PEUGEOT 404 User manual

PEUGEOT
Sphrrire-
a
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
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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
la
l- /1
1-
I 11
'| tl
I l.
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
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
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
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
80
75
70
ó5
ó0
55
50
15
40
35
25
20
t5
I
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

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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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