PEUGEOT 505 Full Service & Repair Manual 1979-1993
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Basic Information Identification Make: Peugeot Model: 505 Years Covered: 1979-1993 Introduction Market Position Segment: Executive/Large Family Car Philosophy: Peugeot's offering in the larger family sedan segment, known for comfort, handling, and durability. Competitive Analysis Competitors: Competed with vehicles like the Ford Granada, Opel Rekord/Omega, Volkswagen Passat (larger variants), Renault 25, and various Japanese sedans. Key Features Handling: Praised for its sophisticated suspension design, offering a comfortable ride and engaging handling, particularly for its class. Durability: Built to last, with many examples enduring high mileages, especially with proper maintenance. Interior Comfort: Spacious and comfortable interior, often with well-appointed trim levels. Engine Options: A range of robust petrol and diesel engines, known for their reliability and performance. Manual Details Coverage Areas Manual Type: Factory Service & Repair Workshop Manual Language: English Format: Digital Download (PDF) Usage Rights: Unlimited installations and lifetime use Update Policy: No expiry dates, no renewal fees Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, rebuilding, tuning, timing systems, lubrication, cooling systems Fuel System: Carburetor systems (Zenith, Solex, Weber), Bosch K-Jetronic fuel injection, fuel pumps, lines, filters, evaporative emission controls Ignition System: Distributor ignition, electronic ignition systems, spark plugs, coils, timing adjustments Transmission Manual: Clutch assembly, gearbox overhaul, gear shifting mechanisms, driveshafts, universal joints Transmission Automatic: Automatic transmission operation, fluid changes, hydraulic controls, torque converter Drivetrain: Rear-wheel drive system, differential overhaul, axle shafts, bearing specifications Suspension Front: McPherson strut suspension, control arms, ball joints, bushings, shock absorber replacement Suspension Rear: Independent rear suspension (trailing arms, Panhard rod), springs, shock absorbers, bushings Steering System: Power steering system, steering rack, steering column, wheel alignment specifications Braking System: Front disc brakes, rear drum brakes (some models with rear discs), hydraulic system, brake fluid specifications, ABS (later models) Electrical System: Wiring diagrams, starter motor, alternator, battery, lighting systems, fuses, relays, dashboard instrumentation Climate Control: Heater core, ventilation system, air conditioning system (if equipped), refrigerant handling Body And Chassis: Body panel removal and installation, door mechanisms, glass replacement, trim components, rustproofing Body Electrical: Power windows, central locking, interior lighting, exterior lighting diagnostics Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections and replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Repair: Step-by-step repair instructions for all major and minor components, including complete engine and transmission rebuilds Diagnostics: Detailed diagnostic procedures for engine, fuel, ignition, electrical, and mechanical systems Specifications: Torque specifications, clearances, timing marks, fluid capacities, electrical resistance values Exploded Diagrams: Detailed exploded view diagrams for most components, illustrating part relationships and assembly sequences Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems Technical Depth Detail Level: Professional-grade, step-by-step instructions suitable for novice to expert mechanics Photo Quality: Detailed photographs illustrating procedures and component identification Manual Specifications File Format Format: PDF Compatibility: Windows and macOS Searchability: Searchable text content Print Quality Print Option: Printable (single pages or entire manual) Binding Type Binding: N/A (Digital) Paper Type Paper Type: N/A (Digital) Engine Specifications Primary Engine Engine Types: Inline-4 petrol, Inline-6 petrol, Diesel Displacement Petrol 1.8L: 1796 cc (e.g., XU7 engine) 2.0L: 1995 cc (e.g., XN1, PRV V6 variants) 2.2L: 2155 cc (e.g., Douvrin J6, XU8 - Turbo) 2.8L V6: 2849 cc (PRV V6 engine) Displacement Diesel 2.1L Diesel: 2135 cc (XD2 engine) 2.3L Diesel Turbo: 2304 cc (XD3T engine) Performance Petrol Power Output Range: Approximately 80 hp (1.8L) to 136 hp (2.8 V6), with Turbo variants reaching higher outputs (e.g., 160 hp for 505 Turbo). Performance Diesel Power Output Range: Approximately 70 hp (2.1D) to 96 hp (2.3DT). Fuel System Induction Petrol: Carburetor (various models) and Bosch K-Jetronic mechanical fuel injection. Induction Diesel: Indirect injection via Bosch inline or rotary injection pumps. Transmission Standard Transmission Type: 4-speed manual (early models), 5-speed manual (later models) Optional Transmission Type: 3-speed ZF automatic, 4-speed automatic (later models) Features Clutch Type: Single dry plate clutch Drive Layout: Rear-wheel drive (RWD) Dimensions Exterior Length Sedan: Approx. 4700-4800 mm (depending on variant) Width Sedan: Approx. 1720-1740 mm Height Sedan: Approx. 1450-1460 mm Wheelbase: Approx. 2800 mm Weights Curb Weight Range: Approx. 1200-1400 kg (depending on engine and body style) Safety Features Ratings Crash Test History: No standardized crash test ratings available for all covered years as per modern protocols. Early models focused on passive safety features. Active Features Braking System Type: Front ventilated discs, rear drums standard. Some later/higher trims featured rear discs. ABS Availability: Optional on later models, particularly on higher trim levels and V6 variants. Passive Features Seatbelts: Front and rear seatbelts, with pretensioners on front belts in later models. Chassis Design: Reinforced passenger cell, deformable crumple zones. Headlights: Halogen headlights on most models, some with aerodynamic composite headlights. Technology Features Infotainment Radio Options: Factory fitted radios (AM/FM, cassette player) were common, with basic tuning and volume controls. Speaker System: Typically 2 or 4...
Halogen headlights on most models, some with aerodynamic composite headlights.
Technology Features
Infotainment
Radio Options:
Factory fitted radios (AM/FM, cassette player) were common, with basic tuning and volume controls.
Speaker System:
Typically 2 or 4 speaker systems, offering rudimentary audio quality by modern standards.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels and larger engined models.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth, USB, or smartphone integration. Basic antenna system for radio.
Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type (refer to specific engine recommendations).
Spark Plug Replacement:
Every 20,000-40,000 km, depending on plug type (copper, platinum).
Timing Belt Replacement:
For XU engines, typically 80,000-120,000 km or 5-7 years. Critical replacement item to prevent catastrophic engine damage.
Fluid Specifications
Engine Oil Viscosity:
Varies by engine and climate. Common recommendations include 10W-40, 15W-40 for petrol; 15W-40 or 20W-50 for diesel. Refer to manual for precise specs.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion inhibitors. Usually a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, viscosity varies (e.g., 75W-90, 80W-90).
Transmission Fluid Automatic:
Typically Dexron II or equivalent ATF fluid. Refer to manual for exact specification.
Known Issues
Rust:
Common on wheel arches, sills, boot floor, and around windows, especially in damp climates. Early rustproofing was not as advanced as later standards.
Electrical Gremlins:
Older wiring can degrade, leading to intermittent issues with lights, wipers, or dashboard components. Ground points are critical.
Fuel System Leaks:
Ageing rubber fuel lines and seals can lead to leaks. K-Jetronic systems can develop issues with the fuel distributor or cold start valve.
Suspension Bushings:
Wear in suspension bushings can lead to vague handling and knocking sounds. Regular inspection and replacement are necessary.
Exhaust Manifold Cracks:
Cast iron exhaust manifolds, particularly on some petrol engines, can develop cracks due to thermal cycling.
Cooling System:
Radiator leaks, thermostat failures, and deterioration of coolant hoses are common maintenance items.
Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot, a French automaker with a long history dating back to 1810, known for engineering prowess and sporty vehicles.
Model Evolution
Predecessor:
Peugeot 504, a highly successful and durable model.
Design Influence:
Designed by Pininfarina, sharing styling cues with other Peugeot models of the era and the Fiat 132.
Body Styles:
Available as a 4-door sedan, 5-door station wagon (break), and 2-door coupe.
Production
Production Period:
1979-1992 (in Europe), continued production in other markets like Argentina until 2002.
Production Locations
Manufacturing Sites:
Primarily France (Sochaux), but also assembled in other countries.
Awards & Recognition
Recognitions
Model Awards:
While specific awards for the 505 are not widely publicized as major accolades, it was consistently recognized for its comfort, durability, and competent handling during its production run.
Ratings
Reliability Perception:
Generally considered a reliable vehicle when well-maintained, with strong mechanical components.
Certifications
Manual Certification:
This is a professional factory service manual, not a consumer certification.
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