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PEUGEOT 505 Digital Workshop Repair Manual 1979-1993

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🏷️ Basic Information Identification Make: Peugeot Model: 505 Year Range: 1979-1993 Codes Internal Model Code: Type 551 👋 Introduction Market Position Positioning: The Peugeot 505 represented Peugeot's last rear-wheel-drive, body-on-frame saloon, positioned as a comfortable, robust, and spacious executive car, often favored for its blend of French comfort and durability. Competitive Analysis Competitors: Competed against models like the Ford Granada, Vauxhall Carlton/Senator, BMW 5 Series, Mercedes-Benz E-Class, and Volvo 240/740 series in its respective markets. Key Features Manual Advantages: High-quality photos, illustrations, and diagrams; comprehensive A-Z coverage; trusted seller; potential for significant cost savings on service and repairs; easy to use and print. 📋 Manual Details Coverage Areas Primary Coverage: Full Workshop Repair and Maintenance Additional Coverage: Diagnostics, Rebuilding, Refurbishment, Restoration Page Count Estimated Page Count: Extensive (Varies by specific model/engine variant, but implies comprehensive coverage) Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Format: Digital (Viewable and Printable) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (Front Wheel Drive Components, Driveshafts, Differential) Chassis: Suspension (Front & Rear), Steering System, Braking System (Hydraulic, ABS if applicable), Wheels & Tires Electrical: Ignition System, Starting System, Charging System, Lighting System, Instrumentation, Wiper/Washer System, Horn, Power Accessories (Windows, Locks, Seats), Body Control Modules, Wiring Diagrams Body: Body Panels, Doors, Hood, Trunk, Roof, Bumpers, Glass, Interior Trim, Seats, Safety Restraints (Seatbelts) Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-ups, Belt Inspections Repair: Engine Overhaul, Transmission Overhaul, Brake Caliper Rebuild, Suspension Component Replacement, Steering Rack Replacement, Electrical Component Diagnosis and Replacement, Bodywork Repairs Diagnostics: Troubleshooting Guides, Symptom-based Diagnostics, Diagnostic Trouble Codes (if applicable), Electrical System Testing Technical Depth Depth: Comprehensive from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format Compatibility: Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, 7) and macOS Print Quality Printability: Printable individual sections or full manual Binding Type Binding: Digital (No physical binding) Paper Type Paper Type: Digital (No physical paper) ⚙️ Engine Specifications Primary Engine Engine Families: Simca-derived 'Douvrin' (PSA XN), Peugeot's own 'PRV' V6, and later turbodiesel engines (XD series) Performance Horsepower Range: 70 hp (1.8L Diesel) to 166 hp (2.8L V6) Torque Range: 103 lb-ft (1.8L Diesel) to 162 lb-ft (2.8L V6) Fuel System Fuel Delivery: Carburetor (Solex, Weber) or Bosch L-Jetronic/K-Jetronic fuel injection, Diesel Indirect Injection Engine Variants Gasoline: 1.8L (1796cc), 2.0L (1971cc), 2.2L (2155cc), 2.8L V6 (2849cc PRV) Diesel: 1.9L (1905cc Diesel), 1.9L (1905cc Turbodiesel), 2.1L (2112cc Turbodiesel) 🔧 Transmission Standard Manual Transmission: 4-speed and 5-speed manual gearboxes (e.g., MA5, ML4) Optional Automatic Transmission: 3-speed ZF 3HP22 automatic transmission Features Clutch Type: Dry single-plate clutch 📐 Dimensions Exterior Wheelbase: 2,800 mm (110.2 in) Length: 4,705 mm (185.2 in) Width: 1,730 mm (68.1 in) Height: 1,450 mm (57.1 in) Weights Curb Weight: 1,200 - 1,400 kg (2,645 - 3,086 lb) depending on engine and trim 🛡️ Safety Features Ratings Crash Test Results: While official ANCAP/Euro NCAP ratings for this era are scarce, the 505 featured a robust chassis designed for durability and occupant protection by contemporary standards. Active Features Braking System: Front disc brakes, Rear drum brakes (early models) or Rear disc brakes (later models/higher trims). Optional ABS on later models. Passive Features Restraints: Three-point seatbelts (front and rear), optional airbags on very late models. Body Structure: Reinforced safety cage, crumple zones 💡 Technology Features Infotainment Audio System: Factory fitted radios (e.g., Clarion, Blaupunkt) with AM/FM, cassette player. Limited to basic audio functions by modern standards. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on higher trims and later models. Connectivity Connectivity Features: None by modern standards. Limited to factory radio antenna connection. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions and oil type. Timing Belt Replacement: Every 50,000-60,000 miles (80,000-96,000 km) for gasoline engines. Crucial to avoid catastrophic engine damage. Fluid Specifications Engine Oil: API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 5W-40. Check manual for specific engine recommendation. Coolant: Ethylene glycol based, typically a 50/50 mix with distilled water. Peugeot specific coolant may be recommended. Transmission Fluid Manual: API GL-4 SAE 75W-90 or 80W-90 gear oil. Transmission Fluid Automatic: ZF TE-ML 11B specification (e.g., Dexron II/III compatible, but check specific ZF requirements). Known Issues Common Problems: Rust on bodywork (wheel arches, sills), ageing electrical connectors, carburetor issues, wear in suspension bushings, differential whine, cooling system leaks (especially radiators and hoses), potential for gearbox synchromesh wear. Diesel Specific: Glow plug issues, injection pump problems, turbocharger wear on turbodiesel models. 📚 Vehicle History Brand Heritage Peugeot Legacy: Peugeot, founded in 1810, has a long history of innovation and quality in automotive manufacturing, known for its comfortable and reliable vehicles. Model Evolution 505 Development:...
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PEUGEOT 505 Digital Workshop Repair Manual 1979-1993
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
505
Year Range:
1979-1993
Codes
Internal Model Code:
Type 551
👋 Introduction
Market Position
Positioning:
The Peugeot 505 represented Peugeot's last rear-wheel-drive, body-on-frame saloon, positioned as a comfortable, robust, and spacious executive car, often favored for its blend of French comfort and durability.
Competitive Analysis
Competitors:
Competed against models like the Ford Granada, Vauxhall Carlton/Senator, BMW 5 Series, Mercedes-Benz E-Class, and Volvo 240/740 series in its respective markets.
Key Features
Manual Advantages:
High-quality photos, illustrations, and diagrams; comprehensive A-Z coverage; trusted seller; potential for significant cost savings on service and repairs; easy to use and print.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Workshop Repair and Maintenance
Additional Coverage:
Diagnostics, Rebuilding, Refurbishment, Restoration
Page Count
Estimated Page Count:
Extensive (Varies by specific model/engine variant, but implies comprehensive coverage)
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (Viewable and Printable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (Front Wheel Drive Components, Driveshafts, Differential)
Chassis:
Suspension (Front & Rear), Steering System, Braking System (Hydraulic, ABS if applicable), Wheels & Tires
Electrical:
Ignition System, Starting System, Charging System, Lighting System, Instrumentation, Wiper/Washer System, Horn, Power Accessories (Windows, Locks, Seats), Body Control Modules, Wiring Diagrams
Body:
Body Panels, Doors, Hood, Trunk, Roof, Bumpers, Glass, Interior Trim, Seats, Safety Restraints (Seatbelts)
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-ups, Belt Inspections
Repair:
Engine Overhaul, Transmission Overhaul, Brake Caliper Rebuild, Suspension Component Replacement, Steering Rack Replacement, Electrical Component Diagnosis and Replacement, Bodywork Repairs
Diagnostics:
Troubleshooting Guides, Symptom-based Diagnostics, Diagnostic Trouble Codes (if applicable), Electrical System Testing
Technical Depth
Depth:
Comprehensive from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Compatibility:
Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, 7) and macOS
Print Quality
Printability:
Printable individual sections or full manual
Binding Type
Binding:
Digital (No physical binding)
Paper Type
Paper Type:
Digital (No physical paper)
⚙️ Engine Specifications
Primary Engine
Engine Families:
Simca-derived 'Douvrin' (PSA XN), Peugeot's own 'PRV' V6, and later turbodiesel engines (XD series)
Performance
Horsepower Range:
70 hp (1.8L Diesel) to 166 hp (2.8L V6)
Torque Range:
103 lb-ft (1.8L Diesel) to 162 lb-ft (2.8L V6)
Fuel System
Fuel Delivery:
Carburetor (Solex, Weber) or Bosch L-Jetronic/K-Jetronic fuel injection, Diesel Indirect Injection
Engine Variants
Gasoline:
1.8L (1796cc), 2.0L (1971cc), 2.2L (2155cc), 2.8L V6 (2849cc PRV)
Diesel:
1.9L (1905cc Diesel), 1.9L (1905cc Turbodiesel), 2.1L (2112cc Turbodiesel)
🔧 Transmission
Standard
Manual Transmission:
4-speed and 5-speed manual gearboxes (e.g., MA5, ML4)
Optional
Automatic Transmission:
3-speed ZF 3HP22 automatic transmission
Features
Clutch Type:
Dry single-plate clutch
📐 Dimensions
Exterior
Wheelbase:
2,800 mm (110.2 in)
Length:
4,705 mm (185.2 in)
Width:
1,730 mm (68.1 in)
Height:
1,450 mm (57.1 in)
Weights
Curb Weight:
1,200 - 1,400 kg (2,645 - 3,086 lb) depending on engine and trim
🛡️ Safety Features
Ratings
Crash Test Results:
While official ANCAP/Euro NCAP ratings for this era are scarce, the 505 featured a robust chassis designed for durability and occupant protection by contemporary standards.
Active Features
Braking System:
Front disc brakes, Rear drum brakes (early models) or Rear disc brakes (later models/higher trims). Optional ABS on later models.
Passive Features
Restraints:
Three-point seatbelts (front and rear), optional airbags on very late models.
Body Structure:
Reinforced safety cage, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios (e.g., Clarion, Blaupunkt) with AM/FM, cassette player. Limited to basic audio functions by modern standards.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on higher trims and later models.
Connectivity
Connectivity Features:
None by modern standards. Limited to factory radio antenna connection.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions and oil type.
Timing Belt Replacement:
Every 50,000-60,000 miles (80,000-96,000 km) for gasoline engines. Crucial to avoid catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 5W-40. Check manual for specific engine recommendation.
Coolant:
Ethylene glycol based, typically a 50/50 mix with distilled water. Peugeot specific coolant may be recommended.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
ZF TE-ML 11B specification (e.g., Dexron II/III compatible, but check specific ZF requirements).
Known Issues
Common Problems:
Rust on bodywork (wheel arches, sills), ageing electrical connectors, carburetor issues, wear in suspension bushings, differential whine, cooling system leaks (especially radiators and hoses), potential for gearbox synchromesh wear.
Diesel Specific:
Glow plug issues, injection pump problems, turbocharger wear on turbodiesel models.
📚 Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot, founded in 1810, has a long history of innovation and quality in automotive manufacturing, known for its comfortable and reliable vehicles.
Model Evolution
505 Development:
Successor to the Peugeot 504, the 505 was developed as a larger, more modern executive car. It retained the 504's rear-wheel-drive platform and excellent ride comfort but featured updated styling and engineering by Pininfarina.
Production
Production Period:
1979-1992 (Europe), Extended production in other regions (e.g., Argentina until 2000, China).
Manufacturing Locations:
France (Sochaux), UK (Ryton), Finland, Argentina, China, Indonesia, Nigeria, Uruguay
🏆 Awards & Recognition
Recognitions
Domestic Market Awards:
Peugeot 505 was generally well-regarded for its comfort and handling in European automotive press, often praised as a competent European executive car. Specific awards are less prominent than its general positive reception.
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