Peugeot 405 Manual

Throttle housing - removal and refitting
Fuel/exhaust systems - multi-point fuel injection models / Throttle housing - removal and refitting


Note: At the time or writing no information was available for the Sagem-Lucas system.

Removal
1 Disconnect the battery negative terminal.

Bosch Jetronic system
2 Remove the airflow meter with reference to Section 2.

3 Disconnect the accelerator cable from the throttle housing.

4 Either drain the cooling system or clamp the coolant hoses as close as possible to the throttle housing, then disconnect the coolant inlet hose (see illustration).

12.4 Disconnecting the coolant inlet hose
12.4 Disconnecting the coolant inlet hose

5 Disconnect the throttle switch wiring multiplug (see illustration).

12.5 Disconnecting the multi-plug
12.5 Disconnecting the multi-plug

6 Loosen the clip and detach the plastic duct from the throttle housing (see illustration).

12.6 Detach the plastic duct
12.6 Detach the plastic duct

7 Disconnect the coolant return hose, distributor vacuum hose and breather hose from the throttle housing (see illustration).

12.7 Disconnect the coolant return (A), distributor vacuum hose (B) and
12.7 Disconnect the coolant return (A), distributor vacuum hose (B) and breather hose (C)

8 Unscrew the Allen bolts and remove the throttle housing (see illustration).

12.8 Removing the throttle housing
12.8 Removing the throttle housing

Bosch LU2-Jetronic system 9 Release the securing clip, and disconnect the wiring plug from the throttle position switch.

10 Loosen the securing clamp, and disconnect the air trunking from the front of the throttle body.

11 Disconnect the accelerator cable.

12 Disconnect the vacuum and/or breather hoses from the throttle body, noting their locations to ensure correct refitting.

13 Unscrew the three throttle body securing nuts, and recover the washers. Remove the throttle cable bracket from the top throttle body securing stud, noting its orientation.

Bosch Motronic system
14 Slacken the retaining clip, then disconnect the inlet duct from the throttle housing and recover the sealing ring.

15 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.

16 Depress the retaining clip and disconnect the wiring connector(s) from the throttle potentiometer, and, where necessary, from the electric heating element, the air temperature sensor.

17 Slacken and remove the three retaining screws and remove the throttle housing from the inlet manifold. Recover the O-ring from manifold and discard it; a new one must be used on refitting.

Magneti Marelli 8P system 18 Remove the air cleaner-to-throttle housing duct as described in Section 2.

19 As applicable, carefully lever the accelerator linkage rod off its throttle housing balljoint, or 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. Where necessary, also disconnect the kickdown cable as described in Chapter 7B (see illustration).

12.19 Accelerator cable and kickdown cable connections on the throttle
12.19 Accelerator cable and kickdown cable connections on the throttle housing (Magneti Marelli 8P fuel injection system)

20 Depress the retaining clips, and disconnect the wiring connectors from the throttle potentiometer, the electric heating element, the air temperature sensor and idle control stepper motor (as applicable).

21 Release the retaining clips (where fitted), and disconnect all the relevant vacuum and breather hoses from the throttle housing. Make identification marks on the hoses, to ensure they are connected correctly on refitting.

22 Slacken and remove the three retaining screws, and remove the throttle housing from the inlet manifold. Remove the O-ring from the manifold, and discard it - a new one must be used on refitting.

Refitting
23 Refitting is a reversal of the removal procedure, noting the following points: a) Fit a new O-ring to the manifold, then refit the throttle housing and securely tighten its nuts or screws (as applicable).

b) Ensure all hoses are correctly reconnected and, where necessary, are securely held in position by the retaining clips.

c) Ensure all wiring is correctly routed, and the connectors are securely reconnected.

d) On completion, adjust the accelerator cable as described in Section 3 and, where necessary, the kickdown cable as described in Chapter 7B.


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