Peugeot 405 Manual

Exhaust manifold - removal and refitting
Fuel/exhaust systems - carburettor models / Exhaust manifold - removal and refitting


Removal
1 Disconnect the hot-air inlet hose from the manifold shroud and remove it from the vehicle (see illustration).

15.1 Remove the hot-air intake hose . . .
15.1 Remove the hot-air intake hose . . .

2 Slacken and remove the retaining screws, and remove the shroud from the top of the exhaust manifold (see illustration).

15.2 . . . then undo the three retaining screws (arrowed) and remove the
15.2 . . . then undo the three retaining screws (arrowed) and remove the exhaust manifold shroud (TU engine)

3 On TU engine models apply the handbrake then jack up the front of the vehicle and support on axle stands (see УJacking and Vehicle SupportФ).

4 Undo the nuts/bolts securing the exhaust front pipe to the manifold, then remove the bolt securing the front pipe to its mounting bracket. Disconnect the front pipe from the manifold, and where applicable recover the gasket.

5 Where fitted, loosen the clamp nuts and release the power-assisted steering and coolant pipes from the brackets (see illustration).

15.5 Power-assisted steering and coolant pipe clamps (arrowed) (XU injection
15.5 Power-assisted steering and coolant pipe clamps (arrowed) (XU injection engine shown)

6 Undo the retaining nuts securing the manifold to the head (see illustration).

15.6 The exhaust manifold retaining nuts (TU engine)
15.6 The exhaust manifold retaining nuts (TU engine)

Manoeuvre the manifold out of the engine compartment, and discard the manifold gaskets.

Refitting
7 Refitting is the reverse of the removal procedure, noting the following points: a) Examine all the exhaust manifold studs for signs of damage and corrosion; remove all traces of corrosion, and repair or renew any damaged studs.

b) Ensure that the manifold and cylinder head sealing faces are clean and flat, and fit the new manifold gaskets (see illustration).

15.7 New gaskets fitted to the exhaust ports on the cylinder head (XU engine)
15.7 New gaskets fitted to the exhaust ports on the cylinder head (XU engine)

Tighten the manifold
retaining nuts to the specified torque.

c) Reconnect the front pipe to the manifold using the information given in Section 16.


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