Peugeot 405. Manual - part 59

20 Working in the engine compartment,
locate the speedometer cable ball, which
rests in a grommet in the engine compartment
bulkhead, then pull the ball sharply to release
the cable from the speedometer.
21 Unscrew the two lower and single upper
instrument panel securing screws (see
illustration).
22 Insert a soft plastic or wooden lever
between the top instrument panel securing
clip (the upper securing screw location) and
the facia, and carefully lever the clip down
until the instrument panel can be withdrawn
forwards (see illustration).
23 Disconnect the wiring plugs from the rear
of the panel, and withdraw the panel from the
facia (see illustration).

Refitting

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

a) Before refitting, ensure that the Velcro

strip, which retains the wiring looms, is in
position at the top of the instrument panel
aperture.

b) Reconnect the speedometer cable by

pushing the cable ball into position in the
bulkhead grommet.

c) Tighten the steering column securing nuts

to the specified torque.

10 Instrument panel

components - 
removal and refitting

3

General

1 Remove the instrument panel as described
in Section 9,  then proceed as described
under the relevant sub-heading.

Gauges - models up to 1992

2 Release the securing clips, and unscrew
the three securing screws, then remove the
panel surround/lens assembly from the
instrument panel.
3 Unscrew the relevant securing screws or
nuts, then withdraw the gauge from the front
of the panel.
4 Refitting is a reversal of removal.

Gauges - models from 1993

5 Working at the rear of the panel, remove the
lens securing screws from around the edge of
the panel (see illustration).
6 Remove the two recessed lens securing
screws from the rear of the panel (see
illustration).
7 Release the securing clips by carefully
prising with a screwdriver, then withdraw the
lens assembly.
8 Where necessary, for access to the gauge
fixings at the rear of the gauge, remove the
screws and withdraw the cover from the rear
of the instrument panel (see illustration).
9 Unscrew the nuts from the gauge contact
studs, or remove the gauge securing screws,
as applicable (see illustration).
10 Where applicable, working at the front of
the gauge, remove the gauge securing screws
(see illustration).

Body electrical system  12•13

9.22  Lever the upper securing 

clip down . . .

10.6  Remove the two recessed lens

securing screws

10.5  Two of the instrument panel lens

securing screws (arrowed)

9.23  . . . until the instrument panel can be

withdrawn

9.21  Unscrew the lower instrument panel

securing screws

9.19  Prise the trim panel from the facia

12

Coat the ball with soapy
water to aid refitting.

10.8  Removing the cover from the rear of

the instrument panel

10.9  Fuel gauge securing nuts (arrowed)

11 Carefully withdraw the gauge from the
front of the instrument panel, taking care not to
damage the circuit board. Where applicable,
recover the spacers from the gauge studs (see
illustrations).
12 Refitting is a reversal of removal. Make
sure that the spacers are in position on the
gauge studs, where applicable.

Illumination and 
warning light bulbs

13 Twist the relevant bulbholder anti-
clockwise to release it from the rear of the
panel. The bulbs are integral with the
bulbholders.

11 Clock - removal and refitting

3

Models up to 1992

Removal

1 Disconnect the battery negative lead.
2 Working beneath the facia ventilation
nozzles, prise out the three blanking plates
covering the instrument panel visor securing
screws.
3 Remove the screws, and lift off the
instrument panel visor (see illustration 9.3b).
4 Working at the rear of the clock, release the
securing clips, then pull the clock from the
rear of the facia panel.
5 Disconnect the wiring plug and withdraw
the clock (see illustration).

Refitting

6 Refitting is a reversal of removal.

Models from 1993

Removal

7 Disconnect the battery negative lead.
8 Remove the centre console as described in
Chapter 11, Section 29.
9 Open the ashtray cover, and unscrew the
two screws located at the bottom of the
ashtray housing.
10 Where applicable, remove the radio/
cassette player as described in Section 20.
On models not fitted with a radio/cassette
player, prise out the oddments tray.
11 Remove the two securing screws from the
top of the radio/cassette player/oddments
tray housing, then withdraw the housing from
the facia. Where applicable, disconnect the
wiring plug(s) from the rear of the housing.
12 Prise the blanking plate from the top
corner of the facia centre ventilation nozzle
housing. Remove the now-exposed securing
screw.
13 Remove the four housing securing screws
located under the heater control panel. Two
screws are accessible from the front of the
housing, and a two screws from underneath.
14 Carefully prise the switches from below
the centre facia ventilation nozzles to reveal
the remaining housing securing screw.
Remove the screw (see illustration).
15 Pull the housing forwards, and disconnect
the wiring from the clock, then withdraw the
housing (see illustration).
16 Working at the rear of the clock, remove

the two securing screws, then withdraw the
clock from the housing.

Refitting

17 Refitting is a reversal of removal. Refit the
radio/cassette player, referring to Section 20.

12 Cigarette lighter - 

removal and refitting

2

Front cigarette lighter - 
models up to 1992

Removal

1 Disconnect the battery negative lead.
2 Prise the lower stowage tray from the
centre console.
3 Prise the side panels from the front of the
console.
4 Working behind the ashtray housing,
disconnect the wiring from the cigarette
lighter and the illumination bulb.
5 Again working behind the housing, depress
the cigarette lighter securing clips, and push
the unit forwards from the housing.

Refitting

6 Refitting is a reversal of removal.

Front cigarette lighter - 
models from 1993

7 Disconnect the battery negative lead.
8 Remove the centre console as described in
Chapter 11, Section 29.
9 Open the ashtray cover, and unscrew the

12•14 Body electrical system

10.10  Remove the gauge 

securing screws . . .

10.11b  . . . and recover the spacers from

the studs

11.15  . . . then withdraw the housing

11.14  Remove the centre facia ventilation

nozzle housing lower securing screw . . .

11.5  Removing the clock - 

models up to 1992

10.11a  . . . then withdraw the gauge . . .

two screws located at the bottom of the
ashtray housing.
10 Where applicable, remove the radio/
cassette player as described in Section 20.
On models not fitted with a radio/cassette
player, prise out the oddments tray.
11 Remove the two securing screws from the
top of the radio/cassette player/oddments
tray housing, then withdraw the housing from
the facia. Disconnect the wiring plug(s) from
the rear of the housing.
12 Working behind the housing, depress the
cigarette lighter securing clips, and push the
unit forwards from the housing.

Rear cigarette lighter

13 The procedure is similar to that described
previously for the front lighter, except that
access is obtained by removing the rear
ashtray from the centre console.

13 “Lights-on” 

warning system - 
general information

1 The purpose of this system is to inform the
driver that the lights have been left on once
the ignition has been switched off; the buzzer
will sound when a door is opened. The system
consists of a buzzer unit which is linked to the
driver’s door courtesy light switch.
2 On models up to 1992, the buzzer unit is
located behind the fuses in the facia fusebox,
and access can be obtained once the fusebox
cover has been removed. The unit is a push-fit
in the panel, and can be identified by the slots
in its cover (see illustration).
3 On models from 1993, the buzzer unit is
located in the relay block, behind the fusebox
(see illustration).
4 Refer to Section 4 for information on
courtesy light switch removal.

14 Horn - removal and refitting

2

Removal

1 There may be a single horn or double horns
mounted behind the front bumper (on some

models, one horn is mounted on each side of
the vehicle).
2 Disconnect the battery negative lead.
3 Where applicable, remove the wheel arch
liner(s) to improve access.
4 Reach up behind the bumper, and
disconnect the wiring from the horn.
5 Unscrew the nut securing the horn to the
mounting bracket, and withdraw the horn (see
illustration).

Refitting

6 Refitting is a reversal of removal.

15 Speedometer cable - 

removal and refitting

4

Removal

1 Working in the engine compartment, locate
the speedometer cable ball, which rests in a
grommet in the engine compartment
bulkhead, then pull the ball sharply to release
the cable from the speedometer.
2 Remove the instrument panel (Section 9).
3 Tie a length of string to the end of the
speedometer cable at the speedometer end.
4 Working at the gearbox/transmission end of
the cable, remove the pin securing the cable
end fitting to the gearbox/transmission
housing.
5 Pull the cable through the bulkhead
grommet into the engine compartment, then
withdraw the cable from the vehicle. If
desired, access to the bulkhead grommet can

be obtained from the driver’s footwell after
unclipping the carpet trim panel from the
lower facia.
6 Untie the string from the end of the cable,
and leave the string in position to aid refitting.

Refitting

7 Refitting is a reversal of removal, but use
the string to pull the cable into position, and
make sure that the cable ball is correctly
located in the bulkhead grommet. Coat the
ball with soapy water to aid refitting. If it
proves difficult to engage the speedometer
cable with the rear of the speedometer,
proceed as follows.

a) Cut the two clips securing the ball/sleeve

assembly to the speedometer cable, and
slide the ball/sleeve down the cable.

b) Push the cable until it engages with the

speedometer, then slide the ball sleeve
into position, and engage it with the
bulkhead grommet.

c) Fit a hose clip or cable-tie to the lower

end of the ball/sleeve to secure it in
position on the cable.

d) If it still proves difficult to engage the cable

with the speedometer, remove the
instrument panel, then carry out the above
procedure, engaging the end of the cable
with the speedometer directly by hand,
before refitting the instrument panel.

16 Wiper arm - 

removal and refitting

1

Removal

1 Operate the wiper motor, then switch it off
so that the wiper arm returns to the at-rest
position.

2 Where applicable, disconnect the washer
fluid hose from the end of the connector on
the scuttle grille panel (see illustration).
3 Lift up the wiper arm spindle nut cover, then

Body electrical system  12•15

14.5  Horn securing nut (arrowed) - viewed

from underneath vehicle

16.2  Disconnect the washer fluid hose

from the connector

13.3  “Lights on” warning buzzer (arrowed)

- models from 1993 (viewed with facia

removed and inverted)

13.2  “Lights on” warning buzzer (arrowed)

- models up to 1992

12

Stick a piece of masking
tape along the edge of the
wiper blade, to use as an
alignment aid on refitting.

slacken and remove the spindle nut (see
illustration). Lift the blade off the glass, and
pull the wiper arm off its spindle. If necessary,
the arm can be levered off the spindle using a
suitable flat-bladed screwdriver.

Refitting

4 With the wiper arm and spindle splines
clean, refit the arm to the spindle. Align the
wiper blade with the tape used on removal.
5 Refit the spindle nut, tightening it securely,
and clip the nut cover back into position.
6 Reconnect the washer fluid hose.

17 Windscreen wiper motor and

linkage - removal and refitting

3

Removal

1 The assembly is located in the scuttle at the
rear of the engine compartment.

2 Disconnect the battery negative lead.
3 Remove the scuttle grille panel as
described in Chapter 11.
4 Where applicable, unscrew the securing
bolts, and withdraw the cover from the motor.
5 Disconnect the motor wiring connector.
6 On models where there is insufficient
clearance for the wiper linkage to pass
between the brake master cylinder and the
scuttle, move the master cylinder to one side
as follows. Remove the nuts securing the
brake master cylinder to the vacuum servo
unit, then lift the master cylinder from the
studs, and pull it back slightly. Do not
disconnect any brake pipes.
7 On models with an electronic control
module housing located in the rear corner of
the engine compartment, which obscures the
end wiper linkage securing bolt, the housing
must be removed as follows. Lift off the
housing cover, then detach the control
modules, and remove the housing. Take great
care not to damage the control modules -
ideally, they should be removed from the
vehicle and stored in a safe place
(alternatively, temporarily refit the housing and
the control modules, once the wiper
mechanism has been removed.
8 Unscrew the nuts securing the motor and
linkage to the scuttle, then manipulate the
assembly out from the engine compartment
(see illustrations).
9 If desired, the motor can be separated from
the linkage after unscrewing the nuts securing
the linkage to the motor spindle, and the three
bolts securing the motor to the mounting
bracket (see illustration).

Refitting

10 Refitting is a reversal of removal.

18 Tailgate wiper motor -

removal and refitting

3

Removal

1 Disconnect the battery negative lead.
2 Remove the wiper arm (see Section 16).
3 Unscrew the large spindle nut, and recover
the washer and seal.
4 Open the tailgate.
5 Remove the screws, and withdraw the
plastic trim panel from inside the tailgate.
6 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.
7 Unscrew the motor bracket securing bolts,
then withdraw the motor assembly from the
tailgate, and disconnect the wiring plug (see
illustration).

Refitting

8 Refitting is a reversal of removal.

19 Washer system 

components - 
removal and refitting

2

Windscreen/headlight 
washer fluid reservoir

Removal

1 The reservoir is located in the right-hand
corner of the scuttle at the rear of the engine
compartment.
2 Disconnect the battery negative lead, then
disconnect the wiring from the fluid pump(s).
3 Unscrew the two securing bolts, and lift the
reservoir from the scuttle.
4 If the reservoir still contains fluid, empty out
the contents into a container, then disconnect
the fluid hose from the pump, and withdraw
the reservoir.

Refitting

5 Refitting is a reversal of removal.

12•16 Body electrical system

16.3  Slackening the wiper arm nut

17.8b  Windscreen wiper linkage 

securing nut (arrowed)

18.7  Tailgate wiper motor securing bolts

(arrowed)

17.9  Wiper motor spindle-to-linkage 

nut (A) and motor securing bolts (B)

17.8c  Withdrawing the windscreen wiper

motor and linkage assembly

17.8a  Windscreen wiper motor 

securing nut (arrowed)