Peugeot 405 Manual

Facia assembly - removal and refitting
Bodywork and fittings / Facia assembly - removal and refitting


Models up to 1992
Removal
1 Disconnect the battery negative lead.

2 Remove the steering wheel as described in Chapter 10.

3 Remove the steering column shrouds as described in Section 28.

4 Remove the instrument panel (Chapter 12).

5 Remove the radio/cassette player as described in Chapter 12.

6 Remove the securing screws, where applicable, and withdraw the side panels from the centre console.

7 Remove the headlight beam adjuster switch as described in Chapter 12.

8 Prise out the ashtray and the oddments tray from the facia centre panel.

9 Remove the two bolts from the ashtray recess, and the single bolt from the radio/cassette player recess (see illustrations).

30.9a Remove the two bolts (arrowed) from the ashtray recess . . .
30.9a Remove the two bolts (arrowed) from the ashtray recess . . .

30.9b . . . and the single bolt (arrowed) from the radio/cassette player
30.9b . . . and the single bolt (arrowed) from the radio/cassette player recess

10 Remove the two screws from the top of the oddments tray recess.

11 Pull the centre facia panel forwards from the facia, then reach behind the panel and disconnect the wiring from the switches, clock, and cigarette lighter, as applicable.

Note the locations of the wiring connectors to ensure correct refitting, and remove the facia panel.

12 Unscrew the four screws securing the heater control panel to the facia (see illustration).

30.12 Two of the heater control panel securing screws
30.12 Two of the heater control panel securing screws

13 Turn the two securing clips through a quarter-turn, then drop the fusebox panel down from the facia.

14 Unscrew the two bonnet release lever bolts from the bracket under the facia.

15 Disconnect the wiring from the instrument panel lighting rheostat.

16 Disconnect the two main feed connectors from the fusebox (see illustration).

30.16 Disconnect the two main feed connectors (arrowed) from the fusebox
30.16 Disconnect the two main feed connectors (arrowed) from the fusebox

17 Working at each side of the facia, disconnect the facia wiring harness connectors, marking them to ensure correct refitting.

18 Remove the side footwell trim panel (the left-hand side panel for right-hand-drive models, or the right-hand side panel for lefthand- drive models), then unbolt the earth lead from the footwell (see illustration).

30.18 Unbolt the earth lead (arrowed) from the footwell
30.18 Unbolt the earth lead (arrowed) from the footwell

19 Where applicable, remove the securing bolt, and release the relay bracket from the lower steering column mounting bracket (see illustration).

30.19 Remove the bolt securing the relay bracket to lower steering column
30.19 Remove the bolt securing the relay bracket to lower steering column bracket

20 Working in the scuttle at the rear of the engine compartment, unscrew the three facia securing nuts (see illustration).

30.20 Facia securing nut (arrowed) in scuttle
30.20 Facia securing nut (arrowed) in scuttle

21 Remove the single bolt on each side, securing the lower facia mounting brackets to the footwells (see illustration).

30.21 Lower facia mounting bracket-tofootwell bolt (arrowed)
30.21 Lower facia mounting bracket-tofootwell bolt (arrowed)

22 Remove the remaining two lower facia mounting bolts, one each side of the centre console.

23 Reach up behind the heater control panel, and remove the upper facia securing bolt (see illustration).

30.23 Upper facia securing bolt (arrowed)
30.23 Upper facia securing bolt (arrowed)

24 Unbolt the bracing bracket between the gear lever bracket and the centre of the facia.

25 Disconnect the remaining steering column stalk switch wiring connectors.

26 Disconnect the wiring from the brake light switch.

27 Disconnect the wiring from the cigarette lighter and the ashtray illumination light.

28 Make a final check around the facia, to ensure that all relevant wiring has been disconnected.

29 Carefully pull the facia panel forwards, feeding the speedometer cable and the wiring harnesses through the apertures in the facia as it is withdrawn. Note the routing of all harnesses and the speedometer cable to ensure correct refitting.

30 With the aid of an assistant, withdraw the facia assembly through one of the door apertures.

Refitting
31 Refitting is a reversal of removal, bearing in mind the following points.

a) Make sure that the facia locating spigots engage correctly with the holes in the bulkhead.

b) Ensure that the wiring harnesses and the speedometer cable are correctly routed through the facia as it is refitted, as noted during removal.

c) Ensure that all wiring connectors are correctly reconnected.

d) Refit the radio/cassette player and the instrument panel with reference to Chapter 12.

e) Refit the steering wheel (see Chapter 10).

Models from 1993
Removal
32 Disconnect the battery negative lead.

33 Remove the centre console as described in Section 29.

34 Unscrew the two screws located at the bottom of the ashtray housing (see illustration).

30.34 Unscrew the two screws below the ashtray housing
30.34 Unscrew the two screws below the ashtray housing

35 Where applicable, remove the radio/ cassette player as described in Chapter 12.

On models not fitted with a radio/cassette player, prise out the oddments tray.

36 Remove the two securing screws from the top of the radio/cassette player/oddments tray housing, then withdraw the housing from the facia (see illustrations). Where applicable, disconnect the wiring plug(s) from the rear of the panel.

30.36a Remove screws from top of radio/ cassette player/oddments housing . .
30.36a Remove screws from top of radio/ cassette player/oddments housing . . .

30.36b . . . then withdraw the housing
30.36b . . . then withdraw the housing

37 Prise the blanking plate from the top corner of the facia centre ventilation nozzle housing. Remove the now-exposed securing screw (see illustration).

30.37 Prise out the blanking plate to expose the ventilation nozzle housing
30.37 Prise out the blanking plate to expose the ventilation nozzle housing upper securing screw (arrowed)

38 Remove the four housing securing screws located under the heater control panel. Two screws are accessible from the front of the housing, and two screws from underneath (see illustrations).

30.38a Remove the two screws from the front of the ventilation nozzle housing
30.38a Remove the two screws from the front of the ventilation nozzle housing . . .

30.38b . . . and the two screws from underneath
30.38b . . . and the two screws from underneath

39 Carefully prise the switches from below the centre facia ventilation nozzles to reveal the remaining housing securing screw.

Remove the screw (see illustrations).

30.39a Prise the switches from the housing . . .
30.39a Prise the switches from the housing . . .

30.39b . . . then remove the remaining housing securing screw
30.39b . . . then remove the remaining housing securing screw

40 Pull the housing forwards, and disconnect the wiring from the clock, then withdraw the housing (see illustration).

30.40 Withdrawing the ventilation nozzle housing
30.40 Withdrawing the ventilation nozzle housing

41 Working in the drivers footwell, release the securing clips and remove the carpet trim panel from above the pedals. Disconnect the three wiring connectors (see illustrations).

30.41a Remove the carpet trim panel . . .
30.41a Remove the carpet trim panel . . .

30.41b . . . then disconnect the three wiring connectors (arrowed)
30.41b . . . then disconnect the three wiring connectors (arrowed)

Where applicable, release the wiring harnesses from the clips on the facia.

42 Remove the securing screw, then pull up the drivers footwell side trim panel to release the securing clips. Remove the panel, to expose the wiring connector bracket (see illustrations).

30.42a Remove the securing screw . . .
30.42a Remove the securing screw . . .

30.42b . . . then remove the footwell side trim panel
30.42b . . . then remove the footwell side trim panel

43 Release the two securing clips, and pull the wiring connector bracket from the footwell. Disconnect the connectors from the bracket (see illustration).

30.43 Pull the connector bracket from the footwell
30.43 Pull the connector bracket from the footwell

44 Where applicable (if the earth cable connects to the facia wiring harness), unbolt the earth cable from the footwell, then release the wiring harness from the clips under the facia.

45 Working at the centre of the facia, remove the securing screws, and withdraw the facia centre side trim panels, to expose the heater air ducts (see illustrations).

30.45a Remove the securing screws . . .
30.45a Remove the securing screws . . .

30.45b . . . and withdraw the facia centre side trim panels
30.45b . . . and withdraw the facia centre side trim panels

46 Where applicable remove the screws, and withdraw the air ducts (see illustration).

30.46 Withdrawing an air duct
30.46 Withdrawing an air duct

47 Cut the cable-tie securing the wiring harness to the bracket at the centre of the drivers side facia.

48 Release the plastic clips securing the large connector block to the bracket on the drivers side of the centre facia, then release the connectors from the connector block, and separate the two halves of each connector (see illustration).

30.48 Release the connector block from the bracket on the drivers side of
30.48 Release the connector block from the bracket on the drivers side of the facia

49 Similarly, working at the passengers side of the centre facia, remove the plastic clips securing the connector block to the bracket on the floor and to the heater assembly.

50 Working in the passengers footwell, release the securing clips, and remove the carpet trim panel from under the facia.

51 Remove the securing screw, then pull up the passengers footwell side trim panel to release the securing clips. Remove the panel, to expose the wiring connector block. Release the connector block from the footwell, and separate the two halves of each wiring connector.

52 Unbolt the earth lead from the passenger footwell, then release the wiring harnesses from any clips in the footwell (see illustration).

30.52 Unbolt the earth lead from the passengers footwell
30.52 Unbolt the earth lead from the passengers footwell

53 Remove the securing screw, and withdraw the bonnet release lever from the side of the footwell (see illustration).

30.53 Remove the screw and withdraw the bonnet release lever
30.53 Remove the screw and withdraw the bonnet release lever

54 Remove the steering column shrouds as described in Section 28, but note that, where applicable, there is no need to disconnect the wiring from the radio/cassette player remote control switch - feed the switch wiring up through the facia (the wiring should have been disconnected from the rear of the radio/cassette player), and withdraw the wiring complete with the lower shroud.

55 Remove the steering column as described in Chapter 10.

56 Remove the two securing screws, and withdraw the wiring connector/control unit bracket from the left-hand side of the steering column bracket (see illustration).

30.56 Remove the securing screws and withdraw connector/control unit brackets
30.56 Remove the securing screws and withdraw connector/control unit brackets

57 Where applicable, similarly remove the wiring connector bracket from the right-hand side of the steering column bracket.

58 Remove the instrument panel as described in Chapter 12.

59 Working in the drivers footwell, disconnect the wiring plug from the stop light switch, then release the switch wiring harness from the clips under the facia.

60 Unplug the main wiring harness connectors, from the connector block mounted under the drivers side of the facia (see illustration).

30.60 Unplug the main wiring harness connectors
30.60 Unplug the main wiring harness connectors

To improve access to the wiring connectors, the connector block can be lowered from the facia by removing the two front bolts securing the bracket to the facia, and the rear nut securing the bracket to the stud on the bulkhead.

61 On left-hand-drive models, remove the screw securing the wiring bracket to the drivers side of the bulkhead, next to the clutch pedal.

62 Where applicable, pull the relay out of its connector at the rear of the steering column bracket, then pull the connector out of the bracket (see illustrations).

30.62a Pull the relay out of its connector . . .
30.62a Pull the relay out of its connector . . .

30.62b . . . then pull the connector from the steering column bracket
30.62b . . . then pull the connector from the steering column bracket

62 Remove the heater control unit as described in Chapter 3.

63 Working in the engine compartment, remove the scuttle grille panel (Section 25).

64 Remove the securing clip, and withdraw the plastic shield from the passengers side of the scuttle (see illustrations).

30.64a Remove the securing clip . . .
30.64a Remove the securing clip . . .

30.64b . . . and withdraw the shield from the scuttle
30.64b . . . and withdraw the shield from the scuttle

65 On left-hand-drive models, working in the scuttle, remove the heater inlet duct grille, and move the connector block/electronic control unit housing to one side for access to the facia securing nuts.

66 Working inside the vehicle, unscrew the two bolts securing the facia side brackets to the footwells (one bolt in each footwell) (see illustration).

30.66 Unscrew the bolts securing the facia brackets to the footwells
30.66 Unscrew the bolts securing the facia brackets to the footwells

67 Similarly, unscrew the two centre facia lower securing bolts, one on each side of the facia centre section (see illustration).

30.67 Unscrew the centre facia lower securing bolts
30.67 Unscrew the centre facia lower securing bolts

68 Unscrew the centre facia upper securing bolt, located above the heater control unit (see illustration).

30.68 Unscrew the centre facia upper securing bolt . . .
30.68 Unscrew the centre facia upper securing bolt . . .

69 Unscrew the two rear centre facia securing bolts, securing the facia brackets to the heater assembly (see illustration).

30.69 . . . and the rear centre facia securing bolts
30.69 . . . and the rear centre facia securing bolts

70 Working in the engine compartment, unscrew the three facia securing nuts located in the scuttle (see illustration).

30.70 Facia securing nut (arrowed) in scuttle
30.70 Facia securing nut (arrowed) in scuttle

71 Make a final check to ensure that all relevant wiring harnesses have been unclipped and released from the facia assembly then, with the aid of an assistant, pull the facia back from the bulkhead. Note the location and routing of all wiring harnesses, particularly note the location of the Velcro fixings.

72 Release the speedometer cable sleeve from the instrument panel housing in the facia, then manipulate the facia assembly out through one of the door apertures (see illustration).

30.72 Release the speedometer cable sleeve from the facia
30.72 Release the speedometer cable sleeve from the facia

Refitting
73 Refitting is a reversal of removal, bearing in mind the following points.

a) Reconnect the wiring plugs to the large connector block on the drivers side of the facia before refitting the facia fixings, and bolting the connector block in position.

b) Check that the air ducts are correctly located and engaged with their relevant vents. Access to the passengers side air duct can be improved by removing the glovebox (see Section 28).

c) Ensure that all wiring harnesses are correctly located and routed as noted before removal, and ensure that the Velcro fixings are in position, where applicable.

d) Refit the heater control unit (Chapter 3).

e) Refit the instrument panel with reference to Chapter 12.

f) Refit the steering column (Chapter 10).

g) Refit the centre console with reference to Section 29.


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