Peugeot 405 Manual

Distributor - removal and refitting
Ignition system / Distributor - removal and refitting


Removal
Breakerless ignition system 1 Disconnect the battery negative terminal.

Where necessary, to improve access to the distributor, remove the ignition HT coil as described in Section 3 and the inlet duct as described in the relevant Part of Chapter 4.

2 Peel back the waterproof cover then slacken and remove the distributor cap retaining screws. Remove the cap and position it clear of the distributor body (see illustrations). Recover the seal from the cap.

If necessary disconnect the HT leads from the spark plugs after noting their positions.

4.2a Peel back the waterproof cover . . .
4.2a Peel back the waterproof cover . . .

4.2b . . . then undo the retaining screws . . .
4.2b . . . then undo the retaining screws . . .

4.2c . . . and remove the cap from the end of the distributor
4.2c . . . and remove the cap from the end of the distributor

3 Depress the retaining clip and disconnect the wiring connector from the distributor.

Disconnect the hose from the vacuum diaphragm unit (see illustrations).

4.3a Disconnect the distributor wiring connector . . .
4.3a Disconnect the distributor wiring connector . . .

4.3b . . . and the vacuum diaphragm hose
4.3b . . . and the vacuum diaphragm hose

4 Check the cylinder head and distributor flange for signs of alignment marks. If no marks are visible, using a scriber or suitable marker pen, mark the relationship of the distributor body to the cylinder head. Slacken and remove the two mounting nuts and withdraw the distributor from the cylinder head (see illustrations).

4.4a Alignment marks across the distributor and cylinder head housing
4.4a Alignment marks across the distributor and cylinder head housing

4.4b Unscrew the retaining nuts . . .
4.4b Unscrew the retaining nuts . . .

4.4c . . . and withdraw the distributor from the cylinder head
4.4c . . . and withdraw the distributor from the cylinder head

Remove the O-ring
from the end of the distributor body and discard it; a new one must be used on refitting.

Integral ignition system with distributor
5 Disconnect the battery negative terminal. If necessary, to improve access to the distributor, remove the airflow meter as described in Chapter 4.

6 Peel back the waterproof cover, slacken and remove the distributor cap retaining screws, then remove the cap and position it clear of the distributor body. Recover the seal from the cap. If necessary, disconnect the HT leads from the spark plugs after noting their positions - on 16-valve engines it will be necessary to remove the cover plate over the spark plugs.

7 On 8-valve engines slacken and remove the two mounting bolts and washers, and withdraw the distributor from the cylinder head. Remove the O-ring from the end of the distributor body, and discard it; a new one must be used on refitting.

8 On XU9J4 16-valve engines undo the three Torx-headed screws securing the rotor to the rotor drive flange and lift off the rotor, then unscrew the screw from the centre of the drive flange and withdraw the flange. Remove the plastic base plate from the end of the cylinder head (see illustrations).

4.8a On XU9J4 16-valve engines undo the rotor screws and remove the rotor
4.8a On XU9J4 16-valve engines undo the rotor screws and remove the rotor

4.8b Rotor drive flange
4.8b Rotor drive flange

Refitting
Breakerless ignition system 9 Lubricate the new O-ring with a smear of engine oil and fit it to the groove in the distributor body. Examine the distributor cap seal for wear or damage and renew if necessary.

10 Align the distributor rotor shaft drive coupling key with the slots in the camshaft end noting that the slots are offset to ensure that the distributor can only be fitted in one position (see illustration).

4.10 Off-set drive slots on the camshaft
4.10 Off-set drive slots on the camshaft

Carefully insert the
distributor into the cylinder head whilst rotating the rotor arm slightly to ensure that the coupling is correctly engaged. Refit the distributor retaining nuts, tightening them lightly only.

11 Ensure that the seal is correctly located in its groove then refit the cap assembly to the distributor and tighten its retaining screws securely. Fold the waterproof cover back over the distributor cap ensuring it is correctly located. Where necessary reconnect the HT leads to the spark plugs.

12 Reconnect the vacuum hose to the diaphragm unit and the distributor wiring connector. Where necessary, refit the ignition HT coil as described in Section 3, and the inlet duct as described in Chapter 4.

13 Reconnect the battery negative terminal, then check and if necessary adjust the ignition timing as described in Section 6. Tighten the distributor mounting nuts to the specified torque.

Integral ignition system with distributor
14 On XU9J4 16-valve engines refit the plastic base plate to the end of the cylinder head, then refit the drive flange using locking fluid on the threads of the drive flange screw.

Tighten the centre screw. Refit the rotor and tighten the Torx-headed screws.

15 On 8-valve engines lubricate the new Oring with a smear of engine oil and fit it to the groove in the distributor body. Examine the distributor cap seal for wear or damage and renew if necessary. Align the distributor rotor shaft drive coupling key with the slots in the camshaft end noting that the slots are offset to ensure that the distributor can only be fitted in one position. Carefully insert the distributor into the cylinder head whilst rotating the rotor arm slightly to ensure that the coupling is correctly engaged. Refit the distributor retaining nuts, tightening them securely.

16 Ensure that the seal is correctly located in its groove then refit the cap assembly to the distributor and tighten its retaining screws securely. Fold the waterproof cover back over the distributor cap ensuring it is correctly located.

17 Where necessary reconnect the HT leads to the spark plugs (see illustration) and on 16-valve engines refit the cover plate.

4.17 Distributor cap and HT leads on the XU9J4 16-valve model
4.17 Distributor cap and HT leads on the XU9J4 16-valve model


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