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PEUGEOT 505 Workshop Repair Manual All 1979-1993 ModelS COVERED

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🏷️ Basic Information Identification Make: Peugeot Model: 505 Model Years Covered: 1979-1993 Codes Chassis Codes: Type 551 (Sedan), Type 551L (Station Wagon) 👋 Introduction Market Position Positioning: The Peugeot 505 was a large, rear-wheel-drive executive car known for its comfortable ride, robust build, and European styling. It served as Peugeot's flagship model during its production run. Competitive Analysis Competitors: Competed with other European executive sedans and wagons of the era, such as the Ford Granada, Opel Senator, Renault 25, and various models from BMW, Mercedes-Benz, and Volvo. Key Features Features: Spacious interior, comfortable ride quality, durable construction, available in sedan and station wagon (Break) variants, strong diesel engine options, and renowned Pininfarina styling. Manual Value Utility: Essential for owners and independent repair shops looking to maintain and repair the Peugeot 505, offering detailed technical guidance to ensure longevity and performance. 📋 Manual Details Coverage Areas Regions Covered: Global (applicable to all markets where Peugeot 505 was sold) Trim Levels Covered: All trim levels including GL, GR, GT, GTi, STI, Turbo, Diesel, Familiale Page Count Estimated Page Count: Likely several hundred pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Purpose: Designed for professional technicians and knowledgeable DIY mechanics to perform all maintenance and repair tasks. Language Language: English (implied by product description common to international markets) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Internal combustion engines (petrol and diesel), including assembly, disassembly, troubleshooting, diagnostics, and component specifications. Fuel System: Carburetor systems (e.g., Solex, Zenith), fuel injection systems (e.g., Bosch L-Jetronic, Motronic), fuel pumps, filters, lines, and diagnostics. Ignition System: Distributor-based ignition, electronic ignition systems, spark plugs, coils, wiring, and timing adjustments. Cooling System: Radiator, water pump, thermostat, hoses, fan, coolant specifications, and leak detection. Exhaust System: Exhaust manifold, catalytic converter (where applicable), muffler, pipes, and mounting. Transmission Manual: Clutch assembly, manual gearbox components, shift mechanisms, lubrication, and troubleshooting. Transmission Automatic: Automatic transmission service, fluid specifications, torque converter, valve body, and electronic control (where applicable). Drivetrain: Front-wheel drive components, driveshafts, CV joints, differentials, and rear-wheel drive axle (for certain variants). Suspension: Front MacPherson struts, rear trailing arms/coil springs, shock absorbers, control arms, anti-roll bars, and alignment specifications. Steering: Steering rack and pinion, power steering system (fluid, pump, hoses), steering column, and linkage. Brakes Front: Ventilated disc brakes, calipers, pads, rotors, and brake lines. Brakes Rear: Disc or drum brakes (depending on model year/trim), calipers/wheel cylinders, pads/shoes, rotors/drums, and brake lines. Parking Brake: Mechanism, cables, and adjustment. Electrical System: Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting, and instrument cluster. Body Electrical: Power windows, door locks, mirrors, wipers, horn, and interior lighting. HVAC: Heating, ventilation, and air conditioning system components, operation, and servicing. Bodywork: Body panel removal/installation, door mechanisms, latches, hinges, and trim. Interior: Seat removal/installation, dashboard components, interior trim panels. Sensors: Information on various sensors for engine management, temperature, oil pressure, etc. Actuators: Details on components like fuel injectors, ignition coils, and electric motors. Emission Control: Information on emission control systems, including catalytic converters (where fitted) and related components. Procedures Included Maintenance: Routine service, oil changes, filter replacements, fluid checks and changes, lubrication, and tune-ups. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, fault codes (where applicable). Repair: Step-by-step instructions for component removal, overhaul, reassembly, and installation. Overhaul: Detailed instructions for the complete disassembly and reconditioning of major components like engines and transmissions. Adjustment: Precise instructions for adjusting systems such as ignition timing, carburetor idle speed, valve lash, and parking brake. Specifications: Torque values, clearances, fluid capacities, and other critical technical data for all repair procedures. Diagnostics: Guidance on identifying problems through visual inspection, testing, and the use of diagnostic equipment. Troubleshooting Flowcharts: Likely includes diagnostic flowcharts to systematically identify and resolve faults. Wiring Diagrams: Includes detailed electrical wiring diagrams for the entire vehicle, essential for diagnosing electrical issues. Specifications Tables: Comprehensive tables of specifications for all major components and systems. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures. Detail Level: Step-by-step instructions, exploded views, diagrams, illustrations, and torque specifications. Diagrams Illustrations: Extensive use of detailed exploded views and schematic diagrams for clarity in disassembly, reassembly, and identification. Diagnostic Tools: May mention specific diagnostic tools or techniques required for certain systems, though limited by the era's technology. 📊 Manual Specifications File Format Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.) Searchability: Likely text-searchable PDF for quick information retrieval. Print Quality Quality: High-quality PDF, suitable for printing individual pages or sections. Binding Type Type: Not applicable (digital download) Paper Type Type: Not applicable (digital download) ⚙️ Engine Specifications Primary Engine Petrol Engines: 1.6L (XM7, XM7P), 1.8L (XN1, XN1A), 2.0L (XN2), 2.2L (ZDJL), 2.5L (J7S - Turbocharged petrol) Diesel Engines: 2.1L (XD2 Diesel), 2.3L (XD3 Diesel), 2.3L (XD3T...
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PEUGEOT 505 Workshop Repair Manual All 1979-1993 ModelS COVERED
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
505
Model Years Covered:
1979-1993
Codes
Chassis Codes:
Type 551 (Sedan), Type 551L (Station Wagon)
👋 Introduction
Market Position
Positioning:
The Peugeot 505 was a large, rear-wheel-drive executive car known for its comfortable ride, robust build, and European styling. It served as Peugeot's flagship model during its production run.
Competitive Analysis
Competitors:
Competed with other European executive sedans and wagons of the era, such as the Ford Granada, Opel Senator, Renault 25, and various models from BMW, Mercedes-Benz, and Volvo.
Key Features
Features:
Spacious interior, comfortable ride quality, durable construction, available in sedan and station wagon (Break) variants, strong diesel engine options, and renowned Pininfarina styling.
Manual Value
Utility:
Essential for owners and independent repair shops looking to maintain and repair the Peugeot 505, offering detailed technical guidance to ensure longevity and performance.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (applicable to all markets where Peugeot 505 was sold)
Trim Levels Covered:
All trim levels including GL, GR, GT, GTi, STI, Turbo, Diesel, Familiale
Page Count
Estimated Page Count:
Likely several hundred pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Purpose:
Designed for professional technicians and knowledgeable DIY mechanics to perform all maintenance and repair tasks.
Language
Language:
English (implied by product description common to international markets)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Internal combustion engines (petrol and diesel), including assembly, disassembly, troubleshooting, diagnostics, and component specifications.
Fuel System:
Carburetor systems (e.g., Solex, Zenith), fuel injection systems (e.g., Bosch L-Jetronic, Motronic), fuel pumps, filters, lines, and diagnostics.
Ignition System:
Distributor-based ignition, electronic ignition systems, spark plugs, coils, wiring, and timing adjustments.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications, and leak detection.
Exhaust System:
Exhaust manifold, catalytic converter (where applicable), muffler, pipes, and mounting.
Transmission Manual:
Clutch assembly, manual gearbox components, shift mechanisms, lubrication, and troubleshooting.
Transmission Automatic:
Automatic transmission service, fluid specifications, torque converter, valve body, and electronic control (where applicable).
Drivetrain:
Front-wheel drive components, driveshafts, CV joints, differentials, and rear-wheel drive axle (for certain variants).
Suspension:
Front MacPherson struts, rear trailing arms/coil springs, shock absorbers, control arms, anti-roll bars, and alignment specifications.
Steering:
Steering rack and pinion, power steering system (fluid, pump, hoses), steering column, and linkage.
Brakes Front:
Ventilated disc brakes, calipers, pads, rotors, and brake lines.
Brakes Rear:
Disc or drum brakes (depending on model year/trim), calipers/wheel cylinders, pads/shoes, rotors/drums, and brake lines.
Parking Brake:
Mechanism, cables, and adjustment.
Electrical System:
Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting, and instrument cluster.
Body Electrical:
Power windows, door locks, mirrors, wipers, horn, and interior lighting.
HVAC:
Heating, ventilation, and air conditioning system components, operation, and servicing.
Bodywork:
Body panel removal/installation, door mechanisms, latches, hinges, and trim.
Interior:
Seat removal/installation, dashboard components, interior trim panels.
Sensors:
Information on various sensors for engine management, temperature, oil pressure, etc.
Actuators:
Details on components like fuel injectors, ignition coils, and electric motors.
Emission Control:
Information on emission control systems, including catalytic converters (where fitted) and related components.
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, fluid checks and changes, lubrication, and tune-ups.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault codes (where applicable).
Repair:
Step-by-step instructions for component removal, overhaul, reassembly, and installation.
Overhaul:
Detailed instructions for the complete disassembly and reconditioning of major components like engines and transmissions.
Adjustment:
Precise instructions for adjusting systems such as ignition timing, carburetor idle speed, valve lash, and parking brake.
Specifications:
Torque values, clearances, fluid capacities, and other critical technical data for all repair procedures.
Diagnostics:
Guidance on identifying problems through visual inspection, testing, and the use of diagnostic equipment.
Troubleshooting Flowcharts:
Likely includes diagnostic flowcharts to systematically identify and resolve faults.
Wiring Diagrams:
Includes detailed electrical wiring diagrams for the entire vehicle, essential for diagnosing electrical issues.
Specifications Tables:
Comprehensive tables of specifications for all major components and systems.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Detail Level:
Step-by-step instructions, exploded views, diagrams, illustrations, and torque specifications.
Diagrams Illustrations:
Extensive use of detailed exploded views and schematic diagrams for clarity in disassembly, reassembly, and identification.
Diagnostic Tools:
May mention specific diagnostic tools or techniques required for certain systems, though limited by the era's technology.
📊 Manual Specifications
File Format
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)
Searchability:
Likely text-searchable PDF for quick information retrieval.
Print Quality
Quality:
High-quality PDF, suitable for printing individual pages or sections.
Binding Type
Type:
Not applicable (digital download)
Paper Type
Type:
Not applicable (digital download)
⚙️ Engine Specifications
Primary Engine
Petrol Engines:
1.6L (XM7, XM7P), 1.8L (XN1, XN1A), 2.0L (XN2), 2.2L (ZDJL), 2.5L (J7S - Turbocharged petrol)
Diesel Engines:
2.1L (XD2 Diesel), 2.3L (XD3 Diesel), 2.3L (XD3T Turbo Diesel)
Performance
Horsepower Range:
Approximately 70 hp (naturally aspirated diesel) to 160 hp (Turbocharged petrol).
Torque Range:
Approximately 130 Nm to 250 Nm (depending on engine).
Fuel System
Petrol Fuel Delivery:
Carburetor (Solex, Zenith) and Bosch L-Jetronic fuel injection for later models (GTi, Turbo).
Diesel Fuel Delivery:
Rotary injection pumps (e.g., Bosch VE) for naturally aspirated and turbocharged diesel engines.
🔧 Transmission
Standard
Manual Transmission:
4-speed and 5-speed manual transmissions.
Optional
Automatic Transmission:
3-speed and 4-speed automatic transmissions (e.g., ZF 3HP22, ZF 4HP22).
Features
Drive Type:
Rear-wheel drive (RWD).
📐 Dimensions
Exterior
Length:
Approx. 4,760 mm (sedan) / 4,800 mm (wagon).
Width:
Approx. 1,730 mm.
Height:
Approx. 1,450 mm (sedan) / 1,470 mm (wagon).
Wheelbase:
Approx. 2,800 mm.
Cargo
Trunk Volume:
Significant for its class, especially the wagon variant.
Weights
Curb Weight:
Approx. 1,300 - 1,500 kg (depending on engine and body style).
🛡️ Safety Features
Ratings
Crash Test Results:
While official modern ratings are scarce, contemporary reviews generally praised its robust construction for the era.
Active Features
Brakes:
Front ventilated discs, rear discs or drums. Optional ABS on later models.
Passive Features
Seatbelts:
Front and rear seat belts. Pretensioners may be present on later models.
Body Structure:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, often with optional upgraded sound systems.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on higher trim levels or later models.
Connectivity
Features:
Limited by era; primarily mechanical and basic electrical systems. No modern connectivity features.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000-7,500 km or 6-12 months, depending on driving conditions and oil type. Manual will provide exact intervals.
Transmission Fluid:
Manual: check level regularly, change as per schedule. Automatic: check level regularly, change fluid and filter typically every 40,000-80,000 km. Manual will provide exact intervals.
Fluid Specifications
Engine Oil:
Varies by engine type and ambient temperature. Common specifications include API SF/SG, SAE 10W-40, 15W-40, 5W-40. Manual will specify exact grade and capacity.
Coolant:
Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Manual will specify type and capacity.
Power Steering Fluid:
Hydraulic fluid specific to Peugeot or Dexron II/III for automatic transmission fluid used in some power steering systems. Manual will specify.
Known Issues
Common Problems:
Rust around wheel arches and sills, aging rubber components (bushings, hoses), carburetor tuning issues, potential electrical gremlins (older wiring), fuel pump reliability.
Diesel Specific Issues:
Glow plug system issues, injector pump wear on high-mileage engines.
📚 Vehicle History
Brand Heritage
Heritage:
Peugeot, a French automotive manufacturer, has a long history of producing reliable and comfortable vehicles, often characterized by advanced engineering and distinctive styling.
Model Evolution
Evolution:
The 505 succeeded the 604 and was a development of the 504 platform, featuring modernized styling by Pininfarina and updated mechanicals. It was one of Peugeot's last rear-wheel-drive sedans.
Production
Production Years:
1979-1992 (Europe), continued production in other markets (e.g., Argentina, Nigeria) until later dates.
Manufacturing Locations:
France (Sochaux), and licensed production in various countries.
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the 505 are not widely publicized, it was recognized for its comfort, durability, and value in contemporary automotive press.
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