Peugeot 405 Manual

Bosch Monopoint system components - removal and refitting
Fuel/exhaust systems - single-point fuel injection models / Bosch Monopoint system components - removal and refitting


Note: Check the availability of individual components with your Peugeot dealer before dismantling.

Fuel injector
Note: Refer to the warning note in Section 1 before proceeding. If a faulty injector is suspected, before condemning the injector, it is worth trying the effect of one of the proprietary injector-cleaning treatments.

1 Remove the inlet air temperature sensor as described later in this Section.

2 Lift out the injector and recover its lower sealing ring.

3 Refitting is a reversal of the removal procedure ensuring that the injector sealing ring(s) and injector cap O-ring are in good condition. When refitting the injector cap ensure that the injector pins are aligned with the cap terminals, the terminals are marked У+Ф and У-Ф for identification (see illustrations).

15.3a Undo the injector cap screw, noting the use of rag to catch fuel spray
15.3a Undo the injector cap screw, noting the use of rag to catch fuel spray . . .

15.3b . . . then lift off the cap and withdraw the injector
15.3b . . . then lift off the cap and withdraw the injector

15.3c On refitting, ensure cap terminals are aligned with injector pins
15.3c On refitting, ensure cap terminals are aligned with injector pins (arrowed)

Fuel pressure regulator Note: Refer to the warning note in Section 1 before proceeding. 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 not be disturbed unless absolutely necessary.

4 Disconnect the battery negative terminal.

5 Remove the air cleaner-to-throttle body duct, using the information given in Section 2.

6 Using a marker pen, make alignment marks between the regulator cover and throttle body, then slacken and remove the cover screws (see illustration). As the screws are slackened, place a clean rag over the cover to catch any fuel spray which may be released.

15.6 Fuel pressure regulator retaining screws (arrowed)
15.6 Fuel pressure regulator retaining screws (arrowed)

7 Lift off the cover, then remove the spring and withdraw the diaphragm, noting its correct fitted orientation. Remove all traces of dirt and examine the diaphragm for signs of splitting. If damage is found, it will probably be necessary to renew the throttle body assembly.

8 Refitting is a reverse of the removal procedure, ensuring that the diaphragm and cover are fitted the correct way round, and that the retaining screws are securely tightened.

Idle control stepper motor 9 Disconnect the battery negative terminal.

10 Depress the retaining clip and disconnect the wiring connector from the idle control stepper motor.

11 Undo the retaining screws and remove the motor from the front of the throttle body (see illustration).

15.6 Fuel pressure regulator retaining screws (arrowed)
15.6 Fuel pressure regulator retaining screws (arrowed)

12 Refitting is a reverse of the removal procedure, ensuring that the motor retaining screws are securely tightened.

Throttle potentiometer
13 The throttle potentiometer is a sealed unit, and under no circumstances should it be disturbed. For this reason, on some models, it is secured to the throttle body assembly by tamperproof screws. If the throttle potentiometer is faulty, the complete throttle body assembly must be renewed - refer to your Peugeot dealer for the latest information.

Inlet air temperature sensor Note: Refer to the warning note in Section 1 before proceeding.

14 The inlet air temperature sensor is an integral part of the throttle body injector cap.

To remove the cap, first disconnect the battery negative terminal, then remove the air cleaner-to-throttle body duct using the information given in Section 2.

15 Undo the three retaining screws and remove the circular plastic ring from the top of the throttle body and recover its sealing ring (see illustrations).

15.15a Undo the three retaining screws (arrowed) . . .
15.15a Undo the three retaining screws (arrowed) . . .

15.15b . . . then lift off the plastic ring and recover the sealing ring
15.15b . . . then lift off the plastic ring and recover the sealing ring

16 Depress the retaining clip and disconnect the wiring connector from the injector wiring connector (see illustration).

15.16 Disconnecting the injector wiring connector. Injector screw is arrowed
15.16 Disconnecting the injector wiring connector. Injector screw is arrowed

17 Undo the injector cap retaining screw, then lift off the cap and recover the gasket and/or sealing ring (as applicable). Note that as the cap screw is slackened, place a rag over the injector to catch any fuel spray which may be released.

18 Refitting is a reversal of the removal procedure ensuring that the injector cap gasket and/or O-ring is in good condition.

Take care to ensure that the cap terminals are correctly aligned with the injector pins and securely tighten the cap retaining screw.

Coolant temperature sensor 19 Refer to Chapter 3.

Electronic control unit (ECU) 20 The ECU is located in the plastic box which is mounted onto the rear of the battery mounting tray.

21 To remove the ECU, first disconnect the battery.

22 Unclip the cover from the box, then lift the retaining clip and disconnect the wiring connector from the ECU.

23 Undo the retaining nut and release the relay unit from the rear of the ECU box.

24 Undo the retaining screws and remove the ECU and box assembly from the battery tray. If necessary, undo the retaining screws and separate the ECU and box.

25 Refitting is a reverse of the removal procedure ensuring that the wiring connector is securely reconnected.

Fuel injection system relay unit 26 The relay unit is mounted onto the rear of the ECU plastic box which is situated directly behind the battery.

27 To remove the relay unit, first disconnect the battery.

28 Undo the retaining nut, then disconnect the wiring connector and remove the relay unit from the vehicle.

29 Refitting is the reverse of removal, ensuring that the relay unit is securely clipped in position.

Crankshaft sensor
30 The crankshaft sensor is situated on the front face of the transmission (clutch) housing.

31 To remove the sensor, first disconnect the battery negative terminal.

32 Trace the wiring back from the sensor to the wiring connector, and disconnect it from the main harness.

33 Prise out the rubber grommet, then undo the retaining bolt and withdraw the sensor from the transmission.

34 Refitting is a reverse of the removal procedure. Ensure that the sensor retaining bolt is securely tightened, and that the grommet is correctly seated in the transmission housing.

Vehicle speed sensor
35 The vehicle speed sensor is an integral part of the speedometer drive housing. Refer to Chapter 7A, Section 7 for removal and refitting details.


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