Peugeot fuel gage indicator Phenomenon

This is how a fuel pump looks like. There are several types for different models of make but all performing the same purpose. They are immersed in the fuel tank which is right under the rear passenger seat.





The thin film resistor with the float assy will provide fuel level signal to the meter at the dashboard. This carbon film resistor wears out over time and will give you the "swing" effect thus inaccuracies.

I have not found a replacement part for this as I believed ( I could be wrong ) it comes together with the fuel pump unit.

Peugeot 406 Rear 3rd Brake light

There are many questions as to the versions of the Rear 3rd Brake light. Is it LEDs or using the old filament bulbs. Well, there are 2 types actually.

For the benefit of all I have the pics of both. They both have their advantages and disadvantages. I personally like the LEDs ones as they consume less power and doesn't generate that much heat. The filament bulbs produces brighter light causing more heat that could warp the red plastic casing.

To replace the LEDs needs a little "spanner" know how. One will need to de-solder the burnt out LEDs and replace them using super bright ones which can be bought from electrical spare parts shops inexpensively.

As for the filament bulds replacement, it's easier by just pulling them off the housing and inserting them.

Both of the above requires careful removal of the whole light unit that are mounted on the roof. If you are not careful, you could break the whole casing. So do it with "passion"

Sunday Fun Drive

It starter out early at 9 am on the 8th Jul 07 at Seberang Jaya Mosque. A short briefing and the route map were given out.















The Road is wet. Probably just after a downpour. But the view of the surrounding green hills with low hanging clouds gives you a relaxing feel coupled with cabin temperature set at 23 degrees, IT IS COMFORTABLE !!!

I was going a bit too fast and did not get a better view of the bridge. But anyway, here it is. Maybe will do better next time.

I was following a Honda Stream that was going fast too. Here again the view gives you a sense of WoW feeling.

As we convoy into Lenggong. Notice the straight road infront ? Just too bad it's a double white line all the way .

Sunday Fun Drive

A group of us decided take drive along the scenic Kulim - Grik highway. Will update the photos soon. But here is the Planned scheduled. I have also pasted the rough Map of the route we will be taking.( courtesy of Ooifa )

9.00 am: Start off from Seberang Jaya Mosque , use the BW Kulim Expressway Distance abt 20km toll RM 2.60

9.15 - 10.15am : Kulim to Grik . Distance 115Km , time estimate 1 hr, toll free

10.15 - 10.45am : Teh Tarik at Grik Batu 2 R&R 10.45am -2pm : Grik to Kuala Kangsar ( abt 94Km ) Along the way,suggest to visit the "Perak Man"(who should be 10,000 years old if still alive) at Muzium Arkeologi Lenggong. estimate to spend 1 hr there.Brief stopover at the Tasik Raban Resort before the Raja Muda Nazrin Bridge.Then have lunch at Sauk/Sauk New Village. Halal: Ikan Bakar. Non Syriah compliance: Steam fresh water fish at seafood restaurant.air liur meleleh woh!Eat durian as dessert. Buy Ikan Perkasam (local delicacy)

2pm - 3pm : Kuala Kangsar - JURU by Plus Highway . Distance abt 100km, toll RM13.60

3pm : High tea at Juru Autocity

406 Cabin temperature Sensor Unit

If your cabin temperature goes haywire, this guy could be the culprit. The temp sensor is located above the head where the reading lights is located. The IR open/close door tx/rx is also housed there.

Took out the temp sensor unit and cleaned. Dirt was wrapping the sensor thus the feedback wasn't that responsive. It has a small dc fan that will suck in cabin air while the thermister will sense the temp which provide feedback signals to control the hot/cold air flap to mix the set/desired temperature. After cleaning the thermister and the fan fins, the unit now is more responsive.


Damp/moist Cotton bud will do the trick. This is quite an easy task.

The Motor spins better and the thermister senses better now.


Happy Motoring..........

2 Flush or not 2 Flush ?

There is this hot debate regarding the 406 Gearbox - ZF 4HP20.

One school of though felt that flushing will improve gearbox functionalities as all the smug, slug and "impurities" will be flushed out and thus will keep the GB in optimum state.

Another school of thought think otherwise. Flushing will actually cause more harm than good. This is due to the Gearbox ATF filter also known as "Main Pick Up" is made of materials that filters very fine debris. It's so fine that flushing would not help as it will actually clog the filter faster.

here is the picture of the ATF Filter.

Another angle.

The Filter material.


Now, the questions is 2 Flush or not 2 Flush ..??

The choice is yours .....

Rejuvenating 405 - Cooling coil replacement

My 405 is already 12yrs old. Mileage passed 200K km. Engine still in excellent condition. Recently did a "dashboard down" due to Aircond cooling coil sprung a leak. With the dashboard down, replaced new heater matrix. Now, despite being a dozen yr old, she is still able to set comfortable cabin temperature. It's climatic controls function still works !!!

Here are some of the pics I capture for references as to what is behind the dashboard.


This is how the firewall looks like.


The cooling coil are practically blocked and the airflow are "weak"
It was actually worst than this as some of the "biscuit of mud" actually dropped-off before this pic is taken.

This is part of the cooling coil assy. This shows how the airflow from the blower motor to the cooiling coil. So sometimes when we have foul smells, weak airflow, not cold enough, it's most probably the cooling coil is blocked !!. I am still trying to figure out a way to clean the cooling coil without having to remove the dashboard.. it's possible .... maybe some of you out there can come up with a better toolings/gadgets to make it easier.


This is where the flap motor that controls the hot/cold air mixing for the "desired" temperature.

adious amigo for now

External Air Ventilation Motor for 405/406

Hi Guys,
This is how a Ventilation Motor unit looks like. It is use for opening and closing the Vent for 405 and 406. Probably also use for others models and makes. It is basically a DC drive motor and the plastic gear will wear out after sometime. For those who are into DIY, then getting the unit out is a bit of a challenge. Servicing the motor should be simple enough.

Repalcement parts can be obtain from discarded toys especially the gears. Use silicon grease to lubricate and this motor should be good for at least another 5 years.

Observe the arrow indicating it's position when reinstalling it back.

Inside view of the gear set up.

This damn plastic gear that wears off easily.

Replacement gear from my children's discard toys.

This unit is located just above the glovebox. Removing the glovebox for 406 is easier. Just pull the 2 plastic pin at the hinges at the glove box. For the 405, would be very tedious.

The Vent motor has one brown connector plug & 2 x screws holding it on.Watch and observe the small plastic gear that attaches the motor to the flap, Have a look at how it goes together before taking the 2 x screws out.

Happy Motoring....

Most sought after logo in Malaysia

This will be the most sought after logo in Malaysia with the launching of the new beAstari. Take a look .. isn't this look nice ?

Mono Point Injection

Hi Guys,
My 405SR was converted from Carburetor setup to Monopoint injection system. This conversion is nice in a way as I get to use back my Xu9 engine which is still in good condition despite it had aready clocked 200000km. My Carb was leaky and looks like the way to rejuvenate it, conversion was the way to go. What is evident after the conversion was the fact that the idling is consistent while I save on fuel with more predictable power.

What I have "lost" was the Carby and the manifold, fuel pump, dizzy+ignition amp, flywheel,SR rpm meter, wire harness and ++.

What I have gained was ECU,Flywheel with speed sensor, Manifold + injector unit,fuel pump in the fuel tank,RPM meter,wire harness,O2 sensor,Map sensor ++

Here is the picture that might say it all.


Here is the birdeye view of the new setup.

regards