Peugeot 405 Manual

Body front panel assembly - removal and refitting
Bodywork and fittings / Body front panel assembly - removal and refitting


Warning: On models equipped with air conditioning, the bolts securing the condenser and the reservoir to the front panel must be removed. Where the front panel is being removed to enable engine removal, the compressor must also be unbolted from the engine, which will then allow the complete assembly to be moved clear for engine removal. Do not disconnect any refrigerant pipelines unless the system has been recharged - refer to the precautions given in Chapter 3.

Removal
1 Open the bonnet.

2 Disconnect the battery negative lead.

3 To improve access, apply the handbrake, then jack up the front of the vehicle an support securely on axle stands (see УJacking and Vehicle SupportФ).

4 Remove the front wheel arch liners, with reference to Section 25.

5 Remove the front bumper, as described in Section 6.

6 Remove the front direction indicator lights, as described in Chapter 12.

7 Disconnect the front light wiring connectors, located at each front corner of the engine compartment on models up to 1992, or in the right-hand corner of the engine compartment on models from 1993 (see illustrations).

11.7a Disconnecting the front light wiring connectors - models up to 1992
11.7a Disconnecting the front light wiring connectors - models up to 1992

11.7b Disconnect the front light wiring connectors (arrowed) . . .
11.7b Disconnect the front light wiring connectors (arrowed) . . .

11.7c . . . and disconnect the plug from the terminal block - models from
11.7c . . . and disconnect the plug from the terminal block - models from 1993

8 Unbolt the earth leads from the front corners of the engine compartment (see illustration).

11.8 Unbolt the earth leads from the corners of the engine compartment
11.8 Unbolt the earth leads from the corners of the engine compartment

9 Where applicable, remove the headlight adjusters from the brackets on the front panel, with reference to Chapter 12.

10 Where applicable, disconnect the headlight washer tubes.

11 Locate the bonnet release cable connecting plate, which is positioned at the top of the body front panel. Where applicable, remove the anti-squeal foam from the cable connector, then disconnect the release lever cable from the connector. Unclip the cable from the front panel assembly.

12 Unscrew the bolts securing the bottom of the front panel to the lower crossmember - there may be two or three bolts, depending on model (see illustration).

11.12 Removing a body front panel lower securing bolt
11.12 Removing a body front panel lower securing bolt

13 Remove the radiator as described in Chapter 3, but note that provided the radiator is adequately supported in the engine compartment, there is no need to disconnect the coolant hoses (this will avoid the need to drain the cooling system).

14 Remove the two upper securing bolts from each end of the front panel (see illustration).

11.14 Unscrew the body front panel upper securing bolts
11.14 Unscrew the body front panel upper securing bolts

15 Carefully release the clips securing the lower headlight trim strips to the front wings.

16 Make a final check to ensure that all relevant wiring has been disconnected to enable removal of the front panel assembly, then withdraw the assembly forwards from the front of the vehicle (see illustration).

11.16 Withdrawing the body front panel assembly
11.16 Withdrawing the body front panel assembly

Refitting
17 Refitting is a reversal of removal.


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