Peugeot 405 Manual

Bosch L3.1-Jetronic system components - removal, refitting and adjustments
Fuel/exhaust systems - multi-point fuel injection models / Bosch L3.1-Jetronic system components - removal, refitting and adjustments


Throttle initial position 1 Disconnect the accelerator cable and throttle switch.

2 Loosen the throttle switch unit mounting bolts and turn the unit fully anti-clockwise, then tighten the mounting bolts.

Primary barrel
3 Prise out the tamperproof cap from the throttle stop screw and loosen the screw until it is clear of the throttle lever (see illustration).

14.3 Tamperproof cap covering primary throttle stop screw (arrowed)
14.3 Tamperproof cap covering primary throttle stop screw (arrowed)

4 Place a 0.05 mm feeler blade between the lever and the screw and tighten the screw until it just contacts the feeler blade without trapping it (see illustration). The throttle lever must not be moved.

14.4 Adjusting the throttle initial position
14.4 Adjusting the throttle initial position

5 Remove the feeler blade then turn the screw in by a further quarter turn. Fit a new tamperproof cap.

Secondary barrel
6 The procedure is as described for the primary barrel but using the secondary throttle adjustment screw (see illustrations).

14.6a Secondary throttle adjusting screw (arrowed) . . .
14.6a Secondary throttle adjusting screw (arrowed) . . .

14.6b . . . and viewed from underneath
14.6b . . . and viewed from underneath

7 On completion of the adjustment, apply a drop of thread locking compound to the head of the adjustment screw.

8 Adjust the throttle switch.

9 Reconnect the throttle switch and accelerator cable.

Throttle switch
10 To remove the unit, disconnect the multiplug and unbolt the unit from the throttle housing.

11 To adjust the switch proceed as follows.

12 The throttle valve initial opening position must be correctly adjusted.

Idling switch
13 Loosen the switch bolts and turn it clockwise as far as it will go, then bring it back until the switch can be heard to operate (see illustration).

14.13 Throttle switch unit mounting bolts (A) and plug terminal numbers
14.13 Throttle switch unit mounting bolts (A) and plug terminal numbers

14 Tighten the mounting bolts with the switch held in this position.

15 To check that the adjustment is correct, disconnect the multi-plug and connect an ohmmeter to terminals 2 and 18 on the switch.

16 The ohmmeter should read zero ohms.

17 Fully depress the accelerator pedal, when the ohmmeter should read infinity.

18 If these readings are incorrect, re-adjust the switch.

Full load switch
19 Connect the ohmmeter to terminals 3 and 18 on the switch. The reading should indicate infinity.

20 Fully depress the accelerator pedal, when the reading should be zero ohms.

21 If these readings are incorrect, renew the throttle switch.

22 Reconnect the multi-plug.

Airflow meter and ECU
23 The airflow meter and ECU are removed as described in Section 2.

Fuel rail and injectors
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.

24 Depressurise the fuel system.

25 Disconnect the sensor pipe on the fuel pressure regulator and remove the bolt from the regulator support bracket on the inlet manifold.

26 Number the injector electrical plugs then disconnect them from the injectors.

27 Disconnect the inlet and outlet fuel hoses, being prepared for any fuel spillage.

28 Unbolt the fuel rail and pull it and the injectors upward to release them from the cylinder head (see illustrations).

14.28a Removing a fuel rail bolt . . .
14.28a Removing a fuel rail bolt . . .

14.28b . . . and pulling up the rail and injectors
14.28b . . . and pulling up the rail and injectors

29 Pull out the clips securing the injectors to the fuel rail and pull out the injectors. Number them for refitting in the same positions (see illustration).

14.29 Removing an injector from the fuel rail
14.29 Removing an injector from the fuel rail

30 Check the condition of the O-ring seals and renew them as necessary (see illustration).

14.30 Injector O-ring seals (arrowed)
14.30 Injector O-ring seals (arrowed)

31 Clean the injector nozzles using injector cleaning fluid. Note: Fouling of the injector nozzles can cause the following symptoms.

a) Difficult hot starting.

b) Persistent stalling.

c) Misfiring when cold.

d) Misfire when hot between 1000 and 2000 rpm.

e) Loss of performance.

32 Refitting is a reversal of removal.

Fuel pressure regulator
33 Depressurise the system.

34 Disconnect the sensor pipe.

35 Disconnect the fuel hose.

36 Remove the bolt from the support bracket on the inlet manifold.

37 Unbolt and remove the regulator from the fuel rail (see illustration).

14.37 Regulator-to-fuel rail bolts (arrowed) - assembly removed for clarity
14.37 Regulator-to-fuel rail bolts (arrowed) - assembly removed for clarity

38 Refit in reverse order.

Fuel pump damper
39 Depressurise the fuel system.

40 Disconnect the fuel hose unions from the damper (see illustration).

14.40 Fuel pump damper showing fuel hose connections
14.40 Fuel pump damper showing fuel hose connections

41 Unscrew the nut securing the damper to the support bracket and remove the damper.

42 Refit in reverse order.

Supplementary air device 43 Disconnect the battery then remove the battery and battery tray.

44 Remove the nuts securing the water housing to the cylinder head.

45 Disconnect the wiring and air hoses from the air device (see illustration).

14.45 Disconnecting the supplementary air device plug
14.45 Disconnecting the supplementary air device plug

46 Tilt the water housing to gain access to the air device securing bolts and remove the bolts and air device.

47 Refit in reverse order.

Injection thermistor
48 Disconnect the wiring from the thermistor on the water housing (see illustration).

14.48 Disconnecting the injection thermistor wiring
14.48 Disconnecting the injection thermistor wiring

49 Drain the cooling system.

50 Unscrew the thermistor from the water housing.

51 Refit in reverse order, using a new sealing washer.

52 Top-up and bleed the cooling system.

Fuel filter
53 Disconnect the battery negative lead.

54 Depressurise the fuel system.

55 Disconnect the inlet and outlet hoses from the filter (see illustration).

14.55 Fuel filter showing fuel hoses (A) and clamp bolt (B)
14.55 Fuel filter showing fuel hoses (A) and clamp bolt (B)

56 Loosen the rubber mounting strap clamp nut and slide the filter from the clamp.

57 Refit in reverse order, ensuring any directional arrows on the filter are facing the direction of fuel flow.


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