Peugeot 405 Manual

Magneti Marelli system components - removal and refitting
Fuel/exhaust systems - single-point fuel injection models / Magneti Marelli 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.

Note: If a faulty injector is suspected, before condemning the injector, it is worth trying the effect of one of the proprietary injectorcleaning treatments. If this fails, the vehicle should be taken to a Peugeot dealer for testing using the appropriate specialist equipment. At the time of writing, it appears that neither the fuel injector nor its seals are available separately and, if faulty, the complete upper throttle body assembly must be renewed. Refer to your Peugeot dealer for further information on parts availability.

1 Disconnect the battery negative terminal.

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

3 Release the retaining tangs and disconnect the injector wiring connector (see illustration).

16.3 Injector wiring connector (arrowed)
16.3 Injector wiring connector (arrowed)

4 Undo the retaining screw, then remove the retaining clip and lift the injector out of the housing, noting its sealing ring. Note that as the screw is slackened, place a rag over the injector to catch any fuel spray which may be released.

5 Refitting is a reverse of the removal procedure ensuring that the injector sealing ring is in good condition.

Fuel pressure regulator
Note: Refer to the warning note at the start of this Section before proceeding.

Note: At the time of writing, it appears that the fuel pressure regulator is not available separately. If the fuel pressure regulator assembly is faulty, the complete upper throttle body assembly must be renewed. Refer to a Peugeot dealer for further information on parts availability. Although the unit can be dismantled for cleaning, if required, it should not be disturbed unless absolutely necessary.

6 Disconnect the battery negative terminal.

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

8 Using a suitable marker pen, make alignment marks between the regulator cover and throttle body, then undo the four retaining screws. Note that as the screws are slackened, place a rag over the cover to catch any fuel spray which may be released.

9 Lift off the cover, then remove the spring and withdraw the diaphragm whilst noting its correct fitted orientation. Remove all traces of dirt and examine the diaphragm for splitting. If damage is found, it will be necessary to renew the complete upper throttle body assembly as described earlier in this Section.

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

Idle control stepper motor 11 Disconnect the battery negative terminal.

12 To remove the stepper motor, depress the retaining tabs and disconnect the wiring connector. Undo the two retaining screws and withdraw the motor from the side of the throttle body assembly.

13 Refitting is a reverse of removal.

Throttle potentiometer
14 Disconnect the battery negative terminal, then depress the retaining tabs and disconnect the wiring connect from the throttle potentiometer (see illustration).

16.14 Throttle potentiometer wiring connector (arrowed)
16.14 Throttle potentiometer wiring connector (arrowed)

15 Undo the two retaining screws and remove the throttle potentiometer from the side of the throttle body assembly.

16 Refitting is a reversal of the removal procedure ensuring that the throttle potentiometer tang is correctly engaged with the throttle spindle.

Inlet air temperature sensor 17 The inlet air temperature sensor is screwed into the underside of the upper throttle body where it is situated on the lefthand side of the fuel injector.

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

19 Disconnect the wiring connector, then undo the retaining screw and remove the inlet air temperature sensor from the throttle body.

Note: The sensor retaining screw is very difficult to reach. If it proves impossible to unscrew, the throttle body will have to be removed to permit sensor removal.

20 Refitting is a reverse of removal.

Manifold absolute pressure (MAP) sensor
21 The MAP sensor is mounted onto a bracket which is situated on the engine compartment bulkhead, behind the throttle body.

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

23 Slacken and remove the three retaining bolts, then free the MAP sensor from the bracket. Disconnect the wiring connector and vacuum hose and remove the sensor from the engine compartment.

24 Refitting is a reversal of the removal procedure.

Coolant temperature sensor 25 Refer to Chapter 3.

Crankshaft sensor
26 Refer to Section 14.

Electronic control unit (ECU) 27 Refer to Section 14.

Fuel injection system relay unit 28 Refer to Section 14.

Throttle body heating element 29 The throttle body heating element is situated in the front of the throttle body.

30 To remove the element, first disconnect the battery negative terminal.

31 Remove the air cleaner housing-tothrottle body duct using the information given in Section 2.

32 Disconnect the wiring connectors from the inlet air temperature sensor and the injector. Also disconnect the main wiring connector from the throttle body and free the connector from its mounting bracket.

33 Undo the retaining screws and free the accelerator mounting bracket from the throttle body. As the bracket is released, recover the spring from the front of the heating element.

34 Ease the heating element out from the throttle housing and remove it along with the wiring connector and wiring harness. Examine the O-ring for signs of damage or deterioration and renew if necessary.

35 Refitting is a reversal of removal; where necessary, use a new O-ring.


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