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PEUGEOT
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404
PEUGEOT 404 User Manual
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3rd
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GEN
E
RATOR
9enerolor
botiery
reloy
RI
Clutch
on
Clutch
oíÍ
I
De
mog
nel
resi
slor
OPERATION
DIAGRAM
cot
L
95
F5
bottery
fuse
18A
Economy
Íesi
slot
7
circuit
closer
BATT
E
R}
4
=lrlrlNr,
switch
Distribulor
F6
g€nerotor
tu9è
184
R2
Coupler
control
Fuses
plote
ond
energency
connexigns
____l
ca
80
88
R7
COUPL
ER
I
I
-
Bottery
feeding
ot
speeds
obove
ló
mph
-
Generotor
feeding
only
-
Bottery
íeeding
only
Generotor
feeding.
ot
speeds
lower
thon
ló
mph
P404
FIG
5:6
Jaeger
coupling
elêctrical
circuit.
POGEL
is
the
manual
override
control
47
45
47
Table of Contents
Default Chapter
4
Table of Contents
4
Introduction
7
Description
8
The Engine
8
Working on Engine in Car
8
Removing and Replacing the Cylinder Head
9
Removing the Engine
9
Method of Slinging the Engine
10
Tightening Sequence
10
Cylinder Liners Locked with Locking Screw
11
Refitting the Cylinder Head
11
Servicing the Head and Valve Gear
11
Valve Spring Dimensions
11
Removing the Valve Timing Gear and Camshaft
12
Replacing Timing Gear and Camshaft
12
Valve Dimensions
12
Valves
12
Timing Adjustment Check
13
Timing Gear Adjustment Check
13
Removing and Refitting the Oil Pump
14
The Lubrication Circuit
14
Flywheel Repair Dimensions
15
Removing the Big-End Cap Nuts
15
Removing the Clutch and Flywheel
15
Splitting Big-Ends, Removing Rods and Pistons
15
Piston Dimensions for XC5 and Later Engines
16
Pistons, Rings and Gudgeon Pins and Cylinder Liners
16
The Cylinder Liner
16
Correcting Rods
17
Installing Perfect Circle Scraper Rings
17
Oil Scrape Rings, XC5 Engines
17
Connecting Rod Bearings
18
Gudgeon Pins
18
Installing the Crankshaft
19
Oil Filter
20
Reassembling Stripped Engine
20
Replacing Engine in the Car
20
Rocker Clearance Adjustment
20
Closed Crankcase Ventilation
21
Engine Stalls
21
Engine will Not Start
21
Fault Diagnosis
21
Fuel Pump, Operating Principles
22
Removing and Dismantling the Fuel Pump
22
Routine Maintenance
22
The Fuel System
22
Capacity Test
23
Chapter 2 The Fuel System
23
Pressure Test
23
Reassembling the Fuel Pump
23
Testing the Fuel Pump
23
Carburetor
24
Fuel Pump Pressure Test
24
The Accelerator Pump
24
To Start the Engine When Cold
24
Cold Start Jets
25
Normal Running Jets
25
Slow-Running Adjustment
25
Starting Checks
25
The Engine
25
Dismantling the Carburetor
26
Exploded View of the Solex PBICA Carburetor
26
Inspecting and Cleaning
26
Assembling the Pump Diaphragm Spring
27
Assembly of Pump Discharge Nozzle and Pilot Jet
27
Fitting the Pump Body Centralizing Screws
27
View with Float Chamber Cover Removed
27
Reassembly the Carburetor
28
Excessive Fuel Consumption
29
Idling Speed too High
29
Leakage or Insufficient Fuel Delivered
29
Noisy Fuel Pump
29
Adjusting the Contact Breaker Points
30
The Ignition System
30
Exploded View of the Distributor
31
Ignition Faults
31
The Distributor
31
Method of Finding the Crankshaft Position for Correct Ignition Timing
32
Sparking Plugs
32
Timing the Ignition
32
Contact Points
33
Primary Circuit
33
Secondary Circuit
33
Testing the Ignition System
33
Distributor Rotor
34
Engine Misfires
34
Engine will Not Fire
34
Routine Maintenance, Fan Belt Tension
36
The Cooling System
36
Cross-Section of the Magnetic Clutch Fan
37
Fan Belt Adjustment
37
Removing the Water Pump Center Nut
37
The Water Pump Attached to Engine
37
Fan Belt Tension
38
Pump Dismantling
38
Testing the Electro-Magnet Winding
38
Water Pump Removal and Installation
38
Pump Reassembly
39
Testing the Thermo-Switch
39
Corrosion
40
Internal Water Leakage
40
Poor Circulation
40
Thermostat
40
Chapter 1 The Clutch
42
Clutch Control Adjustment
42
Sectional Views of the Two Clutch Types
43
Driven Plate and Pressure Plate
44
Electro-Magnetic Jaegar Coupler
44
Refitting the Clutch
44
Removing the Clutch
44
Coupler Removal
45
Exchanging Powder on Original Coupler
45
Refitting the Coupler
45
Starter Crownwheel Replacement
45
Jaegar Coupling Electrical Circuit
46
Operation Diagram
46
Refitting the Conac
47
Removing and Replacing the Subal
47
Removing Conac
47
Removing the Jaegar Coupling
47
Components of Hydraulic Clutch Operation
48
Chapter 7
49
Clutch Fault Diagnosis
49
Drag or Spin
49
Hydraulic Clutch Operation
49
Master Cylinder
49
Suspension
49
Removing the Gearbox
50
The Gearbox or Transmission
50
Gearbox Dismantling
51
Refitting the Gearbox
51
Sectioned View of the C3 Type Gearbox
51
Dismantling the Main Drive Gear
52
Removing the Gearbox from the Car
52
Sectional View of the BA7 Type Gearbox
52
Dismantling the Mainshaft
53
Reassembling the Main Drive Gear
53
Reassembling the Mainshaft
53
Reassemlbing the Gearbox
53
Fitting the Special Gauge
54
Installing the Mainshaft in the Gearbox Case
54
Main Drive Gear
54
Rear Housing Extension
55
Removing the Speedometer Drive Socket
55
Dismantling the BA7 Gearbox
56
Removing the Half Housing
56
Removing the Rear Housing
56
Removing the Shifting Forks
56
Assembling the BA7 Gearbox
57
Locking Springs and Balls
57
Removing the Locking Plug
57
Removing the Reverse Shifting Fork
57
Fitting Reverse Pinion and Fork
58
Fitting Locking Balls and Springs
59
Fitting the Shifting Forks
59
Method of Locating Locking Ball and Spring
59
ZF Automatic Transmission
59
Checking Alignment of Clutch Housing Faces
60
Fitting the Gear Housing Bolts
60
Refitting the Gear Assembly
60
Adjusting the Gear Change Lever
61
Fitting the Rear Housing
61
Maintenance
61
Towing
61
Difficulty in Engaging Geers
62
Jumping out of Gear
62
Noise Gearbox
62
Removing the Transmission
62
Propeller Shaft, Rear Axle, Rear Suspension
64
Removing and Replacing the Centre Needle Bearing
64
Replacing the Centre Needle Bearing
64
The Drive Shaft
64
Removing and Replacing the Rear Axle Shaft
65
Removing Rear Axle
65
The Rear Axle
65
Diagnosing Rear Axle Faults
66
Rear Suspension
66
Removing the Rear Axle Shaft
66
Excessive Backlash
67
Noisy Axle
67
Oil Leakage
67
Rear Shock Absorber Removal and Refitting
67
Front Hub Removal and Dismantling
68
Front Suspension and Hubs
68
Sectioned View through the Front Suspension
69
Front Hub Reassembly and Refitting
70
Front Suspension Unit Dismantling
70
Front Suspension Unit Removal
70
Upper Suspension Fixing Screws and Balance
70
Front Suspension Unit Reassembly
71
The Upper Suspension Seal Assembly
71
The Coil Spring Prepared for Installation
72
The Lower Suspension Ball Head Joint
72
Driving in the Serrated Pins with Block Z in Position
73
Front Arm Attachment on the Crossmember
73
Front Crossmember Removal and Refitting
73
Refitting the Front Suspension Unit
73
Bottoming of Suspension
74
Suspension Geometry
74
Wheel Balancing
74
Wheel Wobble
74
Removing the Rack and Pinion Unit
76
The Steering Gear
76
Dismantling the Rack and Pinion
77
Reassembling the Rack and Pinion
77
The Rack and Pinion Assembly
77
View of Front Axle and Steering Gear
77
Adjusting the Steering Rack Ball Head
78
Adjusting the Pinion Side Rack Damper Plunger Clearance
79
Adjusting the Rack Ball Head Assembly
79
Connecting Link Ball Joints
79
Exploded View of Connecting Link Outer Ball Joint
80
Refitting the Rack and Pinion Unit
80
Road Testing the Steering
80
Wander
80
Heavy Steering
81
Lost Motion
81
Brake Shoe Adjustment
82
Front Brakes
82
The Braking System
82
Brake System Layout
83
Rear Brakes
83
Brake Drums and Brake Shoes
84
Front Brake Shoe Removal
84
Preventative Maintenance
84
Righthand Brake
84
Front Brake Shoe Reassembly
85
Relining Brake Shoes
85
Brake Shoe Springs
86
Checking the Brake Pedal Travel
86
Hydraulic Equipment
86
Reassembling Lefthand Front Brake
86
Removing a Flexible Hose
87
The Master Cylinder
87
Bleeding the Hydraulic System
88
Bleeding the System
88
Front Brake Hoses
88
Handbrake Adjustment
88
Front Wheel Cylinder
89
Hydraulic Fluid
89
Adjusting the Handbrake Controls
90
Disc Front Brakes
90
Rear Wheel Cylinder
90
Components of Front Brake Caliper Assembly
91
Removing Brake Pads
91
Renewing Brake Pads
91
Bleeding the Brakes
92
Brakes Grab or Pull to One Side
92
Excessive Pedal Movement
92
Spongy Pedal
92
The Battery
94
The Electrical System
94
Exploded View of Ducellier 7210 G Generator
95
Exploded View of Paris Rhone G 11 R 110 Generator
95
The Charging System
97
Commutator Servicing
98
Servicing Brushes
98
The Armature
98
The Starters
98
Commutator
99
Solenoid
99
Starter Adjustment
99
Starter Drive
99
Accessories
100
Fuses and Fuse Ratings
100
Lights
100
Side, Indicator and Brake Lights
100
Checking the Diodes
101
Battery Discharged
102
Battery will Not Hold a Charge
102
Insufficient Charging Current
102
Printed Circuit Instrument Panel
102
Bodywork Finish
104
Removing and Refitting the Sunroof
104
The Bodywork
104
Adjusting the Door Catches
105
Door Catch Adjustments
105
Refitting the Sun Roof
105
Removing and Replacing the Windscreen Glass
105
Preparation of Windscreen for Fitting
106
Removing and Replacing the Rear Window
106
Section of Rear Window and Seal
106
Section of the Windscreen and Seal
106
Preparation of New Glass
107
Refitting the Window Glass
107
Removing the Window
107
Replacing Door Window of 404 Cabriolet
107
Details of Cable Assembly of Window Lift
108
Details of Door Ventilator
108
Replacing Window Lifter and Cable Assembly
108
Ventilator Adjustment
108
Folding Top Attachments and Correct Stowage
109
Removing and Refitting a Ventilator
109
Ventilator Mobile Frame Details
109
Heating and Ventilation
110
Lowering Procedure for Folding Top on Convertible
110
Seat Belt Anchorages
110
Seat Belts
110
Technical Data
111
Wiring Diagrams and Special Tools
111
Electrical Equipment
119
Torque Wrench Settings
120
Wiring Diagram of Saloon and Estate Cars
121
Wiring Diagram Coupe 1968
122
Wiring Diagram Saloon 1970
122
Timing Adjustment Check Rod
123
Wiring Diagram of the Jaegar Coupler
123
Hints on Maintenance and Overhaul
124
Quality of Workmanship
124
Safe Working Conditions
124
Work Demanding Special Care
124
Glossary of Terms
128
Index
132
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PEUGEOT 404 Specifications
General
Brand
PEUGEOT
Model
404
Category
Automobile
Language
English
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