Peugeot 405 Manual

Inlet manifold - removal and refitting
Fuel/exhaust systems - multi-point fuel injection models / Inlet manifold - removal and refitting


Removal
1 Disconnect the battery negative terminal and proceed as described under the relevant sub-heading.

Bosch L3.1-Jetronic system 2 Remove the fuel rail as described previously. There is no need to disconnect any fuel hoses. Lay the rail to one side.

3 Disconnect the brake servo vacuum hose see illustration).

18.3 Disconnecting the brake servo vacuum hose
18.3 Disconnecting the brake servo vacuum hose

4 Remove the throttle housing as described previously.

5 Disconnect and unbolt the ignition coil.

6 Disconnect the supplementary air device air hose from the manifold (see illustration).

18.6 Supplementary air device air hose connection on inlet manifold
18.6 Supplementary air device air hose connection on inlet manifold

7 Remove the bolt from the starter bracket see illustration).

18.7 Removing the bolt from the starter bracket
18.7 Removing the bolt from the starter bracket

8 Unbolt the oil filler tube support bracket see illustration).

18.8 Oil filler tube support bracket
18.8 Oil filler tube support bracket

9 Remove the manifold securing bolts and the two 5 mm Allen bolts (a long Allen key is required).

10 Lift off the manifold.

Bosch LU2-Jetronic, Motronic and Magneti Marelli systems
11 The procedure is similar to that described above, noting the following points.

a) Note that vacuum, coolant hose and wiring connections to the manifold and associated components vary depending on model. When disconnecting any pipes, hoses, or wires, take note of their locations to ensure correct refitting.

b) Where applicable, ignore the references to the coil, supplementary air device and/or starter bracket.

c) Ensure that any disturbed gaskets are renewed.

d) Note that not all manifolds are secured by Allen bolts.

Refitting
12 Refitting is a reversal of removal using a new gasket/seal or jointing compound as necessary. Ensure that the locating dowels are in position and tighten all bolts to their specified torque (see illustrations).

18.12a Applying jointing compound to the inlet manifold
18.12a Applying jointing compound to the inlet manifold

18.12b Ensure locating dowels (arrowed) are in position
18.12b Ensure locating dowels (arrowed) are in position

18.12c Fitting the inlet manifold
18.12c Fitting the inlet manifold

18.12d Tightening the manifold securing bolts
18.12d Tightening the manifold securing bolts

Note: The engine gasket kit contains gaskets for both carburettor and injection type manifolds. The injection type gasket has cutouts for the injector ports. Ensure that the correct gasket is fitted. The carburettor type will partially obstruct the injector ports causing erratic running and loss of power.


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