Peugeot 405 Haynes (petrol). Manual - part 16
15 Exhaust manifold - removal
and refitting
3
Removal
1 Disconnect the hot-air inlet hose from the
manifold shroud and remove it from the
vehicle (see illustration).
2 Slacken and remove the retaining screws,
and remove the shroud from the top of the
exhaust manifold (see illustration).
3 On TU engine models apply the handbrake
then jack up the front of the vehicle and
support on axle stands (see “Jacking and
Vehicle Support”).
4 Undo the nuts/bolts securing the exhaust
front pipe to the manifold, then remove the
bolt securing the front pipe to its mounting
bracket. Disconnect the front pipe from the
manifold, and where applicable recover the
gasket.
5 Where fitted, loosen the clamp nuts and
release the power-assisted steering and
coolant pipes from the brackets (see
illustration).
6 Undo the retaining nuts securing the
manifold to the head (see illustration).
Manoeuvre the manifold out of the engine
compartment, and discard the manifold
gaskets.
Refitting
7 Refitting is the reverse of the removal
procedure, noting the following points:
a) Examine all the exhaust manifold studs for
signs of damage and corrosion; remove
all traces of corrosion, and repair or
renew any damaged studs.
b) Ensure that the manifold and cylinder
head sealing faces are clean and flat, and
fit the new manifold gaskets (see
illustration). Tighten the manifold
retaining nuts to the specified torque.
c) Reconnect the front pipe to the manifold
using the information given in Section 16.
16 Exhaust system -
general information, removal
and refitting
3
General information
1 The exhaust system sections are joined by
flanged joints or clamped cone joints. Except
on TU engines the manifold to downpipe joint
is of the spring-loaded ball type, to allow for
movement in the exhaust system. On TU
engines the spring-loaded joint is located at
the rear of the front pipe. On early models
earth straps are fitted between the underbody
and the exhaust system (see illustration).
2 The system is suspended throughout its
entire length by rubber mountings.
Removal
3 Each exhaust section can be removed
individually, or alternatively, the complete
system can be removed as a unit. Even if only
one part of the system needs attention, it is
often easier to remove the whole system and
separate the sections on the bench.
4 To remove the system or part of the
system, first jack up the front or rear of the car
and support it on axle stands (see “Jacking
and Vehicle Support”). Alternatively, position
the car over an inspection pit or on car ramps.
Front pipe
5 Undo the nuts/bolts securing the front pipe
flange joint to the manifold, and the single bolt
securing the front pipe to its mounting
bracket. Separate the flange joint and collect
the gasket or spring cup and springs.
6 Slacken and remove the nuts from the front
pipe rear flange joint, and recover the clamp
or spring cups and springs. Withdraw the
front pipe from underneath the vehicle, and
recover the gasket.
Front pipe extension
7 Undo the nuts from the front pipe rear
flange joint, and the clamp bolts from the
extension pipe rear joint.
8 Withdraw the extension from under the
vehicle and recover the gaskets.
Intermediate pipe
9 Undo the clamp bolts at each end of the
intermediate pipe, then remove the pipe from
under the vehicle.
Centre silencer
10 Slacken the clamping ring bolts and
disengage the clamps from the front and rear
flange joints.
4A•10 Fuel/exhaust systems - carburettor models
15.1 Remove the hot-air intake hose . . .
15.5 Power-assisted steering and coolant
pipe clamps (arrowed)
(XU injection engine shown)
16.1 Exhaust-to-floor panel earth strap
fitted to early models
15.7 New gaskets fitted to the exhaust
ports on the cylinder head (XU engine)
15.6 The exhaust manifold retaining nuts
(TU engine)
15.2 . . . then undo the three retaining
screws (arrowed) and remove the exhaust
manifold shroud (TU engine)