PEUGEOT 404 User manual

PEUGEOT

Sphrrire-

FOREWORD

The Peugeot 404 Service Monuol hos been compiled

to provide the service technicion with complete moin-

tenonce ond repoir inÍormotion on the vorious units

of the 404,U. S. Model.

Though primorily designed os o reÍerence Íor the

experienced service mon, it olso inciudes step-by-step

procedures in mony oÍ the overhoui operotions. This

mr^rnttr-rl qrrï1 ï1 larnanlc *raininry

u uyr-r courses glven to

mechcrnics of cruthorized Peugeot deolerships.

Repoir methods crre outlined in this book with the

use of Peugeot Speciol Tools, recommended shop

equipment, ond stondord hond tools. Genuine Peugeot

ports ore employed Ín the repoirs outlined.

Peugeot, Inc. reserves the right to moke chonges ot

ony time without notice.

All doto, illustrotions, ond speciÍicotions contoined

in ihis mcnuol ore bosed on the lotest inÍormotion

ovoiloble crt the time oí publi.coti.on. Amendments will

be mode, os necessory, by meons of Service Circulors.

PEUGEOT, INC.

R. F. Krieger

Service Monoger

ril

Hectrical [quipment

Accessori es

Section lndex

Engine

Clutch

ïransntission

Propeller ShaÍt

Rear Axf e

Stesring

Brakes

Rear $uspension

tllheels and ïires

Body

Lulrication & '[|aintenance

ENGINE l-j

Contents

Description

Specificqtions

Section j

Removql of the Engine

Engine mounts

Reinstq.llotion of the Engine

Compiete Disossembly of the

Inspection ond Reossembly Engine

l- /1

I 11

'| tl

I l.

t- !z

1-l ?

1-1 ^

1-14

1-1 t

1 t-

Cronkshqft

Thrust segrnents

Cylinder s.leeves

Moin beorings

Connecting rod beorrngs

Pistons

Piston rings

Connectlng rods

Cqmshqft

Vqlve timing

Timing choin mechonism

tensionner

I 1^

Oil pump

Oi.l filter 1- lB

l- lo

1-19

t- zu

I ar

r-z L

'I ar

t-zI

'| ar

I a1

t-z!

I aa

L-ZZ

I a^

t- zz

I aa

t-zz

'I a^

!-zz

T-ZJ

I a.

Engine Iubricqtion

Vqlve lifters . .

Cylinder heod gosket

Cylinder heod

Sn^-l, * r.

"yurÀ prug protector tube

Vqlve seots ond guides

Vqlves

Vqlve springs

Push rods

Rocker qrms

Rocker orm ossembly

Heqd boit torquing seguence

Adjustment of rocker orm

I- ZJ

t- z3

Theoretjc odjustment of vqjve timing

r-2 ENGINE

Contents (continued)

Engine Cooling

Rqdiqtor

Thermostqt

Automqtic fon clutch

Automqtic fon clutch thermocontact

Woter pump removql

Snoninl tnnl.

Engine Cqrburetion qnd Exhoust

D.istributor

High tension wiring

r-24

I-24

1 ^t

L- 24

I-24

r-25

Woter pump instollqtion I-25

Wqterpumpdisossembiy... I-25

Wcter pump checks I-26

Woter pump reossembly I-26

r-z I

T-28

o Corburetor I-28

Removql of the corburetor 1-30

Disqssembly of the cqrburetor 1-30

Instqllqtion of the corburetor

1-30

I-3 I

1-3 i

I-32

r-32

I-33

1-33

Idle qdjustment

Frrol nrrmn

r qv. y urrrP

Air Íilter

Engine Electricql

Ignition timing

Spork plugs

DESCRIPTION

The XC tvne encine is on

the 203 ond 403 engines.

ness qnd durobility.

ENGINE

qll new engine, designed in the Íine trodition of

It retqins oll oÍ its quolities of strength, rugged-

t-3

It is qn oversquqre, in-line, wqter cooled four-cylinder engine with q dis-

plocement oÍ 98.7 cubic inches. This design offers considerqbly reduced

piston trqvel while minimizing stress on the moving ports.

By tiltinq the engine qt o 45o ongle, the following odvontoges ore obtqined:

lower hood line, lower center of grovity, better weight distribution on the

front end qnd eqsler occessibility oÍ oll engine components.

Some other speciol feotures of this engine ore its superior breothing spheri-

cql offset combustion chombers qnd its sonicolly tuned j.nduction system.

1-/ ENGINE

SPECIFICATIONS

EngineType. .....XC

Roted Horse Power (SAE) 72 BHP @ 5400 RPM

TqxobleHorsePower(UsA) .....17.5

Number of Cylinders . Four, inclined ot 45o to the right

Loy-out . In line

Bore . 3.31" (84 m.m.)

Stroke . 2.87" (73 m.m.)

Displocement.... ..98.74cu,in.(1618c.c.)

PistonAreo. ..... ..34.3Sq. Inches

Piston Speed ot Moximum BHP . 2580 feet per minute

/a^**-^^^i^- D-+r^ '1 Á L

VVlllPl YÈ>lull I IULIU t .1 .

SpeciÍic BHP per Liter o 5400 RPM 44.5 HP

MoximumRPM.. ...5400RPM

Mqximum Torque 94 ]b. ft. qt 2250 RPM

Cylinders . Wet removoble liners

Crqnkshoft ...3Beorings-RemovobleCounterweights

CylinderHeod. ....Hemispheric,Alpox (cold)

Vqlves . . . Inclined overheqd, push rod operoted

Timing . Double link choin, hydroulicolly controlled tensionner

F "al D"*^ \,4^^h^-i^nl

urrrP . .

Ccnburetor . Solex 32 PBICA Downdroft

Ignition Timing Control Centrlfugol qnd Vocuum

Ignition Timing . . . llo Before top deqd center (stqtic)

Canlnnl R"o^Lan ênn n)^'t

Spcrk Plugs AC 44F, Autolite AE6, Chompion L8, LlO

Oil Filter Full flow, Screen Type

q,,-^ a^^^^i+., AI/. ^,,-^+^

vu,rry vuyuurLt . . . . a/4 vuutrè

Cooiing System Copocity , . . B% Qucrts

Bottery

ENGINE

POWER.TORQUE CURVES

These curves correspond to S.A.E. Testing Procedures with the use of regulor grode gosoline, ond

the recommended odjustments of the engine.

I-5

BHP

ó5

ó0

R.P.M. 1000 I 500 2000 2250 3000 3500 4000 4500 5400

Rt{p I5 25.50 35 ÁÀ tr 59 64 6B 72

t 9l r{ q s-lu-1 L78. I86.8 9I. B94 91. i88.2 84.6 79.5 68.7

t-6 ENGIN

REMOVAL OF THE ENGINE

I - Put fender covers in ploce ond dis-

connect the bqttery.

2 - Droin the cooling system. Sove the

coolont which contqins petmonent onti-

freeze.

3 - Remove - windshield wosher jets

- hood

- cronk hondle

- windshield wosher jor

- ccnburetor oil bqth oir cleoner

- ccnburetor qi.r cleoner ond

silencer hoses

- igni.tion coil

- bottery

- tov,m horn

4. Disconnect rodiotor, heqter hoses, ond

corburotor heqter hose.

5 - Remove rqdiotor with the return heoter

hose.

ó - Remove the 2 bolts securing the stcrter

in iho hall hnrrsinn

7 - Disconnect: the storter cobles qnd wire

the generator wires

the temperoture goge wire

the fon thermql contoct wire

the oil pressure contqct wire

8 - Disconnect: the occelerqtor coble ond

the choke cqble.

9. Remove the fuel line from the oil

breother.

l0 . Remove the bdíles from the beil

housing.

Il - Remove the 2bolts securing the exhoust

nino ln lho mnnifnlÀ an.] tho hnl+ h^i.l-

Pfyv !v

ing the exhoust pipe clomp onthetrons-

-i^^i^- L^,,-i-^

rrrtèètvrl rruu-Irtv.

- Support the bell housing or front of

trcnrsmission with q slinq such qs shown

or on q stcrnd.

13 - Remove the 3 Alien bolts securing the

holi hnrrcinn in lh,

.- .^.e engrne.

l4 - Attqch the chqinhooks or llftinq device

to the two liftinq eyes of the engine

block.

15. Remove the engine securing nuts from

the front mounts.

16 - Free the

hrr ^"lli-^

vf yqrr!rrv

17 - When the

ihc rinhi

cqI.

engine from the trqnsmission

it to the front.

enoine is frec. trrrn il towcrd

to temove it soíely from the

ENGINE r-7

ENGINE MOUNTS

The engine-tronsmi ssion ossembly, mounted

ot three poinis, is inclined 5o toword the

Front Engine Mounf

At the íront, the engine rests on two rubber

blocks ot the centerline of the engine.

On the righf support, on interlocking cover

prevents the rubber mount írom excessive

stretch i ng.

On the lefi, o sofety plote will keep suf-

ficient cleoronce iÍ the rubber block is

cru shed.

The torque of the mount ottochment bolts

is 15 ít. lbs.

The torque oÍ the cenfer nut is 40 ft. lbs.

Reor Engine Mount

The reor of the tronsmission is supported

in o vulconized rubber ring.

Two dompener weights qftoched to fhe reor

mount obsorb lhe resonont vibrotion of the

engine cronkshoít.

The right weight (7) is the longer, 6ó mm.,

ond hos o resononf Írequency of I 15

herizion woves. The left weight (ó) is

52.5 mm. in length with o hertzion fre-

quency oÍ 128.

The two weighis must be reploced only

os o pockoge, port #1874.01, in order to

mointoin o difference of l3 hertzion woves

between them.

The reor suppori rubber will be domoged

by oil, greose, point, or trichlorethylene.

It is odvised to coot eoch side oÍ the

mount with Permotex *3 when instollino.

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