Peugeot 405. Manual - part 40

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).

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). 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 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. 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.

5

Ignition system amplifier
unit(s) - removal and refitting

2

Removal

1 Disconnect the battery negative terminal.

Breakerless ignition system

2 The amplifier unit is mounted onto the side
of the distributor body (see illustration). To
improve access to the unit, disengage the hot
air inlet hose from the control valve and
manifold shroud and remove it from the
vehicle.
3 Disconnect the wiring connector then undo
the two retaining screws and remove the
amplifier unit.

Integral ignition system

4 The amplifier unit is located in the right-
hand rear corner of the engine compartment.
5 To remove the unit, disconnect the wiring
connector, undo the two retaining screws and
remove the amplifier from its mounting
bracket.

Ignition system  5B•5

4.10  Off-set drive slots on the camshaft

5.2  On breakerless ignition systems the

amplifier unit is mounted on the side 

of the distributor body

4.17  Distributor cap and HT leads on the

XU9J4 16-valve model

4.8b  Rotor drive flange

4.8a  On XU9J4 16-valve engines undo the

rotor screws and remove the rotor

5B

Direct ignition system

6 Both amplifier units are located on a
bracket situated in the left-hand rear corner of
the engine compartment, to the rear of the
battery.
7 To remove either unit, disconnect the wiring
connector, undo the two retaining screws and
remove the amplifier unit from its mounting
bracket.

Refitting

8 Refitting is a reversal of the removal
procedure.

6

Ignition timing - 
checking and adjustment

3

Breakerless 
Electronic ignition system

1 To check the ignition timing, a stroboscopic
timing light will be required. It is also
recommended that the flywheel timing mark is
highlighted as follows.
2 Remove the plastic cover from the aperture
on the front of the transmission clutch
housing. Using a socket and suitable
extension bar on the crankshaft pulley bolt,
slowly turn the engine over until the timing
mark (a straight line) scribed on the edge of
the flywheel appears in the aperture. Highlight
the line with quick-drying white paint - typist’s
correction fluid is ideal (see illustrations).
3 Start the engine, allow it to warm up to
operating temperature, and then stop it.
4 Disconnect the vacuum hose from the
distributor diaphragm, and plug the hose end.
5 Connect the timing light to No 1 cylinder
spark plug lead (No 1 cylinder is at the
transmission end of the engine) as described
in the timing light manufacturer’s instructions.
6 Start the engine, allowing it to idle at the
specified speed, and point the timing light at

the transmission housing aperture. The
flywheel timing mark should be aligned with
the appropriate notch on the timing plate
(refer to the Specifications for the correct
setting). The numbers on the plate indicate
degrees Before Top Dead Centre (BTDC).
7 If adjustment is necessary, slacken the two
distributor mounting nuts, then slowly rotate
the distributor body as required until the
flywheel mark and the timing plate notch are
brought into alignment. Once the marks are
correctly aligned, hold the distributor
stationary and tighten its mounting nuts.
Recheck that the timing marks are still
correctly aligned and, if necessary, repeat the
adjustment procedure.
8 When the timing is correctly set, increase
the engine speed, and check that the pulley
mark advances to beyond the beginning of
the timing plate reference marks, returning to
the specified mark when the engine is allowed
to idle. This shows that the centrifugal
advance mechanism is functioning; if a
detailed check is thought necessary, this must
be left to a Peugeot dealer having the
necessary equipment. Reconnect the vacuum
hose to the distributor, and repeat the check.
The rate of advance should significantly
increase if the vacuum diaphragm is
functioning correctly, but again a detailed

check must be left to a Peugeot dealer.
9 When the ignition timing is correct, stop the
engine and disconnect the timing light.

Integral and 
Direct ignition systems

10 On these systems, there are no timing
marks on the flywheel or crankshaft pulley.
The timing is constantly being monitored and
adjusted by the engine management ECU,
and nominal values cannot be given.
Therefore, it is not possible for the home
mechanic to check the ignition timing.
11 The only way in which the ignition timing
can be checked is using special electronic
test equipment, connected to the engine
management system diagnostic connector
(refer to the relevant Part of Chapter 4 for
further information).
12 On models with Magneti Marelli engine
management systems, adjustment of the
ignition timing is possible. However,
adjustments can be made only by re-
programming the ECU using the special test
equipment (see relevant Part of Chapter 4).
13 On all other models, with Bosch engine
management systems, no adjustment of the
ignition timing is possible. Should the ignition
timing be incorrect, then a fault must be
present in the engine management system.

5B•6 Ignition system

6.2a  Removing the plastic cover from the

timing aperture

6.2b  Timing marks on the flywheel and

timing plate

9

Front brakes

Disc diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

266.0 mm

Disc thickness:

New:

Solid disc  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.4 mm

Minimum thickness:

Solid disc  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.0 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.0 mm

Maximum disc run-out  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Brake pad minimum thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Rear drum brakes

Drum internal diameter:

New

228.6 mm

Maximum diameter after machining  . . . . . . . . . . . . . . . . . . . . . . . . . .

229.6 mm

Brake shoe lining minimum thickness  . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Rear disc brakes

Disc diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247.0 mm

Disc thickness:

New

8.0 mm

Minimum thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.0 mm

Maximum disc run-out  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Brake pad minimum thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Chapter 9
Braking system

Anti-lock Braking System (ABS) - general information . . . . . . . . . . . .23
Anti-lock Braking System (ABS) components - 

removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Brake pedal - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front brake caliper - removal, overhaul and refitting  . . . . . . . . . . . . .10
Front brake disc - inspection, removal and refitting . . . . . . . . . . . . . . .7
Front brake pad wear check  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Front brake pads - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Handbrake - checking and adjustment  . . . . . . . . . . . . . . . . . . . . . . .17
Handbrake cables - removal and refitting  . . . . . . . . . . . . . . . . . . . . .19
Handbrake lever - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . .18
Handbrake “on” warning light switch - removal and refitting . . . . . . .20
Hydraulic fluid level check  . . . . . . . . . . . . . . . . . .See “Weekly Checks”
Hydraulic fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Hydraulic pipes and hoses - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . .3

Hydraulic system - bleeding  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Master cylinder - removal, overhaul and refitting  . . . . . . . . . . . . . . . .13
Rear brake caliper - removal, overhaul and refitting  . . . . . . . . . . . . .11
Rear brake disc - inspection, removal and refitting  . . . . . . . . . . . . . . .8
Rear brake drum - removal, inspection and refitting  . . . . . . . . . . . . . .9
Rear brake pad wear check . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Rear brake pads - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Rear brake pressure-regulating valve (underbody-mounted) -

removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Rear brake shoe wear check  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Rear brake shoes - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Rear wheel cylinder - removal, overhaul and refitting  . . . . . . . . . . . .12
Stop-light switch - removal, refitting and adjustment  . . . . . . . . . . . .22
Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . .15
Vacuum servo unit check valve - removal, testing and refitting  . . . . .16

9•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

1

General information

The braking system is of the servo-

assisted, dual-circuit hydraulic type. The
arrangement of the hydraulic system is such
that each circuit operates one front and one
rear brake from a tandem master cylinder.
Under normal circumstances, both circuits
operate in unison. However, in the event of
hydraulic failure in one circuit, full braking
force will still be available at two wheels.

Some large-capacity engine models have

disc brakes all round as standard; other
models are fitted with front disc brakes and
rear drum brakes. ABS is fitted as standard to
certain models, and is offered as an option on
most other models (refer to Section 23 for
further information on ABS operation).

The front disc brakes are actuated by

single-piston sliding type calipers, which
ensure that equal pressure is applied to each
disc pad.

On models with rear drum brakes, the rear

brakes incorporate leading and trailing shoes,
which are actuated by twin-piston wheel
cylinders. On models not equipped with an
underbody-mounted rear brake pressure
regulating valve, the wheel cylinders
incorporate integral pressure-regulating
valves, which control the hydraulic pressure
applied to the rear brakes. The regulating
valves help to prevent rear wheel lock-up
during emergency braking. On some models,
an underbody-mounted load-sensitive rear
pressure-regulating valve is fitted. A self-
adjust mechanism is incorporated, to
automatically compensate for brake shoe
wear. As the brake shoe linings wear, the
footbrake operation automatically operates
the adjuster mechanism, which effectively

lengthens the shoe strut and repositions the
brake shoes, to remove the lining-to-drum
clearance.

On models with rear disc brakes, the

brakes are actuated by single-piston sliding
calipers which incorporate mechanical
handbrake mechanisms. A load-sensitive
pressure-regulating valve is fitted to regulate
the hydraulic pressure applied to the rear
brakes. The regulating valve is similar to that
fitted to drum brake models with ABS, and
helps to prevent rear wheel lock-up during
emergency braking.

On all models, the handbrake provides an

independent mechanical means of rear brake
application.

Note: When servicing any part of the

system, work carefully and methodically; also
observe scrupulous cleanliness when
overhauling any part of the hydraulic system.
Always renew components (in axle sets, where
applicable) if in doubt about their condition,
and use only genuine Peugeot replacement
parts, or at least those of known good quality.
Note the warnings given in “Safety first” and at
relevant points in this Chapter concerning the
dangers of asbestos dust and hydraulic fluid. 

2

Hydraulic system - bleeding

2

General

1 The correct operation of any hydraulic
system is only possible after removing all air
from the components and circuit; this is
achieved by bleeding the system.
2 During the bleeding procedure, add only
clean, unused hydraulic fluid of the
recommended type; never re-use fluid that
has already been bled from the system.
Ensure that sufficient fluid is available before
starting work.
3 If there is any possibility of incorrect fluid
being already in the system, the brake
components and circuit must be flushed
completely with uncontaminated, correct
fluid, and new seals should be fitted to the
various components.
4 If hydraulic fluid has been lost from the
system, or air has entered because of a leak,
ensure that the fault is cured before
proceeding further.

Torque wrench settings

Nm

lbf ft

Hydraulic pipe unions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

Front brake caliper:

Guide pin bolts (Girling caliper)**  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Caliper mounting bolts (Bendix caliper):*^:

Early (solid) type hub carrier  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

89

Later (hollow) type hub carrier  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

77

Caliper mounting bracket bolts (Girling caliper):*^

Early (solid) type hub carrier  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

89

Later (hollow) type hub carrier  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

77

Rear brake caliper:

Guide pin bolts*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Caliper mounting bracket bolts*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

41

Master cylinder-to-servo unit nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

Brake pedal pivot bolt nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Vacuum servo unit securing nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

ABS wheel sensor securing bolts*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

7

ABS wheel sensor adjuster bolt (Bendix “integral” ABS)  . . . . . . . . . . . .

3

2

ABS hydraulic modulator mounting nuts  . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Roadwheel bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

63

*Use thread-locking compound.
**Use new bolts coated with thread-locking compound
^Refer to note in Chapter 10, Section 2.

9•2 Braking system

Warning: Hydraulic fluid is
poisonous; wash off
immediately and thoroughly in
the case of skin contact, and

seek immediate medical advice if any fluid
is swallowed or gets into the eyes. Certain
types of hydraulic fluid are inflammable,
and may ignite when allowed into contact
with hot components; when servicing any
hydraulic system, it is safest to assume

that the fluid is inflammable, and to take
precautions against the risk of fire as
though it is petrol that is being handled.
Hydraulic fluid is also an effective paint
stripper, and will attack plastics; if any is
spilt, it should be washed off immediately,
using copious quantities of fresh water.
Finally, it is hygroscopic (it absorbs
moisture from the air) - old fluid may be
contaminated and unfit for further use.
When topping-up or renewing the fluid,
always use the recommended type, and
ensure that it comes from a freshly-
opened sealed container.

Warning: Do not attempt to
bleed any part of the hydraulic
system on models equipped
with the Bendix “integral” ABS.

Special equipment is required, and the
task must be referred to a Peugeot dealer.