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Peugeot 504 1968-1983 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 504 Production Years: 1968-1983 👋 Introduction Market Position Positioning: The Peugeot 504 was positioned as a robust, comfortable, and reliable family sedan/coupe/wagon, known for its durability and excellent ride quality, especially in its early years. Competitive Analysis Competitors: Competed against vehicles like the Ford Cortina, Opel Rekord, Renault 16, and Fiat 131 Mirafiori in its respective markets. Key Features Design: Designed by Pininfarina, giving it elegant and timeless styling that aged well. Ride Comfort: Renowned for its exceptional ride comfort, thanks to its sophisticated suspension system, particularly the independent rear suspension (IRS) found in most versions. Durability: Built to last, with a reputation for mechanical robustness and resistance to corrosion in many markets. Versatility: Available in various body styles including sedan, coupe, convertible, estate (wagon), and pickup truck, catering to a wide range of needs. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and troubleshooting for all systems. Page Count Estimated Page Count: Hundreds of pages (specific number not provided, but described as 'hundreds'). Manual Type Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description, typical for downloaded manuals). Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed information on all engine variants (petrol and diesel), including disassembly, assembly, troubleshooting, and overhaul procedures. Fuel System: Carburetor and fuel injection systems (as applicable to specific models), fuel pump, fuel lines, and tank service. Ignition System: Spark plugs, coils, distributor, ignition timing, and troubleshooting of ignition faults. Cooling System: Radiator, water pump, thermostat, cooling fan, hoses, and troubleshooting of overheating issues. Exhaust System: Exhaust manifolds, pipes, mufflers, and catalytic converters (if applicable). Transmission: Manual and automatic transmission overhaul, maintenance, clutch operation, and driveshafts. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, and alignment specifications. Steering: Steering gearbox, tie rods, steering column, power steering system (if equipped), and troubleshooting. Brakes: Front and rear brake systems (disc and drum), master cylinder, brake lines, calipers, wheel cylinders, and parking brake. Electrical System: Battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, and diagnostic procedures. Bodywork: Body panel repair, door mechanisms, window regulators, locks, hinges, and exterior trim. Chassis: Frame and chassis component inspection, repair, and specifications. Heating Ventilation Air Conditioning: HVAC system components, blower motor, heater core, and ventilation controls. Interior: Seat mechanisms, dashboard components, and interior trim. Procedures Included Maintenance: Regular servicing, oil changes, filter replacements, fluid checks, lubrication, and tune-up procedures. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common problems across all systems. Repair: Detailed step-by-step repair instructions for component replacement and overhaul. Rebuilding: Complete engine, transmission, and other major component rebuilding procedures. Adjustment: Adjustment procedures for carburetor, ignition timing, brakes, and other critical components. Installation: Instructions for installing new or replacement parts. Technical Depth Depth: Professional-level detail, suitable for both novice DIYers and experienced mechanics. Diagrams Illustrations: Hundreds of detailed photos and exploded diagrams for clear visual guidance. Specifications: Includes torque specifications, clearances, fluid capacities, and other critical technical data. 📊 Manual Specifications File Format Format: PDF Compatibility: Fully compatible with Windows and MAC computers. Accessibility: Instant download for use on computer, tablet, or smartphone. Usage Rights: Unlimited usage on multiple devices; no expiry dates or renewal fees. Printability: Printable pages (single or entire manual). Print Quality Quality: High-resolution PDF ensuring clear display of text and images. Binding Type Binding: N/A (Digital PDF format, no physical binding). Paper Type Paper: N/A (Digital PDF format, no physical paper type). ⚙️ Engine Specifications Primary Engine Engine Options Overview: The 504 was offered with a range of Peugeot's durable XN/XL/XR/XD series engines. These included petrol (OHC) and diesel engines. Petrol Engine Variants: Common petrol engines included the 1.6L (1595cc), 1.8L (1796cc), and 2.0L (1971cc) inline-four cylinders. Later models also featured fuel injection. Diesel Engine Variants: Offered with 1.9L (1948cc) and 2.1L (2112cc) diesel engines, known for their economy and longevity. Performance Horsepower Range: Horsepower varied significantly based on engine size and configuration, typically ranging from around 70 hp for base diesel models to over 100 hp for larger petrol engines, and up to 130-140 hp for performance variants like the 504 Ti. Torque Range: Torque figures also varied, with diesel engines providing higher torque at lower RPMs, suitable for cruising and towing. Fuel System Carburetor Types: Typically equipped with Solex, Weber, or Zenith carburetors, depending on the engine and market. Fuel injected models (e.g., 504 Ti) used Bosch or similar injection systems. Fuel Type: Unleaded gasoline (later models) and Diesel fuel. 🔧 Transmission Standard Standard Transmission: Most models were initially equipped with a 4-speed manual transmission. A 5-speed manual was also available on some variants. Optional Optional Transmission: A 3-speed automatic transmission (often a BorgWarner or ZF unit) was an option on many petrol models. Features Clutch Type: Single dry plate clutch for manual transmissions. Driveshaft...
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Sku: 203957
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Peugeot 504 1968-1983 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
504
Production Years:
1968-1983
👋 Introduction
Market Position
Positioning:
The Peugeot 504 was positioned as a robust, comfortable, and reliable family sedan/coupe/wagon, known for its durability and excellent ride quality, especially in its early years.
Competitive Analysis
Competitors:
Competed against vehicles like the Ford Cortina, Opel Rekord, Renault 16, and Fiat 131 Mirafiori in its respective markets.
Key Features
Design:
Designed by Pininfarina, giving it elegant and timeless styling that aged well.
Ride Comfort:
Renowned for its exceptional ride comfort, thanks to its sophisticated suspension system, particularly the independent rear suspension (IRS) found in most versions.
Durability:
Built to last, with a reputation for mechanical robustness and resistance to corrosion in many markets.
Versatility:
Available in various body styles including sedan, coupe, convertible, estate (wagon), and pickup truck, catering to a wide range of needs.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, and troubleshooting for all systems.
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as 'hundreds').
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description, typical for downloaded manuals).
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed information on all engine variants (petrol and diesel), including disassembly, assembly, troubleshooting, and overhaul procedures.
Fuel System:
Carburetor and fuel injection systems (as applicable to specific models), fuel pump, fuel lines, and tank service.
Ignition System:
Spark plugs, coils, distributor, ignition timing, and troubleshooting of ignition faults.
Cooling System:
Radiator, water pump, thermostat, cooling fan, hoses, and troubleshooting of overheating issues.
Exhaust System:
Exhaust manifolds, pipes, mufflers, and catalytic converters (if applicable).
Transmission:
Manual and automatic transmission overhaul, maintenance, clutch operation, and driveshafts.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, and alignment specifications.
Steering:
Steering gearbox, tie rods, steering column, power steering system (if equipped), and troubleshooting.
Brakes:
Front and rear brake systems (disc and drum), master cylinder, brake lines, calipers, wheel cylinders, and parking brake.
Electrical System:
Battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, and diagnostic procedures.
Bodywork:
Body panel repair, door mechanisms, window regulators, locks, hinges, and exterior trim.
Chassis:
Frame and chassis component inspection, repair, and specifications.
Heating Ventilation Air Conditioning:
HVAC system components, blower motor, heater core, and ventilation controls.
Interior:
Seat mechanisms, dashboard components, and interior trim.
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, fluid checks, lubrication, and tune-up procedures.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common problems across all systems.
Repair:
Detailed step-by-step repair instructions for component replacement and overhaul.
Rebuilding:
Complete engine, transmission, and other major component rebuilding procedures.
Adjustment:
Adjustment procedures for carburetor, ignition timing, brakes, and other critical components.
Installation:
Instructions for installing new or replacement parts.
Technical Depth
Depth:
Professional-level detail, suitable for both novice DIYers and experienced mechanics.
Diagrams Illustrations:
Hundreds of detailed photos and exploded diagrams for clear visual guidance.
Specifications:
Includes torque specifications, clearances, fluid capacities, and other critical technical data.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Fully compatible with Windows and MAC computers.
Accessibility:
Instant download for use on computer, tablet, or smartphone.
Usage Rights:
Unlimited usage on multiple devices; no expiry dates or renewal fees.
Printability:
Printable pages (single or entire manual).
Print Quality
Quality:
High-resolution PDF ensuring clear display of text and images.
Binding Type
Binding:
N/A (Digital PDF format, no physical binding).
Paper Type
Paper:
N/A (Digital PDF format, no physical paper type).
⚙️ Engine Specifications
Primary Engine
Engine Options Overview:
The 504 was offered with a range of Peugeot's durable XN/XL/XR/XD series engines. These included petrol (OHC) and diesel engines.
Petrol Engine Variants:
Common petrol engines included the 1.6L (1595cc), 1.8L (1796cc), and 2.0L (1971cc) inline-four cylinders. Later models also featured fuel injection.
Diesel Engine Variants:
Offered with 1.9L (1948cc) and 2.1L (2112cc) diesel engines, known for their economy and longevity.
Performance
Horsepower Range:
Horsepower varied significantly based on engine size and configuration, typically ranging from around 70 hp for base diesel models to over 100 hp for larger petrol engines, and up to 130-140 hp for performance variants like the 504 Ti.
Torque Range:
Torque figures also varied, with diesel engines providing higher torque at lower RPMs, suitable for cruising and towing.
Fuel System
Carburetor Types:
Typically equipped with Solex, Weber, or Zenith carburetors, depending on the engine and market. Fuel injected models (e.g., 504 Ti) used Bosch or similar injection systems.
Fuel Type:
Unleaded gasoline (later models) and Diesel fuel.
🔧 Transmission
Standard
Standard Transmission:
Most models were initially equipped with a 4-speed manual transmission. A 5-speed manual was also available on some variants.
Optional
Optional Transmission:
A 3-speed automatic transmission (often a BorgWarner or ZF unit) was an option on many petrol models.
Features
Clutch Type:
Single dry plate clutch for manual transmissions.
Driveshaft Type:
Rear-wheel drive (RWD).
📐 Dimensions
Exterior
Length:
Approximately 4480 - 4670 mm depending on body style and specific year.
Width:
Approximately 1670 - 1720 mm.
Height:
Approximately 1420 - 1470 mm.
Weights
Curb Weight:
Ranged from approximately 1100 kg to 1400 kg depending on body style and engine.
🛡️ Safety Features
Ratings
Safety Features Overview:
While Euro NCAP ratings were not standard for this era, the 504 was known for its robust body structure for its time. Later models incorporated some passive safety improvements.
Active Features
Brakes:
Front disc brakes, rear drum brakes. Some later or higher-spec models may have offered four-wheel disc brakes.
Passive Features
Seatbelts:
Seat belts (often front lap/shoulder belts, rear lap belts) were standard, with later models likely featuring improved restraint systems.
Body Construction:
Reinforced safety cage and crumple zones (for its era).
💡 Technology Features
Infotainment
Radio:
Factory fitted or dealer installed radios were common, typically AM/FM, with later models offering cassette players.
Driver Assistance
Features:
No advanced driver-assistance systems (ADAS) were present in this era. Features were limited to basic operational controls.
Connectivity
Features:
No modern connectivity features such as Bluetooth or USB ports were integrated into the original design.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 km (3,000-5,000 miles) or 6-12 months, depending on driving conditions and oil used. Check manual for specific recommendations.
Tune Up Intervals:
Spark plugs, points, and condenser (if applicable) may require checking/replacement every 10,000-20,000 km (6,000-12,000 miles).
Timing Belt Chain:
Most 504 engines utilized timing chains, which are generally designed for the life of the engine but may require tensioner adjustment or replacement at higher mileages. Some later OHV engines might have used belts.
Fluid Specifications
Engine Oil:
Viscosity grades like 10W-40 or 20W-50 were common for petrol engines. Diesel engines might have preferred 15W-40 or 20W-50 diesel-specific oils. Consult manual for exact API/ACEA specifications.
Coolant:
A mixture of antifreeze (ethylene glycol based) and distilled water, typically a 50/50 ratio. Specific antifreeze type compatibility is crucial.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, typically 75W-90 or 80W-90 viscosity. Manual mentions specific Peugeot grades.
Transmission Fluid Automatic:
ATF (Automatic Transmission Fluid) – specific type (e.g., Dexron II or equivalent) will be detailed in the manual.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Always use fresh, sealed fluid.
Known Issues
Rust:
Common for vehicles of this era, particularly wheel arches, sills, and floor pans. Early models had better rust protection than some later ones.
Carburetor Issues:
Carburetors can become gummed up over time and require cleaning or rebuilding. Idle speed and mixture adjustments are common maintenance tasks.
Electrical Gremlins:
Aging wiring harnesses, corroded connectors, and failing components (e.g., switches, relays) can lead to intermittent electrical issues.
Suspension Wear:
Bushings, ball joints, and tie rod ends can wear out, leading to poor handling and uneven tire wear. The IRS can require attention to its pivot points.
Engine Mounts:
Worn engine and transmission mounts can cause vibration and excessive movement.
📚 Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot has a long history of producing durable, comfortable, and stylish vehicles, and the 504 embodies these characteristics.
Model Evolution
Facelifts Updates:
The 504 underwent several facelifts and updates throughout its long production run, including revised grilles, bumpers, lighting, and interior trim to keep it contemporary.
International Production:
Produced in France, but also widely manufactured under license in various countries, including Argentina, Kenya, Nigeria, and China, extending its lifespan and availability globally.
Production
Production Duration:
A remarkable 38-year production run for the original design, with some variants continuing production into the early 2000s in certain markets.
🏆 Awards & Recognition
Recognitions
European Car Of The Year:
While the 504 did not win European Car of the Year, it was highly regarded for its design and comfort, and its direct predecessor, the Peugeot 404, did win in 1969.
Reliability Awards:
The 504 consistently ranked high in reliability surveys in its class during the 1970s and early 1980s, particularly its diesel variants which were lauded for longevity.
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