Peugeot 405 Manual

Magneti Marelli system components - removal, refitting and adjustments
Fuel/exhaust systems - multi-point fuel injection models / Magneti Marelli system components - removal, refitting and adjustments


1.8 litre models
Fuel injectors
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 Disconnect the battery negative terminal.

2 Remove the air cleaner-to-throttle housing duct as described in Section 2.

3 Undo the two bolts securing the wiring tray to the top of the manifold, and position the tray clear of the injectors.

4 Depress the retaining clip(s) and disconnect the wiring connector(s) from the injector(s).

5 Slacken the retaining screw and remove the injector retaining plate; Nos 1 and 2 injectors are retained by one plate, Nos 3 and 4 by another.

6 Place a wad of clean rag over the injector, to catch any fuel spray which may be released, then carefully ease the relevant injector(s) out of the manifold. Remove the Orings from the end of each disturbed injector, and discard them - these must be renewed whenever they are disturbed.

7 On refitting the injectors, fit new O-rings to the end of each injector. Apply a smear of engine oil to the O-ring, to aid installation, then ease the injector(s) back into position in the manifold.

8 Ensure each injector connector is correctly positioned, then refit the retaining plate and securely tighten its retaining screw.

Reconnect the wiring connector(s) to the injector(s).

9 Refit the wiring tray to the top of the manifold and securely tighten its retaining bolts.

10 Refit the air cleaner-to-throttle body duct and reconnect the battery. Start the engine and check the injectors for signs of leakage.

Fuel pressure regulator
11 Refer to Section 13.

Throttle potentiometer
12 The throttle potentiometer is fitted to the right-hand side of the throttle housing. To remove the potentiometer, first disconnect the battery negative terminal.

13 Depress the retaining clip and disconnect the potentiometer wiring connector.

14 Slacken and remove the two retaining screws, and remove the potentiometer from the throttle housing.

15 Refitting is the reverse of removal, ensuring that the potentiometer is correctly engaged with the throttle valve spindle.

Electronic Control Unit (ECU) 16 Refer to Section 13.

Idle speed control stepper motor 17 The idle speed control stepper motor is located on the front of the throttle housing assembly. Before removing the motor, first disconnect the battery negative terminal.

18 Release the retaining clip and disconnect the wiring connector from the motor.

19 Slacken and remove the two retaining screws, and withdraw the motor from the throttle housing.

20 Refitting is a reversal of the removal procedure.

Manifold absolute pressure (MAP) sensor
21 Refer to Section 13.

Coolant temperature sensor 22 Refer to Chapter 3.

Inlet air temperature sensor 23 The inlet air temperature sensor is located in the throttle housing.

24 To remove the sensor, first remove the throttle potentiometer as described in paragraphs 12 to 14.

25 Depress the retaining clip and disconnect the wiring connector from the air temperature sensor.

26 Remove the screw securing the sensor connector to the top of the throttle housing, then carefully ease the sensor out of position and remove it from the throttle housing.

Examine the sensor O-ring for signs of damage or deterioration, and renew if necessary.

27 Refitting is a reversal of the removal procedure, using a new O-ring where necessary, and ensuring that the throttle potentiometer is correctly engaged with the throttle valve spindle.

Crankshaft sensor
28 Refer to Section 13.

Fuel injection system relay unit 29 Refer to Section 13.

Throttle housing heating element 30 The throttle housing heating element is fitted to the top of the throttle housing. To remove the element, first disconnect the battery negative terminal.

31 Depress the retaining tangs and disconnect the wiring connector from the heating element.

32 Undo the screw(s) securing the wiring connector to the throttle housing, then displace the connector and carefully withdraw the heating element from the throttle housing (see illustration). Examine the element O-ring (where fitted) for signs of damage or deterioration, and renew if necessary.

17.32 Throttle housing heating element
17.32 Throttle housing heating element

33 Refitting is a reversal of the removal procedure, taking great care to ensure that the element wiring does not become trapped as the wiring connector bolt(s) are tightened.

2.0 litre models
Fuel rail and injectors
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.

34 Disconnect the battery negative terminal.

35 Remove the air cleaner-to-throttle housing duct, using the information in Section 2.

36 Disconnect the vacuum pipe from the fuel pressure regulator.

37 Release the retaining clip and free the various hoses from the top of the fuel rail.

38 Bearing in mind the information given in Section 7, slacken the retaining clip, and disconnect the fuel feed and return hoses from the ends of the fuel rail. Where the original crimped-type Peugeot hose clips are still fitted, cut them off and discard them; use standard worm-drive hose clips on refitting.

39 Depress the retaining clips and disconnect the wiring connectors from the four injectors.

40 Slacken and remove the three fuel rail retaining bolts, then carefully ease the fuel rail and injector assembly out from the inlet manifold, and remove it from the vehicle.

Remove the O-rings from the end of each injector and discard them; these must be renewed whenever they are disturbed.

41 Slide out the retaining clip(s) and remove the relevant injector(s) from the fuel rail.

Remove the upper O-ring from each injector as it is removed, and discard it; all O-rings must be renewed once they have been disturbed.

42 Refitting is a reversal of the removal procedure, noting the following points: a) Fit new O-rings to all disturbed injectors.

b) Apply a smear of engine oil to the O-rings to aid installation, then ease the injectors and fuel rail into position, ensuring that none of the O-rings are displaced.

c) On completion, start the engine and check for fuel leaks.

Fuel pressure regulator
43 Refer to Section 13.

Throttle potentiometer
44 Remove the throttle housing as described in Section 12.

45 Undo the two retaining screws and remove the potentiometer from the base of the throttle housing.

46 On refitting, ensure that the potentiometer is correctly engaged with the throttle valve spindle, and securely tighten its retaining screws.

47 Refit the throttle housing as described in Section 12.

Electronic control unit (ECU) 48 The ECU is situated inside its own protective compartment in the battery tray. To remove the ECU, first disconnect the battery negative terminal.

49 Unclip the lid from the plastic box and disconnect the wiring connector from the ECU.

50 Slide the ECU out of the box and, if necessary, undo the retaining nuts and separate it from its mounting plate.

51 Refitting is the reverse of removal, ensuring that the wiring connector is securely reconnected.

Idle speed control stepper motor 52 Refer to the information given in paragraphs 17 to 20 of this Section.

Manifold absolute pressure (MAP) sensor
53 The MAP sensor is situated on the righthand side of the engine compartment, mounted on the front suspension mounting turret. To remove the sensor, first disconnect the battery negative terminal.

54 Undo the three retaining nuts and free the sensor from the underside of the mounting bracket.

55 Depress the retaining clip, disconnect the wiring connector and vacuum hose from the sensor, and remove the sensor from the engine compartment.

56 Refitting is a reversal of the removal procedure.

Coolant temperature sensor 57 Refer to Chapter 3.

Inlet air temperature sensor 58 The inlet air temperature sensor is located in the base of the throttle housing.

59 To remove the sensor, first remove the throttle housing as described in Section 12, then undo the two retaining screws and remove the throttle potentiometer from the base of the housing.

60 Trace the wiring back from the sensor to its wiring connector, and remove the screw securing the connector to the throttle housing.

61 Carefully ease the sensor out of position, and remove it from the throttle housing.

Examine the sensor O-ring for signs of damage or deterioration, and renew if necessary.

62 Refitting is a reversal of removal, using a new O-ring where necessary.

Crankshaft sensor
63 Refer to Section 13.

Fuel injection system relay unit 64 Refer to Section 13.

Throttle housing heating element 65 Refer to the information given in paragraphs 30 to 33 of this Section.

Vehicle speed sensor
66 The vehicle speed sensor is an integral part of the transmission speedometer drive assembly. Refer to Chapter 7A for removal and refitting details.

Knock sensor
67 The knock sensor is screwed onto the rear face of the cylinder block.

68 To gain access to the sensor, firmly apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see УJacking and Vehicle SupportФ). Access to the sensor can then be gained from underneath the vehicle.

69 Trace the wiring back from the sensor to its wiring connector, and disconnect it from the main loom.

70 Slacken and remove the bolt securing the sensor to the cylinder block, and remove it from underneath the vehicle.

71 Refitting is a reversal of the removal procedure, ensuring that the sensor wiring is correctly routed and its retaining bolt securely tightened.


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