Peugeot 405 Manual

Exterior light units - removal and refitting
Body electrical system / Exterior light units - removal and refitting


Note: Disconnect the battery negative lead before removing any light unit, and reconnect the lead after refitting the unit.

Headlight
Removal
1 Working in the engine compartment, release the clip securing the cover to the rear of the headlight unit.

2 Disconnect the wiring plugs from the bulbs located in the headlight unit.

3 Remove the direction indicator light as described during the bulb renewal procedure in Section 5.

4 On models with cable-operated headlight adjusters, disconnect the adjuster from the headlight as follows.

a) Tun the adjuster and pull it from the bracket on the body front panel.

b) Carefully pull the balljoint from the socket in the rear of the headlight (see illustration).

7.4 Removing a cable-operated headlight adjuster
7.4 Removing a cable-operated headlight adjuster

5 On models with electrically-operated headlight adjusters, disconnect the wiring plug from the adjuster in the rear of the headlight.

6 Remove the radiator grille panel as described in Chapter 11.

7 Carefully prise the lower trim plate from the bottom of the headlight (see illustration).

7.7 Removing the trim plate from the bottom of the headlight
7.7 Removing the trim plate from the bottom of the headlight

8 Unscrew the two outer headlight securing bolts, and pull the unit forwards from the body panel (see illustration).

7.8 Outer headlight securing bolts (arrowed)
7.8 Outer headlight securing bolts (arrowed)

9 If desired, the headlight lens can be renewed by prising off the metal securing clips and withdrawing the lens from the front of the light unit (see illustration).

7.9 Removing a headlight lens securing clip
7.9 Removing a headlight lens securing clip

10 Before fitting a new lens, ensure that the seal located in the groove around the front of the headlight is in good condition, and renew if necessary.

Refitting
11 Refitting is a reversal of removal, but on completion have the headlight beam alignment checked at the earliest opportunity.

Front direction indicator 12 The procedure is described as part of the bulb renewal procedure in Section 5.

Front direction
indicator side repeater
13 The procedure is described as part of the bulb renewal procedure in Section 5.

Front spoiler-mounted
driving light/foglight
14 Two alternative types of light assembly may be fitted, depending on model. The light may be mounted either directly in the front spoiler, or in a cowl screwed to the front spoiler.

Cowl-mounted light
15 Reach up behind the spoiler, and disconnect the wiring from the light.

16 Remove the two screws securing the light cowl to the spoiler, then withdraw the cowl/light assembly rearwards from the bumper (see illustration).

7.16 Remove the front driving light/ foglight cowl securing screws
7.16 Remove the front driving light/ foglight cowl securing screws

17 The light unit can be removed from the cowl after unscrewing the knurled securing nut at the rear of the unit (see illustration).

7.17 Unscrew the nut (arrowed) to separate the light from the cowl
7.17 Unscrew the nut (arrowed) to separate the light from the cowl

18 Refitting is a reversal of removal, but on completion, check and if necessary adjust the light beam alignment. Adjustment can be made using the knurled nuts at the rear of the unit.

Light mounted directly in spoiler Note: Some models are fitted with front foglights which have no securing screws visible from the front of the lens. At the time of writing, no information was available for this type of foglight.

19 To improve access, jack up the front of the vehicle and support securely on axle stands (see УJacking and Vehicle SupportФ).

20 Trace the wiring back from the rear of the foglight, and disconnect the wiring connector.

21 Slacken and remove the foglight securing nut, and withdraw the light unit from the spoiler. Recover any washers and spacers, noting their locations to ensure correct refitting.

22 Refitting is a reversal of removal, ensuring that any washers and spacers on the securing stud are positioned as noted before removal.

Rear light cluster
Saloon models
23 Open the boot lid.

24 Squeeze the two retaining clips, and withdraw the bulbholder from the rear of the light unit.

25 Disconnect the wiring plug from the bulbholder.

26 Pull up the luggage compartment weatherstrip, and release the luggage compartment inner trim panel from the rear panel to expose the light unit securing nuts.

27 Unscrew the securing nuts, then withdraw the unit from outside the vehicle. Withdraw the outboard side of the unit first, then disengage the inboard edge from the body (see illustrations).

7.27a Unscrew the securing nuts (arrowed) . . .
7.27a Unscrew the securing nuts (arrowed) . . .

7.27b . . . then withdraw the rear light unit - Saloon model
7.27b . . . then withdraw the rear light unit - Saloon model

28 Refitting is a reversal of removal Estate models
29 The stop/tail lights and the direction indicator lights are located in the rear wing panels. The remaining rear lights are located in the tailgate.

30 Open the tailgate.

31 Turn the retaining clip and open the light unit cover flap.

32 Squeeze the two retaining clips, and withdraw the bulbholder from the rear of the light unit.

33 Disconnect the wiring plug from the bulbholder.

34 Unscrew the securing nuts and withdraw the light unit from outside the vehicle (see illustrations).

7.34a Rear wing-mounted light cluster securing nuts (arrowed) - Estate model
7.34a Rear wing-mounted light cluster securing nuts (arrowed) - Estate model

7.34b Withdrawing a rear wing-mounted light cluster - Estate model
7.34b Withdrawing a rear wing-mounted light cluster - Estate model

7.34c Tailgate-mounted rear light cluster securing nuts (arrowed) - Estate
7.34c Tailgate-mounted rear light cluster securing nuts (arrowed) - Estate model

35 Refitting is a reversal of removal.

Number plate light
Saloon models
36 Remove the two securing screws, then withdraw the light unit from the bumper and disconnect the wiring plug (see illustration).

7.36 Number plate light securing screws (arrowed) - Saloon model
7.36 Number plate light securing screws (arrowed) - Saloon model

37 Refitting is a reversal of removal.

Estate models
38 Carefully prise the unit from the tailgate and disconnect the wiring plug.

39 Refitting is a reversal of removal.


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