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PEUGEOT 505 Service Repair Manual 1979-1993
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Basic Information Identification Make: Peugeot Model: 505 Codes Model Code: 505 Series Introduction Market Position Market Position: The Peugeot 505 was a large family car positioned as a comfortable and...
Type: Cars
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| Basic Information | |
| Identification | |
| Make: | Peugeot |
| Model: | 505 |
| Codes | |
| Model Code: | 505 Series |
| Introduction | |
| Market Position | |
| Market Position: | The Peugeot 505 was a large family car positioned as a comfortable and robust European sedan and estate, often competing with models like the Ford Scorpio, Renault 25, and Volkswagen Passat in its segment. |
| Competitive Analysis | |
| Competitive Analysis: | Known for its distinctive Pininfarina styling, rear-wheel drive platform (unique in its class for much of its life), and a focus on ride comfort and durability, the 505 offered a compelling alternative to front-wheel-drive rivals. |
| Key Features | |
| Key Features: | Rear-wheel drive chassis, strong engine options (including diesel), spacious interior, elegant styling, and a reputation for build quality. Available as a sedan and an estate (station wagon). |
| Manual Details | |
| Coverage Areas | |
| Years Covered: | 1979-1993 |
| Page Count | |
| Page Count: | Hundreds of pages |
| Manual Type | |
| Manual Type: | Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Comprehensive coverage including gasoline and diesel variants, engine assembly, disassembly, diagnostics, tuning, and component replacement. |
| Fuel System: | Carburetor systems (Zenith, Solex), fuel injection systems (Bosch L-Jetronic, K-Jetronic on later models), fuel pumps, lines, tanks, and emissions control. |
| Cooling System: | Radiator, fan systems (mechanical and electric), water pump, thermostat, hoses, and coolant specifications. |
| Exhaust System: | Exhaust manifold, catalytic converter (where applicable), mufflers, pipes, and emissions regulations. |
| Transmission: | Manual and automatic transmission overhauls, fluid changes, clutch service, gear shift mechanisms, and torque converter diagnostics. |
| Drivetrain: | Front-wheel drive system, differential, driveshafts, CV joints, and wheel bearings. |
| Suspension: | Front MacPherson struts, rear trailing arms, shock absorbers, springs, control arms, bushings, and alignment specifications. |
| Steering: | Power steering system, steering rack, tie rods, steering column, and linkage. |
| Brakes: | Front disc brakes, rear drum or disc brakes, hydraulic system, master cylinder, brake lines, calipers, pads, shoes, and parking brake. |
| Electrical System: | Wiring diagrams, battery, alternator, starter motor, lighting systems, ignition system, fuses, relays, and diagnostics. |
| Climate Control: | HVAC system, heater core, blower motor, air conditioning system (if equipped), refrigerant handling, and controls. |
| Body And Chassis: | Body panels, doors, windows, locks, interior trim, chassis components, and rust prevention. |
| Body Electronics: | Wiper system, horn, power windows, central locking (if equipped). |
| Procedures Included | |
| Maintenance: | Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid replacement, and general inspection procedures. |
| Repair: | Step-by-step instructions for component removal, installation, and repair across all major vehicle systems. |
| Troubleshooting: | Diagnostic flowcharts, common problem identification, and solutions for various mechanical and electrical issues. |
| Rebuilding: | Detailed instructions for engine, transmission, and carburetor rebuilding. |
| Refurbishment: | Guidance on restoring and refurbishing components for longevity and optimal performance. |
| Technical Depth | |
| Depth: | Comprehensive, ranging from basic scheduled maintenance to complex engine rebuilds and electrical system diagnostics. |
| Manual Specifications | |
| File Format | |
| File Format: | Searchable PDF |
| Print Quality | |
| Print Quality: | High-resolution scans suitable for clear printing. |
| Binding Type | |
| Binding Type: | N/A (Digital PDF) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Gasoline Engines: | 1.8L (XN1), 2.0L (XN6, RG2), 2.2L (ZDJ, PRV V6 - in some markets). |
| Diesel Engines: | 2.1L (XD2 diesel), 2.3L (XD3 diesel, XD3T turbodiesel). |
| Performance | |
| Horsepower Range: | Approximately 70 hp (naturally aspirated diesel) to 130 hp (V6 gasoline) and up to 160 hp for later turbodiesel models. |
| Torque Range: | Varies significantly by engine, with diesel variants offering strong low-end torque suitable for cruising and towing. |
| Fuel System | |
| Fuel Injection: | Bosch L-Jetronic and K-Jetronic systems were used on later gasoline models for improved efficiency and performance. |
| Transmission | |
| Standard | |
| Manual Transmission: | 4-speed and 5-speed manual transmissions were common, with a 5-speed often being standard on higher trims or later models. |
| Optional | |
| Automatic Transmission: | 3-speed and 4-speed ZF automatic transmissions were available as options. |
| Features | |
| Transmission Fluid: | Specific ATF (Automatic Transmission Fluid) types are required for automatic gearboxes, and manual gearboxes use GL-4 or GL-5 gear oil. |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approx. 2,800 mm (110.2 in) |
| Length: | Approx. 4,785 mm (188.4 in) |
| Width: | Approx. 1,740 mm (68.5 in) |
| Height: | Approx. 1,460 mm (57.5 in) |
| Weights | |
| Curb Weight: | Varies by model and engine, typically 1,200 kg to 1,400 kg. |
| Safety Features | |
| Ratings | |
| Crash Test Results: | While specific official ratings for all years are scarce, the 505 was built to contemporary European safety standards of its era. Later models benefited from passive safety improvements. |
| Active Features | |
| Brakes: | Four-wheel disc brakes were available on higher-spec models, offering superior stopping power. |
| Passive Features | |
| Seat Belts: | Standard seat belts; pre-tensioners may be present on later models. |
| Body Structure: | Reinforced safety cage and crumple zones designed to absorb impact energy. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Basic radio/cassette systems were standard. Higher trims might have featured more advanced sound systems of the era. |
| Driver Assistance | |
| ABS: | Anti-lock Braking System (ABS) became available on higher-specification models in the later years of production. |
| Connectivity | |
| Connectivity Features: | Limited by era; primarily mechanical and electrical systems. No modern infotainment or Bluetooth connectivity. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically every 5,000-10,000 km (3,000-6,000 miles), depending on driving conditions and oil type. |
| Transmission Fluid Change: | Manual transmission fluid: Inspect every 20,000 km, change as needed. Automatic transmission fluid: Typically every 40,000-60,000 km. |
| Spark Plug Replacement: | Varies by engine and plug type, generally 20,000-40,000 km. |
| Fluid Specifications | |
| Engine Oil: | API SG or SH, viscosity typically 10W-40 or 15W-50, though specific engine requirements vary (check manual for precise spec). |
| Coolant: | Ethylene glycol-based coolant with anti-corrosion additives. Specific Peugeot recommendations should be followed. |
| Brake Fluid: | DOT 3 or DOT 4 brake fluid. |
| Known Issues | |
| Rust: | Common on older vehicles, particularly wheel arches, sills, and door bottoms. Regular inspection and treatment are recommended. |
| Electrical Connectors: | Corrosion or degradation of electrical connectors can lead to intermittent faults in various systems. |
| Fuel System: | Carburetor issues (clogging, adjustment problems) and aging fuel lines are common maintenance points. |
| Suspension Bushings: | Wear in suspension bushings can lead to degraded handling and noise. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Peugeot, a French automotive manufacturer with a history dating back to 1810, is known for its diverse range of vehicles, often emphasizing ride comfort, build quality, and innovative engineering. |
| Model Evolution | |
| Model Evolution: | The 505 succeeded the 504. It was designed by Pininfarina and introduced in 1979. It underwent several facelifts and updates throughout its production run, including engine upgrades and styling tweaks, particularly in the early 1980s and towards its end of production. |
| Production | |
| Production Years: | 1979-1992 (Europe), continued production in other regions (e.g., Argentina, Nigeria) until 2003. |
| Manufacturing Locations: | Primarily France (Sochaux), with assembly plants in various countries. |
| Awards & Recognition | |
| Recognitions | |
| Recognitions: | The Peugeot 504 (predecessor) was European Car of the Year in 1969. While the 505 did not win the overall award, it was consistently recognized for its comfort, durability, and value in automotive press reviews throughout its lifecycle. |