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Peugeot 505 1979-1993 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Peugeot Model: 505 Product Name: Peugeot 505 1979-1993 Workshop Service Manual Repair Codes Model Years Covered: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 👋 Introduction Market Position Target Audience: Professional technicians and DIY mechanics. Competitive Analysis Advantage: Instant download, printable format, comprehensive coverage for a long production run. Key Features Documentation Type: Factory Original Service Manual, Workshop Manual, Repair Manual, Wiring Diagrams. Accuracy: Written by manufacturers, considered the most accurate and complete available. 📋 Manual Details Coverage Areas Primary Coverage: Workshop, Service, Repair Secondary Coverage: Periodic maintenance, Troubleshooting, Overhaul procedures, Diagnostics Page Count Estimated Page Count: Hundreds (specific count not provided, but indicated as comprehensive) Manual Type Type: Factory Service Manual/Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed repair, overhaul, and diagnostics for all gasoline and diesel engines offered during the model run. Transmission: Coverage of manual and automatic transmission repair, adjustment, and fluid specifications. Drivetrain: Front-wheel drive system components, including axles, CV joints, and differential. Suspension: Front and rear suspension systems, including shock absorbers, struts, springs, bushings, and alignment procedures. Steering: Power steering system components, steering rack, tie rods, and adjustments. Brakes: Hydraulic brake systems, including disc and drum components, master cylinder, calipers, wheel cylinders, brake fluid, and bleeding procedures. Electrical System: Comprehensive wiring diagrams, fuse box layout, component testing, ignition system, charging system, lighting, and accessories. Fuel System: Fuel injection systems (Bosch L-Jetronic, Motronic depending on engine) and carbureted systems, fuel pumps, injectors, and filters. Cooling System: Radiator, thermostat, water pump, coolant hoses, and fan system. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, and pipework. Body And Chassis: Body panel removal and installation, door mechanisms, glass replacement, structural repairs. Climate Control: HVAC system diagnosis and repair, air conditioning components. Procedures Included Maintenance: Scheduled maintenance charts, fluid changes, filter replacements, spark plug intervals. Repair: Step-by-step instructions for component removal, installation, and repair across all major vehicle systems. Troubleshooting: Diagnostic guides for common problems, symptoms, and their causes. Overhaul: Detailed procedures for complete engine and transmission rebuilds. Diagnostics: Guidance on identifying and resolving mechanical and electrical faults. Electrical Diagnostics: Detailed troubleshooting trees and wiring diagrams for all electrical circuits, including lighting, ignition, starting, charging, and accessory systems. Engine Rebuild: Step-by-step instructions for cylinder head removal and overhaul, piston and connecting rod installation, crankshaft installation, and complete engine assembly. Transmission Overhaul Manual: Detailed breakdown and reassembly procedures for manual gearboxes, including gear sets, synchromesh mechanisms, and shift linkage. Transmission Overhaul Automatic: Procedures for servicing and rebuilding automatic transmissions, including valve body diagnosis, clutch pack replacement, and torque converter servicing. Brake System Repair: Front and rear brake caliper overhaul, brake pad and shoe replacement, wheel cylinder repair, and brake fluid flush and bleed procedures. Suspension Alignment: Specifications for front and rear wheel alignment, including camber, caster, and toe angles, along with adjustment procedures. Body Repair: Guidelines for panel replacement, door hinge adjustment, window regulator repair, and sealing component replacement. Torque Specifications: Comprehensive list of torque values for critical fasteners across all vehicle systems (engine, transmission, suspension, brakes, body). Diagnostic Charts: Flowcharts and diagnostic trees for common drivability, electrical, and mechanical issues. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed diagnostics and rebuilds. Diagnostic Tools: Information for using basic diagnostic tools, multimeters, pressure gauges, and specialized Peugeot diagnostic equipment of the era. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable due to PDF format (implied by digital delivery). Print Quality Printability: Full Printable Zoom Functionality: YES (Zoom IN/OUT) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Method Delivery: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Types Overview: The Peugeot 505 featured a range of inline-4 gasoline and diesel engines, including the Douvrin J-Type and PRV V6 (in later, higher-spec models, though not explicitly confirmed for all years in this generic manual). Common gasoline engines included 1.6L, 1.8L, and 2.0L variants. Diesel engines included 2.1L and 2.3L naturally aspirated and turbocharged variants. Performance Performance Characteristics: Horsepower and torque varied significantly based on engine displacement, fuel system (carburetor vs. injection), and aspiration (naturally aspirated vs. turbo diesel). Specific figures would require model/engine variant selection. Fuel System Fuel Delivery Types: Carbureted (e.g., Solex, Zenith) on earlier or base models, and electronic fuel injection (e.g., Bosch L-Jetronic, Motronic) on later or more powerful variants. Diesel engines used injection pumps (e.g., Bosch, Lucas). Engine Types Overview Specific Engine Codes Common: Examples of engine types that might be covered include the PSA Douvrin J-series gasoline engines (e.g., J5, J7) and PSA XD...
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Peugeot 505 1979-1993 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
505
Product Name:
Peugeot 505 1979-1993 Workshop Service Manual Repair
Codes
Model Years Covered:
1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993
👋 Introduction
Market Position
Target Audience:
Professional technicians and DIY mechanics.
Competitive Analysis
Advantage:
Instant download, printable format, comprehensive coverage for a long production run.
Key Features
Documentation Type:
Factory Original Service Manual, Workshop Manual, Repair Manual, Wiring Diagrams.
Accuracy:
Written by manufacturers, considered the most accurate and complete available.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop, Service, Repair
Secondary Coverage:
Periodic maintenance, Troubleshooting, Overhaul procedures, Diagnostics
Page Count
Estimated Page Count:
Hundreds (specific count not provided, but indicated as comprehensive)
Manual Type
Type:
Factory Service Manual/Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed repair, overhaul, and diagnostics for all gasoline and diesel engines offered during the model run.
Transmission:
Coverage of manual and automatic transmission repair, adjustment, and fluid specifications.
Drivetrain:
Front-wheel drive system components, including axles, CV joints, and differential.
Suspension:
Front and rear suspension systems, including shock absorbers, struts, springs, bushings, and alignment procedures.
Steering:
Power steering system components, steering rack, tie rods, and adjustments.
Brakes:
Hydraulic brake systems, including disc and drum components, master cylinder, calipers, wheel cylinders, brake fluid, and bleeding procedures.
Electrical System:
Comprehensive wiring diagrams, fuse box layout, component testing, ignition system, charging system, lighting, and accessories.
Fuel System:
Fuel injection systems (Bosch L-Jetronic, Motronic depending on engine) and carbureted systems, fuel pumps, injectors, and filters.
Cooling System:
Radiator, thermostat, water pump, coolant hoses, and fan system.
Exhaust System:
Exhaust manifolds, catalytic converters, mufflers, and pipework.
Body And Chassis:
Body panel removal and installation, door mechanisms, glass replacement, structural repairs.
Climate Control:
HVAC system diagnosis and repair, air conditioning components.
Procedures Included
Maintenance:
Scheduled maintenance charts, fluid changes, filter replacements, spark plug intervals.
Repair:
Step-by-step instructions for component removal, installation, and repair across all major vehicle systems.
Troubleshooting:
Diagnostic guides for common problems, symptoms, and their causes.
Overhaul:
Detailed procedures for complete engine and transmission rebuilds.
Diagnostics:
Guidance on identifying and resolving mechanical and electrical faults.
Electrical Diagnostics:
Detailed troubleshooting trees and wiring diagrams for all electrical circuits, including lighting, ignition, starting, charging, and accessory systems.
Engine Rebuild:
Step-by-step instructions for cylinder head removal and overhaul, piston and connecting rod installation, crankshaft installation, and complete engine assembly.
Transmission Overhaul Manual:
Detailed breakdown and reassembly procedures for manual gearboxes, including gear sets, synchromesh mechanisms, and shift linkage.
Transmission Overhaul Automatic:
Procedures for servicing and rebuilding automatic transmissions, including valve body diagnosis, clutch pack replacement, and torque converter servicing.
Brake System Repair:
Front and rear brake caliper overhaul, brake pad and shoe replacement, wheel cylinder repair, and brake fluid flush and bleed procedures.
Suspension Alignment:
Specifications for front and rear wheel alignment, including camber, caster, and toe angles, along with adjustment procedures.
Body Repair:
Guidelines for panel replacement, door hinge adjustment, window regulator repair, and sealing component replacement.
Torque Specifications:
Comprehensive list of torque values for critical fasteners across all vehicle systems (engine, transmission, suspension, brakes, body).
Diagnostic Charts:
Flowcharts and diagnostic trees for common drivability, electrical, and mechanical issues.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed diagnostics and rebuilds.
Diagnostic Tools:
Information for using basic diagnostic tools, multimeters, pressure gauges, and specialized Peugeot diagnostic equipment of the era.
Special Tools:
Identification and usage instructions for any specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Likely searchable due to PDF format (implied by digital delivery).
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery Method
Delivery:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Types Overview:
The Peugeot 505 featured a range of inline-4 gasoline and diesel engines, including the Douvrin J-Type and PRV V6 (in later, higher-spec models, though not explicitly confirmed for all years in this generic manual). Common gasoline engines included 1.6L, 1.8L, and 2.0L variants. Diesel engines included 2.1L and 2.3L naturally aspirated and turbocharged variants.
Performance
Performance Characteristics:
Horsepower and torque varied significantly based on engine displacement, fuel system (carburetor vs. injection), and aspiration (naturally aspirated vs. turbo diesel). Specific figures would require model/engine variant selection.
Fuel System
Fuel Delivery Types:
Carbureted (e.g., Solex, Zenith) on earlier or base models, and electronic fuel injection (e.g., Bosch L-Jetronic, Motronic) on later or more powerful variants. Diesel engines used injection pumps (e.g., Bosch, Lucas).
Engine Types Overview
Specific Engine Codes Common:
Examples of engine types that might be covered include the PSA Douvrin J-series gasoline engines (e.g., J5, J7) and PSA XD series diesel engines (e.g., XD88). Later models may have used Peugeot's own designs or shared engines.
🔧 Transmission
Standard
Standard Transmission:
Typically a 4-speed or 5-speed manual transmission was standard on many variants.
Optional
Optional Transmission:
A 3-speed or 4-speed automatic transmission was available as an option on most models.
Features
Transmission Features:
Front-wheel drive layout. Manual transmissions often featured a clutch assembly requiring periodic inspection and replacement.
📐 Dimensions
Exterior
Body Styles:
Primarily a four-door sedan, with a five-door station wagon (Break) variant also prominent.
Weights
Curb Weight Range:
Curb weight varied depending on engine and body style, generally ranging from approximately 1200 kg to 1450 kg (2650 lbs to 3200 lbs).
🛡️ Safety Features
Ratings
Safety Ratings:
Euro NCAP or equivalent safety ratings from the era are not readily available in a standardized format for this specific manual. Vehicle safety features would align with contemporary standards of the 1980s and early 1990s.
Active Features
Active Safety:
Four-wheel disc brakes (front ventilated discs, rear discs on most models), power-assisted steering, independent front suspension.
Passive Features
Passive Safety:
Safety belt systems, reinforced chassis structure, impact-absorbing steering column.
💡 Technology Features
Infotainment
Infotainment Features:
Base models featured basic analog radios with cassette players. Higher trims might have offered more advanced audio systems. The manual would cover their repair and electrical integration.
Driver Assistance
Driver Assistance Features:
Limited by the era; advanced driver-assistance systems were not standard. Features would be akin to power steering and anti-lock braking systems (ABS) if equipped on later models.
Connectivity
Connectivity Options:
No integrated connectivity like Bluetooth or USB was available. Vehicle communication was primarily through the electrical system for diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used. The manual would specify exact intervals and oil grades.
Timing Belt Interval:
For engines with timing belts (e.g., Douvrin engines), replacement intervals are critical, often around 60,000-80,000 miles (96,000-128,000 km). The manual would provide precise recommendations and procedures.
Fluid Specifications
Engine Oil Type:
Varies by engine and climate, typically SAE 10W-40 or 15W-50 for gasoline engines, and SAE 15W-40 or 20W-50 for diesel engines. Manual specifies API service classifications.
Coolant Type:
Ethylene glycol-based coolant (e.g., Peugeot recommends specific anti-freeze/anti-corrosion mixtures). Manual will detail type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify the exact type and change interval.
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil for manual transmissions. Specific viscosity grade (e.g., 75W-90, 80W-90) will be in the manual.
Transmission Fluid Type Automatic:
ATF (Automatic Transmission Fluid) of the specified type (e.g., Dexron II or equivalent). Manual will detail type and capacity.
Power Steering Fluid:
Specific type of hydraulic fluid recommended for the power steering system. Manual will detail viscosity and specification.
Differential Fluid:
Specifications for the final drive/differential oil, typically a GL-5 gear oil with specific viscosity.
Known Issues
Common Issues:
Rusting, particularly in wheel arches and sills. Electrical gremlins due to age. Potential for head gasket leaks on some engine variants. Wear in suspension bushings and ball joints. Clutch wear. Diesel engines can be robust but require proper maintenance.
Troubleshooting Focus:
The manual is essential for diagnosing and rectifying common issues like starting problems, rough idling, brake fade, and suspension noises.
📚 Vehicle History
Brand Heritage
Peugeot Heritage:
Peugeot, a French automotive manufacturer founded in 1810, has a long history of producing robust and reliable vehicles known for their comfort and driving dynamics.
Model Evolution
505 Evolution:
The Peugeot 505 was introduced in 1979 as the successor to the Peugeot 504. It was designed by Pininfarina and offered a more modern and spacious alternative, blending comfort with Peugeot's characteristic handling. It underwent facelifts and minor updates throughout its production run, including interior and exterior styling revisions.
Production
Production Period:
1979–1993 in Europe, with production continuing in Argentina and Egypt for longer periods.
Manufacturing Locations:
Primarily France, but also assembled in other countries through CKD kits.
🏆 Awards & Recognition
Recognitions
Model Recognitions:
The Peugeot 505 was well-regarded for its comfort, handling, and durability in its time, often praised for its ride quality and space, making it a popular choice in its segment. Specific awards are not highlighted in the product description but it was a successful model for Peugeot.
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