Peugeot 405. Manual - part 52

 

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Peugeot 405. Manual - part 52

 

 

14 Unscrew the three nuts securing the
regulator mechanism to the door (see
illustration)
.
15 Unscrew the two nuts securing the
window lift rail to the door.
16 Carefully tilt the assembly and lift it out
through the lower aperture in the door (see
illustration)
.

Refitting

17 Refitting is a reversal of removal, but refit
the window glass as described previously in
this Section.

Rear door sliding window glass

18 Proceed as described for the front door
window glass, noting the following points.

a) Fully lower the window glass.
b) The rear glass guide rail must be removed

before removing the glass. The guide rail
is secured by two bolts (see illustration).

Rear door fixed window glass

Removal

19 Remove the door inner trim panel as
described in Section 13.
20 Carefully peel the plastic sealing sheet
from the door.
21 Unscrew the two bolts securing the rear
window guide rail.
22 Where applicable, prise the trim strip from
the fixed window seal.
23 Pull the weatherstrip from the lower edge
of the window aperture.
24 Partially pull the weatherstrip from the rear
and upper edge of the window aperture.
25 Slide the rear window guide rail
downwards into the door.
26 Remove the fixed glass, complete with
the seal, by tilting and pulling forwards (see
illustration)
. Note that the rear window guide
rail remains attached to the sliding glass.

Refitting

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

a) To ease refitting of the weatherstrips, coat

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

b) If the plastic sealing sheet was damaged

during removal, fit a new sheet.

c) Refit the door inner trim panel with

reference to Section 13.

Rear door regulator

28 The procedure is as described previously
in this Section for the front door regulator.
Note that there is no need to remove the fixed
window glass.

16 Boot lid (Saloon models) -

removal, refitting and
adjustment

2

Removal

Open the boot lid, and using a pencil or felt
tip pen, mark the outline position of each boot
lid hinge relative to the boot lid, to use as a
guide on refitting.

Have an assistant hold the boot lid open
then, using a pair of pliers, disconnect the
spring assisters from the brackets on the
body - take care, as the springs are under
tension. Note which bracket slots the ends of
the springs are positioned in, to ensure
correct refitting (see illustration).
Unscrew the bolts securing the hinges to
the boot lid, and lift off the boot lid.

Refitting

Refitting is a reversal of removal, noting the
following points.

a) Align the hinges with the marks made on

the boot lid before removal.

b) Make sure that the spring assisters are

refitted to their original slots in the body
brackets.

c) On completion, check the alignment of

the boot lid with the surrounding panels,
and check the operation of the lock, and if
necessary adjust as follows.

Adjustment

The alignment of the boot lid can be
adjusted by slackening the hinge bolts, and
moving the boot lid on the hinges (the holes in
the hinges are elongated).
There are adjustable rubber stops at each
side of the lid to prevent damage to the
surrounding panels when closing the lid. There
are also rubber stops under each hinge arm,
which should be adjusted to prevent the lid
from opening too far and causing damage to
the front corners of the lid (see illustration).

1  Guide rail upper bolt
2  Guide rail lower bolt

3  Guide rail
4  Weatherstrip

11•10 Bodywork and fittings

15.14  Unscrew the front door window

regulator securing nuts (arrowed)

15.18  The rear glass guide rail must be

removed before removing the rear door

sliding window glass

16.6  Rubber stop (arrowed) 

under boot lid hinge arm

16.2  Note which slots (arrowed) the ends

of the boot lid assister springs are

positioned in before disconnecting them

15.26  Removing the rear door fixed

window glass

15.16  Removing the front door window

regulator assembly

A  Guide rail lowered into door   B  Weatherstrip

Check that the boot lid lock operation is
satisfactory, and if necessary adjust by
moving the lock striker (bolted to the boot lid)
within its elongated holes.

17 Boot lid lock components

(Saloon models) - removal
and refitting

3

Boot lid lock cylinder

Note: New pop-rivets will be required to refit
the body rear trim panel, and on some models
the lock cylinder.

Removal

Open the boot lid.
Pull the weatherseals from the edge of the
rear luggage compartment trim panel, then
carefully pull the trim panel from the upper
edge of the luggage compartment.
Drill out the securing rivets from the top of
the body rear trim panel, then unclip the trim
panel and withdraw it from the rear of the
vehicle (see illustration).
Working in the luggage compartment, where
applicable unscrew the pinch-bolt, and
disconnect the operating rod from the lock
cylinder (see illustration). Similarly, disconnect
the central locking motor rod, where applicable.
Drill out the rivets, or unscrew the securing
bolts, as applicable, and withdraw the lock
cylinder from the body panel.

Refitting

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

a) Refit the body rear trim panel (and the

lock cylinder, where applicable) using new
pop-rivets.

b) Check the operation of the lock

mechanism before refitting the trim panels.

c) If necessary, on models where the

operating rod is secured to the lock
cylinder with a pinch-bolt, adjust the rod
as necessary (by slackening the pinch-
bolt) until the lock operation is
satisfactory.

Boot lid lock

Removal

Proceed as described in paragraphs 1 and 2.

Unscrew the two securing bolts, then
withdraw the lock and disconnect the
operating rod.

Refitting

Refitting is a reversal of removal, but check
the operation of the lock before refitting the
trim panel.

Boot lid lock striker

10 The striker is secured to the boot lid by
two bolts, and can be adjusted by moving it
within the elongated bolt holes.

18 Tailgate and support struts

(Estate models) - removal,
refitting and adjustment

3

Tailgate

Removal

Open the tailgate.
Remove the securing screws, and withdraw
the plastic trim panel from the inside of the
tailgate.
Working around the edge of the carpeted
trim panel, release the securing clips, ideally
using a forked tool to avoid breaking the clips.
Withdraw the carpeted panel.
Disconnect the heated rear window wiring
connectors from the contacts on the tailgate.
Disconnect the wiring plug from the
luggage compartment light switch, and from
the alarm sensor switch, where applicable.
Where applicable, working through the
aperture in the tailgate, disconnect the

tailgate wiper motor and the central locking
motor wiring plugs.
Disconnect the washer fluid hose from the
washer nozzle.
Release the wiring harnesses and the
washer fluid hose from any clips inside the
tailgate.
Pull the wiring grommets from the top
corners of the tailgate.
10 If the original tailgate is to be refitted, tie
string to the ends of all the relevant wiring,
then feed the wiring through the top of the
tailgate. Untie the string, leaving it in position
in the tailgate to assist refitting.
11 Support the tailgate, then prise out the
support strut spring clips, and pull the struts
from the balljoints on the tailgate.
12 Unscrew the nuts securing the hinges to
the top of the tailgate, and carefully lift the
tailgate from the vehicle (see illustration).

Refitting

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

a) If the original tailgate is being refitted,

draw the wiring and washer fluid hose
(where applicable) through the tailgate, or
through the body panel (as applicable)
using the string.

b) If necessary, adjust the rubber buffers to

obtain a good fit when the tailgate is shut.

c) Before refitting the tailgate trim panels,

check and if necessary adjust the position
of the tailgate lock within its elongated
holes to achieve satisfactory lock operation.

Adjustment

14 If necessary, the rubber buffers at the
sides of the tailgate can be adjusted to
achieve firm closure of the tailgate without
slamming. The tailgate lock operation can be
adjusted by altering the position of the lock
within its elongated holes.

Support struts

Removal

15 Support the tailgate in the open position,
with the help of an assistant, or using a stout
piece of wood.
16 Using a suitable flat-bladed screwdriver,
release the spring clip, and pull the support
strut from its balljoint on the tailgate (see
illustration)
.

Bodywork and fittings  11•11

18.12  Hinge-to-tailgate nuts 

(arrowed)

18.16  Prising the spring clip from a

tailgate strut balljoint

17.4  Unscrew the lock operating rod

pinch-bolt (arrowed)

17.3  Drill out the rivets (arrowed) from the

body rear trim panel

11

17 Similarly, release the strut from the
balljoint on the body, and withdraw the strut
from the vehicle.

Refitting

18 Refitting is a reversal of removal, but
ensure the spring clips are correctly engaged.

19 Tailgate lock components

(Estate models) - removal
and refitting

3

Tailgate lock cylinder

Note: New pop-rivets will be required to refit
the lock cylinder.

Removal

Open the tailgate.
Remove the securing screws, and withdraw
the plastic trim panel from the inside of the
tailgate (see illustration).
Working around the edge of the carpeted
trim panel, release the securing clips, ideally
using a forked tool to avoid breaking the clips.
Withdraw the carpeted panel (see
illustration)
.
Drill out the rivets securing the lock cylinder
assembly to the tailgate (see illustration).
Unhook the operating rod(s), and withdraw
the assembly from the tailgate.
Remove any rivet swarf from the inside of
the tailgate.

Refitting

Refitting is a reversal of removal, but use
new rivets to secure the assembly to the
tailgate.

Tailgate lock

Removal

Proceed as described in paragraphs 1 to 3.
Unscrew the two bolts securing the lock to
the mounting bracket (see illustration).
10 Unhook the lock operating rod, and
withdraw the lock.

Refitting

11 Refitting is a reversal of removal, but
before refitting the tailgate trim panels, check
the operation of the lock, and if necessary
adjust by moving the lock within its elongated
bolt holes.

Tailgate lid lock striker

12 The striker is secured to the body by two
bolts.

20 Central locking 

components 
removal and refitting

3

Note: Before attempting work on any of the
central locking system components,
disconnect the battery negative lead.
Reconnect the lead on completion of work.

Electronic control unit

Removal

Remove the glovebox as described in
Section 28 to reveal the control unit (see
illustration)
.
Where applicable, remove the two securing
screws, then unclip the control unit from its
location, and disconnect the wiring plug (see
illustration)
.

Refitting

Refitting is a reversal of removal.

Door lock motor

The motors are fitted to the door lock
assemblies. To remove a motor, remove the
lock assembly as described in Section 14,
then remove the screws securing the motor to
the lock assembly.

Tailgate lock motor

Removal

Open the tailgate.
Remove the securing screws, and withdraw
the plastic trim panel from the inside of the
tailgate.
Working around the edge of the carpeted
trim panel, release the securing clips, ideally
using a forked tool to avoid breaking the clips.
Withdraw the carpeted panel.
Unscrew the bolt securing the lock motor to
the tailgate (see illustration).
Manipulate the motor out from the aperture
in the tailgate, then disconnect the lock
operating rod and disconnect the wiring plug
(see illustration).

Refitting

10 Refitting is a reversal of removal.

11•12 Bodywork and fittings

19.2  Withdraw the plastic trim panel 

from the tailgate . . .

19.4  Tailgate lock cylinder securing rivets

(arrowed)

20.2  Removing the central locking

electronic control unit - 

models from 1993

20.1  Central locking electronic control unit

(arrowed) viewed with glovebox removed -

models up to 1992

19.9  Tailgate lock securing bolts (arrowed)

19.3  . . . then withdraw the carpeted panel

Boot lid lock motor

Removal

11 Open the boot lid.
12 Pull the weatherseals from the edge of the
rear luggage compartment trim panel, then
carefully pull the trim panel from the upper
edge of the luggage compartment.
13 Remove the securing screws, then
withdraw the lock motor and disconnect the
control rod.
14 Disconnect the wiring plug, and withdraw
the motor.

Refitting

15 Refitting is a reversal of removal.

Fuel filler flap lock motor -
Saloon models

Removal

16 On Saloon models, the motor is located in

the luggage compartment, behind the right-
hand side trim panels.
17 Carefully prise the carpeted trim from the
side of the luggage compartment, to expose
the lock motor.
18 Open the fuel filler flap, and unscrew the
bolt securing the motor to the body.
19 Working inside the luggage compartment,
unscrew the securing bolt, then withdraw the
motor and disconnect the wiring plug.

Refitting

20 Refitting is a reversal of removal. If
necessary, glue the trim back into position.

Fuel filler flap lock motor -
Estate models

Removal

21 On Estate models, the motor is located in
the luggage compartment, behind the rear
window washer reservoir.

22 Working inside the luggage compartment,
open the cover flap to expose the rear washer
fluid reservoir.
23 Remove the two securing screws, then lift
out the reservoir to expose the lock motor.
Note that there is no need to disconnect the
washer fluid tubing.
24 Proceed as described in paragraphs 18
and 19 (see illustrations).

Refitting

25 Refitting is a reversal of removal.

Remote control receiver unit

Removal

26 The unit is located in the roof console.
27 Unclip the sunvisors from the roof console.
28 Carefully prise the courtesy light assembly
from the console to expose the two roof
console front securing screws. Disconnect the
wiring plug and remove the light.
29 Similarly, prise the map reading light and
the light surround from the console to expose
one of the front securing screws. Disconnect
the wiring plug and remove the light.
30 Prise the blanking plate from the console
then, where applicable, push the sunroof
switch from the console.
31 Remove the two console securing screws
exposed by removal of the map reading light
and sunroof switch, then lower the console
from the roof (see illustration).
32 Disconnect the wiring plug from the
receiver unit.
33 Release the clips, and withdraw the
receiver unit from the console (see illustration).

Refitting

34 Refitting is a reversal of removal.

Remote control transmitter
batteries - renewal

Early models

35 Using a small screwdriver, carefully prise
the rear cover from the transmitter unit, and
remove the three batteries, noting which way
round they are fitted (see illustration).
36 Fit the new batteries, ensuring that they
are fitted the correct way round; the battery
and transmitter terminals are marked “+” and
“-” to avoid confusion. Clip the transmitter
back together.

Bodywork and fittings  11•13

20.24a  Remove the bolt securing the fuel

filler flap lock motor to the body

20.33  Central locking remote control

receiver securing clips (arrowed)

20.31  Removing a roof console 

securing screw

20.24b  Removing the fuel filler flap lock

motor - Estate model

20.9  Disconnecting the wiring plug from

the tailgate lock motor

20.8  Unscrewing the tailgate lock motor

securing bolt

11

20.35  Rear cover removed from remote

transmitter to expose batteries (arrowed)

 

 

 

 

 

 

 

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