CITROEN CX 2000 Repair Manual Download Page 124

Page: 124 / 394

Summary of Contents for CX 2000

Page 1: ......

Page 2: ...DYWORK Volume 3 deals with the CX Diesel cd E The above volumes are sold separately They are presented bound in dark red Fibrex with a 1 MULTO 1 type mechanism to facilitate the insertion of supplements or the extraction of a cl3 particular operation required by the workshop L a COMPOSITION Every volume comprises the list of operations contained in the volume these operations filed in numerical se...

Page 3: ...ools specially designed for CX vehicles Additional tools of local manufacture are indicated in the text by a number preceded by the index MR manufacturing drawings for these tools appear at the end of the particular volume filed in numerical order TIGHTENING TORQUES Torques are expressed in the following units either in metres Newton m N the legal unit for measuring torque with the corresponding a...

Page 4: ...3 623 engine Characteristics and special features of the anti pollution system I SWEDISH Jlurket r c kicles Adjusting the carburettor adjusting the idling speed Checking and adjusting the anti pollution system SIVI DfSH Mdrkct rvhicles J Characteristics and special features of the electronic fuel injection system L etKJnic Checking and adjusting the electronic fuel injection system 1 Jetrolzic Che...

Page 5: ...reserve of pressure hydraulic system Checking the hydraulic components on the vehicle FRONT AXLE O7 Characteristics and special features of the front axle Checking and adjusting the front axle Checking the camber Checking and adjusting the castor angle Checking and adjusting the wheel alignment Checking and adjusting the steering geometry Checking the steering for straight line deviation whirfes c...

Page 6: ...tJ _ Pngc s 5 8 Estntc SIIpw IIf 1976 1 Pugc s 9 12 I strriv cut pajf I nil r c hicles 9 1975 Page 13 Tvrqrl COIlI erter l l976 I ogc 14 Air rotiditioffir g 7 1076 PcIgc 16 Air covditiorli lg 7 1976 J l orytrc coilr f rter air contlitiotfirfg 12 1976 I Iect r ic j l if iectiov Characteristics of the electrical units Checking the electrical units Checking and adjusting the headlamps Checking and ad...

Page 7: ...conilerter MG MA series MG M 22 621 9 hp MK MA series MK M 23 623 13 hp MJ MA series MJ M 23 623 13 hi CX 2400 GTI j 1977 A ME MA series ME M 23 62i 13 hp Mal7ual speed gearbox ESTATES AND AMBULAkES 1 Guarantee Official French fiscal Commercial symbol symbol symbol Engine type ratinq cx 2000 l 1976 MD MA series MD M 20 616 llhp CX 2200 Diesel 2 1976 __t MH MA series MH M 22 621 9 hp CX 2400 9 1976...

Page 8: ...2 a m OPERATION No MA 000 GmeraII characteristics 7 ...

Page 9: ...ecial equipment _ _ _ __ _ 185 R 14 X M S 185R14X M S 185R 14 X MtS From September 1976 onwards Michelin type ZX tyres have been replaced by t ype XZX The size and pressure remain the same In case of replacement of two TX tyres by two XZX tyres it is preferable to fit the latter at the rear All CX 2200 vehicles and CX 2000 with power steering Tyres tubeless __ _ _ _ ___ ___ __ _ _ _ _ I85 HR 14 XV...

Page 10: ... within limits o C 7 W Maximum starting gradient at G f IV _______ _ _ cx 2200 cx 2000 900 1984 630 1389 3040 6702 1500 3307 1 in8 l 3 cx 2200 900 1984 645 I422 3060 6746 1500 3307 1 in8 l 3 IMPORTANT NOTE Referehces to trailers without brakes DO NOT APPLY in U K III GENERAL INFORMATION Capacities Fuel tank _ __ 68 litres 15 galls Cooling system including beater unit 16 dm2 248 sq in radiator 11 l...

Page 11: ... 2 185 R 14 X M S 1 9 27 l 2 2 1 30 l 2 1 2 3 33 1 2 NOTE Vehicles are fitted with TUBELESS tyres as standard equipment They can be fitted with tyres with inner tubes of the same type the pressures remaining the same The tyre pressures are indicated on a label located on the panel at the front of the door on the driver s side From September 1976 onwards MICHELIN ZX tyres are replaced by XZX tyres ...

Page 12: ...with a 1300 kg 2866 lb trailer with brakes 3370 7429 Maximum authorised trailer weiqht within limits of G T W 1500 3307 Maximum starting gradient at G T It 1 in 9 11 IMPORTANT NOTE References to trailers without brakes bc NOT APPLY in U K III GENERAL INFORMATION Capacities Fuel tank _ 68 litres 15 galls Cooling system Heater unit included 20 dm2 310 sq in 10 6 litres 18 6 pts Heater unit alone 0 6...

Page 13: ...r 1976 these vehicles can be fitted with a gearbox with torque converter as optional equipment Wheels and tyres Wheelrims _ __ _ _ 5 l 2 F x 14 FHA Tyres tubeless psi _ _ 2 2 Authorised alternatives Pressure in bars Tyres Ppecial equipment 185R14 X M S 185R14X M S 185R14X M S Pressure in bars psi 2 2 32 2 2 32 2 4 35 I II GENERAL DIMENSIONS Dimensions Front track 1 474m 4ft loins Rear track 1 360 ...

Page 14: ...x 20 dm2 310 sq in radiator _ 10 6 litres 18 6 pts mTorque converter gearbox 23 dm2 356 sq in radiator 12 5 litres 22 pts Heater unit alone _ I 0 6 litres 1 05 pts Engine oil after draining _ _ _ _ _ 4 650 litres 8 2 pts difference between Min and Max n dipstick 1 l litres 1 9 pts Hydraulic system approx _ _ _ __ _ _ _ 4 litres 7 pts 1 Gearbox a Z UI I U gcarho TOTAL EP 80 _ __ ___ _ _ 1 600 litre...

Page 15: ...E IN BARS PSI MICHELIN I TYRES r FRONT 185 HR 14 XVS TU STANDARD FITTING 1 9 27 5 REAR SPARE 175 HR 14 XVS TU 2 1 30 5 2 3 33 5 185 HR 14 XVS TU AUTHORISED 1 9 27 5 1 9 27 5 2 1 30 5 ALTERNATIVE 185 14 X M S 1 9 27 5 1 9 27 5 2 1 30 5 NOTE Vehicles are fitted with TUBELESS tyres as standard equipment They can be fitted with tyres with inner tubes of the same type the pressures remaining the same T...

Page 16: ...___ _ __ __ _ __________ ___ ___ ___ __ __ __ _ _ ___ ____ _ 68 litres 15 galls Cooling system f itfcltrrlivg hcatcr rirlil Manual or torque converter gearbox _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ 10 6 litres 18 6 pts Optional torque converter t air conditioning unit _ 12 5 litres 22 pts Heater unit alone _ _ _ _ _ _ _ _ _ _ _ __ ___ _ _ _ _ _ _ _ _ _ 0 6 litres 1 05 pts Engine oil after draining _ _ _...

Page 17: ...2 4 35 185 HR 14 XVS TU 2 29 1 2 1 30 5 2 3 33 5 185 HR14 XVS TU 2 29 1 2 1 30 5 2 3 33 5 185 R 14 X M S 2 29 2 1 30 5 1 2 3 33 5 NOTE Vehicles are fitted with TUBELESS tyres as standard equipment They can be fitted with tyres with inner tubes of the same type the pressures remaining the same Tyre pressures are indicated on a label on the panel at the front of the door on the driver s side II GENE...

Page 18: ...2866 lb trailer with brakes 3395 7485 Maximum trailer weight within limit of G T W 3395 kg 7485 lb 1500 3307 Maximum starting gradient Cat G T W J llS lin9 IMPORTANT NOTE References to trailer without brakes DO NOT APPLY in U K III GENERAL lNFORMATlOt 4 Capacities Fuel tank __ _ _______ __ ____ _ _ _ _ _ _ _ _ _ _ Cooling system itzcludivg heater fluit Heater unit alone _ __ _ _ _ _ __ _ __ Engine...

Page 19: ...X M S 185 R 14 X M S 185 HR14 X M S Pressure in bars psi __ 2 1 30 5 2 2 32 1 2 4 35 1 NOTE Vehicles are fitted with TUBELESS tyres as standard equipment They can be fitted with tyres with inner tubes of the same type the pressures remaining the same Tyre pressures are indicated on a label located on the panel at the front of the door on the driver s s id e II GENERAL DIMENSIONS Front track Rear t...

Page 20: ...110 6856 Max trailer weight within limit of G T W 3110 kg 6856 lb 1500 3307 Max starting gradient at G 7 W I 12 1 in 8 l 2 I1 l GENERAL INFORMATION Copoci ies Fuel tank _ ___ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___ ___ _______ 68 litres 15 galls Cooling system ilzcluding heater unit __ _ ___ _ __ _ _ ___ ___ _ _____ _ _ _ 12 3 litres 21 6 pts Heater unit alone _ 0 6 litres 1 05 pts Engine oil a...

Page 21: ...9 27 5 I 2 2 32 e Manual 185 HR 14 XVS TU t Authorised steering 2 29 1 1 9 27 5 I 2 2 32 5 Alternative Manual or 185 R 14 X M t S E 1 steering I Power 2 29 1 9 27 5 2 2 32 1 aa 2 NOTE The vehicles are fitted with TUBELESS tyres as standard equipment they can be fitted with tyres with inner tubes of the same type the pressures remaining unchanged Tyre pressures are indicated on a label located on t...

Page 22: ..._ _ _ _ _ _ 1 175 m 3 ft 10 l 4 ins Weights in kg lb Kerb weight 1530 3373 Weight on front axle 925 2039 Weight on rear axle 605 1334 Gross Vehicle Weight G V W 2095 4619 Maximum authorised weight on front axle 1075 2370 Maximum authorised weight on rear axle 1030 2271 111 GENERAL INFORMATION Capacities Fuel tank 68 litres 15 galls Cooling system including the heater units 11 8 litres 20 8 pts Hea...

Page 23: ......

Page 24: ......

Page 25: ......

Page 26: ......

Page 27: ......

Page 28: ......

Page 29: ......

Page 30: ......

Page 31: ......

Page 32: ......

Page 33: ......

Page 34: ......

Page 35: ......

Page 36: ......

Page 37: ......

Page 38: ... and rear The clearance between each embellisher must not exceed 5 mm Mark and punch the eight fixing holes using a pin punch and fit the round headed self tapping screws Tighten them Position the outer embellishers mark and punch each fixing hole using a pin punch and fit the self tapping fixing screws Tighten them 2 Fitting the bumper and protective pads e I Fit the protective pads and secure th...

Page 39: ......

Page 40: ...g a piece of string draw a line passing through each point and draw the axis of the strips Mark the axis of the strip fixing holes see diagram page 2 as well as the holes at a 17 and CC a 18 Drill the holes 5 mm diameter Fit the plastic clips Position the strips on the clips 2 2 Fitting the rubbing roils 2 ot the centre of the doors 0 2 Mark the front and rear points at a distance of 260 mm at the...

Page 41: ...tion of the alternator by short circuiting either the positive or the u EXC terminals and the earth terminal d Take care not to reverse the leads connected to the regulator e Do not attempt to re energize the alternator this is never necessary and in any case would damage both the alternator and the regulator f Do not connect a suppressor capacitor at the u EXC terminal of the alternator or the re...

Page 42: ...its original containers carefully sealed We advise the use of litre for toppinq up or five litre containers for refillinq to avoid havinq to keep opened containers 2 2 T 4 CHECKS BEFORE CARRYING OUT WORK Z c E Before working on the hydraulic system in case of incorrect operation ensure the following a a a T FOI the c r ufrol y or f l rnc ch uir l livkrrgc s o I uuits or f lo gmltp o h d c u i it s...

Page 43: ...se with LHM fluid This bench is ciitltc d IY and its accessories are marked in green Never use the bench with another fluid or for testing components operating with another fluid units of a D car using LHS2 for instance NOTE The Le Bozec pump used on test benches for checking DIESEL injectors can be resorted to for testing components operating with LHM mineral fluid provided that the bench is clea...

Page 44: ...bs 4 5 mm pipe 5 8 to 0 mN 0 8 to 0 9 1 kg 6 6 to 8 0 ft lbs 6 O mm pipe 1 9 to 11 mN 0 9 to 1 1 m kg c Fittilzg I Only use joints of a quality compatible with LHM mineral fluid The design of the various seals ensures that their sealing action increases with fluid pressure The oiltiqhtness e is therefore not improved by greater tiqhtness of the unions 2 To connect a rubber tube a rubber rinq of su...

Page 45: ...hing it with the fingers use a wooden spatula instead 1 Cut the tubing and roughen the ends over a lenqth of some 3 5 in with abrasive paper N 600 2 Carefully deqrease the roughened ends and the sleeve with trichlorethylene 3 Heat the Rilsan adhesive in a water bath to raise its temperature to 60 C Do root c sc c c d his Icv p rntriw NOTE This operation is essential to cut down drying time 4 Coat ...

Page 46: ......

Page 47: ...plication of pressure Coating of base Coating of material Drying Positioning Application of pressure Coating of base Coating of material Drying 3 8 mins Positioning Application of pressure Coating of the base Drying Positioning Smoothing TYPE OF ADHESJVE Examples REST AGRAF Neoprene Ref Choisyprene TEROSON Ref Terokal 2444 MINNESOTA synthetic rubber adhesive Ref EC 1236 MIPLACOL Acrylo nitrite Ref...

Page 48: ...askets Ets N BREGER Ets RAVICOLOR MAGNUS Dry cleanser to be used before application of Loctite products COMET Department D A V A III SEALING PASTES PRODUCT PROTO JOINT CURTYLON LOWAC FRENETANCH FRENEBLOC FORMAJOINT SILICOMET noir blark CHARACTERISTICS Resist mechanical stress and oil derived products MANUFACTURERS USAGE JEAN BRASSART CEFILAC Department Joint Curty Clean with alcohol Resists hydroc...

Page 49: ...rusted in position V GREASES AND LUBRICANTS USAGE PRODUCT CHARACTERISTICS MANUFACTURERS RHONE POULENC Greasing of fluid bloc S I 33 LAMBERT RIVIERE suspension bushes Silicone grease GRAISSE 33 MEDIUM DOW CORNING S A R L GRAISSE 1495 Highly adhesive universal MOLYDAL grease Greasing of drive shafts MOLYKOTE LONGTERM 2 Extreme pressure grease good DOW CORNING S A R L adhesive and is waterproof TOTAL...

Page 50: ...e SENLIS 43 route de la Metzeau 68100 MULHOUSE 1 rue Goethe 75016 PARIS 140 avenue Paul Doumer 92500 RUEIL MALMAISON 16 rue de Miromesnil 75008 PARIS 12 rue du Moulin de Cage 92390 VILLENEUVE LA GARENNE 167 rue de Fontenay 94300 VINCENNES 135 boulevard Serurier 75019 PARIS 52 avenue de la Concorde 93270 SEVRAN 60 rue des Orteaux 75020 PARIS 28 avenue de 1 Opera 75002 PARIS 35 rue L Sampaix 75010 P...

Page 51: ...Supplement No 1 to Manual 818 1 CORR ...

Page 52: ... ratio _ _ _ _ 5600 rpm NOTE For CX 2200 and CX 2400 vehicles fitted with a torque converter the maximum rpm in 3rd gear is 5600 rpm Lubrification i Under pressure supplied by o gear type oil pump driven by the camshaft 2 External oil filter cartridge PURFLUX LS 105 type d z i Fuel supply a i a Engines fitted u ifh a rnrbuwffor WEBER compound type twin choke carburettor s ee Operations MA 142 00 1...

Page 53: ......

Page 54: ......

Page 55: ... the paint mark uppermost 5 speed manual gearbox and torque converter gearbox bearer under the engine gearbox unit on the engine side adirrstable OH the subjranra by means oj slots vertical flexible mounting on the gearbox side torque bar at the upper se ction green paint mark at CC a n to be positioned uppermost 072 jittiug NOTE The 5 speed manual gearbox has a different vertical flexible mountin...

Page 56: ... Pressed steel sealed by a cork gasket 3 Crankshaft Five bearing forged steel crankshaft The junctions between the crankshaft webs and the crankpins the crankshaft webs and journals as well as the thrust faces for the bearing half rings and the oil seal are rolled Iwalmc r l i r iw lro ir g sur ncc horr r c ssI NOTE There is an oil seal on the flywheel side of the crankshaft in the form of a bush ...

Page 57: ...CRANKSHAFT c 2 2 amam aamm t z NOTE The Replacement Parts Department only supplies one class of crankshaft AA Tight ening torque for the balance weight fixing screws 7 2 to 8 da Nm 52 to 57 34 ft Ib ...

Page 58: ...NKSHAFT BEARINGS AND RINGS Crankshaft end float b 045 to 0 16 mm NOTE On engines fitted with a torque converter gearbox the half rings for adjusting the crankshaft end float have an additional lead tin surface treatment ...

Page 59: ...ONS The Replacement Parts Department only supplies connecting rods in sets of 4 class 1 End float of connecting rods on crankshaft _ _ _ ___ 0 037 to 0 247 mm Variation in the weight of the connecting rods on the same engine 7 g max ...

Page 60: ...ax correct fitting the arrow must point towards the engine flywheel 7 co m C Piston rings PISTON IDENTIFICATION MARKS Correct fitting of piston rings The mark TOP 1 or the manufacturer s mark must face the crown of the piston 1 Compression ring no mark 2 Oil scraper ring marked 3 Scraper collector ring marked 3 or 4 NOTE Since February 1976 the scraper ring 2 on I a85 cc engines is conical and not...

Page 61: ...nt only supplies barrel piston gudgeon pin and piston ring assemblies in sets of 4 Thickness of barrel base gasket uncompressed 0 1 i 0 015 mm profusion of barrel with gasket uncompressed 0 04 to 0 135 mm Variation in weight gudgeon pins piston and piston rings on the same engine 5 g max ...

Page 62: ...barrel piston gudgeon pin and piston ring assemblies in sets of 4 Thickness of barrel base gasket uncompressed _ _ 0 1 2 JO O1O mm protrusion of barrel with gasket uncompressed _ _ _ _ 0 045 to 0 115 mm Variation in weight pistons gudgeon pins and gudgeon pin circlips on the same engine 5 g max ...

Page 63: ... the cylinder head 1985 cc Oval clinching the identification mark CEFILAC 1 towards the cylinder head 2175 cc Round clinching diameter 96 5 mm the identification mark CEFILAC towards the cylinder head 2350 cc TIGHTFNING SEQUENCE Tiqhtening torques f cold Initial tightening 3 da Nm 21 3 4 ft Ib Final tightening 6 to 6 5 da Nm 43 l 2 to 47ft Ib b Valve seats The valve seats are fitted by temperature...

Page 64: ...Op MA 100 00 13 c Valve guides and valves 5 7 q j Y NOTE Inlet and exhaust valves are fitted with oil seals ...

Page 65: ... and exhaust f Retaining clips Identical inlet and exhaust 6 Timing a Camshaft Chain driven camshaft resolving in three cupro lead bearings Camshaft end float a I hi krlc ss a o s I 0 05 to 0 30 mm Thickness of flange 5 44 to 5 46 mm Amount of cam lift Inlet __ _ _ _ _ _ _ __ ___ 6 63 2 0 02 mm Exhaust ___ _ _ _ 6 14 0 02 mm WARNING Never attempt to rotate the engine by means of the camshaft pulle...

Page 66: ... oil TOTAL ALTIGRADE GTS 20 W 50 2 Capacity of sump after dismantling _ 5 800 litres IO 2 pts after draining and changing the filter l 5 306 litres 9 3 pts after draining 4 650 litres 8 2 pts Oil pressure At a temperature of 100 S C at 2000 rpm 3 bar min 43 5 psi at 4000 rpm 4 to 5 bar 58 to 72 l 2 psi Calibration of pressure switch 475 to 675 mbar 7 to 9 8 psi warning lamp goes oat Calibration of...

Page 67: ...16 OPERATION No MA 100 00 Charactcristics and special features of the engine LUBRICATION SYSTEM ...

Page 68: ...y screws 16 to 17 da Nm 116 to 123 ft lb b Crankcase Screws and nuts securing the timing cover 1 4 to 1 9 da Nm 10 to 14 ft lb c Timing Screw on the camshaft thrust bearing _ 1 4 to 1 9 da Nm 10 to 14 ft lb Timing chain guide securing screw __ 1 4 to 1 9 da Nm 10 to 14 ft lb Timing chain tensioner securing screw 0 9 to 1 I da Nm 6 5 to 8 ft lb d Lubrication system Oil filter mounting LOCTITE FRENE...

Page 69: ...d its gasket ofii rr s i d Will a rarb wt or I b The injection manifold and the racker cover I iU CfPd r zgir rs 1 2 Adiust the engine cold Inkt 0 15 mm With lb wgir cold i Exhaust 0 20 mm 3 Fit the rocker cover and its gasket Tightening torque of fixing screws 0 5 to 0 8 daNm 3 5 tc 6 ft lbs Fit the injection manifold f i nczvd br 1 Lower the wheel to the ground and disengage the gear r ACCEPTABL...

Page 70: ...s 3 of the camshaft bearing housing Rotate the crankshaft so as to fully open the exhaust valve of No 4 cylinder Lock the securing screw 3 for the bearing housing Position the control pulley Tightening torque for nut 2 8 daNm 58 ft lbs Adjust the rocker arms as indicated previously ...

Page 71: ...erter using a screwdriver 1 Remove spore wheel cylinder head carburettor engine 1 the injection manifold and the rocker cover fuel injection engine 1 2 Bring piston of cylinder No 4 to TDC with the valves in rocking position x NOTE The TDC mark on engine flywheel co be see at point a on the clutch housing 3 Adjust clearance of inlet valve 1 of No 1 cylinder to 1 10 mm theoretical clearance 1 4 Tur...

Page 72: ... I protective plug I block ou U I RIK cn hur r io md while OH S0l li Y rn br rv tors 1 The Replacement Parts Deportment supplies under Reference Number 4035 T CInew kit for removing and refitting the protective plugs on WEBER and SOLEX carburettors NOTE The first kits supplied by the Replacement Parts Department Ref 4029 T con be supplemented with tools D 4031 T and F 4032 T o TOOLS INCLUDED IN KI...

Page 73: ...OLEX carburettor 5 501 075 U white Protective cop for throttle spindle stop screw SOLEX carburettor 5 507 643 K white IJTILIZATION I REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MIXTURE ADJUSTMENT SCREW ON A WEBER OR SOLEX CARBURETTOR plug a NOTES 1 On GS vehicles fitted with a WEBER carburettor it is necessary to emcwe the air filter to carry out this operation 2 On GS vehicles fitted with a...

Page 74: ...gainst gun A Position the gun and tool assembly against plug CI moking sure that the nozzle of the gun is properly centred against the plug ond that the assembly is aligned as precisely as possible in the axis of the plug Actuate the gun and screw the tool into the plug L H thread Remove the gun leaving tool D on the carburettor 3 Remove plug Q Load gun A screw tool C in I lmrk of gun A Actuate th...

Page 75: ...or make SNI it is ill ii he rig t1n I O iili S C dingrrr lx I Actuate the gun until the plug is properly located NOTE If the air filter has been removed refit it and nfe i rwm r I a II REMOVING AND FITTING THE PROTECTIVE CAP FOR THE MIXTURE CONTROL SCREW WITH COLLAR ON A SOLEX CARBURETTOR cap b b REMOVAL 1 Break the head of cap b usingtoolF If this value is not obtained unscrew the mixture control...

Page 76: ...t Actuate the gun and remove the cop FITTING 3 re rno cap b See fig I of diagram below Fit cap into the collar of the mixture control screw Load qun A Screw tool E onto the wn Place the tool and gun assembly against the cop 1 1 Actuate the gun once 4 Adjust the exhaust emission I 5 nop cop b into position Load the gun and ctuote it o second time onto the cop to set it in position as per fig 2 of d...

Page 77: ...L POLLU 2000 type REMOVAL 1 Remove cop c using flat nose pliers 2 Adjust the butterfly opening Adjust the butterfly opening using the test bench according to the Norms laid down in the Etudes Equipement 1 Nos 14 1116 ter and 14 l 16 quater f SC o r rcc ucs o Ihr scrs o r ml Cf Ol es bcorhcs i FITTING 3 Fit cop c Load gun A Screw tool H onto the gun Fit cop c onto the throttle spindle stop screw Pl...

Page 78: ...lowing the inlet manifold the air filter the crankcase gases recycling system V WORKING ON THE ENGINE Adjusting the rocker arms Replacing or removing the following the cylinder head the camshaft the rockers the valves _ the barrels and pistons VI WORKING ON THE IGNITION Replacing or reconditioning the distributor partly or cpmpletely Adjusting or replacing the spark plugs Adjusting the ignition ti...

Page 79: ...ke butterfly Mechanically controlled acceleration pump cam on 1st choke Choke on 1st body vacuum assisted cold start strangler flap Fitted damper on idling speed system with incorporated fast idle device ADJUSTMENTS DESCRIPTION Primary choke Venturi bore Main jets removable Air corrrction jets Emulsion tubes Idling jets removable _ Air bleed idling jets Acceleration pump injector high type weighte...

Page 80: ...op 12 contacts edge of lever 14 Measure distance between the edge of the first choke butterfly and the carburettor body This measurement must he a 1 25 0 05 mm If not adjust the positive opening distance of the butterfly by means of adjusting stop 12 This clearance should always he measured with ad justing stop lock nut 11 fully tightened 3 Adjustment of clearonce of strangler flap 13 activated by...

Page 81: ...Adjusting the float Check that pin 8 is properly positioned on tongue e c Nand hook it onto the needle valve Hold ccwe vertically so thot the tongue e c P of float comes into contact with the needle valve ball without pushing it in Take the measurement of the float with needle valve in closed position as shown opposite with gasket 7 on cover This measurement must be 7 i 0 25 mm If not adjust tongu...

Page 82: ...tterfly Mechanically controlled acceleration pump corn on first choke Cold start device operates on the 1st choke vucuum assisted cold start stranqler flop ldlinq speed circuit with incarporoted dumper ADJUSTMENTS Description Venturi bore Main jets removable 1 Air correction jets Emulsion tubes Idling jets removable Air bleed idling jets Acceleration pump injector hiqh type weiqhted Econostat jet ...

Page 83: ... 350 IDENTIFICATION MARK W 74 50 34 DMTR 35 250 IDENTIFICATION MARK W 69 50 c 1 00 hocir modc l I 6 CHARACTERISTICS I _Anti pollution carburettor twin choke GC compound Btype with mechanically operated second choke butterily Mechonicolly controlled acceleration pump cam 1 on first choke Cold start device operates on first choke VOCUU assisted cold start stronqler _ Electric cut out on idling speed...

Page 84: ...ghted type d 45 Volume of pump total cm3 120 t 0 2 partial or r vre Co IIr wS S cm3 0 5 0 7 Outlet tube 200 d COLD START DEVICE Return spring for the anti flooding membrane 550 g or 850 g i Pressure calibrator for membrane control 1 40 Return spring for the clutch flap 180 g Ni 47 600 140 Positive opening of butterfly under operation of coldstart device d 1 25 2 0 05 Cam for cold start device N 45...

Page 85: ...Op MA 142 00 SD 1 CX VEHICLES ANTI POLLUTION SYSTEM FOR SWEDISHMARKET VEHIC LES ...

Page 86: ...a short period of time the diaphragm in valve 2 The air supplied by pump 1 is released into the atmosphere the calibrated hole u a on the diaphraqm balances the pressure on either side of it and the diaphragm returns to its initial position allowinq air to be once more injected into the exhaust manifold 2 With the choke out With the choke in this position the quantities of unburned hydrocarbons an...

Page 87: ...Key to diagram 1 Air pump 5 Choke control knob 2 Air supply valve 6 WEBER electric contact 3 One way valve 7 CARTIER relay 4 Air injectors situated in the cylinder head 8 Throttle butterfly ...

Page 88: ...the manifold On CX 2000 vehicles injkction of air will be stopped when the enqine water temperature reaches 45 3 C Thermal switch 8 opens relay 9 1s no lonqer enerqized but electro valve 7 remains live relay lead and is earthed via the choke control The air pressure at the outlet of air pump 12 increases the effect of the low pressure on the diaphraqm in valve 11 the air pressure is felt above the...

Page 89: ... 5 Control relay for butterfly opening device 6 Electronic tachometer housing 7 WEBER H electro valve 8 Engine coolant temperature switch 9 Relay controlling exhaust manifold air injection 10 Choke control 11 Air supply valve 12 Air pump 13 One way valve 14 Cylinder head 15 Jet calibrated to 0 40 ...

Page 90: ... on an engine on which the rocker clearances and the ignition are correctly set with a clean air filter and with the engine in good order 2 Check that the butterflies return fully to their stops 3 30 not let pnythinq except the ignition and the engine cooling fan or ions impose any load on the alternator 4 Run the engine to bring the oil temperature up to 70 to 80 C wait for the electric cooling f...

Page 91: ...crewinq its two fixihg screws on the carburettor in order to reduce the clearance ot the fixing point of the rod opening the first choke butterfly NOTE On vehicles fitted with air conditioninq the compressor must be switched off during adjustment 1 Wait for the electric cooling fans to cut in 2 Engine idling speed with the gear lever in the o Neutral or Parking aposition adjust screw 3 for the ope...

Page 92: ...control 5 E 2 P neurotic components 7 Disconnect from the air supply valve 3 the pipe from the valve to the exhaust manifold 2 j Plug the tube so as to avoid the exhaust pressure deteriorating the end of the tube and the valve Use the starter to rotate the engine In this position the air pump must not supply air through the opening in the air supply valve previously disconnecied CHECKING THE AIR I...

Page 93: ...g rocker clearances Inlet 0 15 mm Exhaust 0 20 mm Checking and adjusting the CO is carried out in the following conditions 1 Disconnect from the air supply valve 3 the pipe from the valve to the exhaust manifold 2 Bring the engine oil up to a temperature of 85 5 C 3 Wait for the cooling ion 01 ims J to cut in 4 Adjust screw 3 for opening of first choke butterfly in order to obtain on idling speed ...

Page 94: ...e pipe in order to avoid the exhaust pressure deteriorating the end of the tube and the valve Use the starter to rotate the engine In this position the air pump 6 j must not supply air through the previously disconnected opening in the air supply valve 5 CHECKING THE AIR INJECTION Push back the choke In this position the air pump 6 must supply air through the previously disconnected opening in the...

Page 95: ...lve is not energized ensure using a test lamp that the winding in relay 2 is not enerqized for an engine speed below Nd under deceleration or an engine speed below NC under acceleration Accelerate the engine up to engine speed NC n the winding in relay 2 must be enerqized If not replace the electronic unit 3 after having checked the connections 2 Pneumatic components Ensure that the vacuum reaches...

Page 96: ...nces Inlet 0 15 mm Exhaust 0 20 mm Checking or adjusting the CO reading is carried out in the following conditions 1 Disconnect from the air supply valve the pipe from the valve to the exhaust mariifold 2 Bring the engine ail up to a temperature of 85 5 C 3 Wait until the cooling fan f or fnvs 1 cut in 4 Adjust screw 3 for the first choke butterfly in order to obtain on idling speed of 850 to 900 ...

Page 97: ...ELECTRONIC FUEL INJECTION OPERATION No MA IE 144 00 hnrcrctwistics o the H I c trouic a clcctrovic Op MA IE 144 00 1 fuel iujrctian swtem I a L JETRONIC H System ...

Page 98: ...o the duration of injection which in turn is optimally determined for any given engin operating condition by an electronic control unit E C U from information supplied by several electric sensors One of the principal contributions of the H L Jetronic H system is the reduction in the level of pollution of the exhaust emissions The L Jetronic v system is made up of the following components 1 Electri...

Page 99: ...OPERATION No MA IE 144 00 Cbtirnctcristics oj hc I jetrorlic rlectronic he1 iujcctim systvrn Op MA IE 144 00 3 GENERAL LAYOUT L 14 19 ...

Page 100: ...ted very close to the inlet valve in order to improve engine performance The supplementary air control 6 is located in parallel with the butterfly and supplies the supplementary air required by the engine to run smoothly when cold _ Once the engine has reached its normal running temperature the idling speed air flow is provided by a by pass valve 5 which by passes the butterfly as well 2 co T It i...

Page 101: ... the system In the fuel return pipe the pressure regulator 3 maintains under fuel load a relative constant fuel pressure of 2 bars 29 psi The pressure regulator is connected to the intake manifold by a flexible pipe0 This allows the difference of pressure betw een the fuel and the inlet manifold to remain constant Thus the necessary quantity of fuel delivered by the injectors 5 depends exclusively...

Page 102: ...OPERATION No MA IE 144 00 ch arartcristics of the KL Jetrouic elcctrcwic juel ir2jcctirm system Op MAalE 144 00 7 FUEL CIRCUIT I ...

Page 103: ...8 OPERATION No MA IE 144 00 Characteristics of the L Jetrovzic n electronic fuel ivzjectian system t E C U ELECTRONIC CONTROL UNIT I I I I I ...

Page 104: ...e impulses coming from the distriLti are transformated into square waves by the waveform shaper Since injection only occurs twice for each camshaft rotation whereas the distributor provides 4 impulses in the same amount of time the frequency of the impulses must be divided by 2 in the frequency divider These signals are used to charge a condenser The condenser discharge determines the beginning of...

Page 105: ... The operating clearance determines the degree of damping The use of a damping blade cancels the effects on the angular position of the sensor flap of pressure variation s in the inlet collector A potentiometer actuated by the sensor flap spindle transforms movement of the sensor flap into an electrical circuit which is transtiitted to the E C U The voltage of the electrical current is inversely p...

Page 106: ...OPERATION No MA IE 14400 nracteristics of the I L elronic x cl tronic fuel injrction sysfem Op MA IE 14400 11 AIR FLOW SENSOR otentiometer uuuuLluu ...

Page 107: ...12 OPERATION No MAJE 144 00 Charactvis ics o the x L etmnic I dectmnic fuel injection system INJECTORS L 14 21 I ...

Page 108: ... under pressure is free to pass through The movement of the magnetic core is approximately 0 15 mm The duration of opening is determined by the E C U as a function of the operating conditions of the engine at the moment in question TEMPERATURE SENSORSt When the engine is started for a temperature of approximately 20 C it needs two to three times more fuel than when it has reached normal operating ...

Page 109: ...l cannot pass through When the magnetic core is attracted the injector seat is freed off the fuel flows past the core and reached the spiral effect injector which injects the fuel simultaneously giving it a spiral motion and vaporizing it very finely THERMAL SWITCH The thermal switch cuts out the operation of the cold start injector when the temperature of the engine reaches ir 35 C For any temper...

Page 110: ...Op MA IE 144 00 15 COLD START INJECTOR THERMAL SWITCH ...

Page 111: ...SUPPLEMENTARY AIR CONTROL SWITCH ON THROTTLE BUTTERFLY SPlkDLE ...

Page 112: ... was selected for its good heat transfer charac teristics and so as to subject the unit to the changing ambient temperature of the engine The opening section of the supplementary air control is automatically adjusted according to the temperature so that the required idling speed is maintained regardless of engine temperature When the latter increases the air channel is gradually reduced until it i...

Page 113: ...tor Once the engine is running the airflow sensor energizes the pump Thanks to this type of system if an injector is faulty leaks the cylinder in question cannot be flooded if one has ommitted to switch the ignition off PETROL FILTER 1 A fuel filter fitted between the pump and the injectors prevents any impurities from reaching the injectors PETROL PRESSURE REGULATOR 2 The fuel pressure is maintai...

Page 114: ...Op MA IE 144 00 19 One way valve Safety valve PRESSURE REGULATOR Id 17 t Return to tank ...

Page 115: ...CIRCUIT DIAGRAM L Sl 19 I III I I _ 1 r 7 2 0 1 J r i ...

Page 116: ...r grade of plugs 1 6 Remove the E C U before putting the vehicle through a paint stoving oven 7 Check the conditions of the various connections 8 Never disconnect the E C U while the ignition is on 9 When checking compression disconnect the positive terminal of the coil in order to stop the injection signal 10 When carrying out a check requiring an ohmmeter use exclusively a battery powered ohmmet...

Page 117: ...2 OPERATION No MA IE 144 O I k J c r g Ulld ufijljr slirlg rhc i l ct o lic clectNNlic IIVI inicclion system 1 THE ENGINE DOES NOT START OR IS DIFFICULT TO START IP T O ...

Page 118: ......

Page 119: ...OPERATION N MA IE 144 0 I I i g N f nrl clslir g Ill 0 I j ro ic 1 jIC Irollic k Op MA IE 144 O 3 I illj c lior sy lvm I 2 HE ENGINE STARTS THEN STOPS ...

Page 120: ... s gzjg y T f z I i m i l ...

Page 121: ......

Page 122: ... 3 UNSTABLE OR INCORRECT IDLING SPEEI I EXCESSIVE FUEL CONSUMPTION 3 P T O ...

Page 123: ...L L ...

Page 124: ......

Page 125: ... 2P T O 4 THE ENGINE MISFIRES AT ALL SPEEDS ...

Page 126: ......

Page 127: ... ...

Page 128: ...5 LACK OF POWER I ...

Page 129: ... C ...

Page 130: ...10 OPERATION No MA IE 144 0 I7ec fr q c711d f7tiji1slit1 Il c ct I J ro tic n lvcIrortic k l rcJl ir jc clio i s fs er ...

Page 131: ... throttle butterfly spindle idling speed function 11 Switch on throttle butterfly spindle maximum power function 12 E C U Diagram 1 I ANNEXE A Checking the ignition Page 25 B Checking the air circuit Page 26 C Checking the fuel system and the fuel pressure Page 27 D Adjusting the idling speed and the exhaust emission Page 28 NOTE On the wiring harness for the injectors the numbers of the terminals...

Page 132: ... must register the ignition impulses If it does not check the ignition ANNEXE A 2 Fuel pump feed on operating the starter DIAGRAM 2 Disconnect the E C U Switch on the ignition On operating the starter the fuel pump secureri rrt rler the I c hiclc uoor IIJO K ti ronr l eol I must be heard to operate by someone standing close by If not switch off the ignition and test the circuit using a battery ope...

Page 133: ...f E E a a 2 DIAGRAM 1 I t 5 E 0 t DIAGRAM 2 t Battery 0 1 ...

Page 134: ...DIAGRAM 3 Battery ____ _ A fi c i J J I 0 ___ DIAGRAM 4 ...

Page 135: ...ls 86 b H and G85 on the relay box f j nor thc I I h ntllnr tp must be between 52 and 78 12 P 4 Supplementary air control DIAGRAM 4 4 c 5 6 Disconnect the E C U E Check that the supplementary air control is properly connected arrow on the casing In If it is fitted the wrong way round the port may be blocked The resistance between terminals 34 1 and 48 on the supplementary air control must be 50 Q ...

Page 136: ...or air tightness 6 Resistors and injectors A dirty injector may cause o lock of power or on unstable idling speed It is possible to test the functioning of the injectors with the engine idling by disconnecting each injector in turn the engine rpm should decrease each time Disconnect the E C U The resistance of an injector is 2 to 3 II Each supplementary resistance is 5 to 7 R The volume delivered ...

Page 137: ...2 f DIAGRAM 5 I I 1 L _____ J DlAGRAM 6 G Q O O C O r L i ...

Page 138: ...DIAGRAM 7 r _______ _ I I I 7 u j I I I I I I I I I I I I I I I I I I I 7 Jgrl j I I I I 1 I I I I i L J _____ ___ I i3 5 DIAGRAM I ________ 1 I 27 L ____ 2 ...

Page 139: ...circuit and measure directly the resisitance using the sensor cc 10 C R 7 to 12 kR cc 20 C t R 2 to 3 kQ cct 80 C H R 250 to 400 Q e 2 ii 8 Air temperature sensor DIAGRAM 8 E E U J Disconnect the E C U Using an ohmmeter test the continuity of the circuit and measure the resistance of the sensor between terminals 6 and 27 c 10 CH R 8toIlkQ N t 20 C 1 R 2 to 3 kQ tt 50 C n R x 750 to 900 J ...

Page 140: ...he injector to the thermal switch If the water temperature is below 35 C on operating the starter motor the cold start injector must supply petrol for the followinq amounts of time 7 5 sets for a temperature of 20 C 5 10 c N 3 cc0 c 1 20 c On operating the starter terminal 4 of the E C U terminal board must be enerqized voltmeter between terminals 4 and 0 5 1 10 Switch on throttle butterfly spindl...

Page 141: ...DIAGRAM 9 Battery DIAGRAM l 0 1 i er L ...

Page 142: ...RAM 12 I Air flow sensor Switch on throttle butterfly spindle r _____ __ t Multi stage control vibrator t Multiplying stage t m Relav box g Additional 2 resistors Y I switch Magnetically I triggered distributor Air temp Water temp sensor sensor ...

Page 143: ...een terminals 3 H and 18 of the multiple connector board with the accelerator pedal fully depressed t 12 E C U DIAGRAM 12 s i 2 Visually check the condition of the terminals male connectors on the E C U and female connectors on the multiple connector socket With the engine running tap lightly on the E C U to detect any possible defect in the soldering dry joints ...

Page 144: ...ELECTRICAL CIRCUIT I _ _ _ _ _ _ __ _ I 1 _ _ _ 11 j q 1 r t ...

Page 145: ...OPERATION No MA IE 144 0 hcrkir g m cl nrl tts ir I W a I J m i otectrot ic Op MA IE 144 O 25 fi cl irijection systc rti ANNEXE A CHECKING THE IGNITION THE ENGINE TURNS BUT DOES NOT FIRE ...

Page 146: ......

Page 147: ...ANNEXE B CHECKING THE AIR CIRCUIT L __ ...

Page 148: ...e regulator the regulated pressure must be 2 5 bars i 36 l 4 psi If one of the readings is incorrect check condition of the flexible vacuum pipe for the pressure regulator as well as its aspect If it is satisfactory replace the pressure requlotor after making sure that its VCICUU pipe is not blocked totally or partially at the manifold end With the engine stopped the pressure must remain stable at...

Page 149: ...ctric cooling fan is to cut in IMPORTANT Use exclusively I high tension tachometer do not damagethe H T lead of the ignition wiring harness ADJUSTMENT 1 Check that the butterfly is not jammed in position when it is resting against its stop 2 Wait for the electric cooling fan s to cut in 3 Use screw 1 to adjust the idling speed to 850 to 900 rpm 4 Check the exhaust emission The resulting amount of ...

Page 150: ...tor float needle valve 500 45 88 3000 65 170 5500 69 5 192 I I Minimum pressure in mbors INSTALLATION OF PETROL PUMP Fitted on the crankcase with one Phenoploste P12 spacer 5 0 1 mm thick two SOCOID a paper gaskets fitted dry Tightening torque for petrol pump nuts 21 mN 2 1 m kg 15 l 4 ft lb CHECKING THE STROKE OF THE PUMP PUSH ROD a With the pump removed and using I depth gouge A take the measure...

Page 151: ...no sudden drop in pressure Check the proper sealing of the carburettor needle valve Unscrew knurled plug B and start the engine Let it run for a few minutes Stop theengine There should be no sudden drop in pressure Remove apportus 4005 T and fit to carburettor the tank supply and return pipes after having removed plug A 1 CHECKING THE PUMP FOR LEAKS Close the pump return pipe Blow compressed air u...

Page 152: ...wise Contact pads pressure for information purposes w 440 A 50 g Distance between contact pads 0 40 mm C Closing angle of cam 55 It 2 3G DWELL ratio 4 61 7 23 i Angular gap between the four opening points symmetry of the cams 1 max 4 Capacity of condenser 4 0 33 i 0 03 IF Minimum resistance of condenser 4 5MQ Centrifugal advance ref n of curve LA2 LA 4 Vacuum advance correction curve advance LD 2 ...

Page 153: ...10 Q H T LEADS Length in mm Resistance of leads at 20 C Manufacturer ELECTRIFIL Reference Bougicord 400 RTF 33 All rY biclas I 1975 1 Description of leads Coil to distributor Distributor to No 1 cylinder Distributor to No 2 cylinder Distributor to N 3 cylinder Distributor to N 4 cylinder 570 to 580 625 to 1025 J 400 to 410 420 to 645 11 520 to 530 555 to 850 11 540 to 550 580 to 880 Q 710 to 720 7...

Page 154: ...uated in the module the earthing is carried 7 out via the fixing bracket for the coil mrd module assembly As an impulse is created by the sensor in the distributor it switches off the transistor and thus cuts off the flow of current in the coil primhry circuit which causes a High Tension 1 current in the coil secondary circuit The module is located in the distributor replocinq the contact breaker ...

Page 155: ...25 at 2500 rpm SPARK PLUGS Spark plug gap 0 6 to 0 7 mm Tightening torque cylinder head cold 2 to 2 5 daNm spl c T hrc nc ig T f cc i T H VO J N 14 5 to 18 ft lb I IGNITION COIL AND TRANSISTORISED MODULE ASSEMBLY IManufacturer AC DELCO Reference N 210 Resistance of coil primary circuit at 205 C 0 48 0 61 R Resistance of coil secondary circuit at 20 C 8500 to 10500 fl H T LEADS Description of leads...

Page 156: ... mark b 8 It must be 10 i 1 before T D C or v or S If not slacken nut 2 and rotate distributor to ohtoin this condition Tighten nut 2 from 1 9 to 2 1 daNm 13 5 to 15 ft lb Stop the engine b U sivR n riin uo ir m d od uc ir r c lwu h TECALEMIT Model Tecamatic 30 SOURIAU models 1615 01 1625 01 or 1256 61 RABOTTI model Robofast 103 These models are mentioned in the Equipment and Repair Materials manu...

Page 157: ...ng properly odj usted loi 1 at 850 50 rpm or 700 50 rpm for torque converter 1 the advance point must remain within 2 1 s n dinpi osfir cs hozrh The start of opening or the dwell angle value of the contact breaker according to the type of test bench used should not vary by more than 2 on each boss of the cam If this is not the case the rotor clrm 01 the contact breaker bock plate ore faulty The di...

Page 158: ... 3000 rpm make 5 sure the contact points are clean and if necessary make sure the test bench battery is fully charged before U replacing the contact breaker unit the spring of which may have weakened 7 co m r 3 Checking the spark regularity 2 Whatever the speed of rotation the angular difference of the four opening positions of the points must n ot 3 exceed lo I 21n xint lm r In oj distributor 325...

Page 159: ...alm of the hand Rotate the L H front wheel and stop when the palm of the hand is pushed back by the force of the compression Slowly rotate the wheel to bring the 10 morkabx of the engine flywheel 1 opposite the fixed mark ca aa b Fit the distributor Remove the distributor cap Insert the distributor into its housing see position on the dioqram below 1 water pump LONGITUDINAL AXIS OF ENGINE __ Posit...

Page 160: ... the ignition coil Turn the distributor until the exact moment when the indicator lamp liqhts up At this point the distributor is al the static advance point Switch off the ignition Tighten nut 1 from 19 to 21 mN 1 9 to 2 1 m kq 1 13 l 2 to 15 ft lb 1 Fit distributor cap and secure it Fit sparking plug in cylinder No 1 2 Checking the ignition timing using a stroboscopic Imp or I test bench See cha...

Page 161: ...ark SC b a It must be 25 before TDC f mark x c x If not slacken the distributor clomp nut and rotate the distributor to obtain this condition Tighten nut from 1 9 to 2 1 doNm 13 1 12 to 15 ft Ib Stop the engine b Usisg n u rlia ms ir x rs h irh This method is recommended for its speed its precision and the ease with which it is carried out Connect the 12 pin plug of the test bench to the correspon...

Page 162: ...t not vary by more than 2 on the four cylinders IVilh n lvsl b rh The impulse must not vary by more than 2 for the four star points II CHECKING AND ADJUSTING THE DISTRIBUTOR ON A TEST BENCH Centrifugal advance LA 5 Vacuum advance LD I 200 226 I 260 I 283 I 3601 310 3 I Vacuum in mbar ...

Page 163: ...ible to correct the advance curve by altering the tension of the springs for the z centrifugal weights To obtain this condition slightly bend irr I V nppropriate clirvcliou the securing brackets 6 for the springs or replace them ot 43 a 3 E E 3 Checking the symmetry of the star points z 0 IFi The angular positioning of the 4 star points must be the same to within 1 whatever the speed of the engine...

Page 164: ...nder Blank off the plug hole use a plug Rotate the L H front wheel and stop when the plug is forced out by the compression Rotate wheel slowly to bring the 10 markiicai on the flywheel 1 opposite fixed mark csb visible throuqh opening S a b 1 Fit the distributor Remove the distributor cop insert the distri butor into its housing see position in dioqrom and photograph on this page Provisionally pos...

Page 165: ...e 2279 T wdun r l imn 0 o IO hnrs 1 to union 6004 T Tiqhten union screw 3 6 Start engine With oil temperature at 100 C pressure should be a 2000 rpm 3 bars mini43 5 psi o 4000 rpm 4 to 5 bars 58 to 72 5psi 7 Rrmave union 6004 T and pressure qouqe Tightening torque 30 to 35 m 3 to 3 5 m kg 21 l 2 to 25 l 2 ft lb Connect supply lead Replace spare wheel NOTE This operation con also be carried out wit...

Page 166: ...p and blow through pipes with compressed air 3 Filling the gauge WARNING This operation is to be carried out with great care so as to fill the gauge with LHM Fluid which is not emtilsified Disconnect tube 2 from the unit so as to get to the filler orifice o b 11 Undo completely the calibrating screw marked with IIPXJ to allow the gauge to be adjusted on completion of the operation a Using CI hypod...

Page 167: ...he min mark on the gauge 4 Connect tube 3 from the gouge to the filler orifice S b I B ADJUSTING THE GAUGE Two methods ore possible Adjusting the gouge using an engine sump simulator Adjusting the gauge on the vehicle 1 Prepare I jar as per diagram on page 2 NOTE This simulator is also suitable for adjusting a gouge on o GS SBirotor n vehicle 2 Connect the rubber tube 2 i unmarked 1 to the tube la...

Page 168: ...arked with IIIOW so as to obtain the correct level within 1 5 mm 1 b Repeot the operation using the max a CX tube in the simulotar jar to check the max level in the gauge 3 Calibrating the gauge a Depress the oil qauqe pump knob 1 1 and maintain it fully depressed When the liquid is stabi ised in the gouge adjust the calibrating screw 1 marked with arrow so that the level indicated on the gauge is...

Page 169: ...COOLING Op MA 230 00 1 I ...

Page 170: ... Prestige torque converter air conditioning 23 dm2 356 5 sq in 8 7 NOTE Radiators originally fitted to the vehicles differ according to the type of vehicle on which they are fitted co _ 03 in the material used for the coolant channels and the distance between the cooling fins T 2 3 Radiator cap or pressure relief valve calibration rap scwzmcl 011 1 bar 14 5 psi I 4 Thermostat Make CALORSTAT Refere...

Page 171: ...radiator CX 2400 GTi except optional towing equipment 1 23 dm2 356 5 sq in radiator CX 2400 and Prestige with optional torque converter and air conditioning and CX 2400 Gti with optional towing equipment 2 1O blade fan 5 blade fan 5 blade fans lo blade fans 1O blade fans 1O blade fan 1O blade fans 10 blade fan lo blade fans The electric cooling fans are controlled by a thermal switch 011 he radiat...

Page 172: ...ng equipment Thermostat closed and heater system open Hot cool n Id coolant I Electric fan 2 Radiator 3 De aerating pipe 4 Header tank expansion chamber 5 Thermostat 2 6 Heater unit 7 Inlet manifold 8 Cvlinder head outlet tank Partial view F II Thermostot closed ...

Page 173: ...oprlonal row ng equ pmenr Thermostat and heater unit open Hot coolant Cold coolant I Electric fan 2 Rodiotor 3 De aerating pipe 4 Header tank 5 Thermostot 6 Heater unit 2 7 Inlet manifold 8 Cylinder heod outlet tonL 3 Portia1 view F Thermostat open ...

Page 174: ... F L Radiator Electric fan 5 I De oeroting pipe I Header tank i Thermostot I Heater unit Inlet manifold i Cylinder head outlet tank Thermostat closed Hot coolant Cold coolont ...

Page 175: ... Ni il J ii N iii i li i r o I li Op MA 230 00 5 1 Radiator 2 Electric fan s 3 De oerot ng pipe 4 Header tank 5 Thermostat 6 Heater unit 7 Inlet manifold 8 Cylinder heod outlet tank 8 I KY Partial view F Partial view F 6 Thermostat open ...

Page 176: ...ermostat and heater unit open Partial view F 8 1 Radiator 2 Electric fon 5 3 De aerating pipe 4 Header tank 5 De aeration chamber 6 Thermostat 7 Heater unit 8 Drain top 9 Cylinder head outlet tank Cold coolant I J1 0 Thermal switch for electric fan s l J 7 6 Thermostat open ...

Page 177: ...ING SYSTEM 2 4 litre engine fuel injection Thermostat and heater unit open Hat coolant Cold coolant Partial view F 1 Rodiotor 2 Electric fon 5 3 De aerating pipe 4 Header tank 5 De aeration chamber 6 Thermostat 7 Heater unit 6 Drain top 9 Thermal switch for fan 0 Bleed screws Thermast t open ...

Page 178: ...thermostat is open 1 v rgiur wnnu J I COMPLETE REFILLING 1 Remove spare wheel 2 Open heater control to fullest extent inside vehicle 1 3 Unscrew the two bleed screws 1 and 2 Place a tronsporent tube 200 mm in length over each screw in order to ovoid the escape of the liquid 4 Disconnect the heater outlet hose and pour in approximately 0 6 litre of cooling liquid Reconnect tube 4 5 Fill remainder o...

Page 179: ...ews Replace spare wheel II PARTIAL FILLING Same operations as for total filling except that the heater unit is not filled by outlet tube 3 to the radiator 111 FILLING AND DE AERATING THE AUXILIARY HEATER UNIT ON CX AMBULANCE VEHICLES Before connecting the auxiliary heater unit water system to the main system the following must be carried out Fill up the auxiliary heater unit and its hoses with hea...

Page 180: ... wrinp SC r j I or I RllI 11010F c L d i NOTE Aligning the alternator pulley is carried out by plocinq shims behind the pulley Tightening torque for nut 4 for the olternatov pulley 4 daNm 29 ft lb 3 Aligning the high pressure pump a Tighten pump on its support plate b Place device 3085 T on the camshaft pulley c Brinq its rod into contact with the groove of the pump pulley NOTE Aliqninq the H P pu...

Page 181: ... 400 N 35 to 40 kg 77 to 88 lb Run in belt 200 to 225 N 20 to 22 5 kg 44 to 50 lb Compressor belt New belt 400 to 450 N 40 to 45 kg 88 to 99 lb Run in belt 2 N 25 kg 1 55 Ib Toothed belt for water pump 150to180N 15to18kg 33to40lb NOTE Insufficient tension reduces considerably the reliability of the toothed belt Tension in excess of 180 N 18 kg 40 Ib will cause whistling noises Consequently adjust ...

Page 182: ...nd Estate Diaphragm mechanism Type 215 DBR 410 Disc Ref tVERT0 62838 if D 136mm 63550 if D 142 mm cx 2200 All CX 2400 vehicles I 235 DBR 490 I 1075 t 235 DBR 410 I 3 1075 t 235 DBR 450 l Iv76 w 62957 d 225 mm l 75 63266 q5 225 mm 3 75 0 63571 47 228 6 mm l 76 1 Prestige 8 76 CX 2400 Injection t 235 DBR 490 Prestige K 76 t All CX 2400 s except Injection 63571 d 228 6 mm ...

Page 183: ... fit a N VERTO Hdisc ref no 63571 i 228 6 mm 1 With 235 DBR 410 mechanism fit a VERTO Ndisc ref no 63266 4 225 mm 1 Replacing the mechanism Replace the 235 DBR 490 and 235 DBR 410 mechanisms by a 235 DBR 450 mechanism with a VERTO P disc ref no 63571 1228 6 mm Thrust bearing self cent in9 Ill SPECIAL FEATURES Clearance between thrust bearing and diaphragm 1 to 1 5 mm ...

Page 184: ...nut 1 Tighten nut 2 until the thrust hearing is in contact with diaphragm hard point 1 NOTE Clutch pedal should be in contact with its upper stop at I n Unscrew nut 2 1 two turns and a half to obtain CIclearance of 1 to 1 5 mmbetween thrust bearing and diaphragm Tighten lock nut 1 Fit spring 3 I ...

Page 185: ...rter 2 30 1 697 type 2 20 1 693 type II SPECIAL FEATURES Adiustments Contact gap in electric switch unit controlling the electro valve NOTE The gap for the 2nd 3rd gear contacts must only be adjusted once the selector shaft stop screws have been adjusted See Op MA 330 00 Gap at 2nd 3rd gear contacts 0 8 to 1 1 mm Gap at lst Rev gear contacts 13 02mm _ Operating pressure for the converter oil syste...

Page 186: ...e electro valve a dozen times Tightening torques Electra valve fixing screw 2 8 daNm 20 l 2 ft Ib Union screw for oil pipe 3 to 3 5 daNm 21 l 2 to 25 l 2 ft Ib Suction filter 3 5 to 4 daNm 25 l 2 to 29 ft Ib Contact fixing screws 0 2 to 0 3 daNm 1 11 2 to 2 ft lb IMPORTANT In the course of repairs it is permissible to replace a 697 type CX 2200 converter by a 693 type CX 2400 one However the rever...

Page 187: ...OPERATION No MA 320 00 l n iz i c m d s we in o w o I r t c cc or r r Op MA 32Oz 00 3 III OPERATIONAL DIAGRAM OF TORQUE CONVERTER Engine running gear lever in neutral ...

Page 188: ...Engine running one qear enqaqed I I 7 I I O 1 ...

Page 189: ... and adjusting the contacts 1 Remove cover 3 from the switch unit controliinq the electro valve 2 Check adjustment of contact gaps Proceed in the same way far each of the 4 contacts a Engage a gear WARNING In order to obtain correct opening of a contact the corresponding gear must be fully engaged otherwise the adjustment would not be correct b Check the contact gap corresponding to the gear engag...

Page 190: ...inal drive ratio Overall ratios I 8 7434 1 13 62 4 769 1 I 15 3411 1 Speed at IOO rpm in km h mph 7 82 4 89 13 51 8 44 1 21 86 13 66 Speedometer drive ratio 5 12 7 85 4 95 1 b ssEconomy option D gearbox on CX 2000 1 107j Gears 1st 2nd 3rd 4th Reverse Gearbox ratios 12 38 3 1666 1 18 33 1 8333 1 3W34 1 1 1333 1 36 27 c 75 1 13 41 3 1538 1 Final drive ratio Overall ratios Speed at 1002 rpm in km h m...

Page 191: ...pre loud Adjusting the selector shaft stops L 35 mln rnclx 0 05 mmmax 3 05 mnl mox c 15 mm Adjusting the 3rd gear stop I curimv wmor i8 Smear thread of stop screw I with sealing compound Engage 3rd qear with 3rd 4th qear slidinq pinion restinq aqainst 3rd qear idlinq pinion Brinq the stop screw into contact with selector shaft then screw it in one turn in order to obtain CIclearonce between the se...

Page 192: ...ssembly nuts dia 8 mm 2 8 daNm 20 2 it Ib Final drive casing assembly nuts dia 1Zmrilj 5 duNm 36 it lb 1 Bush nut for gear selector shaft 1I to 12 daNrn 79 112 to 87 ft Ib Bush nut for dipstick guide 3 to 4 daNm 21 1 2 to 29 ft Ib i Assembling the gearbox casings Sealing Smear the contact faces of the gearbox casings and the rear cover with sealing compound ...

Page 193: ...4 OPERATION No MA 330 00 II J NC I ri ic t r soc ic l lc t1 1 s oj thv Rc cwjo v MANUAL 4 SPEED GEARBOX Adiustment shims 1 37 1 40 1 43 1 46 1 49 1 52 1 55 1 58 I 61 F 64 1 67 H IIIf ...

Page 194: ...GEARBOX Gear sequence L 33 1 a 1st gear 2nd gear 3rd gear 4th gear Reverse gear I 0 ...

Page 195: ... parking Gearbox ratios Speedometer drive ratio 5 X 12 Lkbrication Type of oil TOTAL FLUIDE T _ _ _ _ _ _ _ _ _ _ _ Total capcity including converter _ 5 5 litres 9 7 pts approx Draining _ __ _ 2 to 3 litres 3 5 to 5 3 pts depending on draining time Difference between min and max on dipstick _ 0 15 litres 0 26 pts VERY IMPORTANT It is ABSOLUTELY ESSENTIAL to use TOTAL FLUIDE T Gear control Floor m...

Page 196: ...oll pre load 0 15mm Adiusting the selector shaft stops Smear thread of stop screw 1 with CURTYLON Engage 2nd qear with 2nd 3rd gear sliding pinion resiinq against 2nd gear idling pinion Bring stop screw into contaci with selector shaft then screw it in 1 2 a turn in order to obtain o clearance of 0 4 io 0 7 mm between the selector fork and the face of the slidinq pinion groove 7 m Tighten locknut ...

Page 197: ...GEARBOX Longitudinal section 1 37 1 40 _ 1 43 1 46 1 49 1 52 1 55 1 58 ...

Page 198: ...s dia 8 mm 1 3 daNm 20 1 2 ft Ib Final drive casing assembly nuts dia 10 mm i 5 daNm 36 ft Ib Bush nut for selector shaft _ _ _ 11 to 13 daNm 7 1 2 to 94ft Ib Suction filter 3 5 to 4 daNm 25 l 2 to 29 ft Ib _ Drain and filler plugs 3 5 to 4 5daNmJ 25 1 2to32 1 2ft Ib Screw for return union to valve unit 3 to 3 5 daNm 21 1 2to25 l 2 ft lb ...

Page 199: ...TORQUE CONVERTER GEARBOX gear sequence REVERSE GEAR 1st GEAR 2ud GEAR 3rd GEAR ...

Page 200: ...OPERATION No MA 330 00 horortc ristir s NIIC spc cinl c nturc s of the gc hos Op MA 330 00 11 m 03 GEARBOX LOCKING DEVICE FOR PARKING f ...

Page 201: ...AL FLUIDE T o THEUSEOFANYOTHERLUBRICANTWOULD DESTROY THE CLUTCH AND CONSEQUENTLY THE CONVERTER Fill up the gearbox Co acity 2 3 litres 3 l 2 to 5 l 4 pints according to draining time Check the level with the dipstick 4 Top up the gearbox r nc I b r r niii 10 hini I orwr I 1 IWC ii ctrir l 5 lollon c o Immobilise the front wheels and put the hond broke on b Run the engine at idlinq speed and engage...

Page 202: ... 3 1666 1 15 1025 1 7 82 4 89 2nd 18 33 I 8333 1 8 7435 1 13 51 8 44 3rd i 28 35 1 1 25 1 13 62 5 9615 1 19 82 12 39 4 769 1 4th 33131 0 9393 1 4 4801 1 26 38 16 49 5th 45 33 1 0 7333 1 3 4974 1 33 79 21 12 Rev 13 41 1 3 1538 1 15 0414 1 7 85 4 90 Speedometer drive ratio lo 20 Lubrication Type of oil _ _ __ _ _ _ TOTAL EP 80 Total capacity _ _ _ _ _ _ _ _ 1 7 litres 3 pts Capacity after draining _...

Page 203: ...s Adjusting the stop for 3rd and 5th gears g nrhov lI n r vd Smear thread of stop screws 1 and 2 with sealing compound Engage 3rd qear with 3rd and 4th qeor sliding pinion resting against 3rd gear idling pinion Bring stop screw 1 into contact with selector shaft and scw v it in one turn to obtain the correct clearance between the selector fork and the sliding pinion groove Tighten lock nut Proceed...

Page 204: ...daNm 25 l 2 to 32 I 2 ft Ib Final drive casing assembly nuts dia z 8 mm _ 2 8 daNm 21 11 2 ft Ib Fianl drive casing assembly nuts dia l mm 5 daNm 36 ft fb Selector shaft bush nut _ _ _ _ _ __ 11 to 12 daNm 79 l 2 to 87 ft Ib Assembling the gearbox casings Sealing Smear the contact i ces of the casings and the cover with sealing compound ...

Page 205: ...16 FIVE SPEED MANUAL GEARBOX Adjustment shims L 33 5 1 41 1 46 1 51 1 56 1 61 1 66 R I 1 49 l 52 l 55 l 58 from 4 25 to 5 65 ...

Page 206: ...Op MA 330 00 17 FIVE SPEED MANUAL GEARBOX gear sequence 1 st gear 2nd gear 3rd gear 4th gear 5th gear Reverse gear ...

Page 207: ... 3 to obtain correct position of gear lever NOTE Should it be impossible to effect odjust merit by means of cover 3 make necessary adjustment at control shaft hall joint 5 Tighten three screws 2 Refit dust cover 1 b the gear lever should be located in the longitu dinal axis YY of the vehicle If not Adjust selector shaft boll joint 4 to obtain this position NOTE When adjusting boll joints 4 01 i 5 ...

Page 208: ...p MA 372 00 1 LEFT HAND DRIVE SHAFT greased I E 0 U RIGHT HAND DRIVE SHAFT L 37 2 1 S ft lb 1 65 ft lb 1 I CHARACTERISTICS 1 co nstant velocity ball joint at wheel end i 1 tri axe joint at gearbox end Y 423 mm 4 q gearbox Y 388 mm 5 sp gearbox II SPECIAL FEATURES Lubrication TOTAL MULTIS MS grease ...

Page 209: ...correctors 3 Brake valve return 4 Return from pressure regulator and front and rear correctors 5 Suction l i n e for HP pump 6 Filter on suction l i n e for HP pump 7 Deflector 8 Overflow and return l i n e filter 9 Level indicator float NOTE The reservoir on CX 2000 and CX 2200 vehicles produced after July 1375 is fitted with a pre shaped protective plate located between the central unit and the ...

Page 210: ...iprocating single cylinder pump operated by an eccentric machined on camshaft Operating ratio _ __ _ 1 cycle 2 engine revolutions Piston diameter _ _ 14 mm Piston stroke c c c rrc if 10 t 0 10 mm _ I HI OJJf ji c icntin f output 111fr1cr on 1 of I75 1 nr s ictirl f f 10 i 1 07 cm3per cycle SPECIAL FEATURES Tightening torques Pump fixing screw on crankcase _ _ _ _ __ _ _ _ _ 19 mN 1 9 m kg 14ft b F...

Page 211: ... driven by an eccentric machined on the camshaft Operating ratio _ _ _ _ 1 cycle 2 engine revolutions Piston diameter _ 14 mm Piston stroke I ecrcwtric lijt J _ __ _ _ _ _ _ _ _ ___ 10 2 0 10 mm For iu fomalior output unJer prc ssure oil75 bars 2F3X psi and with fluid at 60 C _ __ _______ _ ___ _ ___ _ _ __ __ _ 1 07 cm3 per cycle SPECIAL FEATURES Adiustments Clearance between pump and body b rc t...

Page 212: ...DIAGRAM OF BREATHER CIRCUIT FOR SINGLE CYLINDER PUMP f e Saloori 1 i cjhirles with mf7 7 inl stcjeriiig IO I 1976 1 ...

Page 213: ...ve 6 Pump valve 7 Pump body CHARACTE RISTICS The pump rotates at half engine speed Output for each pump cycle f or ir orv afiol _ _ _ _ _ 2 8 cm3 Valves 6 oil tight up to _ _ 150 bars 2175 psi SPECIAL FEATURES Piston connecting rods length in step of O l mm 1 28 8 to 30 5 mm Clearance between crown of piston TDC and pump vaIve 0 5 mm ...

Page 214: ...psi _ Cut in pressure __ ___ __ 145 5 bars 2103 73 psi Main accumulator Capacity 0 400 litre 0 70 pints Mark on filler plug 62 Calibrated pressure C or checking purposes 62 2 bars 899 f 29 psi 10 145 SPECIAL FEATURES Pressure regulator Thickness of adjusting shims 0 30 mm For cut out I _ _ _ _ __ __ _ _ ___ 0 30 mm For cut in _ __ _ _ _ 0 30 and 0 70 mm One 30 mm shim brings about a change in pres...

Page 215: ...Op MA 390 00 i DIAGRAMS OF OPERATION CUT OUT 1 a hydou ic CI CIII f ...

Page 216: ...RISTICS Brake accumulator Capacity _ _ _ _ _ ___ _____ _ _ _ __ _ _____ _ _ _ ___ _ _____ ____ ___ ___ _ _ _ _ _ _ 0 400 litre C 70 pts Identification mark on filler plug 62 Calibration pressure f or rhc c kir J 62 _ 3z bars 899 1 dTd psi SPECIAL FEATURES Tightening torque Accumulator onto its mounting _ _ _ _ _ _ 3 daNm 21 l 2 ft lb ...

Page 217: ...essures for slide valve return spring Increasing pressure l lOs_ _ __ _ __ _ __ __ __ ___ _ _ __ _ _ _ 130 bars 1885 psi Decreasing pressure _ I 110 bars 1595 psi Pressure for checking erfectiveness of slide valve seal _ _ _ __ _ _ _ _ __ _ _ ___ 175 bars 2538 psi Pressure switch Calibration pressure Mark 1 on pressure switch _ _ _ 75 to 95 bars 1088 to 1378 psi SPECIAL FEATURES Thickness of adjus...

Page 218: ...eering vehicles HP supply 1 Safety Front suspension va1ve Rear suspension valve 1 Rear brakes Front brakes b Power stesritzg vehicles HP supply I Brake accumulator Brake valve S upply to front brakes I 3 way T Supply to steering governor Safety talve yw Front suspension A Rear suspension y L supp1y to rear brakes Steeiing Supply to control slide valtv a zd operating cylirzder J ...

Page 219: ... suspension Safety lve Rear suspension I I Brake valve i ure limiter 1 Front brakes Rear brakes Source of pressure I Brake cccumulator Supply to I way wion steering governor Front Safety va1ve Rear suspension I Steering supply to slide valve and operating cylinder ...

Page 220: ... I I Brake valve w Brake pressure limiter w Rear brakes It Front brakes Source of pressure I Brake accumulator I 3 way union F Brake valve w Front brakes Supply to steering governor Safety I va1ve y Rear suspension I Steering supply to slide valve and operating cylinder ...

Page 221: ...OPERATION No MA 390 00 hnrncteristics a zd special fc atuws oj the SOIUCC arld scrm o prc ss rc Hydraulic systrm 2 Aisembly diagram Op MA 390 00 13 ...

Page 222: ... _ __ 0 I H 1 r ...

Page 223: ...__ _ _ _______ ...

Page 224: ...___ _ T h I I ...

Page 225: ..._ ...

Page 226: ... i r ii 0 I _ __ _ YC ___ I I I I I I I I I I ...

Page 227: ... filter is clean that hydraulic fluid is ot normal running tempe rature Carry 0 1 a road lent first i vt4icie is mid 8 2 Draining the circuits Place manual height control lever in ion posirios Slacken pressure regulator bleed screw 1 3 Fitting pressure gouge A Disconnect the tube 2 HP outlet from pressure regulator Connect the following assembly into the circuit pressure gaoge A 3way union B and p...

Page 228: ...essure This pressure m st be equal to 170 t 5 bars 2466 73 p i Whenthe c t o t pressure is obtained allow the engine to nrn for a few minutes in order to stabilize pressure Stop engine Examine the pressure gauge and note the fall in pressure for the next 3 minutes If the fall in pressure exceeds 10 bark 4 145psi check seai of plug D and repeat the test sequence If the result of test is the some th...

Page 229: ...flow return pipe to safety valve Secure safety valve screw 1 a 1 7 Checking the safety valve slidevolve a Remove plug from rem suspension outlet on safety v e at Gb a b Disconnect contact breaker lead on coil and turn engine using stmter fluid should start to run through the opening a d N when pressure reaches 1lLl o 130 bars 1585 to 1885 psi c Slacken pressure regulator bleed screw Connect contac...

Page 230: ...note pressure drop during wperiod of 3 minutes If it exceeds 10 bars 145 psi 1 check once more If the result is confirmed check the following c mponenG to determine which one is leaking either the front corrector or the suspension cylinders one or both Testing the 3 components should be carried out by eliminating each one in turn I Testing the front height cmwclor Loosen pressure regulator bleed s...

Page 231: ...ront right hand cylinder is defective Replace or repair it Il Checking the rear suspension Slacken pressure regulator bleed screw Put manual height control in IOU pnsi ios Remove plug E Connect rear suspension supply pipe to safety valve Disconnect rear brake supply pipe 4 from brake valve Plug oriilce of pipe using plug D Tighten pressure regulator bleed screw Place manual height control in aorwn...

Page 232: ...ngle for optical appliatjce readings _ _ _ 0 40 to lo Camber ttot adiastable Camber angle _ __ 00 13 29 Alignment Toe in _ __ 1 to 4 mm IMPORTANT Checking of readings given above should be made with vehicle empty engine running and in normal running position with heights maintained at 165 mm at the front and 215 mm at rear Saloons or 228 mm Estates See Op MA 410 O NOTE Castor allgle at the ball jo...

Page 233: ...r adiustment washer II SPECIAL FEATURES Upper wheelarms Stress on bearings by sclcrlior oi Iro l Ihwst cup _ _ _ _ _ _ 500 N 50 Lateral play of arm before tightening screw 1 I b sv c c iw 01 I SINIICC w s I T kg Wheel balancing dynamic balancing to within 10 grams minimum _ _ _ 0 to 0 9 mm ...

Page 234: ...oc n bushes g Checking and adjusting the castor angle using tool 6309 T s Assemble the components of tool 6309 T and place checking pin A in the groove of pod C 2 Slacken screw D and tilt pad C so that bush B is squarely in contact with it over its entire contact face and f tighten screw D Measure distance L It must be between 49 and 50 5 mm NOTE A I mm rhaug ia the Ihirknrss o he adjr s mw shims ...

Page 235: ...ms oi the irout aslc urrit REPAIRS Old type fluid bloc bushes length 79 5 mm must not be fitted with the later wheelarms and vice versa It is possible on any vehicle to fit one or both sides with the later wheelarms providing the appropriate shims are used ...

Page 236: ...point on each strip Measure the distance Ll when vehicle is at II height of 165 mm at the front and the distance L2 when the vehicle is at CLheight of 165 mm at the front and the distance L2 when the vehicle is at a height of 215 mm at the rear Snloo I vhi r s 1 or 228 mm I I s o c chirlr 1 Note values Ll and L2 which will simplify the following checks 3 Check that the lengths of visible thread on...

Page 237: ...at the following checks should be accurate the zero setting of the turn tables must correspond exactly to the strnifih liwv position of the vehicle a Place the magnetic supports C of the graduated rule forward to its maximum extent against its stop b With the engine idling set the manual control to KJWRl n n ir ji posili Check measurements Ll and L2 c Removr turntable locking pins E Focus beams on...

Page 238: ...in inserts NOTE In the case where the eccentric travel is insufficient Place eccentric ot the centre of its travel Slacken screws 2 and rotate steering shaft until pin inserts In the case where this last operation is unsuccess ful it is necessary to move the steering clamp on the rock control pinion 2nd case The values indicated on rear gradu ated rules ore different Slacken collars 4 and use one ...

Page 239: ... Comber angle must be between 0 13 29 IV CHECKING AND ADJUSTING THE CASTOR ANGLE IMPORTANT For precise results from this check it is imperative to set the vehicle heights as follows 165 mm a front and 215 mm at rear f Salooss or 228 mm Esfafes 1 Setting the vehicle height a Check measurements Ll and L2 f see chapter I b Release pressure in suspension system 2 Setting control opportus 3 Checking ca...

Page 240: ...required for fitting lower wheelorm on front axle a Remove wheel lower arm and castor angle adjusting shims 3 b Determining distribution of shims NOTES A minimum of 1 shim should be set on each side of the wheelarm Movement of 1 mm will vary castor angle by 15 Total thickness of shims fitted must corres pond to the total thickness of shims found on dismantling in order to maintain the correct asse...

Page 241: ...itudinal axis of the vehicle and the overall distance between them is exactly 2 48 meters The rods need not necessarily be at equal distance from the axle but the spacing between them is essential 4 To make the test Pivot one of the two projectors towards the front rod hnd read off on the graduated rule thr value indicated by the luminous mark Then pivot projector towards the rear rod and move thi...

Page 242: ...ocknuts 2 from 3 6 to 4 daNm 26 to 29 ft lb Check the adjustment IMPORTANT The length at a n of the visible thread on the L H and R H trackrods r s lx vq nl IO rrithin 2 7 Slacken collars 3 Turn sleeves 4 1fraction of a turn at a time to obtain correct setting NOTE Turn each sleeve the same amount in order to retain the oiiqnment with the rear axle unit I Son wcidisp on varh sidv o gmd lrrn r d ru...

Page 243: ...dure This check having to be carried out wheel hy wheel it is possible to use the free projector Secure projector to scuttle panel crossmemher and focus it onto a fixed object which will indicate the initial positioning of the vehicle 3 Measure the variation in the wheel alignment wheel by wheel ds o function of the height of the vehicle a From Ihc m nwnl rlri ir g posi ior lo hc hi posilio f ftou...

Page 244: ...ng on steering crossmember 4 1 NOTE 6 Slacken nut 5 and screw 6 1 securing the wind screen crossmember on the side to be moved Slacken the upper fixing nut on the opposite side as well li r order 10 nrmoid rlistorfina II crr ss nP b r 7 Move the crossmember in the direct decided by using 1s a mark extremity a u of screw 3 8 Tighten the fixing nuts and the screw for the crossmember Tightening torqu...

Page 245: ...r ilh power stcvri1r q This operation is to be carried out on a level rmd in the absence of any wind The vehicle pulls ta the right Slacken both nuts l rotate eccentric 2 towards the left Tighten nuts 1 The vehicle pu lls to the left Slacken both nuts 1 rotate eccentric i 2 towards the right Tighten nuts 1 NOTE In case the movement of eccentric 2 1 is not sufficient see para 3 sub para B of chapte...

Page 246: ...ses 9 34 mm 9 48 mm 9 62 mm 9 76 mm 9 90 mm 10 04 mm 12 to 13 daNn DESCRIPTION Alignment trot nr juslabl J Front toe in _ _ _ _ _ _ _ __ _ 1 to 04 mm Camber I uot adjustable J Max difference between the two sides 12 __ _ _ _ _ _ O 24 Heights to bc a crc d to durirrg this chvck At front 165 mm At rear 215 mm I Saloons 228 mm stntvs ...

Page 247: ...rm spindle bearinq _ _ preload of 500 N 50 kg NOTE Bearings and rear arm adjustment cups are identical to those of front wheelarms Greasing of hub and arm joints _ _ _ TOTAL MULTIS MS grease Wheel balancing dyr i balancing to within 10 g max ...

Page 248: ...Outer thrust cups Thicknesses 9 34 mm 9 48 mm 9 62 mm 9 76 mm 9 90 mm 10 04 mm II Face and threat ...

Page 249: ...4 OPERATION No MA 420 00 hamrteri stits n d s c rirrl jvattlws o t l war a dc rrtlit REAR HUB i istate I c hic es L 42 6 face and thread I 1 55 ta 65 daNm 398 ta 470 ft lb face and thread greased ...

Page 250: ... on the vertical centreline of each front wheel 6 b Fit the projector unit on ca h rcnl uhccl I c i Swivel the projectors towards the graduated plate Focus luminous index on graduations 2 d Push the graduated plates against their stops 2 The alignment of the rear axle is correct when there is no difference in the reading between left hcnd 52 and right hand sides i 2 Checking wheel alignment n 2 7 ...

Page 251: ... a wnr nsle unit 3 Checking the camberangle BEM MULLER 665 Junior Proceed as for front wheels at front 165 mm He ns r s lo be srn p lmosly rcs wrlcd Ior his rhrck at rem 215 mm Saloo rsJ a 228 mm f Estatus J V e of the camber angle On 024 ...

Page 252: ...SUSPENSION OPERATION No MA 430 00 hnmrtcristics mrd spccinl jeatrrres oj ha susp sio Op MA 430 00 1 FRONT SUSPENSION f c s 6 E J REAR SUSPENSION I ...

Page 253: ...I CHARACTERISTICS HEIGHT CORRECTOR SUSPENSION CYLINDER All Saloon vehicles L 43 6 SUSPENSION CYLINDER Estate vehicles ...

Page 254: ...l c n uws 0 he susfiv sias Op MA 430 00 3 MANUAL HEIGHT CONTROL hi anual height control quadrant I High position II Intermediate high position III Normal driving position IV Low position G Assembly diagram for manual height control L 43 2 Seen along Fl ...

Page 255: ...ey are incorporated in the pneumatic units NOTE The front and rear dampers ore different on CX 2400 GTI vehicles and therefore the pneumatic units are PNEUMATIC UNITS Volume of front units i Soloor mid I s fll s 1 500 cc f Pressed steel type Volume of rear units i All Saloons 500 cc j Pressed steel type Estates 700 cc Screwed in type i I specific Suspensioncylinders Diameter of pistons Height corr...

Page 256: ...nt wheelarm stops WARNING hc i op I i he ii r 01 I I wd 7cm3 25 cm3 Tightening torques Anti roll bar link rod on upper wheelarm i Bush nut 3 doNm 21 11 2 ft lb NYLSTOP nut 4 5 to 5daNd32 1 2to 36ft lb Link rod on anti roll bar 4 5 to SdaNm 32 1 2to36ft lb Screw securing front anti roll bar bearing 2 7 daNm 19 l 2 ft lb Clamps for adjusting pie load on front anti roll bar 13 doNm 9 l 2 ft lb b2 1 5...

Page 257: ...T REAR Between under face of point b a subfrome ond point of contact of wheels with ground 1 Check tyre pressures 2 Remove corrector protectors and make sure the manual control rods are not exerting pressure on levers 1 and 2 3 Slightly loosen automatic control clump and adjust to obtain 3 Front height 165 8 mm Rear height 215 8 mm Saloons 228 t 8 mm Estates Tightening torque of clomps 1 5 doNm 11...

Page 258: ...rks At front a Raise the vehicle by hand b Release when weight becomes too great to support Vehicle wi1 l drop then rise again and stabilize itself Note front height Push vehicle down by hand Release when resistance becomes too great Vehicle will rise again then drop and stabi lize itself Note front height again c Take the average of these two measurements which should be between 157 and 173 mm in...

Page 259: ......

Page 260: ...STEERING OPERATION No MA 440 00 Ihnrnctrristics nlld spcrt nl ic atrrrcdsoi the sfvc tir g Op MA 440 00 1 ...

Page 261: ...I MANUAL STEERING 1 CHARACTERISTICS STEERING RACK STEERING COLUMN q 1976 I 44 5 Clearance to be obtained between steering column i and spacer 3 Jl J2 is obtained by moving flange 1 along steering pinion ...

Page 262: ...eel 43 30 1 Steering angle Ilot djustahlc 0 outside wheel 32 50 i Turning circle CC between walls Il 80 m I Snloo 2 s 12 70 m Estntc s CC between kerbs I __ _ 10 90 m 11 80 m Steering ratio 24 5 1 REPAIRS The spring on the flange side can be fitted to a preSeptember 1976 vehicle as long as the following are also fitted the new steering shaft with spring centerinq guide the increased calibration sp...

Page 263: ...ically downwards Angle of universal joint 17 to the left approx with steering wheel in straight ahead position Coupling for steering pinion flange steering shaft Flange on steering pinion Steering pinion securing flange Steering rack ball joint f rack Jacked Track rod lock nut Rack housing on steering crossmember Steering crossmember on front subframe Nut for track rod ball joint Tightening torque...

Page 264: ... m t between walls 12 70 m I between kerbs 1 11 80 m t I N l N id I n lix Wheel alignment toe in of wheels to the front i i l I r rjj rll c r ii p cilirJ i 1 1 to 4 mm STEERING AND HYDRAULIC RACK CONTROL ASSEMBLY 1 Steering wheel 2 Anti theft device 3 Control unit 4 Steering shoft 5 Coupling flonge 6 Eccentric for odjusting stroight line running 7 Clomp for coupling hydraulic pipes Jl J2 obtoined ...

Page 265: ...CK CONTROL UNIT OPERATING CYLINDER a Hydraulic rack control unit operating cylinder The rack is connected to the hydraulic control unit operating cylinder Assume S as the piston in chamber 1 and S 2 its surface ns dcjsiguvd iu c hmvhc 1 2 J The steering is balanced when forces F and Fl exerted on each face of the piston are equal therefore F S x F Fl x HP HP 1 operatinq pressure of hydraulic circu...

Page 266: ...and cause slide valve C to move along its bore _ Upward movement Chamber 1 of hydraulic ram supplied in HP Downward movement Chamber 1 of hydraulic ram linked to the return to the reservoir lic Inr i lo fm silio i 0 I yiiilihrif vf Movement of rack causes movement of its control pinion pinion B and pinion D Pinion F being then locked in posi tion pinion D acts on rockers E which in turn brinq back...

Page 267: ...n mesh with pinion B Pinion B is in one piece with Cam H against which piston F through roller G applies pressure according to the following Angle of rotation of shaft A r c cf oj tjcct utric Pressure exerted on piston F I nricrhlc r ssur supplic d In stc ririg go nlor J Pressure of piston F is being exerted in the hollow on cam H which tends to maintain the steering in the straight ahead j positi...

Page 268: ...h rotate and fly towards under the effect of centrifugal force cause lever B to tilt L nrioblc position of slide valve A allows the pressure exerted on the cam cylinder piston to be varied NOTE In order to make possible the powered return function the steerinq governor supplies a pressure of 20 i 15 bars 290 173 psi when the vehicle is stopped f 11i F hc cwgir e wt t iv g i I POWERED RETURN The po...

Page 269: ...teerinq is then in the c straiqht ahead i position NOTE Pressure supplied by the steering governor is applied to piston F via a variable output requlator in order to slow down the return of the steerinq to the v straiqht ahead a position b Variable output regulator Wh I I criq return of piston F causes the following _ Expulsion of fluid through one way valve L Compression of sprinq K which pushes ...

Page 270: ...CROSS SECTION OF CONTROL UNIT L 14 3 n In ...

Page 271: ...10 OPERATION No MA 440 00 hnrnct rictic s nttd s cjcitiljcntr rc s 01the stc c rirtg CROSS SECTION OF STEERING GOVERNOR L 44 16 ...

Page 272: ...he steering wheel spoke must point vertically downwards d Positioning the collars on the wheel alignment adjustment sleeves FRONT e Tightening torques Steering wheel fixing nuts 6 to 8 daNm 45 li 2 to 58 ft lb j Screws securing control nut on body shell 2 1 daNm 15 ft lb Screws securing steering shaft to coupling flange 2 7 doNm 19 li2 ft lb Nuts securing flexible block on rack Crnrh lorkc d iu ps...

Page 273: ...raking system Disc brakes on all four wheels with r u iln ct tlisrs at the front Sn oo I front and rear I sIN s i Four pistons per brake unit at the front Two pistons per brake unit at the rear Power operated hydraulic control brake valve incorporated in system z The front braking system is supplied by the main accumulator c l icI s rli ll vrn l SIC criug J or by the the brake accumulator I orr J ...

Page 274: ...FRONT BRAKE UNlT L 45 3 3 5 daNm 2 3ta Z5daNm w l 25 112 fi lb 16 1 2 to left lb ...

Page 275: ...REAR BRAKE UNIT f N w v 1 2 to 4 7 doNm 130 l 2 to 34 ft lb face J md threod greased ...

Page 276: ...REAR BRAKE UNIT f i o z L 42 6 ...

Page 277: ...cannot pass from the brake valve to the rear brakes and vice versa Force F exerted by the rear suspension pressure is greater than Force R exerted by the sprinq The slide valve is in the position indicated by Figure 2 which allows flow of fluid from brake valve to rear brakes and vice versa c Vvhiclc il2 ntotior rr ith 111 broke pednl ncl fit c Fluid from the front brakes exerts a Force Fl which i...

Page 278: ...e one way valve allows fluid to flow from the rear brakes to the brake valve Force F exerted by the rear suspension fluid under pressure is qreater than force Rl produced by the spring The slide valve is in the position shown on Fig 2 which allows fluid to flow from the brake valve to the rear brakes and vice versa Fluid flowing from the rear brakes exerts a force Fl which is added to force Rl pro...

Page 279: ...OPERATION N MA 450 00 HANDBRAKE Emergency Brake ...

Page 280: ...0 2 mm 0 2 mm 30 mm 40 mm 24 cm2 3 72 36cm2 5 5 sq in sq in 12 mm 12 mm Checking the flatness of a disc take a reading in 8 different points the results should be the same to within 0 02 mm TYPE OF BRAKE PAD LINING Front linings incorporating warning lamps leads j AUTHORISED REPAIR FITTINGS VEHICLE All Snlow L c l ir ll 5 CX 2000 MA series MB CX 2200 MA series MC CX 2400 MA series MJ CX Prestiqe M...

Page 281: ..._ _ _ _ _ _ TEXTAR T 270 Area of one pad _ 12 cm2 1 86 sq in Adjusting the pads the pads must just contact the disc at its highest points Tightening torques Flexible brake pipe on front brake unit tube 3 6 to 4daNm 26 to 29 ft lb Nut securing front brake pipe on subframe 2 1 to 2 4daNm 15 to 17 1 2ft lb Brake valve securing point 1 8 daNm 13 ft lb Pedal assembly securing point 0 5 daNm 3 l 2 ft lb...

Page 282: ...ge 2437 T 3 screws hex head 6 12 mm thread pitch 1 25 length 30 mm Ex Crown wheel securing screw on D a vehicles Method 1 Raise vehicle and assemble equipment as shown above Tighten the three screws to opproximo My 70 mN i 7 m kq 50 l 2 ft lh 2 Sl l did g g rod RS pwp il cl l171 ns p ssibl 10 SC iorr The run out thus registered must not exceed 0 2 mm If this condition cannot be satisfied the disc ...

Page 283: ...ws for leaksby depres sing brake pedal to fullest extent Stop engine Fit rubber protectors over the bleed screws d1Replace front wheels and lower vehicle to the ground B REAR BRAKE BLEEDING 3 Release pressure in circuits a Setmonuol height control to lou posi iou b1Slacken pressure regulator bleed screw 1 c Wait until vehicle has reoched its lowest point Raise rear of vehicles wheels free Remove l...

Page 284: ...e no more air bubbles in the bleed tubes Then tighten the bleed screws c Release broke pedo1 and remove bleed tubes d I nir rhnmhrr I nltcr hnr htg dorm i Ibrouph I i h Nmp IPSS I nir e Check bleed screws and air chamber 1 are properly sealed by fully depressing brake pedal Stop engine Place rubber protective caps over bleed screws f 1 Fit front wheels and lower vehicle to the ground B BLEEDING TH...

Page 285: ...crew I Ill I liClC is ill1 rl i ill N I tYlk n rllrlll Inlo nc un 1 II I r al hnke nr c111uu n 0 b Depress pedal three or four times to move the control slide valve to the end of its stroke and ensure that pedal returns freely to its stop There should be no variation of clearance o J as initially set Tighten pressure regulator bleed screw IV ADJUSTING THE STOPLAMP SWITCH 1 Check adjustment of free...

Page 286: ... shown f rrpu ards until the pads just contact the disc at point of maximumrun out Tighten screws 4 from 6 to 6 5 daNm 43 l 2 to 47 ft lb Check correct contact of pads Screw down stop SCI W 3 until it contacts the brake unit housing tighfrn its lock EN 1 3 Adjusting hondbrake control cables On rnrh hrnkc if Ensure hat the sleeve and its stop 8 are correctly positioned Pull alfcmnf iy on each threa...

Page 287: ... lever 1 Tighten lock nut 3 to 1 5 doNm llft lb 4 Checking tie handbrake Operate handbrake lever several times Check that adjustment does not change and that locking system operates satisfactorily 5 Refit front wheels Tighten screws from 6 to 8 daNm 43 l 2 ta 58 ft lb Lower the vehicle to the ground ...

Page 288: ... marks on diagrams Bc Bl Ve Gr l o s oc r c 01 0 I ocl Ic c olour of whit11 ser1 c s ns icfc rltijicntiot work marks on diagram F Gr F Ve E Bc colourc ri s t c c c O I n Icncl the colour uj rrhich SCJ C T ns ic cvrtijitntiorL mnrk 0 5 rr ol marks on diagram FN Bl F Ve Bc trr id li c d I nd its position cannot give rise to any confusion lMPORTANT Identification marks for components and wiring harne...

Page 289: ...nstrument panel Lighting Windscreen wiper switch Horns Heating relay coil Window winder relay coil ositive battery erminal t 1 16 A Green Interior lamp Boot lamp Cigar lighter Clock Hazard warning lamp Lighting switch E Voltage regulator Reversing lamps Rear window heater Ash tray lighting 10 A Yellow Lighting for cigar lighter Heating control lighting Dashboard lighting ighting switch Side and ta...

Page 290: ......

Page 291: ......

Page 292: ...draulic pressure warning lamp 31 22 Plug for diagnostic operations 65 Warning lamp for hazard warning 17 23 Engine oil pressure switch 34 Sidelamp warning lamp 70 24 Idle cut off 60 Direction indicators warning lamp 23 25 Engine oil temperature switch 35 Headlamp main beam warning lamp 77 26 Enqine coolant temp switch 30 60 Left hand control panel 27 Top dead centre sensor 64 Direction indicator a...

Page 293: ... Front side lamps and rear lamps Number plate lamps Interior lamp Boot lighting BA lSs 19 Festoon 12 v 5w R 136 13 12 v 5w R 136 14 Dashboard lighting 5 BA 9 s T 8 2 12 v 2w R 136 34 Glovebox lighting 1 Warning lamp Lighting for cigar lighter Ashtray lighting 13 1 1 Wedge base 12 v 1 2 w KEY TO CIRCUIT DIAGRAM SYMBOLS Wiring connector Connection block Fuse Switch manual Switch mechanica Switch pre...

Page 294: ......

Page 295: ......

Page 296: ... NOTE For the last group of identification marks four cases may occur 0lortrc d slcc r cJ 011 cl Ic clrl 16 CVlVJlr clj ri hic I7 is irrc lc l nrll Marks on diagrams Bc Bl Ve Gr No s1c j1 v011 a Icad the colour oj rr hich scrr es as idrrt tijicnfiotl mark Marks on diagrams F Gr F Ve F Bc s l llrC s ppr cj o o cod the rolot r oj r bich SOF C S ns idcvttijic ntiotl mark as wc ll Marks on diagrams FN...

Page 297: ...sure warning lamp Hydraulic fluid pressure warning lamp Water temp warning lamp 16 Amps Green Interior lamp Boot lamp Cigar lighter Clock Hazard warning lamps E Voltage regulator Iqnition Reversing lamps switch Rear window heating element Handbrake warning lamp Window winder relay 16 Amps White R H Switch 0 R H window winder L H Switch L H window winder Lighting Switch 10 Amps Yellow Ashtray light...

Page 298: ......

Page 299: ......

Page 300: ... Instrument panel harness Compressor harness jent ark 4 9 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 iz 67 68 69 70 Description and Location Central interior lamp 10 Cigar liqhter and lighting 13 66 Ashtray liqhtinq 67 Handbrake warning lamp flasher unit 15 Switch for R H window winder 51 Switch for L H window winder 47 Flasher unit 21 Anti theft switch 4 8 44 61 Rheostat for fuel qauqe 25 Switc...

Page 301: ...R 136 05 Boot lamp 1 Festoon 12 v 5w R 136 14 Lighting for tachometer 2 BA 9 s T 8 4 14 v 4w and speedometer Lighting for glove box 1 BA 9 s T 8 2 12 v 2w R 136 34 Warning lamps 14 Lighting for cigar lighter 1 Wedge base dia 5 12 v 1 2 w Lighting for ashtray 1 Lighting for pneumatic oil gauge I Lighting for instrument 3 panel Wedge base dia 10 12 v 2w KEY TO CIRCUIT DIAGRAM SYMBOLS I Wiring connec...

Page 302: ......

Page 303: ......

Page 304: ... cases may occur 2 l C0lo red slcrrv on a lead the colour oj r i is irrvler a t Marks on diagrams Bc Bl Ve Gr c i NO slc er c 011 a ledd the colour of rr hich ser es as ideutijicatiotl mark 2 Marks on diagram F Gr F Ve F BG l2 c Coloured sleeve pn a lead the colour o which serr1c s as identification mark as well Marks on diagram FN Bl F Ve Bc Urlidcntijied lead Its position cannot give rise to any...

Page 305: ...d wear warning lamp Fuel gauge Oil pressure and temp warning lamps Hydraulic fluid pressure warning lamp Coolant temp warning lamp Interior lamp Boot lamp Cigar lighter Clock 16 Amps Green Hazard warning E Voltage regulator Ignition Reversing lamps switch Heated rear window element Handbrake warning lamp Relay for window winder 16 Amps White R H switch u R H window winder L H switch L H window win...

Page 306: ......

Page 307: ......

Page 308: ...r handbrake 16 28 Switch for reversinq lamps 8 63 L H control unit 30 Relay for window winder 49 Direction indicators and hazard warning 31 Relay for heater unit 45 lamps _ _ 19 _ 32 Relay for electric fan 58 Horns 41 33 Front R H brake unit _ 28 Windscreen wiper motor 38 34 Windscreen wiper motor _ 38 Windscreen washer pump _ 40 35 Blower motor _ _ _ _ _ _ 45 64 Rear R H lamp cluster 36 Hydraulic...

Page 309: ...136 12 3A 15s 9 12 v 5w R 136 13 R 136 05 IInterior lamp Festoon 12 v 7w Festoon 12 v 5W R 136 14 Boot lamp 4v 4w BA 9 s BA 9 s T 8 4 T 8 2 1 12 v 2w R 136 34 Warning lamps Lighting for cigar light Lighting for ashtray Lighting for pneumatic oil gauge Instrument panel lighti Liqhting for odometers I I dia 5 12 v 1 2 w Wedge base Wedge base dia 10 2 12 v 2w 1 24 V 3w KEY TO CIRCUIT DIAGRAM SYMBOLS ...

Page 310: ......

Page 311: ......

Page 312: ...ur 0i whirb is irrvlri aul i t E marks on diagrams Bc Bl Ve Gr L r No sle r c OII n ICOO hc colour Ii rr hic h sorws ns idc lti icntio mmk marks on diagrams F Gr F Ve F Bc Colourc d slwv ou a lc ad thv colour oj which svrc es ds idwtijicatiou mark as well marks on diagram FN Bl F Ve Bc Uuidctltijied Icncl Its position cannot give rise to any confusion IMPORTANT Identification marks for components ...

Page 313: ...eated rear window Handbrake warning lamp on instru ment panel Glove box lighting Centre and rear interior lamps Bonnet lighting Boot lamp Accessory terminal radio 1 Front window winder relay Lighting switch White Yellow 16 Amps L H R H switches L H 6 RH window winder Map reading lamp 5Amp in line fuse Lighting for heater controls 10 Amps Lighting for ashtray and cigar lighter Lighting for water te...

Page 314: ......

Page 315: ......

Page 316: ...ighter on console and lighting 73 94 Lighting for ashtray 95 dent lark 2 63 b 66 67 68 69 3 5 5 76 77 78 79 80 to9 8 93 94 95 99s Description and Location Anti theft switch _ _ _ 3 12 58 75 L H front door window winder motor i Front L H loudspeaker Front R H window winder switch 43 Front heater control lighting 93 Front L H window winder switch 39 Coolant temp gauge lighting 76 95 Direction indica...

Page 317: ...g P 25 l 12 v 21 w R 136 12 BA15s 19 12 v 5w R 136 13 Festoon 12 v 7w R 136 05 Festoon 12 v 5W R 136 14 BA 9 s T 8 4 14 v 4w BA 9 s T 8 2 12v 2w R 136 34 tiarning lamps 15 Lighting for cigar lighter 1 Lighting for ashtray 1 Wedge base dia 5 12 v 1 2 w Lighting for oil gauge 1 Lighting for instrument 2 12 v 2w panel Wedge base diu 10 Lighting for odometers 1 24 V 3w KEY TO CIRCUIT DIAGRAM SYMBOLS W...

Page 318: ......

Page 319: ......

Page 320: ...f the insulating sleeve r NOTE For the last group of identification marks four cases may occur marks on diagrams Bc Bl Ve Gr No slcc rv ot a lcad tbv colaur o which scrt vs as idvtltijirntiatt mark marks on diagrams F Gr F Ve F Bc UnidetttijiGd lead its position cannot give rise to any confusion IMPORTANT Identification marks for components and wiring harnesses are arbitrary they have been chosen ...

Page 321: ... warning lamp Hydraul fluid pressure warn lamp Water temp warning lamp Tachometer STOP warning lamp 16 A Green Interior lamp Boot lamp Cigar lighter Clock Hazard warning lamps Voltage regulator Reversing lamps Ignition Heated rear window switch E Handbrake warning lamp Rear screen washers and wiper Window winder relay Lighting switch 16 A 10 A White Yellow R H switch R H window winder L H switch R...

Page 322: ......

Page 323: ......

Page 324: ...ng lamp for main beam 82 Coolant temperature switch 35 Warning lamp for handbrake 21 T D C sensor 68 63 L H control unit 28 Switch for reversing lamps 8 Direction indicators and hazard warning 24 29 Relay for window winder 54 1 Horns 46 30 Relay for heater unit 50 Windscreen wiper motor 43 31 Relay for electric fan 63 Windscreen washer pump 45 32 Front R H brake unit 34 64 Fuel gauge rheostat 30 3...

Page 325: ... Boot lamp 1 Festoon 12 v 5 w R 136 14 Lighting for tachometer 2 BA 9 s T md speedometer 8 4 14 v 4w Lighting for glove box 1 BA 9 s T 8 2 12 v 2w R 136 34 Warning lamps 14 Lighting for cigar lighter 1 Wedge base dia 5 12 v 1 2 w Lighting for ashtray 1 Lighting for pneumatic 1 gauge Instrument panel lighting 2 12 v 2w Wedge base dia 10 Lighting for odometers 1 24 v 3w KEY TO ClRCUlT DIAGRAM SYMBOL...

Page 326: ......

Page 327: ......

Page 328: ...oglomp switch Windscreen wtper self park ng position Windscreen washers Rear foglomp switch BLACK R H d rect on tndicotors relay far con pr horn Swedish market Dlrrct supply through green f se to clock and hazard warn ng headlamp wipe 5 A A NO COLOUR E art H R W wor ng lamp Trailer djrectlon rndlr worroi g iomp D lpped beam worn nq lamp Fuel gauqe Speedo ond tocho Accessory Ilqhtlnq Pre heat wornr...

Page 329: ...to TB Ve P n Ve 1 Battery 2 Relay for electro valves 3 Ignition and starting contact 4 Electra valve controlling fast idle 5 Electra valve controlling clutch 6 Gearbox switch housing 7 Control relay for electric fan 8 Thermal switch corrtrolling the electric fans 9 Electric fan 10 Relay controlling supplementary electric fan 11 Supplementary electric fan 12 Warning lamp for converter oil temperatu...

Page 330: ...OPERATION No MA 510 00 b rn l Nl IlI 0 Ill C c tl ifNI ir YlnllalitM j arv 9 107j I Op MA 510 00 b 15 CIRCUIT DIAGRAM ...

Page 331: ...CIRCUIT DIAGRAM FOR CONVERTER AIR CONDITIONING OPTION L Sl 170 ...

Page 332: ...rmostat i ror c i irrr i l i 16 Air conditioning switch 17 Pressure switch on de watering tank f ni or rli irrr i c 18 Compressor clutch f nifsc o di io i l i 19 Control relay for L H supplementary electric fan 21 il r l di io il 20 Control relay for electric fan 21 coolir g o rficJiNlor I nlc r 21 Supplementary electric fan for condenser il rol ni i ll i and water radiator cooling J 22 Control re...

Page 333: ...switch on centre console 5 High pressure switch on de watering tank 6 Electra magnetic clutch for compressor 7 Control electro valve for fast idle and re cycling ram WEBER electro valve 8 Control relay for supplementary air conditioning electric 9 Control relay for electric cooling fan 10 Ignition coil 11 Idle cut off on carburettor 12 Electric cooling fan 13 Thermal switch for electric cut in on ...

Page 334: ...lay with its c o t i 1 contact cuts off supply to electro valve 9 which therefore produces fast idle DESCRIPTION OF COMPONENTS 1 Heater relay s o Q c 2 Air blower S n dnr i i 3 Speed control for blower S nr clnrt J 4 Regulating thermostat 5 Air conditioning switch 6 Pressure switch 01 dc rt cr t rit q lnr k 7 Compressor clutch 8 Control relay for fast idle melectro valve 9 Fast idle electro valve ...

Page 335: ......

Page 336: ......

Page 337: ......

Page 338: ... horn compressor Hazard warning lamps Stoplamps Clock Winding for r elays for front and rear foglamps Front and rear L H and R H sidelamps warninq lamp Number plate lamps Lighting switch 10 Amps Yellow Liqhtinq for instrument panel battery meter clock odo meters Fl Lighting for iqnition switch cigar lighter ashtray water temp gauge and heater controls Map reading lamp and fuse 5 Amps 10 A mps Blue...

Page 339: ...lamps Lighting for cigar lighter Lighting for ashtray Lighting for oil gauge Lighting for instrumen panel Lighting for odometers Yellow for France H4 2 x 51 H2 12 V 55 w 21 w R 136 17 4 2 2 Pear shaped P 25 1 R 136 12 BA 12 v 12 v 21 5 W R 136 12 2 BA 15 d P 25 2 R 136 13 BA 15s 5w 7w 5w 5w 12 v 12 v 12 v 14 v 3 2 R 136 05 Festoon Festoon BA 9s T 874 R 136 14 1 1 2 1 T 8 2 12 v 2w R 136 34 BA 9 s ...

Page 340: ... switch 40 Cigar lighter and lighting 94 l 12 65 Ashtray lighting 113 19 Double relay for injection control 7 to 27 66 Radio equip locat t aerial 83 to 85 20 L H electric fan relay air conditioning 38 39 67 Handbrake flasher unit housing 97 98 21 Rear foglamp cut out relay main beam 104 to 105 68 Electronic control unit injection 8 to 25 22 Front foglamp relay 106 107 69 Lighting for pneumatic oil...

Page 341: ... 94 95 96 97 98 99 100 101 102 103 104 105 106 Description and Location Ignition switch lighting 110 Flasher unit 68 69 Speaker in L H front door 84 Rear R H door lighting switch 90 Fuel pump 7 Rear R H interior lamp 90 Fuel qauge rheostat 82 83 Boot lamp 86 Heated rear window 96 Rear L H interior lamp 89 Rear L H door lighting switch 89 Rear R H lamp cluster Foglamp 105 Reversing lamp 95 Directio...

Page 342: ......

Page 343: ......

Page 344: ......

Page 345: ......

Page 346: ......

Page 347: ......

Page 348: ... 4 A 14 R 11 51O 2 Voltage _ _ _ _ _ _____ 14 v w Direction of rotation f s I rot rlril C C I C J Anti clockwise Maximum power f X I S1 OO I c IN oI r j u __ 740 w 1050 w 1050 w 1120 w Maximum power consumption _ __ ______ 3400 w 3600 W 3600 W 4480 W Cut in speed at 14 V 4 1100 Alternator rpm t Resistance of inductor 4 5 Z O 3 cl 4 5 0 3 Q 4 k O 2 0 4 o 2 12 Nominal length of brushes 14 5 mm 14 5 ...

Page 349: ...lzcJrln id I olnrtcl 011d I ugo lar icr FULMEN Ref No AS 310 SD STECO Ref No 72 514 TUDOR Ref No 725 798 12 V 45 Ah 225 Amps L 2 type battery 3 All rc bic le 5 lo 11 jsI c twin ij I sI rin C C c Srr iiz rinr rJ Polat d a tfi Yugoslar in 12 V 60 Ah 300 Amps L 3 type battery FULMEN AS 311 M 12 V 70 Ah 350 Amps L 3 type battery FULMEN AS 311 S 5 All S 2400 whit Its JVC CJ pnrns 3 al r 4 12 V 55 Ah 27...

Page 350: ...ng a Current consumed pinion locked _ 440 A 6236 and 450 A D 9 E 1 6 b Current consumed when starting at 20 C 150 to 170 A c Current consumed with no load starter removed 50 A maximum BENCH TEST Use a 12 V 200 40 Ah fully charged battery MEASUREMENTS Average torque at 1000 rpm _ Corresponding current _ Torque locked Corresponding current _ Voltage Maximum power _ Voltage Current Torque _ DUCELLIER...

Page 351: ... Nominal diameter of commutator _ _ 32 25 mm Minimum diameter of commutator after rectifying 30 25 mm End float flexible washer _ 0 5 mm Brushes Positive brush reference _ _ 680 568 Negative brush reference 680 567 Maximum force of springs on new brushes 1 5 daNm 11 ft lb Nominal length _ 15 mm Minimum length after wear 8 mm Solenoid Reference _ 680 592 Resistance of pull in coil _ 0 37 i 0 02 Q l...

Page 352: ...e _ 0 5 0 17 0 05 mm Jominal diameter of commutator 36 5 mm Diameter after rectifying 35 5mm End float flexible washer _ 2 2 mm Brushes 52 R Positive brush reference 92 550 N Negative brush reference 92 550 N Maximum force of springs on new brushes I 1 5 daNm 11 ft lb Nominal length 14 mm Minimum length after wear 8 mm Solenoid CED 509 R eference 95 631 U Resistance of pull in coil 1 0 21 Q Heaz y...

Page 353: ...rnator 2750 rpm engine 80 Amps at 8000 rpm alternator 3670 rpm engine F 2 12 V 53 Amp alternator DUCELLIER 7584 and MOTOROLA 510 2 Cut in speed under voltage of 14 V 1100 rpm alternator speed Output under voltage of 14 V z 21 Amps at 1480 rpm alternator 1 680 rpm engine 46 Amps at 3300 rpm alternator 1510 rpm engine 51 Amps at 6000 rpk alternator 2750 rpm engine 53 Amps at 8000 rpm alternator 3670...

Page 354: ...mmeter rheostat Start engine and let it idle Switch off the ignition and immediately switch it back on in order to demagnetize the voltage regulator Accelerate the engine so as to reach the adjustment speed for the alternator Actuate the rheostat smoothly without turning it back in order to increase the current supplied by the alternator and read the corresponding voltage Take several measurements...

Page 355: ...o solenoid supply termina1 6 _ negative terminal to an earthing point on the solenoid f V R poisl GC VI Using a 10 mm box spanner oqainst the shouldering of plastic nut 1 as at F push solenoid core until it is attracted by winding of solenoid 3 fIrI this msr fbc nr rhn irnl hi irip ri 0 hc solwoid COY r plor s I i diOl or ion 0i the solwoid pull i vi di 1 c With the starter pinion 4 in the forward...

Page 356: ...ter the starter pinion 4 is normaHy in free position Measure the distance o d n between the flange of the starter nose at u b H in the bore of the motor housing and the extremity of the starter pinion This reading should equal d 30 5 mm maxi If not recondition the starter Connect the inductor supply wire I I Refit plastic plug 5 1 see page 3 1 ...

Page 357: ...he GS B terminal of the battery as follows either to terminal 2 enerqizinq of the pull in winding of the solenoid OI to the solenoid earth enerqizing of the hold in winding which is prefe rable smaller current but in this case the core of the solenoid has to be pr 41crl iu mmanll uritil it is held iu P C hi nllv 6 With the pinion in the forward position I Z cop between the extremity of the pinion ...

Page 358: ...f the testing apparatus is a broken line Euro pea dip type 1 Set the intersection point of this line on the vertical point of the screen by turning adjusting knobs 1 and 3 Equalize adjustment screwing and unscrewing knobs 1 and 3 1by the sameamount Vertical dius ment Switch on dipped headlamps Turn the adjustment knob 2 so that the hrokr n lirw coincides with the upper line of the shaded cwea on t...

Page 359: ...x Torque at 40 rpm and 13 5 volts 0 2 do Nm 1 45 ft lb Correspondinq current 5 5 A max Torque ot 20 rpm and 13 5 volts 1 07 da Nm 7 74 ft lb min Corresponding current 13 2 A max 2 Second speed Nominal power 15 watts Speed under no load at 13 5 volts 70 rpm Corresponding current 2 3 A Torque motor locked at 13 5 volts 1 5 do Nm IO 85 ft lb min Corresponding current 21 A max Torque at 60 rpm and 13 ...

Page 360: ... 12 mm Brushes ference No _ Minimum length after wear _ 3 mm wear of 5 5 mm Ratio 1 90 7 Tightening torque of fixing nut of wiper motor 1 to 1 5 da Nm H r p nj d c K J djogmms 0 5 in O j 1 2 i10 00 h Il ing rtirn Ior lirl0l ADJUSTMENT OF REAR SCREEN WIPER ARM n Tigtenwiperarm nut to0 6daNm 4 l 4 ft lb A CARTIER timer reference No 25 630 located in the IMT L H lamp cluster housihg allows the wiper ...

Page 361: ...hannels of a radiator supplied by water from the engine cooling system co 5 3 t E REFRIGERATION E I CHARACTERISTICS ASPERA FRIGO type HG 700 or Compressor 1 SANKYO type SD 508 De watering tank SINGER Condenser _ _ _ _ CHAUSSON Evaporator blower SOFICA Flexible hoses _ STRATOFLEX and RANCO Refrigerating fluid R 12 Weight of refrigerating fluid _ _ _ _ _ _ __ 1 kg 2 2 lbs Oil for lubricating compres...

Page 362: ...pressure switch 6 opens the supply circuit to the compressor clutch Condenser 7 Manufacturer CHAUSSON It allows the fluid to condense and to release its latent heat to the outside air circulating around the fins It is secured to the front L H side of the engine cooling radiator At the condenser outlet the fluid is in the high pressure liquid state The fluid flows through the tank 5 which contains ...

Page 363: ...creen 56 Centre outlet on dashboard Distribution of regulated air Vl Distribution flap between outer and inner air intakes controlled by C 1 V2 Flap for cutting off outlets S3 S 4 S5 S6 controlled by C 2 V3 Distribution flap between outlets S3 S4 and S5 S6 controlled by C 2 V4 Distribution flap between outlets S5 and S6 controlled by a lever on the left of the centre outlet on the dashboard V5 Cut...

Page 364: ...re but under the action of the vacuum and flap V 1 via the pneumatic piston blanks off intake E 1 the air drawn in comes from the passenqer compartment recycling position NOTE Identification mark for fittinq the one way valve the outer diameter is reduced on the side of the 3 way union V FAST IDLING SPEED CONTROL This control allows for a faster idling speed when the compressor is operatinq A vacu...

Page 365: ...ol relay for air blower 3 Ambient thermostat located on evaporator 4 Air conditioning switch on centre console 5 High pressure switch on de watering tank 6 Electra magnetic clutch for compressor 7 Electra valve controlling fast idling speed arid pneumatic recycling piston WEBER electro valve 8 Control relay for supplementary electric fan for air conditioning 9 Control relay for electric cooling fa...

Page 366: ...controlled by the coolant temperature in the radiator is off _ Supply to supplementary electric fan 14 alone This is carried out by contacts in relay 8 when its energizing winding is supplied The relay winding is supplied when ignition is on air conditioning switch 4 is off a contact on the ambient temperature thermostat 3 is closed Supply to the electro magnetic clutch for the compressor The clut...

Page 367: ...operating This relay with its N open contact cuts off supply to electro valve 9 which therefore produces fast idle The rest of the operation is identical to the preceding diagram DESCRIPTION OF COMPONENTS 1 Heater relay standard 2 Air blower Stmdnrd 3 Speed control for blower f Stnudnrd 4 Regulating thermostat 5 Air conditioning switch 6 Pressure switch on dc wnkrivg t rrk 7 Compressor cl utch 8 C...

Page 368: ......

Page 369: ......

Page 370: ...fast idling speed is adjustable by means of adjusting screw located on top of the vacuum capsule on the cmburettor NOTE In case the fast idle is impossible to obtain the vacuum capsule may be moved slacken both fixing screws on carburettor in order to reduce the clearance at the fixing point of the rod controlling the first choke butterfly opening 3 Adjusting the pulleys Camshaft pulley water pump...

Page 371: ...d with the necessary equipment for refilling SOGEV equipment IT IS IMPERATIVE before driving the vehicle to another workshop equipped with the special equipment to carry out the following To leave the blanking plugs on the compressor in order to avoid ingress of air the new compressor contains refrigerating fluid To blank the intake and outlet hoses and to fix them tempororily Todisconnect the sup...

Page 372: ...any port of the refriqerotinq circuit d Never switch on the air conditioninq system if either of the cooling fans are disconnected 1 Drain the circuit NOTE This operation must be carried out in a well ventilated room The refriqerating circcit must be drained before any work can be carried out on it a Remove pluq 7 from compressor intake valve and connect in its place at a flexible pipe 4 b Remove ...

Page 373: ...t to eliminate by evaporation j any trace of water which would hinder the operation of the refrigerating system In the case of replacing the compressor fully unscrew screws 2 1 and 3 1 then screw in screw 2 two turns after having connected flexible pipe 4 to the intake valve In other cases see paras 1 and 2 a Connect flexible pipe 4 i to the intake valve and flexible pipe 6 1 from the vacuum pump ...

Page 374: ...ottom of the refill the noise stops when the refill is empty this can be confirmed by shaking the refill NOTE In certain cases heating the refill with one s palms may be insufficient The operation must then he completed by using refrigerating fluid in a gaseous state The procedure is the following Hold refill the right way up Set air conditioning levers to the SC cold Band maximum ventilation posi...

Page 375: ...ect it to the battery terminal d Rotate the clutch in order to line up mark a visihlc tllrou h Ihv i ler opvui p nad lorn d w I TV rnw flnle with the axis of the filler opening Then make a mark on the clutch and the compressor co sing and then rotate the clutch by opproximotely 110 clockwise seen from pulley end Disccninect the supply lead from the battery a terminal e Insert gouge 6009 T into the...

Page 376: ...ists of the following A device to heat the inlet air A device to increase the heating in the passenger compartment A water temperature gauge The crankcase has a plug which can be removed to allow a heating element to be inserted in order to heat the engine coolant ...

Page 377: ...or C A device for heatinq the inlet air by means of the exhaust by having a take off on the exhaust manifold shield ASSEMBLY DIAGRAM Carburettor Calibrated orifi ce for vacuum intake COLD AIR A VACUUM CAPSULE II I I t I Position of capsule when not under vacuum flap open closing plate closed I m t L2 L H ii Thermal sensor filter Position of capsule under vacuum flap closed closing plate open 1 ...

Page 378: ...filter inlet the vacuum capsule controls a flap and a closing plate allowing simultaneously supply or no supply of warm air and no supply or supply of cold air When starting Diagram 1 the capsule is subjected to vacuum the flap stops the supply of cold air and the closing plate allows the supply of warm air to the air filter When the effect of the vacuum ceases the capsule returns to length Ll Dia...

Page 379: ...he position of the bi metallic strips and the valves is such that vacuum in the inlet manifold is communicated to the capsule see para A diagram No 1 For an inlet air temperature above 19 C the bi metallic strips change shape and the position of the valves stops the vacuum from reaching the capsule see para A diagram No 2 For an inlet air temperature between 6 and 19 C the positions of valves and ...

Page 380: ...ater distribution box to side vents III WATER TEMPERATURE GAUGE The presence of a water temperature gauge entails modifying the following components water pump spacer addition of a temperature sensor steerinq column surround location of temperature gauqe engine harness for warning lamp senders addition of lead from temperature sensor to front wiring harness addition of a temperature sensor and a t...

Page 381: ...rrgs OVIO n sov hlcd uud r m Op MA 700 00 1 MOUNTING OF BODY SHELL TO UNDERFRAME L 71 1 SPECIAL FEATURES i gr ts are guide holes Body shell fixing nuts 1 on rubber pads Rubber pod fixing screws 2 on sidemembers 2 5 doNm 18 ft lb 3 daNm 21 l 2 ft lb ...

Page 382: ...nal adjustment of bonnet measurement between front end of bonnet E and front end of wings L2 0 t 3 mm Clearance between rear wings and boot lid J2 6 2 5 mm 1 Difference in level between the left and right hand sides 2 mm max Difference in level between wings and boot lid 1 5 mm max Clearance between upper edge of boot lid and rear window J3 6 5 4 mm Difference in level between boot lid and rear wi...

Page 383: ...J4 10 2 mm Difference in level between window frames 2 EN max _ Clearance between side window frames and roof edge J5 7 2 mm Difference in level between window frames and roof 2 mmmax Clearance between door and rubber seal fixings J6 14 2 mm 4 Flush fit tolerances Protrusion of each component in relation to the one immediately behind it 0 to 2 mmmax II Continuity of the s light line a Difference 2...

Page 384: ...ews 5 2 Transversal and height adjustments Loosen hinge fixing screws Move the door vertically in order to obtain a clearance of Jl 7 2mm between the upper port of the window frame and the roof edging Check the continuity of the a light line 1 and the difference in alignment between door and front wing Inset of front door in relation to front wing maximumof 2 mm Tighten the hinge fixing SCWNS and ...

Page 385: ...ighten fixing screws 4 1 2 Transversal and height adjustments Check clearance between upper edge of window frmne and edqe of roof Jl 7 2mm Check also continuity of the G light line x and the recess of the rear door in relation ta the front door 2 mm max Loosen upper and lower hinge fixing screws Adjust door to obtain positioning IS above Tighten fixing screws of these hinges Secure distance strap ...

Page 386: ...idr trim of rwr window i vu vi h r ciriv Slacken screws 3 1 and adjust boot lid in order to obtain at I b a a cle r nce of 0 3 mm clraranc brtween war window rmd boot lid JZ 6 514mm clearancr brtwrrn boot lid and rwr bumper 10 rmn by way of indication Tighten screws 3 Fix trim and trim fixing screws 2 DU c iih i 3 Adjustment of lock Loosen screws 4 i and mokr vertical odjustmrnt to lock in ordrr t...

Page 387: ...diffe rence in level of 2 mm adjust also to obtain clearance between front edge of wings and bonnet E 0 it3 mm 3 Adjusting the striking plate Loosen screws 3 Centre striking plate in relation to lock Tiqhten screws 3 4 Adjusting the safety catch Loosen screw5 4 1 Adjust safety catch so that With bonnet resting on catch the latter must engage under weight of bonnet alone Tighten screws 4 5 Adjustin...

Page 388: ...ted because either the control cable is not attached to the catch or the cable is broken Introduce tool MR 630 84 21 into the lower front ventilation grille Shine a lighf on tbc bonnrl lock though the radia or grille Engage the point of the tbol into the lock protection housing 1 from the rear and exert pressure in the dire on of arrow CC F non the catch of the lock in order to unlock ...

Page 389: ...s Department 1 Repair kit ZC 9 855 128 U This MSECURIGLACE outfit includes 1 Bottle of abrasive cleaning powder 1 Small bottle of conductive enamel 1 Tube of adhesive 1 Tube of hardener for adhesive 1Small bottle of metallic powder 1 Roll of thick self adhesive tape 1 Warning lamp for detecting cuts 1 Roll of self adhesive tape for detecting cuts thermopaper 1 Plastic spatula 1 Small glass plate f...

Page 390: ...proximately 15 minutes 2nd Part On the glass plate prepare a small quantity of mixture composed of equal parts of UHV hardener and binding agent Add to this paste an equal quantity of the metallic powder contained in the bottle marked Metallpulver Mix well using the spatula Apply the resulting paste on the conductor enamel deposit overlapping on both sides by 10 mm but with the width still restric...

Page 391: ...ittinq the oil filter cortridqe 6401 T Set of 2 grips for adjusting anti roll bar 6501 T Tool for honibrake eccentric nut 6004 T Union for checking oil pressure 6451 T Set of 2 tools for positioning steering crossmember 6009 T Dipstick for checking oil level on SC SANKYO 1 compressor I ...

Page 392: ...ssembly for checking petrol pressure continued 279 1 13462 0 10 bar 0 145 psi Pressure gouge 3085 T Pulley alignement rod Assembly for checking converter oil pressure consisting of the following a 2279 T pressure gauge a metal union A dia 6 mm taken from kit 3112 T 4 4 ...

Page 393: ...MANUFACTURING DRAWINGS FOR TOOLS NOT SOLD 0 12 Electric system 1 Air conditioning system n n a MR 630 7305 Developed length 258 Material Soft steel wire dia T 3 r SO 2 grooves 0 15 ...

Page 394: ...MANUFACTURING DRAWINGS FOR TOOLS NOT SOLD 0 13 Bodywork MR 63OJW21 rr6 Red paint Steel drawn sem hard z6 Developed length 636 360 610 ...

Search results

Summary of Contents for CX 2000

Reviews:

Related manuals for CX 2000

Brands by name

Popular brands

CITROEN CX 2000, Repair Manual

Search results

Summary of Contents for CX 2000

Reviews:

Related manuals for CX 2000

Brands by name

Popular brands