Peugeot 405 Manual

Throttle body - removal and refitting
Fuel/exhaust systems - single-point fuel injection models / Throttle body - removal and refitting


Note: Refer to the warning note in Section 1 before proceeding.

Removal
1 Disconnect the battery negative terminal.

2 Remove the air cleaner housing-to-throttle body duct, using the information given in Section 2 (see illustration).

12.2 Air cleaner housing-to-throttle body duct (Magneti Marelli fuel
12.2 Air cleaner housing-to-throttle body duct (Magneti Marelli fuel injection system)

3 Depress the retaining clips and disconnect the wiring connectors from the throttle potentiometer, the idle control stepper motor (where fitted), and the injector wiring loom connector which is situated on the side of the throttle body (see illustrations).

12.3a Disconnect the wiring connectors from the throttle potentiometer . . .
12.3a Disconnect the wiring connectors from the throttle potentiometer . . .

12.3b . . . the injector wiring loom connector and the stepper motor
12.3b . . . the injector wiring loom connector and the stepper motor

4 Bearing in mind the information in Section 8 about depressurising the fuel system, release the retaining clips and disconnect the fuel feed and return hoses from the throttle body assembly. 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).

12.4 Fuel feed and return hose connections (arrowed) - later model shown
12.4 Fuel feed and return hose connections (arrowed) - later model shown

5 Disconnect the accelerator inner cable from the throttle cam, then withdraw the outer cable from the mounting bracket, along with its flat washer and spring clip.

6 Disconnect the idle control auxiliary air valve and/or purge valve hose from the throttle body (as applicable).

7 Slacken and remove the bolts securing the throttle body assembly to the inlet manifold, then remove the assembly along with its gasket (see illustration).

12.7 Throttle body retaining screws (arrowed) on the Bosch Monopoint system
12.7 Throttle body retaining screws (arrowed) on the Bosch Monopoint system

8 If necessary, with the throttle body removed, undo the retaining screws and separate the upper and lower sections, noting the gasket which is fitted between the two.

Refitting
9 Refitting is a reverse of the removal procedure, bearing in mind the following points:
a) Where applicable, ensure that the mating surfaces of the upper and lower throttle body sections are clean and dry. Fit a new gasket and reassemble the two sections, tightening the retaining screws securely.

b) Ensure that the mating surfaces of the manifold and throttle body are clean and dry, then fit a new gasket. Securely tighten the throttle body retaining bolts.

c) Ensure that all hoses are correctly reconnected and, where necessary, that their retaining clips are securely tightened.

d) On completion, adjust the accelerator cable using the information given in Section 4.


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