Peugeot 405. Manual - part 51

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

Refitting

17 Refitting is a reversal of removal.

12 Door - removal, refitting and

adjustment

3

Removal

1 The door hinges are welded to the body
pillar, and bolted to the door.

2 Where applicable, prise the plastic caps
from the hinge pins.
3 Using a pin-punch, drive the roll-pin from
the door check strap (see illustration).
4 On models with electrical components
inside the door, remove the door trim panel
with reference to Section 13. Working inside
the door, disconnect all the wiring harness
plugs, then feed the wiring through the hole 
in the front edge of the door. Note the routing
of the wiring harness to ensure correct
refitting.
5 The door must now be supported in the
fully open position.

12.3  Drive the roll-pin (arrowed) from the

door check strap

11.16  Withdrawing the body front panel

assembly

11•6 Bodywork and fittings

11.7a  Disconnecting the front light wiring

connectors - models up to 1992

11.7c  . . . and disconnect the plug from the

terminal block - models from 1993

11.14  Unscrew the body front panel 

upper securing bolts

11.12  Removing a body front panel 

lower securing bolt

11.8  Unbolt the earth leads from the

corners of the engine compartment

11.7b  Disconnect the front light wiring

connectors (arrowed) . . .

Support the door by placing
blocks of wood, or a jack
and block of wood, under its
lower edge.

6 Ensure that the door is adequately
supported, then unscrew the pivot pins from
the hinges (see illustration).
7 Lift the door from the vehicle.

Refitting

8 Refitting is a reversal of removal, noting that
the hinge pins fit with their heads towards
each other, ie, the upper pin fits from below
the hinge, and the lower pin fits from above
the hinge.
9 On completion, check the fit of the door
with the surrounding body panels. On early
models, the fit of the doors can be adjusted as
described in paragraph 11.
10 If adjustment of the door lock is required,
this can be achieved by altering the position
of the lock striker within the elongated bolt
holes in the body pillar.

Adjustment - early models only

11 The fit of the door can be adjusted using

shims fitted between the hinge and the door.
To add or remove shims, loosen the bolts
securing the hinge to the door (the door inner
trim panel must be removed for access to the
bolts - see Section 13), then fit or remove
shims as necessary.

13 Door inner trim panel -

removal and refitting

3

Removal

1 If the trim is being in removed in order to
remove the window glass, lower the window
to approximately the two-thirds open position.
2 Carefully prise the surround from the door
interior handle (see illustration).
3 Remove the loudspeaker cover panel,
either by depressing the securing clip at the
lower edge of the panel, or by removing the
three securing screws from the edge of the
panel, as applicable (see illustration).
4 Unscrew the securing screws, withdraw the
loudspeaker, and disconnect the wiring.
5 Lift up the inner door lock operating button
then, using a small screwdriver, depress the
retaining tab, and slide off the button (see
illustration).
6 On models with manually-operated
windows, carefully pull the window regulator
handle from the door.
7 On models with electric windows,
disconnect the battery negative lead, then
prise the switches from the door, and
disconnect the wiring plugs (see illustration).

8 Prise the mirror trim plate from the front
corner of the door (see illustration). Where
applicable, loosen the clamp screw, and
release the mirror adjuster knob from the trim
plate.
9 Remove the securing screws and withdraw
the armrest (where applicable, prise the trim
plate from the armrest to expose the screws)
(see illustration).
10 On later models, prise the trim plate from
the rear of the door pocket, and unscrew the
rear trim panel securing screw (see illustration).
11 Where applicable, using a screwdriver,
release the trim panel securing clip located in
the loudspeaker aperture.
12 Working around the edge of the door,
release the remaining securing clips around
the edge of the trim panel, ideally using a
forked tool to avoid breaking the clips.
13 Lift the panel to release it from the top of
the door, then withdraw the panel. Where
applicable, disconnect the wiring plug from

Bodywork and fittings  11•7

13.3  Removing a loudspeaker cover panel

securing screw

13.8  Prise off the mirror trim plate

13.7  Removing an electric window switch

from the door

13.5  Depress the retaining tab and slide

off the lock operating button

13.2  Removing the door interior handle

surround

12.6  Door pivot pin (arrowed)

11

13.9  Remove the securing screws and

withdraw the armrest

13.10  Removing the rear door trim panel

securing screw - later model

the electric windows control unit, which is
located on a bracket attached to the rear of
the door trim panel.

Refitting

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

a) Before refitting, check whether any of the

trim panel retaining clips were broken on
removal, and renew as necessary.

b) Ensure that the weatherstrip (with the

metal reinforcing strip) is in place on the
top of the trim panel before refitting, and
check that the weatherstrip engages
correctly with the weatherstrip on the
door as the trim panel is refitted.

c) To refit the inner door lock operating

button, first lock the door to ensure that
the link rod is in its lowest position.
Position the button locating tab in the
lower of its two holes, then firmly push

the button onto the rod until it clips into
position and the retaining tab appears in
the upper hole (see illustrations).

14 Door handle and lock

components - removal and
refitting

3

Interior door handle

Removal

1 Remove the door inner trim panel as
described in Section 13.
2 If necessary, peel the plastic sealing sheet
from around the handle assembly.
3 Slide the handle assembly towards the front
of the door, then pull the assembly from the
trim panel and disconnect the link rod (see
illustration). If necessary, release the link rod
from the clips on the door.

Refitting

4 Refitting is a reversal of removal, ensuring
the link rod is correctly reconnected. Where
applicable, fit a new sealing sheet if the sheet
was damaged during removal, and refit the
door trim panel with reference to Section 13.

Exterior door handle

Removal

5 Remove the door inner trim panel as
described in Section 13.
6 Peel back the plastic sealing sheet for
access to the handle securing nut.
7 Unscrew the handle securing nut then,
where applicable, manipulate the plastic shield
from the rear of the lock (see illustrations).
8 Withdraw the handle from outside the door,
and disconnect the lock operating rod from
the handle as it is removed (see illustration).

Refitting

9 Refitting is a reversal of removal, ensuring
that the link rod is correctly reconnected. Fit a
new sealing sheet if the sheet was damaged
during removal, and refit the door trim panel
with reference to Section 13.

Front door lock cylinder

10 The lock cylinder can be removed as
follows, without the need to remove the door
inner trim panel. If no facilities are available to
make up the tools, proceed to paragraph 11.

a) Make up two suitable tools, using a

medium-size self-tapping screw brazed to
a length of rod for each tool (see
illustration).

14.10a  Tool for removing 

door lock cylinder

All dimensions in mm

14.8  Withdrawing the exterior door handle

11•8 Bodywork and fittings

13.14a  Position the lock button locating

tab in the lower position

14.3  Unhooking the link rod from the

interior door handle

14.7c  . . . and withdraw the plastic shield -

later model

14.7b  Unscrew the securing nut . . .

14.7a  Exterior door handle securing nut

(arrowed) - early model

13.14b  Push the button onto the rod until

retaining tab appears in upper hole (arrowed)

b) Open the door, and prise the cover plates

from the rear edge of the door.

c) Insert the tools through the aperture in the

edge of the door, and screw the tools into
the lock securing clip as far as the ends of
the threads on the self-tapping screws.

d) Push the tools to release the securing

clip, and withdraw the lock cylinder from
outside the door (see illustration). Leave
the tools engaged with the clip.

e) Refit the lock, and use the tools to pull the

securing clip into position.

f) Ensure the clip is securely engaged with

the lock cylinder, then unscrew the tools
from the clip, and refit the cover plates.

Removal

11 Remove the door inner trim panel as
described in Section 13.
12 Peel back the plastic sealing sheet for
access to the lock cylinder securing clip.
13 Working inside the door, pull the clip from
the rear of the lock cylinder, then remove the
lock cylinder from outside the door (see
illustrations).

Refitting

14 Refitting is a reversal of removal, but
ensure that the lock cylinder clip is securely
refitted. Fit a new sealing sheet if the sheet
was damaged during removal, and refit the
door trim panel with reference to Section 13.

Door lock

Removal

15 Remove the door interior handle and the
exterior handle, as described previously in this
Section.

16 Working at the rear edge of the door,
unscrew the three lock securing screws (see
illustration).
17 Where applicable, disconnect the wiring
plug from the central locking motor on the
lock assembly.
18 Lower the lock assembly into the door,
and manipulate the lock operating rods until
the assembly can be withdrawn through the
door aperture. If it proves necessary to
disconnect any of the rods, carefully note the
routing and location to ensure correct
refitting.

Refitting

19 Refitting is a reversal of removal, but
ensure that the lock operating rods are
correctly located and routed, and refit the
door exterior and interior handles as
described previously in this Section.

15 Door window glass and

regulator - removal and
refitting

3

Front door window glass

Removal

1 Remove the door inner trim panel as
described in Section 13.
2 Lower the window glass two-thirds of the
way.
3 Carefully peel the plastic sealing sheet from
the door.
4 Pull the weatherstrip from the lower edge of
the window aperture.

5 Partially pull the weatherstrip from the rear
and upper edge of the window aperture.
6 Where applicable, disconnect the electric
window motor wiring connector, and move
the wiring harness to one side.
7 It is now necessary to release the clip
securing the window glass to the regulator
mechanism.
8 On models up to 1992, this is a difficult
operation, as the lugs on the clip must be
released from behind the glass. Peugeot tool
(-)7.1309 is available for this purpose, but the
tool can be improvised by drilling a hole of
suitable diameter in a small block of wood or
plastic. Push the tool onto the rear of the clip
to compress the lugs, whilst at the same time
pushing the window glass to release it from
the clip (see illustration).
9 On models from 1993, the clip is fitted
behind the glass, and can be released by
reaching in through the door aperture and
turning the clip through a quarter-turn.
10 Lift the glass out through the outside of
the window aperture.

Refitting

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

a) On models up to 1992, ensure that the

clip securing the glass to the regulator is
securely engaged.

b) To ease refitting of the weatherstrips, coat

them with soapy water (washing-up liquid
is ideal).

c) If the plastic sealing sheet was damaged

during removal, fit a new sheet.

d) Refit the door inner trim panel with

reference to Section 13.

Front door regulator

Removal

12 Remove the window glass as described
previously in this Section. Alternatively,
release the clip securing the window glass to
the regulator mechanism, then lift the glass up
and secure it to the top of the door using
string adhesive tape - ensure that the glass is
secure, and that there is no danger of it
dropping back into the door.
13 Where applicable, disconnect the wiring
plug(s) from the electric window motor.

Bodywork and fittings  11•9

14.13b  . . . then withdraw the lock cylinder

1  Plastic clip lugs
2  Plastic clip

3  Window glass
4  Tool

15.8  Using a tool to release the window

glass securing clip - models up to 1992

14.16  Remove the door lock 

securing screws

14.13a  Remove the securing clip . . .

14.10b  Using the improvised tools to

release the lock cylinder securing clip

11