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PEUGEOT Manuals
Automobile
404
Owners workshop manual
PEUGEOT 404 Owners Workshop Manual
1618cc, 1960-75
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Also See for 404
:
Service manual
(99 pages)
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Introduction
Description
The Engine
Working on Engine in Car
Removing and Replacing the Cylinder Head
Removing the Engine
Method of Slinging the Engine
Tightening Sequence
Cylinder Liners Locked with Locking Screw
Refitting the Cylinder Head
Servicing the Head and Valve Gear
Valve Spring Dimensions
Removing the Valve Timing Gear and Camshaft
Replacing Timing Gear and Camshaft
Valve Dimensions
Valves
Timing Adjustment Check
Timing Gear Adjustment Check
Removing and Refitting the Oil Pump
The Lubrication Circuit
Flywheel Repair Dimensions
Removing the Big-End Cap Nuts
Removing the Clutch and Flywheel
Splitting Big-Ends, Removing Rods and Pistons
Piston Dimensions for XC5 and Later Engines
Pistons, Rings and Gudgeon Pins and Cylinder Liners
The Cylinder Liner
Correcting Rods
Installing Perfect Circle Scraper Rings
Oil Scrape Rings, XC5 Engines
Connecting Rod Bearings
Gudgeon Pins
Installing the Crankshaft
Oil Filter
Reassembling Stripped Engine
Replacing Engine in the Car
Rocker Clearance Adjustment
Closed Crankcase Ventilation
Engine Stalls
Engine will Not Start
Fault Diagnosis
Fuel Pump, Operating Principles
Removing and Dismantling the Fuel Pump
Routine Maintenance
The Fuel System
Capacity Test
Chapter 2 The Fuel System
Pressure Test
Reassembling the Fuel Pump
Testing the Fuel Pump
Carburetor
Fuel Pump Pressure Test
The Accelerator Pump
To Start the Engine When Cold
Cold Start Jets
Normal Running Jets
Slow-Running Adjustment
Starting Checks
The Engine
Dismantling the Carburetor
Exploded View of the Solex PBICA Carburetor
Inspecting and Cleaning
Assembling the Pump Diaphragm Spring
Assembly of Pump Discharge Nozzle and Pilot Jet
Fitting the Pump Body Centralizing Screws
View with Float Chamber Cover Removed
Reassembly the Carburetor
Excessive Fuel Consumption
Idling Speed too High
Leakage or Insufficient Fuel Delivered
Noisy Fuel Pump
Adjusting the Contact Breaker Points
The Ignition System
Exploded View of the Distributor
Ignition Faults
The Distributor
Method of Finding the Crankshaft Position for Correct Ignition Timing
Sparking Plugs
Timing the Ignition
Contact Points
Primary Circuit
Secondary Circuit
Testing the Ignition System
Distributor Rotor
Engine Misfires
Engine will Not Fire
Routine Maintenance, Fan Belt Tension
The Cooling System
Cross-Section of the Magnetic Clutch Fan
Fan Belt Adjustment
Removing the Water Pump Center Nut
The Water Pump Attached to Engine
Fan Belt Tension
Pump Dismantling
Testing the Electro-Magnet Winding
Water Pump Removal and Installation
Pump Reassembly
Testing the Thermo-Switch
Corrosion
Internal Water Leakage
Poor Circulation
Thermostat
Chapter 1 The Clutch
Clutch Control Adjustment
Sectional Views of the Two Clutch Types
Driven Plate and Pressure Plate
Electro-Magnetic Jaegar Coupler
Refitting the Clutch
Removing the Clutch
Coupler Removal
Exchanging Powder on Original Coupler
Refitting the Coupler
Starter Crownwheel Replacement
Jaegar Coupling Electrical Circuit
Operation Diagram
Refitting the Conac
Removing and Replacing the Subal
Removing Conac
Removing the Jaegar Coupling
Components of Hydraulic Clutch Operation
Chapter 7
Clutch Fault Diagnosis
Drag or Spin
Hydraulic Clutch Operation
Master Cylinder
Suspension
Removing the Gearbox
The Gearbox or Transmission
Gearbox Dismantling
Refitting the Gearbox
Sectioned View of the C3 Type Gearbox
Dismantling the Main Drive Gear
Removing the Gearbox from the Car
Sectional View of the BA7 Type Gearbox
Dismantling the Mainshaft
Reassembling the Main Drive Gear
Reassembling the Mainshaft
Reassemlbing the Gearbox
Fitting the Special Gauge
Installing the Mainshaft in the Gearbox Case
Main Drive Gear
Rear Housing Extension
Removing the Speedometer Drive Socket
Dismantling the BA7 Gearbox
Removing the Half Housing
Removing the Rear Housing
Removing the Shifting Forks
Assembling the BA7 Gearbox
Locking Springs and Balls
Removing the Locking Plug
Removing the Reverse Shifting Fork
Fitting Reverse Pinion and Fork
Fitting Locking Balls and Springs
Fitting the Shifting Forks
Method of Locating Locking Ball and Spring
ZF Automatic Transmission
Checking Alignment of Clutch Housing Faces
Fitting the Gear Housing Bolts
Refitting the Gear Assembly
Adjusting the Gear Change Lever
Fitting the Rear Housing
Maintenance
Towing
Difficulty in Engaging Geers
Jumping out of Gear
Noise Gearbox
Removing the Transmission
Propeller Shaft, Rear Axle, Rear Suspension
Removing and Replacing the Centre Needle Bearing
Replacing the Centre Needle Bearing
The Drive Shaft
Removing and Replacing the Rear Axle Shaft
Removing Rear Axle
The Rear Axle
Diagnosing Rear Axle Faults
Rear Suspension
Removing the Rear Axle Shaft
Excessive Backlash
Noisy Axle
Oil Leakage
Rear Shock Absorber Removal and Refitting
Front Hub Removal and Dismantling
Front Suspension and Hubs
Sectioned View through the Front Suspension
Front Hub Reassembly and Refitting
Front Suspension Unit Dismantling
Front Suspension Unit Removal
Upper Suspension Fixing Screws and Balance
Front Suspension Unit Reassembly
The Upper Suspension Seal Assembly
The Coil Spring Prepared for Installation
The Lower Suspension Ball Head Joint
Driving in the Serrated Pins with Block Z in Position
Front Arm Attachment on the Crossmember
Front Crossmember Removal and Refitting
Refitting the Front Suspension Unit
Bottoming of Suspension
Suspension Geometry
Wheel Balancing
Wheel Wobble
Removing the Rack and Pinion Unit
The Steering Gear
Dismantling the Rack and Pinion
Reassembling the Rack and Pinion
The Rack and Pinion Assembly
View of Front Axle and Steering Gear
Adjusting the Steering Rack Ball Head
Adjusting the Pinion Side Rack Damper Plunger Clearance
Adjusting the Rack Ball Head Assembly
Connecting Link Ball Joints
Exploded View of Connecting Link Outer Ball Joint
Refitting the Rack and Pinion Unit
Road Testing the Steering
Wander
Heavy Steering
Lost Motion
Brake Shoe Adjustment
Front Brakes
The Braking System
Brake System Layout
Rear Brakes
Brake Drums and Brake Shoes
Front Brake Shoe Removal
Preventative Maintenance
Righthand Brake
Front Brake Shoe Reassembly
Relining Brake Shoes
Brake Shoe Springs
Checking the Brake Pedal Travel
Hydraulic Equipment
Reassembling Lefthand Front Brake
Removing a Flexible Hose
The Master Cylinder
Bleeding the Hydraulic System
Bleeding the System
Front Brake Hoses
Handbrake Adjustment
Front Wheel Cylinder
Hydraulic Fluid
Adjusting the Handbrake Controls
Disc Front Brakes
Rear Wheel Cylinder
Components of Front Brake Caliper Assembly
Removing Brake Pads
Renewing Brake Pads
Bleeding the Brakes
Brakes Grab or Pull to One Side
Excessive Pedal Movement
Spongy Pedal
The Battery
The Electrical System
Exploded View of Ducellier 7210 G Generator
Exploded View of Paris Rhone G 11 R 110 Generator
The Charging System
Commutator Servicing
Servicing Brushes
The Armature
The Starters
Commutator
Solenoid
Starter Adjustment
Starter Drive
Accessories
Fuses and Fuse Ratings
Lights
Side, Indicator and Brake Lights
Checking the Diodes
Battery Discharged
Battery will Not Hold a Charge
Insufficient Charging Current
Printed Circuit Instrument Panel
Bodywork Finish
Removing and Refitting the Sunroof
The Bodywork
Adjusting the Door Catches
Door Catch Adjustments
Refitting the Sun Roof
Removing and Replacing the Windscreen Glass
Preparation of Windscreen for Fitting
Removing and Replacing the Rear Window
Section of Rear Window and Seal
Section of the Windscreen and Seal
Preparation of New Glass
Refitting the Window Glass
Removing the Window
Replacing Door Window of 404 Cabriolet
Details of Cable Assembly of Window Lift
Details of Door Ventilator
Replacing Window Lifter and Cable Assembly
Ventilator Adjustment
Folding Top Attachments and Correct Stowage
Removing and Refitting a Ventilator
Ventilator Mobile Frame Details
Heating and Ventilation
Lowering Procedure for Folding Top on Convertible
Seat Belt Anchorages
Seat Belts
Technical Data
Wiring Diagrams and Special Tools
Electrical Equipment
Torque Wrench Settings
Wiring Diagram of Saloon and Estate Cars
Wiring Diagram Coupe 1968
Wiring Diagram Saloon 1970
Timing Adjustment Check Rod
Wiring Diagram of the Jaegar Coupler
Hints on Maintenance and Overhaul
Quality of Workmanship
Safe Working Conditions
Work Demanding Special Care
Glossary of Terms
Index
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