, then use the string to draw the cable into position through the bulkhead into the engine compartment. Once the cable end is fully in position, untie the string.

7 Reconnect the wiring connector (where fitted), and clip the choke lever in its facia panel aperture.

8 From within the engine compartment, ensure that the outer cable is correctly seated in the bulkhead grommet. Work along the cable, securing it in position with all the relevant retaining clips and ties, and ensuring that the cable is correctly routed.

9 Slide the rubber collar and retaining clip onto the end of the cable, then engage the inner end of the cable with carburettor linkage. Align the rubber collar with the carburettor bracket, then refit the retaining clip and securely tighten its retaining bolt.

Adjust the cable as described below.

Adjustment
10 Slacken the clip securing the rubber collar to the outer cable. Where the crimped-type Peugeot hose clip is still fitted, cut the clip and discard it; use a standard worm-drive hose clip on refitting (see illustration).

9.10 Choke cable-to-rubber collar retaining clip (arrowed)
9.10 Choke cable-to-rubber collar retaining clip (arrowed)

11 Ensuring that the choke lever is flush with the facia panel and the carburettor linkage is fully against its stop, move the outer cable in the rubber collar until the position is found where there is only a small amount of free play present in the inner cable. Hold the outer cable in this position, and securely tighten the clip securing the rubber collar to the outer cable.

12 Have an assistant operate the choke lever, and check that the choke linkage closes fully and returns smoothly to its stop. If necessary, repeat the adjustment procedure.


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