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Peugeot 505 1979-1993 All Service Repair Manual

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Basic Information Identification Make: Peugeot Model: 505 Model Generation: First Generation Production Years Covered By Manual: 1979-1993 Introduction Market Position Target Audience: DIY car owners, independent mechanics, and enthusiasts seeking to perform repairs and maintenance. Competitive Analysis Value Proposition: Provides comprehensive repair information, enabling cost savings and empowering vehicle owners with technical knowledge. Key Features Self Reliance: Enables independent repair and maintenance, ensuring quality and control over work performed. Cost Effectiveness: Facilitates significant savings by eliminating the need for professional mechanic labor. Accessibility: Instant download provides quick access to repair information for anytime, anywhere use. Manual Details Coverage Areas General Maintenance: True Troubleshooting: True Engine Service Repair: True Transmission Service Repair: True Brake System: True Wiring Diagram: True Electrical System: True Suspension: True Periodic Lubrication: True Steering: True Cooling System: True Fuel Injection Fuel System: True Emission System: True Engine Control System: True Chassis Body: True Restraint System: True Axle: True Page Count Estimated Page Count: Comprehensive (Exact count not specified, but covers all aspects) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered All Major Systems: Covers all major mechanical, electrical, and body systems. Engine Mechanical: Engine block, cylinder head, pistons, crankshaft, camshaft, valve train, timing systems. Transmission Manual: Clutch, gearbox components, shift mechanisms, driveshafts. Transmission Automatic: Torque converter, planetary gearsets, valve body, hydraulic controls. Brake Hydraulic System: Master cylinder, brake lines, wheel cylinders, brake calipers, brake pads, brake shoes, parking brake. Electrical Charging System: Alternator, voltage regulator, battery, wiring harnesses. Electrical Ignition System: Distributor, ignition coil, spark plugs, ignition control module (if applicable). Fuel System Carbureted: Carburetor types (e.g., Solex, Weber), fuel pump, fuel filter, fuel lines. Fuel System Injection: Fuel injectors, fuel pump, fuel pressure regulator, fuel filter, engine control unit (ECU) basic function. Cooling System: Radiator, water pump, thermostat, cooling fans, coolant hoses, expansion tank. Steering System: Steering rack or box, steering column, power steering pump, hoses, tie rods. Suspension Front: MacPherson struts, control arms, ball joints, sway bar. Suspension Rear: Independent rear suspension (IRS) likely with trailing arms, shock absorbers, coil springs. Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, exhaust pipes. HVAC System: Heating and ventilation controls, blower motor, heater core, AC system components (if equipped). Procedures Included Repair Disassembly Reassembly: Detailed instructions for disassembly, reassembly, repair, servicing, and maintenance. Diagnostics Troubleshooting: Includes procedures for diagnosing and troubleshooting common issues. Refurbishment Renovation: Covers procedures for refurbishment and renovation of various components. Engine Rebuild: Detailed steps for engine overhaul, including component specifications and tolerances. Brake Overhaul: Procedures for rebuilding calipers, wheel cylinders, and replacing brake components. Suspension Component Replacement: Detailed instructions for replacing ball joints, tie rods, bushings, and shock absorbers. Electrical Troubleshooting Charts: Systematic approach to diagnosing electrical faults using wiring diagrams. Technical Depth Depth: In-depth, covering intricacies and peculiarities of design and construction. Torque Specifications: Includes crucial torque specifications for critical fasteners across all systems. Special Tools: References to specific Peugeot special tools required for certain procedures. Diagnostic Techniques: Guidance on using diagnostic tools and techniques relevant to the era. Manual Specifications File Format Format: PDF Reader Requirements: Adobe PDF Reader Decompression Requirements: WinZip (or equivalent) Compatibility Operating Systems: All versions of Windows & Mac Print Quality Printability: Printable pages are assumed for offline use. Binding Type Binding: Digital Download (Not applicable) Paper Type Paper Type: Digital Download (Not applicable) Engine Specifications Primary Engine Engine Variants Covered: Likely covers a range of Peugeot-PSA XU and PRV engines used in the 505, including 4-cylinder petrol (e.g., 1.8L, 2.0L, 2.2L) and diesel engines, and V6 PRV variants (e.g., 2.8L). Performance Horsepower Torque Range: Specific figures vary by engine variant, but generally ranged from approximately 70 hp for early diesel models to 136 hp for later 2.2L petrol engines and upwards of 150 hp for V6 variants. Fuel System Fuel Delivery Systems: Likely covers carbureted systems for earlier models and Bosch L-Jetronic or similar fuel injection systems for later models, as well as diesel indirect injection. Engine Maintenance Valve Adjustment: Procedures for valve clearance adjustment, if applicable (e.g., for pushrod engines). Timing Belt Chain: Information on timing belt or chain replacement intervals and procedures. Ignition System: Details on spark plug replacement, ignition timing, and distributor maintenance (for carbureted models). Transmission Standard Transmission Options: Likely covers both manual (e.g., 4-speed, 5-speed) and automatic transmissions. Optional Automatic Transmission Types: Could include ZF 3HP22 or similar automatic gearboxes used by Peugeot during this period. Features Clutch Service: Procedures for clutch replacement and adjustment on manual transmission models. Transmission Fluid Specifications: Recommended transmission fluid types and capacities. Dimensions Exterior Body Styles: Saloon (sedan), Estate (wagon), and potentially Limousine variants. Wheelbase Dimensions: Wheelbase varied slightly by body style but was substantial for its class. Weights Curb Weight Range: Typically ranged from approximately 1200 kg to 1400 kg depending on engine and...
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Peugeot 505 1979-1993 All Service Repair Manual
Basic Information
Identification
Make: Peugeot
Model: 505
Model Generation: First Generation
Production Years Covered By Manual: 1979-1993
Introduction
Market Position
Target Audience: DIY car owners, independent mechanics, and enthusiasts seeking to perform repairs and maintenance.
Competitive Analysis
Value Proposition: Provides comprehensive repair information, enabling cost savings and empowering vehicle owners with technical knowledge.
Key Features
Self Reliance: Enables independent repair and maintenance, ensuring quality and control over work performed.
Cost Effectiveness: Facilitates significant savings by eliminating the need for professional mechanic labor.
Accessibility: Instant download provides quick access to repair information for anytime, anywhere use.
Manual Details
Coverage Areas
General Maintenance: True
Troubleshooting: True
Engine Service Repair: True
Transmission Service Repair: True
Brake System: True
Wiring Diagram: True
Electrical System: True
Suspension: True
Periodic Lubrication: True
Steering: True
Cooling System: True
Fuel Injection Fuel System: True
Emission System: True
Engine Control System: True
Chassis Body: True
Restraint System: True
Axle: True
Page Count
Estimated Page Count: Comprehensive (Exact count not specified, but covers all aspects)
Manual Type
Type: Service and Repair Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
All Major Systems: Covers all major mechanical, electrical, and body systems.
Engine Mechanical: Engine block, cylinder head, pistons, crankshaft, camshaft, valve train, timing systems.
Transmission Manual: Clutch, gearbox components, shift mechanisms, driveshafts.
Transmission Automatic: Torque converter, planetary gearsets, valve body, hydraulic controls.
Brake Hydraulic System: Master cylinder, brake lines, wheel cylinders, brake calipers, brake pads, brake shoes, parking brake.
Electrical Charging System: Alternator, voltage regulator, battery, wiring harnesses.
Electrical Ignition System: Distributor, ignition coil, spark plugs, ignition control module (if applicable).
Fuel System Carbureted: Carburetor types (e.g., Solex, Weber), fuel pump, fuel filter, fuel lines.
Fuel System Injection: Fuel injectors, fuel pump, fuel pressure regulator, fuel filter, engine control unit (ECU) basic function.
Cooling System: Radiator, water pump, thermostat, cooling fans, coolant hoses, expansion tank.
Steering System: Steering rack or box, steering column, power steering pump, hoses, tie rods.
Suspension Front: MacPherson struts, control arms, ball joints, sway bar.
Suspension Rear: Independent rear suspension (IRS) likely with trailing arms, shock absorbers, coil springs.
Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, exhaust pipes.
HVAC System: Heating and ventilation controls, blower motor, heater core, AC system components (if equipped).
Procedures Included
Repair Disassembly Reassembly: Detailed instructions for disassembly, reassembly, repair, servicing, and maintenance.
Diagnostics Troubleshooting: Includes procedures for diagnosing and troubleshooting common issues.
Refurbishment Renovation: Covers procedures for refurbishment and renovation of various components.
Engine Rebuild: Detailed steps for engine overhaul, including component specifications and tolerances.
Brake Overhaul: Procedures for rebuilding calipers, wheel cylinders, and replacing brake components.
Suspension Component Replacement: Detailed instructions for replacing ball joints, tie rods, bushings, and shock absorbers.
Electrical Troubleshooting Charts: Systematic approach to diagnosing electrical faults using wiring diagrams.
Technical Depth
Depth: In-depth, covering intricacies and peculiarities of design and construction.
Torque Specifications: Includes crucial torque specifications for critical fasteners across all systems.
Special Tools: References to specific Peugeot special tools required for certain procedures.
Diagnostic Techniques: Guidance on using diagnostic tools and techniques relevant to the era.
Manual Specifications
File Format
Format: PDF
Reader Requirements: Adobe PDF Reader
Decompression Requirements: WinZip (or equivalent)
Compatibility
Operating Systems: All versions of Windows & Mac
Print Quality
Printability: Printable pages are assumed for offline use.
Binding Type
Binding: Digital Download (Not applicable)
Paper Type
Paper Type: Digital Download (Not applicable)
Engine Specifications
Primary Engine
Engine Variants Covered: Likely covers a range of Peugeot-PSA XU and PRV engines used in the 505, including 4-cylinder petrol (e.g., 1.8L, 2.0L, 2.2L) and diesel engines, and V6 PRV variants (e.g., 2.8L).
Performance
Horsepower Torque Range: Specific figures vary by engine variant, but generally ranged from approximately 70 hp for early diesel models to 136 hp for later 2.2L petrol engines and upwards of 150 hp for V6 variants.
Fuel System
Fuel Delivery Systems: Likely covers carbureted systems for earlier models and Bosch L-Jetronic or similar fuel injection systems for later models, as well as diesel indirect injection.
Engine Maintenance
Valve Adjustment: Procedures for valve clearance adjustment, if applicable (e.g., for pushrod engines).
Timing Belt Chain: Information on timing belt or chain replacement intervals and procedures.
Ignition System: Details on spark plug replacement, ignition timing, and distributor maintenance (for carbureted models).
Transmission
Standard
Transmission Options: Likely covers both manual (e.g., 4-speed, 5-speed) and automatic transmissions.
Optional
Automatic Transmission Types: Could include ZF 3HP22 or similar automatic gearboxes used by Peugeot during this period.
Features
Clutch Service: Procedures for clutch replacement and adjustment on manual transmission models.
Transmission Fluid Specifications: Recommended transmission fluid types and capacities.
Dimensions
Exterior
Body Styles: Saloon (sedan), Estate (wagon), and potentially Limousine variants.
Wheelbase Dimensions: Wheelbase varied slightly by body style but was substantial for its class.
Weights
Curb Weight Range: Typically ranged from approximately 1200 kg to 1400 kg depending on engine and body style.
Safety Features
Ratings
Crash Test Data: Contemporary crash test data might be limited, but the manual would cover safety systems like seatbelts and their maintenance.
Active Features
Braking System Type: Front ventilated discs and rear drums, with later models potentially featuring all-around discs on higher trims.
Passive Features
Seatbelts: Information on seatbelt operation, adjustment, and replacement.
Technology Features
Infotainment
Audio System: Basic AM/FM radio with cassette player, often with optional upgraded speakers.
Driver Assistance
Power Steering: Hydraulic power steering was common on most variants.
Connectivity
Diagnostic Ports: Early OBD (On-Board Diagnostics) systems were rudimentary or non-existent, with troubleshooting relying on visual inspection and multimeter readings.
Maintenance
Service Intervals
Oil Change Interval: Typically 5,000-10,000 km (3,000-6,000 miles) or annually, depending on driving conditions and oil type.
Spark Plug Replacement: Varies by engine type, but generally every 20,000-30,000 km (12,000-18,000 miles).
Fluid Specifications
Engine Oil Specification: Likely SAE 10W-40 or 15W-40 API SE/SF or higher, depending on climate and engine type. Specific PSA approvals would be detailed.
Coolant Specification: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific Peugeot coolant types would be listed.
Brake Fluid Specification: DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items: Potential issues can include wear on suspension bushings, aging rubber hoses and seals, and issues related to older electronic fuel injection systems. Rust can be a concern on older body panels.
Engine Idling Problems: Can occur with carburetor adjustments or fuel injection system components on higher mileage vehicles.
Vehicle History
Brand Heritage
Peugeot Heritage: Peugeot, a historic French manufacturer known for comfortable and robust sedans.
Model Evolution
505 Development: Developed as the successor to the Peugeot 504, featuring a more modern design and technology, while retaining its predecessor's reputation for comfort and durability.
Production
Manufacturing Locations: Primarily manufactured in France (Sochaux), but also produced or assembled in other countries including Argentina, Nigeria, and China under license.
Production Span: 1979 to 1992 in Europe, with extended production in other markets continuing until the early 2000s.
Awards & Recognition
Recognitions
Industry Acclaim: While specific awards might be hard to pinpoint, the 505 was generally praised for its comfort, handling, and build quality in its era, continuing the Peugeot 504's legacy.
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