Peugeot 405. Manual - part 30

Refitting

8 Refitting is a reversal of the removal
procedure, noting the following points:

a) Prior to refitting, fit a new rubber sealing

ring to the sender unit.

b) Refit the sender unit to the tank, aligning

its arrow with the centre of the three
alignment marks on the fuel tank. Secure
the sender in position with the locking
ring, and check that the locking ring,
sender unit and fuel tank marks are all
correctly aligned.

c) Ensure that the feed and return hoses are

correctly reconnected and securely
retained by their clips.

6

Fuel tank - 
removal and refitting

3

Note: Refer to the warning note in Section 1
before proceeding.

Removal

1 Before removing the fuel tank, all fuel must
be drained from the tank. Since a fuel tank
drain plug is not provided, it is preferable to
carry out the removal operation when the tank
is nearly empty. Before proceeding,
disconnect the battery negative lead and
syphon or hand-pump the remaining fuel from
the tank.
2 Remove the exhaust system and relevant
heat shield(s) as described in Section 16.
3 From underneath the vehicle, disconnect
the handbrake cable at the equaliser bracket.
4 Release the handbrake primary cable from
the clips in the fuel tank. Position the cable
clear of the tank, so that it will not hinder the
removal procedure.
5 Disconnect the wiring connector from the
fuel gauge sender unit, as described in
Section 5.
6 Working at the right-hand side of the fuel
tank, release the retaining clips then
disconnect the filler neck vent pipe and main
filler neck hose from the fuel tank/filler neck.
Where necessary, also disconnect the
breather hose(s). Some breather hoses are
joined to the tank with quick-release fittings; to
disconnect these fittings, slide the cover along

the hose then depress the centre ring and pull
the hose out of its fitting (see illustration).
7 Trace the fuel feed and return hoses back
from the right-hand side of the tank to their
union with the fuel pipes. Slacken the
retaining clips and disconnect both hoses
from the fuel pipes. Where the crimped-type
Peugeot hose clips are fitted, cut the clips and
discard them; use standard worm-drive hose
clips on refitting. Plug the hose and pipe ends,
to prevent the entry of dirt into the system.
8 Place a trolley jack with an interposed block
of wood beneath the tank, then raise the jack
until it is supporting the weight of the tank.
9 Slacken and remove the retaining nut and
bolts, then remove the two support rods from
the underside of the tank (see illustration).
10 Slowly lower the fuel tank out of position,
disconnecting any other relevant vent pipes as
they become accessible (where necessary),
and remove the tank from underneath the car.
11 If the tank is contaminated with sediment
or water, remove the sender unit (Section 5),
and swill the tank out with clean fuel. The tank
is injection-moulded from a synthetic material
- if seriously damaged, it should be renewed.
However, in certain cases, it may be possible
to have small leaks or minor damage repaired.
Seek the advice of a specialist before
attempting to repair the fuel tank.

Refitting

12 Refitting is the reverse of the removal
procedure, noting the following points:

a) When lifting the tank back into position,

take care to ensure that none of the hoses

become trapped between the tank and
vehicle body.

b) Ensure that all pipes and hoses are

correctly routed, and securely held in
position with their retaining clips.

c) Reconnect the handbrake cables and

adjust the handbrake (see Chapter 9).

d) On completion, refill the tank with a small

amount of fuel, and check for signs of
leakage prior to taking the vehicle out on
the road.

7

Accelerator cable - removal,
refitting and adjustment

2

Removal

1 Working in the engine compartment, free
the accelerator inner cable from the
carburettor throttle cam, then pull the outer
cable out from its mounting bracket rubber
grommet  (see illustrations). Where fitted,
slide the flat washer off the end of the cable,
and remove the spring clip.
2 Working back along the length of the cable,
free it from any retaining clips or ties, noting
its correct routing.
3 Where necessary remove the lower trim
from below the driver’s side of the facia panel.
4 Working from inside the vehicle, disconnect
the cable from the accelerator pedal by
depressing the lugs on the plastic end fitting
and pushing the fitting from the pedal (see
illustration).

Fuel/exhaust systems - carburettor models  4A•5

7.1a  Accelerator cable connection on the

throttle quadrant (arrowed)

8  Cover     9  Centre ring     10  Hose

7.4  Accelerator cable connection to

accelerator pedal (arrowed)

7.1b  Outer cable end fitting

6.9  Fuel tank support strap bolt

4A

6.6  Tank breather quick-release connector

5 Release the outer cable from its retainer on
the pedal mounting bracket, then tie a length
of string to the end of the cable.
6 Return to the engine compartment, release
the cable grommet from the bulkhead and
withdraw the cable. When the end of the
cable appears, untie the string and leave it in
position - it can then be used to draw the
cable back into position on refitting.

Refitting

7 Tie the string to the end of the cable, then
use the string to draw the cable into position
through the bulkhead. Once the cable end is
visible, untie the string, then clip the outer
cable into its pedal bracket retainer, and clip
the inner cable into position in the pedal end.
The remaining procedure is a reversal of
removal, but adjust it as follows.

Adjustment

8 Remove the spring clip from the accelerator
outer cable. Ensuring that the throttle cam is
fully against its stop, gently pull the cable out
of its grommet until all free play is removed
from the inner cable.
9 With the cable held in this position, refit the
spring clip to the last exposed outer cable
groove in front of the rubber grommet and
washer. When the clip is refitted and the outer
cable is released, there should be only a small
amount of free play in the inner cable (see
illustration).
10 Have an assistant depress the accelerator
pedal, and check that the throttle cam opens
fully and returns smoothly to its stop.
11 For models fitted with automatic
transmission refer to Chapter 7, Part B.

8

Accelerator pedal - 
removal and refitting

2

Removal

1 Disconnect the accelerator cable from the
pedal as described in Section 7.
2 Remove the screws from the pedal pivot
bush and lift out the pedal (see illustration).
3 Examine the pivot bush and shaft for signs
of wear, and renew as necessary.

Refitting

4 Refitting is a reversal of the removal
procedure, applying a little multi-purpose
grease to the pedal pivot point. On
completion, adjust the accelerator cable as
described in Section 7.

9

Choke cable - removal,
refitting and adjustment

2

Removal

1 Release the choke inner cable from the
carburettor linkage.
2 Slacken and remove the retaining bolt and
remove the outer cable retaining clamp.
3 Slacken the retaining clip securing the
rubber collar to the outer cable, and slide the
collar off the cable. Where the original
crimped-type Peugeot hose clip is still fitted,
cut the clip and discard it; use a standard
worm-drive hose clip on refitting.
4 Working back along the length of the cable,
free it from any retaining clips or ties, noting
its correct routing. Tie a length of string to the
end of the choke inner cable.
5 Working from inside the vehicle, pull the
choke lever fully out, to gain access to the
retaining screw. Unclip the choke lever from
the facia and withdraw the lever and cable
assembly from the facia, disconnecting the
wiring from the lever switch (where fitted) as it
becomes accessible. Once the end of the
cable appears through the lever aperture,
untie the string and leave it in position in the
vehicle - it can then be used to draw the cable
back into position on refitting.

Refitting

6 Tie the string to the end of the choke cable,
then use the string to draw the cable into
position through the bulkhead into the engine
compartment. Once the cable end is fully in
position, untie the string.
7 Reconnect the wiring connector (where
fitted), and clip the choke lever in its facia
panel aperture.
8 From within the engine compartment,
ensure that the outer cable is correctly seated
in the bulkhead grommet. Work along the

cable, securing it in position with all the
relevant retaining clips and ties, and ensuring
that the cable is correctly routed.
9 Slide the rubber collar and retaining clip
onto the end of the cable, then engage the
inner end of the cable with carburettor
linkage. Align the rubber collar with the
carburettor bracket, then refit the retaining
clip and securely tighten its retaining bolt.
Adjust the cable as described below.

Adjustment

10 Slacken the clip securing the rubber collar
to the outer cable. Where the crimped-type
Peugeot hose clip is still fitted, cut the clip
and discard it; use a standard worm-drive
hose clip on refitting (see illustration).
11 Ensuring that the choke lever is flush with
the facia panel and the carburettor linkage is
fully against its stop, move the outer cable in
the rubber collar until the position is found
where there is only a small amount of free play
present in the inner cable. Hold the outer
cable in this position, and securely tighten the
clip securing the rubber collar to the outer
cable.
12 Have an assistant operate the choke
lever, and check that the choke linkage closes
fully and returns smoothly to its stop. If
necessary, repeat the adjustment procedure.

10 Unleaded petrol - general

information and usage

Note: The information given in this Chapter is
correct at the time of writing. If updated
information is required, check with a Peugeot
dealer. If travelling abroad, consult one of the
motoring organisations (or a similar authority)
for advice on the fuel available.

The fuel recommended by Peugeot is given

in the Specifications Section of this Chapter,
followed by the equivalent petrol currently on
sale in the UK.

All Peugeot 405 carburettor models are

designed to run on 95 octane petrol. Both
leaded and unleaded petrol can be used
without modification. Super leaded 
(97 octane, UK “4-star”) and super unleaded
(98 octane) petrol can also be used if wished,
though there is no advantage in doing so.

9.10  Choke cable-to-rubber collar

retaining clip (arrowed)

4A•6 Fuel/exhaust systems - carburettor models

7.9  Adjusting the accelerator cable

8.2  Accelerator pedal pivot bush

11 Carburettor - 

general information

The Solex 34-34 Z1 carburettor is a

downdraught progressive twin-venturi
instrument. The throttle linkages are arranged
so that the secondary throttle valve will not
start to open until the primary valve is about
two-thirds open, but at full throttle both valves
are fully open. The choke control is either
automatic or manual. On some early models a
carburettor cooling system was fitted which
allows the radiator cooling fan to run for a
maximum of 12 minutes after the engine has
been switched off.

The Weber 34TLP carburettor is a single

choke downdraught type instrument fitted
with a manual choke.

12 Carburettor - 

removal and refitting

3

Note: Refer to the warning note in Section 1
before proceeding. Where original crimped-
type Peugeot hose clips are still fitted, the
clips should be cut and discarded; obtain
some worm-drive hose clips for refitting.

Removal

1 Disconnect the battery negative terminal.
2 Remove the air cleaner-to-carburettor duct
as described in Section 2.
3 Disconnect the accelerator cable from the
throttle quadrant as described in Section 8.
4 Disconnect the distributor vacuum pipe
(see illustration).
5 Disconnect the float chamber breather

pipes. The upper pipe connects with the air
filter housing (see illustration).
6 Either drain the cooling system or clamp
the automatic choke and carburettor base
heating pipes, then disconnect the pipes (see
illustrations).
7 Disconnect the float chamber solenoid
valve wiring (see illustration).
8 Disconnect the fuel inlet pipe either at the
fuel pump or the fuel reservoir on the side of
the carburettor and blank off the hose.
9 Remove the single carburettor securing nut
and lift off the fuel reservoir (see illustration).
10 Remove the remaining carburettor nuts
and lift off the carburettor (see illustrations).
11 Remove the insulating spacer and/or
gasket(s)  (see illustration). Discard the
gasket(s); new ones must be used on refitting.
Plug the inlet manifold port with a wad of
clean cloth, to prevent the entry of debris.

Fuel/exhaust systems - carburettor models  4A•7

12.6a  Automatic choke coolant pipe

connection . . .

12.9  Lifting off the fuel reservoir

12.7  Disconnecting the float chamber

breather solenoid wiring

12.6b  . . . and base heating pipes

12.5  Disconnecting the float chamber

breather pipe

4A

12.4  Disconnecting the distributor 

vacuum pipe

12.10a  Remove the remaining nuts . . .

12.10b  . . . and lift off the carburettor

12.11  Removing the insulating spacer

Refitting

12 Refitting is the reverse of the removal
procedure, noting the following points:

a) Ensure that the carburettor and inlet

manifold sealing faces are clean and flat.
Fit a new gasket, and securely tighten the
carburettor retaining nuts.

b) Use the notes made on dismantling to

ensure that all hoses are refitted to their
original positions and, where necessary,
are securely held by their retaining clips.

c) Where the original crimped-type Peugeot

hose clips were fitted, discard them; use
standard worm-drive hose clips when
refitting.

d) Refit and adjust the choke and

accelerator cables as described in
Sections 7 and 9.

e) Refit the air cleaner duct as described in

Section 2.

f) On completion, check and, if necessary,

adjust the idle speed and mixture settings
as described in Chapter 1.

13 Carburettor - fault diagnosis,

overhaul and adjustments

2

Fault diagnosis

1 If a carburettor fault is suspected, always
check first that the ignition timing is correctly
set, that the spark plugs are in good condition
and correctly gapped, that the accelerator
and choke cables are correctly adjusted, and
that the air cleaner filter element is clean; refer
to the relevant Sections of Chapter 1, Chapter
5 or this Chapter. If the engine is running very
roughly, first check the valve clearances as
described in Chapter 1, then check the
compression pressures as described in
Chapter 2.
2 If careful checking of all the above
produces no improvement, the carburettor
must be removed for cleaning and overhaul.
3 Prior to overhaul, check the availability of
component parts before starting work; note
that most sealing washers, screws and
gaskets are available in kits, as are some of
the major sub-assemblies. In most cases, it
will be sufficient to dismantle the carburettor
and to clean the jets and passages.

Overhaul

Note: Refer to the warning note in Section 1
before proceeding. Only carry out the
procedures described in this Section, as
special gauges are required for a more
detailed overhaul. The following procedure
applies to the Solex 34-34 Z1 carburettor.
4 Remove the carburettor from the vehicle as
described in Section 12.
5 Unscrew the idle cut-off solenoid from the
carburettor body, and remove it along with its
plunger and spring. To test the solenoid,
connect a 12-volt battery to it (positive

terminal to the solenoid terminal, negative
terminal to the solenoid body), and check that
the plunger is retracted fully into the body.
Disconnect the battery, and check that the
plunger is pushed out by spring pressure. If
the valve does not perform as expected, and
cleaning does not improve the situation, the
solenoid valve must be renewed.
6 Remove the five screws and lift off the
carburettor upper body.
7 Tap out the float pivot pin and remove the
float assembly, needle valve, and float
chamber gasket. Check that the needle valve
anti-vibration ball is free in the valve end, then
examine the needle valve tip and seat for wear
or damage. Examine the float assembly and
pivot pin for signs of wear and damage. The
float assembly must be renewed if it appears
to be leaking - shake the float to detect the
presence of fuel inside.
8 Unscrew the fuel inlet union and inspect the
fuel filter. Clean the filter housing of debris
and dirt, and renew the filter if it is blocked.
9 Undo the four screws, detach the
accelerator pump cover, and remove the
pump diaphragm and spring, noting which
way around they are fitted. Examine the
diaphragm for signs of damage and
deterioration, and renew if necessary.
Remove the choke pull-down diaphragm and
part-load enrichment diaphragms, and
examine them in the same way.
10 Unscrew the idle jet from the upper body.
11 Unscrew both the primary and secondary
combined air correction jets and emulsion
tubes.
12 Using a long thin screwdriver, unscrew
the main jets from the bottom of the emulsion
tube drillings. Invert the carburettor and catch
the jets as they fall out of the drillings.
13 Remove the idle mixture adjustment
screw tamperproof cap. Screw the screw in
until it seats lightly, counting the exact
number of turns required to do this, then
unscrew it. On refitting, screw the screw in
until it seats lightly, then back the screw off by
the number of turns noted on removal, to
return the screw to its original position.
14 Clean the jets, carburettor body
assemblies, float chamber and internal
drillings. An air line may be used to clear the
internal passages once the carburettor is fully
dismantled. Caution: If high pressure air is
directed into drillings and passages where
a diaphragm is fitted, the diaphragm is
likely to be damaged.

15 Use a straight edge to check all
carburettor body assembly mating surfaces
for distortion.
16 To test the carburettor heating element,
connect a multimeter, set to the resistance

function, between the heater wiring terminal
and the carburettor body. A resistance
reading of approximately 0.25 to 0.5 ohms
should be obtained. If an open-circuit is
present, or an extremely high resistance
reading is obtained, it is likely that the heating
element is faulty. A heating element repair kit
is available from your Peugeot dealer. To
renew the element undo the screw and
remove the retaining plate, then slide the
element holder, pin, element and insulating
plate, noting each component correct fitted
location. Fit the new components, ensuring
each one is correctly positioned, and securely
tighten the retaining screws. Note: Ensure
that the insulating plate is correctly positioned
between the heating element and body so that
there is no danger of the element shorting out
on the carburettor body.
17 On reassembly renew any worn
components and fit a complete set of new
gaskets and seals. A jet kit and a gasket and
seal kit are available from your Peugeot
dealer.
18 Reassembly is a reversal of the
dismantling procedure. Ensure that all jets are
securely locked in position, but take great
care not to overtighten them. Ensure that all
mating surfaces are clean and dry, and that all
body sections are correctly assembled with
their fuel and air passages correctly aligned.
Prior to refitting the carburettor to the vehicle,
set the float height, throttle valve fast idle and
choke pull-down settings as described below.

Adjustments

Idle speed and mixture

19 Refer to Chapter 1.

Float height setting 
(Solex carburettor)

20 Invert the carburettor body, so that the
float is at the top and the needle valve is
depressed. Measure the distance between
the upper edge of the float and the sealing
face of the upper body (with its gasket fitted).
This measurement should be as given in the
Specifications at the start of this Chapter.
21 If necessary, the float height can be
adjusted by carefully bending the small tang
on the float arm which contacts the needle
valve.

Throttle valve fast idle setting 
(Solex carburettor)

22 Invert the carburettor and pull the
carburettor choke linkage to fully close the
choke valve. The fast idle screw will butt
against the fast idle cam and force the throttle
valve open slightly.
23 Using the shank of a twist drill, measure
the clearance between the edge of the throttle
valve and bore, and compare this to the
clearance given in the Specifications at the
start of this Chapter. If necessary, adjust by
turning the fast idle adjustment screw in the
appropriate direction until the specified
clearance is obtained (see illustration).

4A•8 Fuel/exhaust systems - carburettor models

Aerosol cans of carburettor
cleaner are widely available
and can prove very useful in
helping to clear internal

passages of stubborn obstructions.