PEUGEOT 505 Workshop Repair Manual All 1979-1993 ModelS COVERED

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Art.-Nr: 125894

Stichworte: 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 505 Car Cars Peugeot

Produktvarianten

Beschreibung

The Peugeot 505, produced from 1979 to 1993, represents a significant offering in the executive car segment, known for its spacious interior, comfortable ride quality, and durable construction. Available in both sedan and station wagon body styles, this rear-wheel-drive vehicle was a flagship model for Peugeot, blending European styling, often attributed to Pininfarina, with robust engineering. It offered a range of petrol and diesel engines, from efficient naturally aspirated diesels to more powerful turbocharged petrol variants, and was equipped with either manual or automatic transmissions. The 505 competed effectively in its class, valued for its reliability and practicality. This comprehensive workshop service repair manual provides extensive coverage for all Peugeot 505 trim levels, including GL, GR, GT, GTi, STI, Turbo, Diesel, and Familiale, across all global markets. It details maintenance procedures, troubleshooting guides, and repair instructions for every major system, including the engine, fuel, ignition, cooling, exhaust, transmission, drivetrain, suspension, steering, brakes, and electrical systems. With step-by-step instructions, detailed diagrams, illustrations, and essential specifications, this manual is an indispensable resource for owners and technicians alike, ensuring the proper maintenance, repair, and longevity of the Peugeot 505.

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

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:

📖 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

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.