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PEUGEOT 505 Workshop Repair Manual 1979-1993

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Basic Information Identification Make: Peugeot Model: 505 Generation Generation Designation: First Generation (Type 551) Codes Chassis Code: Type 551 Introduction Market Position Positioning: Professional-grade repair information for owners and independent workshops, mirroring dealer-level resources. Competitive Analysis Advantage: Provides the same level of detail and accuracy as original manufacturer manuals, essential for correct repair and maintenance. Key Features Features: Step-by-step instructions, detailed diagrams, electrical schematics, torque settings, fluid capacities, diagnostic procedures, year/model specificity. Manual Details Coverage Areas Model Years Covered: 1979-1993 Body Styles Covered: Saloon (Sedan), Estate (Station Wagon), and potentially the estilvized GTI versions. Page Count Estimated Page Count: Thousands of pages (as per description) Manual Type Type: Workshop Service & Repair Manual Language Language: English (Assumed, standard for global service manuals) Format Format: Digital Download (Acrobat PDF) Manual Coverage Systems Covered Powertrain: Engine (all variants), transmission (manual/automatic), drivetrain, cooling system, fuel system, exhaust system Chassis: Suspension (front/rear), steering system, braking system, wheels and tires Electrical: Wiring diagrams, electrical components, lighting, starting and charging systems, ignition system, instrumentation Body And Interior: Body panels, doors, windows, seats, trim, HVAC (Heating, Ventilation, and Air Conditioning) Climate Control: HVAC system operation, component testing, refrigerant handling (where applicable), heater core replacement. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement Repair: Engine overhaul (rebuilding), transmission repair, brake component replacement, suspension component overhaul, steering system repair, electrical system diagnostics and repair, bodywork repair Diagnostics: Troubleshooting guides, symptom analysis, fault code identification (where applicable), diagnostic procedures for all major systems Body And Trim: Panel replacement, door hinge adjustment, interior trim removal and installation, bumper repairs. Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and torque specifications. Diagnostic Tools References: References to specific Peugeot diagnostic tools or procedures relevant to the era. Includes troubleshooting flowcharts. Manual Specifications File Format Compatibility: Windows and MAC compatible Print Quality Quality: High-quality PDF with clear diagrams and text Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Codes Common: XM7T (1.9L Diesel), XN1T (2.1L Diesel), ZDJL (2.5L Diesel), ZPJ (2.0L Petrol), ZPJ(X) (2.0L Petrol - fuel injected), ZDR (2.2L Petrol), ZDJ (2.8L V6 Petrol) Performance Horsepower Range: Approximately 70 hp (1.9D) to 160 hp (2.8 V6) Torque Range: Approximately 120 Nm (1.9D) to 220 Nm (2.8 V6) Fuel System Fuel Types: Diesel, Unleaded Petrol Injection Types: Carbureted (early models), Fuel Injection (later/higher trims) Engine Codes Specific 2.0L Petrol (Zpj): Inline-4, SOHC, approx. 110-120 hp. Carbureted (e.g., Solex twin-choke) or Bosch L-Jetronic fuel injection. 2.8L V6 Petrol (Zdj): PRV V6, SOHC, approx. 150-160 hp. Fuel injected. 2.1L Diesel (Xn1T): Inline-4, SOHC, indirect injection, approx. 70 hp. Naturally aspirated. 2.5L Diesel (Zdjl): Inline-4, SOHC, indirect injection, approx. 75-95 hp (depending on turbocharging). Turbocharged variants available. Transmission Standard Type: 4-speed or 5-speed Manual Transmission Optional Type: 3-speed or 4-speed Automatic Transmission (e.g., ZF 4HP22) Features Drive Type: Rear-Wheel Drive (RWD) Dimensions Exterior Wheelbase Mm: 2800 Length Mm: 4660 - 4770 (depending on body style) Width Mm: 1730 - 1750 Height Mm: 1450 - 1470 Weights Curb Weight Kg Range: 1250 - 1500 (depending on engine and trim) Interior Seating Capacity: 5-7 passengers, depending on configuration (optional third row). Safety Features Ratings Euroncap Rating: Not directly applicable to early models in modern rating systems, but generally considered robust for its era. Active Features Braking System: Front disc brakes, rear drum brakes (standard); optional front and rear discs on performance variants. Steering: Power assisted rack and pinion steering (standard on most models) Passive Features Seatbelts: Front and rear seat belts Construction: Monocoque body construction with crumple zones. Technology Features Infotainment Audio System: Factory fitted radio cassette player with AM/FM tuner, speaker systems varied by trim level. Driver Assistance Features: Limited by era. Primarily focused on passive safety and mechanical reliability. Some higher trims may have had central locking or electric windows. Connectivity Features: N/A (No modern connectivity features like Bluetooth or USB found in this era of vehicle). Maintenance Service Intervals Oil Change Petrol: Typically every 7,500 - 10,000 km (or annually, whichever comes first). Oil Change Diesel: Typically every 5,000 - 7,500 km (or annually). Timing Belt Replacement: Varies by engine, typically 60,000 - 100,000 km or 4-5 years for petrol engines with interference design. Diesel engines also require regular replacement. Crucial to consult manual for specific engine. Fluid Specifications Engine Oil Petrol: API SG or higher, SAE 10W-40 or 15W-50 (depending on climate). Refer to manual for precise grade. Engine Oil Diesel: API CF or higher, SAE 15W-40 or 10W-30 (depending on climate). Refer to manual for precise grade. Coolant: Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Specific Peugeot coolant recommended. Brake Fluid: DOT 3 or DOT 4. Transmission Fluid Auto: Dexron II or equivalent (e.g., ZF...
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PEUGEOT 505 Workshop Repair Manual 1979-1993
Basic Information
Identification
Make: Peugeot
Model: 505
Generation
Generation Designation: First Generation (Type 551)
Codes
Chassis Code: Type 551
Introduction
Market Position
Positioning: Professional-grade repair information for owners and independent workshops, mirroring dealer-level resources.
Competitive Analysis
Advantage: Provides the same level of detail and accuracy as original manufacturer manuals, essential for correct repair and maintenance.
Key Features
Features: Step-by-step instructions, detailed diagrams, electrical schematics, torque settings, fluid capacities, diagnostic procedures, year/model specificity.
Manual Details
Coverage Areas
Model Years Covered: 1979-1993
Body Styles Covered: Saloon (Sedan), Estate (Station Wagon), and potentially the estilvized GTI versions.
Page Count
Estimated Page Count: Thousands of pages (as per description)
Manual Type
Type: Workshop Service & Repair Manual
Language
Language: English (Assumed, standard for global service manuals)
Format
Format: Digital Download (Acrobat PDF)
Manual Coverage
Systems Covered
Powertrain: Engine (all variants), transmission (manual/automatic), drivetrain, cooling system, fuel system, exhaust system
Chassis: Suspension (front/rear), steering system, braking system, wheels and tires
Electrical: Wiring diagrams, electrical components, lighting, starting and charging systems, ignition system, instrumentation
Body And Interior: Body panels, doors, windows, seats, trim, HVAC (Heating, Ventilation, and Air Conditioning)
Climate Control: HVAC system operation, component testing, refrigerant handling (where applicable), heater core replacement.
Procedures Included
Maintenance: Routine servicing, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement
Repair: Engine overhaul (rebuilding), transmission repair, brake component replacement, suspension component overhaul, steering system repair, electrical system diagnostics and repair, bodywork repair
Diagnostics: Troubleshooting guides, symptom analysis, fault code identification (where applicable), diagnostic procedures for all major systems
Body And Trim: Panel replacement, door hinge adjustment, interior trim removal and installation, bumper repairs.
Technical Depth
Depth: Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and torque specifications.
Diagnostic Tools References: References to specific Peugeot diagnostic tools or procedures relevant to the era. Includes troubleshooting flowcharts.
Manual Specifications
File Format
Compatibility: Windows and MAC compatible
Print Quality
Quality: High-quality PDF with clear diagrams and text
Binding Type
Type: N/A (Digital Download)
Paper Type
Type: N/A (Digital Download)
Engine Specifications
Primary Engine
Engine Codes Common: XM7T (1.9L Diesel), XN1T (2.1L Diesel), ZDJL (2.5L Diesel), ZPJ (2.0L Petrol), ZPJ(X) (2.0L Petrol - fuel injected), ZDR (2.2L Petrol), ZDJ (2.8L V6 Petrol)
Performance
Horsepower Range: Approximately 70 hp (1.9D) to 160 hp (2.8 V6)
Torque Range: Approximately 120 Nm (1.9D) to 220 Nm (2.8 V6)
Fuel System
Fuel Types: Diesel, Unleaded Petrol
Injection Types: Carbureted (early models), Fuel Injection (later/higher trims)
Engine Codes Specific
2.0L Petrol (Zpj): Inline-4, SOHC, approx. 110-120 hp. Carbureted (e.g., Solex twin-choke) or Bosch L-Jetronic fuel injection.
2.8L V6 Petrol (Zdj): PRV V6, SOHC, approx. 150-160 hp. Fuel injected.
2.1L Diesel (Xn1T): Inline-4, SOHC, indirect injection, approx. 70 hp. Naturally aspirated.
2.5L Diesel (Zdjl): Inline-4, SOHC, indirect injection, approx. 75-95 hp (depending on turbocharging). Turbocharged variants available.
Transmission
Standard
Type: 4-speed or 5-speed Manual Transmission
Optional
Type: 3-speed or 4-speed Automatic Transmission (e.g., ZF 4HP22)
Features
Drive Type: Rear-Wheel Drive (RWD)
Dimensions
Exterior
Wheelbase Mm: 2800
Length Mm: 4660 - 4770 (depending on body style)
Width Mm: 1730 - 1750
Height Mm: 1450 - 1470
Weights
Curb Weight Kg Range: 1250 - 1500 (depending on engine and trim)
Interior
Seating Capacity: 5-7 passengers, depending on configuration (optional third row).
Safety Features
Ratings
Euroncap Rating: Not directly applicable to early models in modern rating systems, but generally considered robust for its era.
Active Features
Braking System: Front disc brakes, rear drum brakes (standard); optional front and rear discs on performance variants.
Steering: Power assisted rack and pinion steering (standard on most models)
Passive Features
Seatbelts: Front and rear seat belts
Construction: Monocoque body construction with crumple zones.
Technology Features
Infotainment
Audio System: Factory fitted radio cassette player with AM/FM tuner, speaker systems varied by trim level.
Driver Assistance
Features: Limited by era. Primarily focused on passive safety and mechanical reliability. Some higher trims may have had central locking or electric windows.
Connectivity
Features: N/A (No modern connectivity features like Bluetooth or USB found in this era of vehicle).
Maintenance
Service Intervals
Oil Change Petrol: Typically every 7,500 - 10,000 km (or annually, whichever comes first).
Oil Change Diesel: Typically every 5,000 - 7,500 km (or annually).
Timing Belt Replacement: Varies by engine, typically 60,000 - 100,000 km or 4-5 years for petrol engines with interference design. Diesel engines also require regular replacement. Crucial to consult manual for specific engine.
Fluid Specifications
Engine Oil Petrol: API SG or higher, SAE 10W-40 or 15W-50 (depending on climate). Refer to manual for precise grade.
Engine Oil Diesel: API CF or higher, SAE 15W-40 or 10W-30 (depending on climate). Refer to manual for precise grade.
Coolant: Ethylene glycol-based antifreeze, mixed 50/50 with distilled water. Specific Peugeot coolant recommended.
Brake Fluid: DOT 3 or DOT 4.
Transmission Fluid Auto: Dexron II or equivalent (e.g., ZF HP-22 fluid specification).
Transmission Fluid Manual: GL-4 Hypoid gear oil, SAE 75W-90 or 80W-90.
Power Steering Fluid: ATF (Automatic Transmission Fluid) or specific power steering fluid as per manual.
Known Issues
Common Wear Items: Suspension bushings, ball joints, exhaust system corrosion, aging electrical connectors, diesel injection pump seals.
Potential Problems: Rust (especially in wheel arches and sills), cooling system leaks, clutch wear, starter motor issues.
Vehicle History
Brand Heritage
Peugeot Legacy: Peugeot, a historic French automotive manufacturer with a long tradition of producing comfortable, reliable, and technologically advanced vehicles.
Model Evolution
Evolution Summary: Successor to the Peugeot 504, the 505 was designed to be a larger, more modern, and comfortable car, offering a range of engines from economical diesels to powerful V6 petrol engines. Known for its excellent ride quality and robust build.
Production
Production Years: 1979 - 1992 (Europe), continued production in other markets (e.g., Argentina, Nigeria) until 2007.
Manufacturing Locations: France, Finland, Chile, Argentina, Nigeria, China (as licensed successor)
Awards & Recognition
Recognitions
Awards General: While specific awards are not widely publicized, the Peugeot 505 was highly regarded for its comfort, durability, and driving dynamics, particularly in European markets. It was a strong competitor in its segment.
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