Engine Systems:
Engine overhaul, fuel injection, carburetion, ignition, cooling, lubrication, exhaust, engine management systems
Transmission Systems:
Manual transmission, automatic transmission (including clutch, gearbox, driveshafts, differentials)
Suspension Steering:
Front and rear suspension, shock absorbers, springs, control arms, steering rack, power steering system
Braking Systems:
Front and rear brakes (disc/drum), hydraulic system, ABS (if applicable), parking brake
Electrical Systems:
Wiring diagrams, lighting, starting and charging system, instruments, switches, fuses, relays, electronic control units (ECU)
Body And Chassis:
Bodywork repair, doors, windows, interior trim, bumpers, chassis components, corrosion protection
HVAC System:
Heating, ventilation, and air conditioning (HVAC) system operation and repair
Emission Control Systems:
Covers emission control components and diagnosis for applicable models, including catalytic converters, oxygen sensors, and EGR systems.
Exhaust System:
Information on exhaust manifold, catalytic converter, mufflers, and pipes, including leak detection and component replacement.
Lighting System:
Headlights, taillights, turn signals, brake lights, interior lighting, including bulb types, troubleshooting, and wiring.
Maintenance Procedures:
Routine maintenance, fluid changes, filter replacements, lubrication, tune-ups, inspections
Repair Procedures:
Detailed step-by-step repair instructions for all major components and systems
Diagnostic Procedures:
Troubleshooting guides, fault finding for mechanical and electrical issues, diagnostic trouble codes (DTCs) if applicable
Rebuild Procedures:
Comprehensive instructions for engine rebuilds, transmission overhauls, and component refurbishments
Engine Mechanical Procedures:
Cylinder head removal and installation, piston and connecting rod service, crankshaft bearing inspection and replacement, camshaft timing, valve seat grinding and lapping, oil pump servicing, engine block inspection and machining recommendations.
Fuel System Procedures:
Carburetor overhaul and adjustment (all types specified), fuel pump testing and replacement, fuel injector testing and cleaning, fuel tank removal and cleaning, fuel line routing and replacement.
Ignition System Procedures:
Distributor disassembly and service, ignition coil testing, spark plug type and gap specifications, ignition timing adjustment procedures, electronic ignition module troubleshooting.
Cooling System Procedures:
Radiator removal and testing, water pump replacement, thermostat testing and replacement, cooling fan operation and testing, heater core servicing, coolant flush and replacement procedures.
Transmission Overhaul Manual:
Clutch disc and pressure plate replacement, gearbox component identification and assembly sequence, synchromesh ring inspection, bearing replacement, output shaft and input shaft servicing.
Transmission Overhaul Automatic:
Torque converter removal and installation, valve body testing and cleaning, seal kit replacement, clutch pack inspection, transmission fluid cooler line maintenance.
Suspension Component Replacement:
Ball joint replacement, tie rod end replacement, shock absorber and strut replacement, spring seat replacement, sway bar link and bushing replacement.
Steering System Repair:
Steering rack bellows replacement, power steering pump testing and replacement, steering column universal joint servicing, steering wheel removal and installation.
Brake System Maintenance:
Brake pad and shoe replacement, brake caliper and wheel cylinder overhaul, brake rotor and drum resurfacing/replacement, brake line bleeding procedures, parking brake adjustment.
Electrical Troubleshooting Wiring:
Comprehensive wiring diagrams for all circuits, diagnostic procedures for common electrical faults, troubleshooting flowcharts for lighting, starting, charging, and accessory systems.
Body Panel Repair:
Procedures for panel alignment, door hinge adjustment, window regulator repair, lock mechanism servicing, and potentially basic body filler and painting guidance.
HVAC System Repair:
Refrigerant system servicing (if applicable, with safety precautions), blower motor replacement, heater core flush, control cable adjustment, cabin air filter replacement (if equipped).
Wheel Alignment Specifications:
Provides front and rear wheel alignment specifications (camber, caster, toe) for optimal handling and tire wear.
Fuel Tank And Lines:
Procedures for fuel tank removal, cleaning, fuel sender unit replacement, and fuel line inspection and replacement, including emphasis on safety.
Wiper And Washer System:
Diagnosis and repair of wiper motors, linkages, washer pumps, and nozzles, as well as fluid reservoir maintenance.
Depth Of Information:
Professional-level detail suitable for technicians, with sufficient information for experienced DIY mechanics
Diagnostic Tools:
Covers diagnostic procedures, often implying the use of specialized tools and equipment
Torque Specifications:
Includes critical torque specifications for virtually all fasteners, ensuring proper assembly and preventing damage.
Clearances And Tolerances:
Provides engine bearing clearances, ring gaps, valve clearances, and other critical measurements for rebuilding components.
Special Tools:
Highlights any specific Peugeot or aftermarket tools required for certain procedures, aiding in proper execution.
Cylinder Head Bolt Torque Sequence:
Detailed torque sequences and multi-stage torquing for cylinder head bolts, crucial for proper gasket sealing and preventing warpage.
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 specified in the manual.
Timing Belt Replacement:
For engines utilizing a timing belt (e.g., 4-cylinder petrol, XUD diesels), replacement intervals are critical, typically around 60,000-80,000 miles (96,000-128,000 km) or 5 years. This manual will detail specific intervals and procedures.
Transmission Fluid Change:
Manual transmission fluid change typically every 30,000-50,000 miles (48,000-80,000 km). Automatic transmission fluid and filter service usually recommended every 20,000-30,000 miles (32,000-48,000 km).
Spark Plug Replacement:
Depending on type (conventional, platinum), intervals can range from 15,000-30,000 miles (24,000-48,000 km). Manual will specify correct types and gaps.
Engine Oil Specification:
Likely API SF/SG or ACEA A1/B1, with viscosity grades such as 10W-40 or 15W-50, depending on engine type and ambient temperature. Manual will specify exact grades and capacities.
Coolant Specification:
Ethylene glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Manual will detail capacity and recommended type (e.g., Type D for older Peugeot specifications).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify type and change interval.
Transmission Fluid Manual:
GL-4 gear oil, with specific API classifications and viscosity grades (e.g., 75W-90 or 80W-90). Capacity will be detailed.
Transmission Fluid Automatic:
Dexron II or III specification automatic transmission fluid (ATF). Manual will specify type and capacity.
Common Wear Items:
Due to age, common issues can include worn suspension bushings, aging fuel lines, carburetor or fuel injection system issues, ignition system components (distributor, spark plug wires), exhaust leaks, and potential rust in common areas if not maintained.
Electrical Aging Concerns:
Degradation of wiring insulation, corrosion in electrical connectors, and failure of older electronic components (e.g., fuel injection control modules, relays) can occur over time. The manual's wiring diagrams and troubleshooting are invaluable here.
