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Page 1: ...CKS PdntedinFrance SOCIETE ANONYME AUTOMOBILES CITROEN SA AU CAPI TAL DE 600 000 000 F Rgie pa les cti d s 18 150 de o kl sur les Sociéts Commerci ol es R C PARIS B 642 050 99 SIRET 642 050 199 00016 SI EGE SOCI AL 117 a 167 QUAI ANDRE Cl TROEN 75747 PARIS CEDEX 15 TELEPHONE 578 61 61 1 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 2: ...BODYWORK Volume 3 deals with the CX Diesel The above volumes are sold separately They are presented bound in dark red Fibrex witha MULTO type mechanism to facilitate the insertion of supplements or the extraction of o particular operation required by the workshop COMPOSITION Every volume comprises the llst of operations contained in the volume tliese operations filed in numerical sequence the list...
Page 3: ...ls specially designed for CX vehicies Additional tools of lacal 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 TICHTENING TORQLJES Torques are expressed in the following units either in metres Newton rn N the legal unit for measuring torque with the corresponding a...
Page 4: ...l features of the carburettor M 23 623 engine Characteristics and speciol 1 eatures of the anti pollution system SWEDISH larkel ehicles Adjusting the carburettor adjusting the idling speed Checking and adjusting the anti pollution system SWIiDISH Market tehicies Characteristics ond special feotures of the electronic fuel injection system L Jetronic Checking and adjusting the electronic fuel inject...
Page 5: ...source and reserve of pressure hydraulic system Checking the hydraulic comporients on the vehicie FRONT AXLE 0 Characteristics and special features of the front axle Checking and adjusting the front axle Checking the comber Checking and adjusting the castor angle Checking and adjusting the wheel cxligriment Checking and adjusting the steering geometry Checking the steering for straight line deviot...
Page 6: ...76 Page 5 5 8 Es etc Super 1 1976 Pages 9 12 Instrument panel 711 c iiclcs 9 975 I agc 13 Torque con i eric r 1 1976 _ Pagc 14 Air conditioning _ 7 1976 1 Page 16 Air condit oning 7 1976 Page 17 Iorque coniertcr air conditioning 12 976 Page 15 1 lectron c Juc iii ed on Pae 19 Characteristics of the electrical units Checking the electrical units Checking and adjusting the headlamps Checking and adj...
Page 7: ...CX 2400 9 1976 Manual garbox or torque converter Mi MÅ series Mi M 23 623 13 hp CX 2400 GTI 5 1977 Manual 5 speed gearbox ME MA series ME M 23 622 13 bp ESTATES AND AMBULANCES Commercial symbol Gutee symbol Official symbol Engine type French fiscal ratinq CX 2000 1 1976 MD MÅ series MD M 20 616 11 hp CX 2200 Diesel 2 1976 MH MÅ series MH M 22 621 9 hp CX 2400 9 1976 MF MÅ series MF M 23 623 13 hp ...
Page 8: ...z 2 OPERATION N MA 000 Ge eral character stics PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 9: ... aub pouer steering 185 HR 14 XVS 175 HR 14 XVS 175 HR 14 XVS Tyres tuheless 1 9 bars 27 1 2psi 2 1 bars 30 1 2 psi 2 3 bars 33 2psi Pressures Authorized alternative 185 HR 14 XVS 135 HR 14 XVS 185 HR 14 XVS Tyres tubeless Tyres with inner tubes 14 F 9 13 185 HR 14 XVS 185 HR 14 XVS 185 HR 14 XVS a 185 HR 14 XVS 175 HR 14 XVS 175 HR 14 XVS b 185 R 14X M S 185R14 X M S 185R 14X M S Tyres speciale q...
Page 10: ...5302 iucluding a trailer ujthou t brakes unighing 645 kg 1422 bs CX 2000 900 1984 630 1389 3040 6702 1500 3307 lin8 1 3 IMPORTÅNT NOTE References to trailers without brakes DO NOT APPLY in U K III GENERAL INFORMATION Copacities CX 2200 900 1984 645 1422 3060 6746 1500 3307 lin8 1 3 Fuel tonk 68 litres 15 galls 16 dm2 248 sq in radiator 11 litres 19 3 pts Coolirig system zncludrng heater unit 20 dm...
Page 11: ...ering 1 9 27 1 2 2 1 30 1 2 2 3 33 1 2 NOTE Vehicies 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 The sizes and ...
Page 12: ...00 kg 2866 1b trailer with brakes 1500 3307 Maximum authorised trauler weiqht within limits of G T W 1 in 9 11 Maximum starting gradient at G T W IMPORTANT NOTE References to trailers without brakes DO NOT APPLY in U K III GENERAL INFORMATION Capacities Fuel tank 68 litres 15 gauls Cooling system fleater unit inciuded 20 dm2 310 sq in 10 6 litres 18 6 pts Heater unit alone 0 6 litres 1 05 pts Engi...
Page 13: ...h a gearbox with torque converter as optional equipment Wheels and tyres Ö Wheelrims 0 c Tyres tubeless ressure in bars psi z 5 1 2 F x 14 FHA Front Rear Spare 185 HR 14 XVS 185 HR 14 XVS 185 HR 14 XVS 2 2 32 2 2 32 2 4 35 c Authori sed alternatives Tyres Special equipment Pressure in bars psi 18519 14 X M S 185R14 X M 5 185R14X M S 2 2 32 2 2 32 2 4 35 II GENERAL DIMENSIONS Dimensions Front track...
Page 14: ...res 18 6 pts Manual gearbox 20 dm2 310 sq in radiator Torque converter gearbox 23 dm2 356 sq in radiator 12 5 litres 22 pts 0 6 litres 1 05 pts Heater unit alone Engine ou 4 650 litres 8 2 pts after draining 1 1 litres 1 9 pts difference between Min and Max n dipstick 4 litres 7 pts Hydraulic system approx Gearbox 1 600 litres 2 8 pts a Manual gearbox TOTAL EP 80 0 150 litres 0 26 pts differénce b...
Page 15: ... HR 14 XVS TU 175 HR 14 XVS TU _______________ FITTING ______________ L9 27 5 _______________ 2 1 30 5 1 2 3 33 5 185HR14XVS 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 The tyre pressures...
Page 16: ...ooling fan IMPORTANT NOTE References to trailers without brakes DO NOT APPLY in U K III GENERAL INFORMATION Capacities Fuel tank Cooling system in duc ing hnatur 1 Flit Manual or torque converter gearbox Optional torque converter f air conditioning unit Heater unit alone Engine ou after draining difference between Min and Max on dipstick Hydraulic system approx Gearbox ci Manual guarhox Overall ap...
Page 17: ...l 185 HR14XVS TU a steering 2 29 2 1 30 5 2 3 33 5 AU THORISED Manualor 185R14X M S ALTERNATIVE Power steering 2 29 1 2 1 30 5 1 2 3 33 5 0 5 5 NOTE Vehicles are fitted with TUBÉLESS 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 ...
Page 18: ...kes Maximum trailer weight within limit of G T W 3395 kg 7485 ib Maximum stärtinq gradient atG T W IMPORTANT NOTE References to trailer without brakes DO NOT APPLY in U K III GENERAL INFORMATION Capacities Fuel tank Cooling system includin g heater ijizit Heater unit alone Engine ou after draining difference between Min and Max on dipstick Hydraulic system approx Gearbox af ter draining difference...
Page 19: ... HR 14 XVS 2 4 35 185 R 14 X M S 185 R 14 X M S 185 HR14 X M S 2 1 30 5 2 2 32 2 4 35 c NOTE Vehicies 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 side II GENERAL DIMENSIONS 1 474 m 4 ft 10 ins...
Page 20: ... biade cooiing fan 1300 2866 Grass Train Weight with a 1300 kg 2866 ib trailer with brakes 3110 6856 Max trailer weight within limit of G T W 3110 kg 6856 ib 1500 3307 Max starting gradient at C1 T W 12 1 in 8 1 2 III GENERAL INFORMATION Capocities Fueltank Cooling system izcluding hater anit Heater unit alone Engine ou after draining difference between Min and Max on dipstick Hydraulic system app...
Page 21: ... series MF MFA September 1976 l3hp 4 sitting 1 lying 5 1 2J 14FHA Type and pressure in bars psi MICHELIN TYRES Front Rear Spare Manual 185 SR 14 ZX TU or 185 SR 14 XZX TU Standard steering 2 1 30 5 2 29 2 3 33 1 2 _________________ Power 185 HR 14 XVS TU fitting steering 2 29 1 9 27 5 2 2 32 ________________ Manual 185 HR 14 XVS TU Authorised steering 2 29 1 9 27 5 2 2 32 Manualor 185R14X M S Alte...
Page 22: ...thorised weight on rear axle III GENERAL INFORMATION Capacities Fuel tank Cooling System including the heater units Heater uriit for driver compartment alone Auxiliary heater unit for patient cornpartmerit Engine ou af ter draining difference between Min and Max on dipstick Hydraulic system approx Gearbox after draining difference between Min and Max on dipstick 1 330m 41t 4 1 4ins 1 400 m 4 It 7 ...
Page 23: ... _ _ _ _ _ _ 0 0 0 5 4 R e p e a t c h a s s i s n u m b e r B o d y s h e l l N C h a s s s N p l o t e F r o n t s u b f r a m e N 5 A A C I T R O E N 0 0 0 4 0 1 2 3 4 5 L B o d y c o d e n u m b e r n i z I I i f l f l1 F n f l 0 0 zm z I 0 I l I 0 z z 0 Q r s A A C I T R O E N T Y P E N 0 1 2 3 4 5 6 7 9 1 I i j E n g i n e n u m b e r t 9 5 1 6 2 8 J G e a r b o x n u m b e r 0 0 0 1 3 R e a...
Page 24: ...idcmv hets rh i tri ah rsn i fl Fln sahjran c ou o oli inc IsuuHd in tlfleqn al biaki 0 0 z c c A Lifting poinis under wheels B Bl Jack supports under body for ear jack wheel chunqinq C Supports under front axle in line with the engine mountinqs D Jackiny points under body Bl Lifting points when raisirig the car with a twin post lift with chocks at E E F Lifting points when raising the ear with fo...
Page 25: ...eyes A under the sij btrorr c ho With the wheel s off the ground IMPORTANT NOTE Towing the vehice by iiftinc the runt by ineons of owtnq eyes A IS PROHIBITED A Vvh c not fiIIy ujli ni 11v ir u I N lut1 u Lift the back of the vehicie using the rings provided or that purpose or rnove the vehicie on u trailer PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 26: ...CFIt IrS rn o C fro fl mcl LII arrhs Attach a cable 1 in the holes of the brackets Interpose a wooden beurn 2 under the reur section of the rubber buffers close to their fixin points Interpose a piece of pudding to protect the lower volance and the burnper PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 27: ...z z 0 OPERATION N MÅ 00 2 Reor towing poirits 13 Towinq eyes on the reor bodyshei siderriernhers PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 28: ...TION N MÅ 00 800 IvIrior 111 1 intcr Or im SiOl S Op MÅ 00 800 1 1 EXTERIOR AND INTERIOR DIMENSIONS CONFORT SUPER PALLAS SALOONS L 80 la fl 09E F 1 PI J _____ fk4k _ _ 1 1 I c 8601 1 1 Ill iYL 4 _____ III _____________________ 6opInoHs lp jL iI 068 1 0 _ r ____ NNN 0 CD C0 LO i1 3 LO CN UW __ EEE 0 co co 0 3 0 0 0 z 0 E 0 0 3 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 29: ... maximum roof rack bad is 80 kg 176 Ib evenly distributed The roof rack contact points must be on the gutter at the front at the centre of the front door opening and at the rear in line with the rear door pillar A ___ _ _ PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 30: ...N z z z z z z OPERATION N MÅ 00 800 IvIr or muf ir frHJ S O II EXTERIOR AND INTERIOR DIMENSIONS PRESTIGE SALOON Op MÅ 00 800 3 L 80 13 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 31: ...1 1 1 380 t s uder heigrit 265 388 5 1366 at shoder heHt H 470 1098 between wheeIarches J 1 SP O8 1 1 i l lI j RI O t VW 0N NOIIVN 3 dO fr PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 32: ...0 1000 opening 1734 W 560 59t OPERATION N MA 00 800 k vIr or aud t Iur or nu s o ls Op MA 00 800 5 III EXTERIOR AND INTERIOR DIMENSIONS ESTATE ond Estote variations L 80 2 et L 80 44 9t L _ 2 1 2 CNN II PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 33: ...inq position Tot vol 2 030 Vol 186 1200 240 du 5c 1 IWdth at jdeei9kt 1380Tl 3885 i Width at skoulder keigh 1360 0 JT 958 1124 wheelarches ____ i EP 021 L01 31V1S3 Il f I 1O f 1r LI v J 00800 VA4 0N NOI1VIdO 9 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 34: ...N N MA 00 800 IvIjir 1 1 1 t r or fjm sjr J s Op MA 00 800 7 FAMILIALE Estate L 80 41 a 0 0 co c 0 z 0 0 0 0 a 0 0 co r I 1 __ ____ PLL IL__ 0PEL 0 0 1 0 OEBI 0 0 0 S BE S8P j UIP LL j SD0S 1eno GL O 0JU0D 04 D 0LL L SD0 S J0 fl0 0 4 ______ ______ I0 0 JU0 0 0L D I1If L JLOLPLJLH 0SE PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 35: ...08 8 OPERATION N MA 00 500 1 t HO dO 1 1 f I O II C O ESTATE VEHICLE FOR TRANSFORMING INTO AMBULANCE L 80 46 0 ______________________________________________ puUppp Oap o t E OE8i Il 1 0 p Jo LjM _ _ zL _ _________________________ 6IL OS 0 0c PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 36: ... 3095 839 1474 1734 4984 940 1040 1390 z 0 z 0 m 0 z 0 z z 6E8 Gav OP ERATION N MÅ 0 0 800 v1 rir 1 Hl i ri r din nion Op MÅ 00 800 9 IV EXTERIOR AND INTERIOR DIMENSIONS CX ÅMBULANCE L 80 48 906 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 37: ...ing 1345 2180 with engine running normal driving position _ L4O0 1 i1 L 13251 J 2 580 1 Hl L 24 J _____ 540 1590 2130 2 0 0 LP08 1 HfYI I0 J I 1O Å j 008 00 Vw 0N NOIIVd dO oj PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 38: ...n each embellisher must not exceed 5 mm Mark and punch the eight fixing holes using a pin punch and fit the round headed seif tapping screws Tighten them Position the outer embellishers mark and punch each fixing hole using a pin punch and f it the seif tapping fixing screws Tighten them 1 2 Fitting the bumper and protective pads it the protective pads andsecure them using nuts and contact washers...
Page 39: ...3 1 2 8 Ø 8 2 5 1 2 1 5 1 3 8 3 1 3 3 4 1 4 9 1 7 0 8 1 5 8 5 1 6 5 7 1 _ _1 0 3 Q 5 1 8 3 6 1 9 6 5 1 E 5 2 m m L o w e r r a i l s t I 1 _ _ _ _1 t r n e 1 8 4 2 3 9 0 _ 1 6 2 3 t i m e s 1 7 6 3 1 5 t i m e s 1 6 5 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 40: ...string draw a line passing through each point and draw the oxis of the strips Mark the axis of the strip fixing holes see diagram poge 2 as weil as the holes at o 17 ond a 18 Drill the holes 5 mm diameter Fit the plastic chps Position the strips on the clips 0 1 0 D c 0 0 0 z E 0 0 2 Fitting the rubbing rails 2 at the centre of the doors Mork the front and reor points at o distance of 260 mm at th...
Page 41: ...y is correctly connected negativa terminol to eorth c Do not check the operation of the alternator by shortcircuiting either the positive or the EXC terminals ond 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 ony case would damage both the alternator and the regulator f Do not connect...
Page 42: ... u i of mia a d hiankod olj Like the piping they must be protected against shock and the ingress of dust Rubber tubing and joints must be stored away from dust air light and heat LHM hydraulic fluid must be stored in 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 4 CHECKS BEFORE CAR...
Page 43: ...bench is pciu t d r O 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 testinq components operating with LHM mineral fluid provided that the bench is cleaned first 8 PRECAUTIONS...
Page 44: ...on of the pipe NOTE Tiqhteninq torques 3 5 mm pipe 5 8 to 6 6 ft lbs 4 5mm pipe 8 to P mN 0 8 toO 9 n kg 6 6 to 8 0 ft lbs b 0 m pipe to 11 mN 0 9 to 11 c kg The design of the various seals ensures that their sealing action increases with fluid pressure The oiltightness is therefore not improved by greater tightness of the unions To connect a rubber tube a rubber ring of suitable diameter hos to b...
Page 45: ...hing it with the fingers use a wooden spatula instead 1 Cut the tubing and roughen the ends over a length of some 3 5 in with abrasive paper N 600 2 Carefully degrease the roughened ends and the sleeve with trichiorethylene 3 Heat the Rilsan adhesive in a water bath to raise its temperature to 60C Do not n vcnnd this tc peraturn NOTE This operation is essential to cut down drying time 4 Coat the e...
Page 46: ...and free the deflector separating plate at botton oj reservoir g Glenn filters 5 and 6 the reservoir and the deflector with petrol then blow throuqh with compressed air h Reassembie the unit FILLING o FUl the reservoir with approximately 3 litres of LHM hydraulic fluid b Priming the HP pump Ful the pump with hydraulic fluid through sudtion pipe Start the engine and set manual heiqht control to the...
Page 47: ...ubber adhesive Ref 1313 Preparation of adhesive TEROSON Aluminium Preparation of surfaces Epoxy Lower edge Coating of both faces Ref Térokal Warm water before of windows Application of pressure COLFIX polymerisation Bonding time Ref Masticol Preparation of surfaces COMET Base of mirror Coating of material Special Super dean stems Positioning Ref Glass metal kit Appliccition of pressure Glass Coati...
Page 48: ...ite products Department D A V A Carburettor cleaner Product to be used undiluted SOFRALUS BARDAHL Cleaning of carburettors P D R Is supplied as AGIR ro l an oe so or Carbuclin a liquid REDEX FRANCE III SEALING PASTES USAGE PRODUCT CHARACTERISTICS MANUFACTURERS Resist mechanical stress and PROTO JOINT JEAN BRASSART oil derived products CEFl LAC CURTYLON Clean with alcohol Department Joint Curty LOW...
Page 49: ... z 0 E 0 0 1 V GREASES AND LUBRICANTS USAGE PRODUCT CHARACTERIS TICS MANUFACTURERS RHONE POULENC Greasing of fluidbloc SI 33 LAMBERT RIVIERE Silicone grease suspension bushes GRAISSE 33 MEDIUM DOW CORNING S A R L Highly odhesive universal GRAISSE 1495 MOLYDAL grease MOLYKOTE Extreme pressure grease good Greasing of drive shofts LONGTERM 2 adhesive and is waterproof DOW CORNING S A R L TOTAL MULTIS...
Page 50: ...3 route de la Metzeau 68100 MULHOUSE 1 rue Goethe 75016 PARIS 140 avenue Paul Doumer 92500 RUEIL MALMAISON 15 rue de Miromesnil 75008 PARIS 12 rue du Moulin de Cage 92390 VILLENEUVE LA GARENNE 167 rue de Fontenay 94300 VINCENNES 135 boulevard Sérurier 75019 PARIS 52 avenue de la Concorde 93270 SEVRAN 60 rue des Orteaux 75020 PARIS 28 avenue de lOpéra 75002 PARIS 35 rue L Sampaix 75010 PARIS 23 rue...
Page 51: ...No Manual 818 1 CORR z ENGINE OPERATION N MA 100 00 JaracIrisIicS ainl s ncial faturcs oj Ihe i2ginc Op MA 100 00 0 L 0 0 0 0 z c 4 E 4 0 0 D P T O PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 52: ... 2 0 1 m k g 1 4 5 t t I b a t 3 6 0 0 r p m 5 6 0 0 r p m r p m L u b r i f i c a t i o n U n d e r p r e s s u r e s u p p l i e d b y a g e a r t y p e o i l p u m p d r i v e n b y t h e c a m s h a f t E x t e r n a l o u f i l t e r c a r t r i d g e P U R F L U X L S 1 0 5 t y p e F u e l s u p p l y a L n 9 i n e s f i r r e d w i t h a c a r b u r e t t o r W E B E R c o r n p o u n d t y...
Page 53: ... l y w h e e l L O C T I T E a t t a c h m e n t F R E N E T A N C H I O r f I 8 t o 9 d a N m r I r 5 8 t o 6 5 f t 1 b d i a p h r a g m L O C T I T E u t t a c h m e n t F R E N E T A N C H 9 t o 1 0 d a N m 6 5 t o 7 2 f t I b L O C T I T E F R E N E T A N C H S c r e w s c 8 m m 3 1 t o 3 4 d a N m 2 2 5 t o 2 4 5 f t 1 b 7 2 t o 8 d a N m 5 2 t o 5 8 f t I b 1 0 2 m l i i f l 1 0 PDF compres...
Page 54: ...Ib Or injection pipe attachment 1 2 1 d Nm 15 ft Ib 2 1 daNm l5ft Ib 2 to 2 5 da Nm 14 5 to 18 ftlb l 4tol 9daNm 3to4daNm 22 to 29 ft Ib 10 to 14 ft Ib 1 4 to 1 9 da Nm 10 to 14 ft Ib SS LldaNm 8 ft Ib SS 7 2to8daNm 52 to 58 ft Ib 0 0 co co 0 c 0 0 0 z c E 0 0 0 NOTE For the rernaining tightening torques see page 17 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 55: ...le mounting on the gearbox side 2 torque bars at the upper section 1 torque bar at the upper section torque bar on the gearbox side green paint mark at a to be positioned uppermost yellow paint mark at a on fitting torque bar on the engine side blue paint mark at a NOTE The 5 speed manual gearbox has a different vertical flexible mounting from the torque converter NOTE When fitting position the pa...
Page 56: ...t becxring c Timing chain cover Pressed steel sealed by a cork gasket 3 Crankshaft F ive bearing forged s teel crankshaft The junctions between the crankshaft webs and the crankpins the crankshaft webs and journals as weil as the thrust faces for the bearing haif rings and the oil seal are rolled Irealment Jur im rO i g stirjace hrdicss NOTE There is an oii seal on the flywheel side of the cranksh...
Page 57: ... ifl CRANKSHAFT oE E c 2 0 0 ou 0 u 0 o 1 Il LII ___________________________________ 1 cl ID 4 cl 4 cl 0 0 ou LII LII o NOTE The Replacement Ports Department oniy supplies one class of crankshatt AA 7 2 to 8 da Nm 52 to 57 3 4 ft Ib Tightening torque for the balance weight fixing screws PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 58: ...ND RINGS 0 0 r00 CN C C V 000 0 CO 000 ut3u 0 0 co co 0 0 0 0 0 7 c 0 E 0 0 1 i 1 1 1 ol 1 2 IIL LJLg Op MÅ 100 00 7 0 0 c CN N 2 Lfl 0 Lfl 0 0 0 Crankshaft end float 0 045 to 0 16 mm NOTE On engines fitted with a torque converter gearbox the haif rings for adiusting the crankshaft end float have an additional lead tin surface treatment PDF compression OCR web optimization with CVISION s PdfCompre...
Page 59: ... 081 z z 180 Z solo 066 S x 8 OPERATION N MA 100 00 harac eristics and sncia fnilurns ni thn ni ginn CRANKSHAFT CONNECTING RODS PISTONS oQ c c U c n R 1 ___ _ 1 _ 1 T ___ iL The Replacement Parts Department oniy supplies connecting rods in sets of 4 class 1 0 037 to 0 247 mm End float of connecting rods on crankshaft 7 g max Variation in the weight of the connecting rods on the same engine PDF com...
Page 60: ...rrow must point towards the engine flywheel 0 L c 0 0 0 0 z 1 c Piston rings Correct fitting of piston rings The mark TOP or the manufacturers mark must face the crown of the piston 1 Compression ring no mark 2 Ou scraper ring rnarked 3 Scraper collector ring marked 3 or 4 NOTE Since February 1976 the scraper ring 2 on 1985 cc engines is conical and not tooth shaped PISTON IDENTJFICATJOrv MARKS PD...
Page 61: ...e å 0 10 OPERATION N MÅ 100 00 iaracfcrislics 1 1 1 S lcC 1 tca ll cS t Ilu J c BARRELS AND PISTONS c a K 215 cc 1 1 I ___ ___ ___ Hl _ _______ _ __ __ __ ___ __ ___ ___ 1 8 2 1 __________ __ J __ Q 00 o ________ ______________________ ______ 3 ci L ci ___ p x____ _____ _______ Replacement Parts Department only supplies barrel piston gudgeon pm and piston ring assemb1is in sets of 4 0 1 0 015 mm T...
Page 62: ...__ fl Vr44 _________ fl fl _ __________ C C 7 fl 0 0 0 000 aD aD aD aD LrIILr c C ______ 0 0 0 u fl 7 _ The Replacement Parts Department only supplies barrel piston gudgeon pm and piston ring assernblies in sets of 4 0 1 0 010 mm Thickness of barrel base gasket uncompressed fl 0 045 to O ll5mm Protrusicin of barrel with gasket uncompressed 5 g max Variation in weight pistons gudgeon pins ond gudge...
Page 63: ...on mark CEFILAC or COOPERS towards the cylinder head 1985 cc Oval clinching the idéntificotion mark CEFILAC towords the cylinder heod 2175 cc Round clinching diameter 96 5 mm the identification mark CEFILAC towords the cylinder head 2350cc TIGHTFNING SEOUENCE Tiqhtening torques co d Initicil tightening 3 da Nm 21 3 4 ft Ib Final tightenirig 6 to 6 5 da Nm 43 1 2 to 47 ft Ib b Volve seats The valve...
Page 64: ... 5 6 0 4 5 i s t p o s s i b i l i t y 1 3 0 3 9 t o 1 3 0 5 9 2 n d p o s s i b i l i t y 1 3 2 8 9 t o 1 3 3 0 9 i s t p o s s i b i l i t y 1 3 0 4 5 t o 1 3 0 6 5 2 n d p o s s i b i l i t y 1 3 2 9 5 t o 1 3 3 1 5 F 7 9 9 o t o 8 0 1 5 1 1 8 9 8 0 t o 3 v 4 9 0 2 5 6 0 E X H A U S T 8 9 4 5 t o 8 9 6 0 1 _ _ _ _ _ T 5 0 5 f l 0 0 0 5 1 PDF compression OCR web optimization with CVISION s PdfCo...
Page 65: ...s Identical inlet and exhaust f Retaining clips Identicab inbet and exhaust 6 Timing a Camshaft Chain driven camshaft resolving in three cupro leod bearings Camshaft end fboat oiilv 1 hicku ss oJ Iaiig 0 05 to 0 30 mm Thickness of flange 5 44 to 5 46 mm Amount of cam lift Inlet 6 63 0 02 mri Exhaust 6 14 0 02 mm WARNING Never attempt to rotate the engine by means of the camshaft pulley fixing nut ...
Page 66: ...LTIGRADE GTS 20 W50 Grade of ou Capacity of sump 5 800 litres 10 2 pts alter dismantling after draining and changing the filter 5 300 litres 9 3 pts alter draining 4 650 litres 8 2 pts 011 pressure At a temperature of 100 5 C 3 bar min 43 5 psi at 2000 rpm at 4000 rpm 4 to 5bar 58 to 72 1 2 psi 475 to 675 mbar 7 to 9 8 psi Calibration of pressure switch warning lamp goes out 147 to 150 C Calibrati...
Page 67: ...m p 3 P r e s s u r e r e l i e f v a l v e 4 0 1 1 t e m p e r a t u r e s w i t c h 5 B y p a s s v a l v e i n c o r p o r a t e d i n f i l t e r c a r t r i d g e 6 F i l t e r c a r t r i d g e 7 0 1 1 p r e s s u r e s w i t c h 8 O i l c o o l i n g i n s i d e p i s t o n 9 S u p p l y t o i n l e t v c j l v e r o c k e r a r m s 1 Q S u p p l y t o e x h a u s t v a l v e r o c k e r a ...
Page 68: ...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 0 c Tim inq Screw on the camshaft thrust bearing 1 4 to 1 9 da Nm 10 to 14 ft lb Tming 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 1 da Nm 6 5 to 8 ft lb 0 0 z fl d Lubrication system Ou filter mounting LOCTITE FRENETANC...
Page 69: ...g o The rocker cover und its qasket 1 et1 lit fl tar mr 1 or b The injection monif old und the rocker cover html ln jt e er t l IU S 2 Ådjust the engine cold Inlet 0 15 mm tt Ii il t f4 1 01 1 Exhaust 3 20 mm ACCEPTABLE METHODS Rocking the valves Inlet volve stortinq to open ond exhaust volve closing Bring No 1 in rockihg position adjust No 4 No 3 No 2 No 4 No 1 No 2 No 3 3 Fit the rocker cover an...
Page 70: ... nuts 3 of the camshaft beoring housing Rotate the cronkshaft sa as to fully open the exhoust valve of No 4 cylinder Lock the securing screw 3 for the beorinq housing Position the control pulley Tightening forque for nut 2 8 doNm 58 ft Ibs Adjust the rocker arms as indicated previously PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 71: ...converter using a screwdriver 1 Remove spare wheel cylinder head carburettor engine the injection manifold and the rocker cover fuel injection engine 2 Bring piston of cylinder No 4 to TDC with the valves in rocking position NOTE The TOC mark on engine flywheel can be seen at point o on the clutch housing 3 Adjust clearance of inlet valve 1 of No 1 cylinder to 1 10 mm theoretical clearance 4 Tum c...
Page 72: ...ug bmc k ou H I R R c lr nirv Iors cititi iii iv ou SV hk carhiirt tiors The Replacement Parts Department supplies under Reference Number 4035 T o new kit for removing und refitting the protective plugs an WE BER und SOLEX carburettors NOTE The first kits supplied by the Replocement Parts Department Hel 4029T can be supplemented with tools D 4C31 Tand F 4032 T 3 3 0 0 c 0 fl TOOLS INCLU DED IN KIT...
Page 73: ...e Protective cap for throttle spincile stop screw SOLEX corburettor 5 507 643 K white UTIL 1 Z AT1 ON 1 REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MTXTURE ADJUSTMENT SCREW ON A WEBER OR SOLEX GARBURETTOR plug 0 NOTES 1 On GS vehicles fitted with u WEBER corburettor it is necessary to rernove the air filter to curry out this operation 2 On 05 vehicles fitted with a twin choke SOLEX carburett...
Page 74: ...ion the gun and tool assembly against plug a making sure that the nozzie of the gun is properly centred against the plug and that the assembly is aligned as precisely as possible in the axis of the plug Actuate the gun and screw the tool inta the plug L H thread Remove the gun leaving too1 D on the carburettar 3 Remove plug a Land gun A SO I Ii r arhufl tor Screw too C to the bark af gun A Actuate...
Page 75: ...properly loca ted NOTE If the air filter has been removed refit it and stf 1 nr fl II REMOVING AND FITTINC THE PROTECTIVE CAP FOR THE MIXTURE CONTROL SCREW WITH COLLAR ON A SOLEX CARBURETTOR cap b REMOVAL 1 Break the head of cap b using tool F I 1 11 1 5 ro t fio IJ Ii r 0 1 lai ro idn 0 af a st 1 0 the out out in tool F placed the other way round serves as cx yardstick If this value is not obtain...
Page 76: ...emave the cap Fl TT IN 0 3 Pre snap cap b See hg 1 af diagram below Vit cap inta the caliar af the mixture central screw Laad gun A Screw taal E anta the gun Place the too1 and gun assembly against the cap Actuate the gun once 4 Ådjust the exhaust emission 5 Snap cap b into position Land the gun and actuate it a second time anta the cap to set it in pasitian as per Hg 2 af dia gram below PDF compr...
Page 77: ...lat nose pliers 2 Adjost the butterfly opening Adjust the butterfly opening using the test bench according to the Norms laid down in the Etudes Eguipement Nos 14 1 16 ter and 14 1 16 guater s eli on Iv tja est to tb t iis yes oj ear ni tt Ile r lyst ben eby s 1 FIT TING 3 Fit cap c Load gun Å Screw tool Fl onto the gun Fit cap c onto the throttle spindle stop 5 c re w Place the tool and gun assemb...
Page 78: ...d the air filter the crankcase gases recycling system 0 0 vo vo 0 c 0 0 0 z c E 4 0 0 1 V WORKING ON THE ENGINE Adjusting the rocker arms Replacing or removing the following the cylinder heud 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 ign...
Page 79: ...utterfly Mechanically controlled acceleration pump cern on ist chake Choke on ist hedy vacuum assisted cold start strangler flap Fitted damper on idling speed system with incorparated fast idle device ADJUSTMENTS DESCRIPTION Prirnary choke Secondory choke Venturi bete 22 26 Mein jets removable iiS 135 Air correclion jets AD 1 195 AD 2 180 Emulsion tubes F 30 F 25 Idling jets rernovoble 50 70 Air b...
Page 80: ...lever 14 Measure distance between the edge of the first choke butterfly and the carburettor body This measurement must be a 1 25 0 05 mm If not ad just the positive opening distance of the butterfly by means of adjusting stop 12 This cleorance should always be measured with ad justing stop lock nut 11 fully tightened 3 Adjustment of clearance of strangler flap 13 activated by vacuurn capsule 10 Ac...
Page 81: ... 1 0 0 0 ln Check that pm 8 is properly positioned on tongiie 1 c Iland hook it onto the needle valve Hold cover vertically so that the tongue c of float comes into contact with the needle va ve ball witbout pushing it in Take the measurement of the float with needle volve in closed position aS shown opposite with gasket 7 on cover This measurement must be 7 0 25 mm If not ad just tongue c until c...
Page 82: ...ke butterfly Mechanicoily controiled acceleration pump com on first choke Cold start device operates on the ist choke vacuum ossisted coid stort stronqier fiop Idiinq speed circuit with incorporoted domper 4DJUSTM EN TS Description ist Choke 2nd choke Venturibore 23 26 Mainjets removobie 120 135 Aircorrectionjets Ad 195 AD2 180 Emulsiontuhes F30 F25 Idiinq jets removabie 50 70 Airbieed idiinq jets...
Page 83: ...O I 1 O t 34 DMTR 35 250 IDENTIFICATION MARK W 69 50 2 U bcisic noc cl 0 0 4 OD 0 0 0 0 0 z 0 5 E 0 3 0 0 vo CHARACT ERISTICS Anti pollution carburettor twin choke compound type with rnechanically operated second choke butterfly Mechanically controlled acceleration pamp cam on irst choke Cold start device operates on first choke vacuuni assisted cold start strangler Electric out out on idling spee...
Page 84: ...094 Injector upper non weighted type 45 Volume of pump total cm3 120 0 2 portial for re fere fe ll r o5es cm3 0 5 0 7 Outlet tube 200 COLD START DEVICE Return spring f or the anti flooding membrane 550 g5 or 850 Pressure calibrator for membrane control 40 Return spring for the clutch flap 180 g 47600140 Positiv openingof butterfly under operation of cold start device 1 25 0 05 Cam for cold start d...
Page 85: ...OO SD lild s wcial I l urcs of tiJ auii Op MA 142OO SD JrJlIFFIiOl S SI fl WLI ISII ItRKLI VklII L ES 0 0 0 c 0 0 z c E 0 0 CX VEHICLES ANTI POLLUTION SYSTEM FOR SWEDISH MARKET VEHIC LES PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 86: ... of the butterfly 8 This in tum draws in f or a short period of time the diaphragm in valve 2 The air supplied by pump 1 is releosed into the atmosphere the calibrated hole a on the diaphragm balancesthe pressure on either side of it and the diaphraqm 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...
Page 87: ... 3 o1 iiIio sv slcni Sil II I SjI LRkI III I S Key to diagram 1 Air pump 2 Air supply valve 3 One way valve 4 Air injectors situated in the cylinder head 5 Choke control knob 6 WE BER electric contact 7 CARTIER relay 8 Throttle butterfly PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 88: ...nifold On CX 2000 vehicles injection of air will be stopped when the enqine water temperature reaches 45 3 C Thermal switch 8 opens relay 9 is no longer energized but electrovalve 7 remains live relay lead and is earthed via the chake contral The air pressure at the outlet of air pump 12 increases the effect of the low pressure an the diaphragm in valve 11 the air pressure is felt above the diaphr...
Page 89: ...tterfly openinq device 4 PIERBURG 3 way electro valve 5 Control relay for butterfly opening device 6 Electronic tachometer housing 7 WEBER electro valve 8 Engine coolant temperature switch 9 Relay controlling exhaust manifold air injectiori 10 Choke control 11 Air supply valve 12 Air pump 13 One way valve 14 Cylinder head 15 Jet calibrated to 0 40 PDF compression OCR web optimization with CVISION ...
Page 90: ...d order 2 Check that the butterflies return fully to their stops 3 Do not let anything except the ignition and the engine cooling fan or fans impose any bad on the alternator 4 Run the engine to brinq the ou teniperature up to 70 to 800 C watt for the electric cooling fan or fans to cut in 1 M 20 616 M 22 617 M 23 623 ENGINES iv ich s el ho OcqIii c o Ilec t r or dir coit di on og Op MA 142 0 1 IM...
Page 91: ...ssible to obtain the capsule can be moved by unscrewinq its rwo fixing screws on the carburettor in order to reduce the clearance at the fixing point of the rod opening the first choke butterfly III M 22 617 ENGINES ich des ui il lorque ro erier M 23 623 ENGINES ichi vhs iii ii orque cunderfer ii ii ur fl i bou a r condil onn R NOTE On vehicies fitted with air conditioninq the compressor must be s...
Page 92: ...2 Pneumatic components Disconnect from the cir suppiy valve 3 the pipe from the vaive to the exhoust manif old 2 Plug the tube so as to avoid the exhaust pressure deteriorotinig the end of the tube and the volve lise the storter to rotate the engine In this position the air pump must not suppiy oir throuqh the openinq in the oirsuppIy valve previously disconnected CHECKING THE AIR NJECTION Push ba...
Page 93: ... 63 00 spark plugs AC 42 FS engine with the following rocker clearances Inlet 0 15 mm Exhaust 0 20 mm Checking and odjusting 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 ou up to a temperature of 85 s C 3 Wait for the cooling fan or fatis to cut in 4 Adjust screw 3 for opening of first ...
Page 94: ...connect from the air supply valve 5 the pipe 4 from the valve to the exhaust manifold Plug the pipe in order to avoid the exhaust pressure deteriorating the end of the UWe and the valve lJsethe starter to rotate the engine In this position the air pump 6 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 ...
Page 95: ...se the electro valve is not energized ensure using a test lamp that the winding in relay 2 is not energized for an engine speed below Nd TT under deceleration or an engine speed below Nc TT under acceleration Accelerate the engine up to engine speed Nc the winding in relay 2 must be energized If not replace the electronic unit 3 after having checked the connections 2 Pneumatic components Ensure th...
Page 96: ...wing rocker clearances 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 nir supply volve the pipe from the valve to the exhaust marilfold 2 Bring the engine cii up to a ternperature of 85 5 C 3 Waituntil the cooling fant or faits out in 4 Adjust screw 3 for the first choke butterfly in order to obfain on idling spee...
Page 97: ...1 ELECTRONIC FUEL INJECTION OPERATION N MA lE 144 00 LharacicrisIics of th L Jelrouic e eclro c Op MA lE 144 00 fu l injCtiQ 1 sstern 1 JETRONIC Systern PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 98: ...hich in tum 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 L Jetronic system is the reduction in the level of pollution of the exhaust emissions The L Jetronic system is mode up of the following components 1 Electric fuel pump 2 Fuel filter 3 Thermal ...
Page 99: ...z 0 1 9 9 OPERATION N MA lE 144 00 Charictristics of I L Jc1ronic electronic Op MA IE 144 00 3 uel in jectiofl sVStcm GENERAL LAYOUT L 14 19 111 II LJ 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 100: ...the inlet valve in order to improve engine performance The supplementary air coritrol 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 It is important that the syste...
Page 101: ... return pipe the pressure regulator 3 maintains under fuel bad a relative constant fuel pressure of 2 bars 29 psi The prssure regulator is connected to the intake manifold by a flexible pipe This albows the difference of pressure between the fuel and the inlet manifold to remain constant Thus the necessary quantity of fuel delivered by the injectors 5 depends exclusively on its duration of opening...
Page 102: ...DD z 0 1 818 OPERATION N MA IE 144 00 Chc racteristics of the L Jetronic elecironic Op MA IE 144 00 7 fuel injection system FUEL CIRCUIT 0 0 co co 0 0 0 z E 0 0 tI PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 103: ...o l v i b r a t o r M u l t i p l y i n g s t a g e O u t p u t s t a g e i l F r e q u e n c y d i v i d e r E n r i c h m e n t o f W a v e f o r m s h a p e r u p m i x t u r e A 1 I i L _ _ _ _ _ _ _ _ J _ J S t a r t i n g s w i t c h M a g n e t i c a l l y t r i g g e r e d d i s t r i b u t o r A i r t e m p e r s e n s o r m m f l 4 0 z Z C 1 0 r c z 1 W a t e r t e m p e r a t u r e s e ...
Page 104: ... C U must divide the frequency by 2 The impulses coming from the distribnto are transformoted into square waves by the wave form shc per Since injection only occurs twic for ecich 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 conden...
Page 105: ...arance determines the degree of damping The use of a damping blade cancels the effects on the angular position of the sensor fiap of pressure variations in the inlet collector A potentiometer actuated by the sensor flap spindle transforms movement of the sensor 1lap into an electrical circuit which is trarisinitted to the E C U The voltage of the electrical current is inversely proportional to the...
Page 106: ...ATION N MA IE 144 00 Cbaracteristics o the L jetrovic electronic Op MÅ IE 144 00 11 tu et inj eclio j sy5 lem AIR FLOW SENSOR L 14 10 77 19 1 14 13 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 107: ...z z fl H 12 OPERATION P4 MA IE 144 DO Characteristics o the L Jetronjc electronjc fuel in er ian systern INJECTORS L 14 21 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 108: ...ore is attracted and the needle lifts off its seat the fuel under pressure is free to pass through The movement af the magnetic care is approximately 0 15 mm The duration of opening is determined by the EC U as a function of the operating conditions of the engine at the moment in question cx c 0 0 z E 1 0 TEMPERATURE SENSORS When the engine is started for a temperature of approximately 20 C it nee...
Page 109: ...of the electro magnet and its seal fuel cannot pass through When the magnetic core is attracted the injector seat is freed off the fuel fiows post the core andreached 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 ...
Page 110: ...18 1 m OPERATION N MA IE 144 00 haraclerislics of tbc I Jetronic Op MAIE 144OO 15 Ju el iii cc1 0 1 5 vs lem COLD START INJECTOR THERMAL SWITCH PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 111: ... 15 OPERATION N MAIE 144 00 aIdc risthx of th I JvfI0 H fln iijhcf off 5 5 vill SUPPLEMENTARY AIR CONTROL Sliqhtly open Clo ed SWITCH ON THROTTLE BUTTERFLY SPINDLE PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 112: ...or 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 accordirig to the temperature so that the required idling speed is maintained regardiess of engine temperature When the latter increases the air channel is gradually reduced until it is completely c...
Page 113: ... at the same time as the starter motor Once the engine is running the air flow 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 REGU...
Page 114: ...E 144 00 JararlerisIic s of Ibc JcIroii c Op MA IE 144 00 19 luc J C JOi S SI ELECTRIC PETROL PUMP L 14 14 Safety vczIve fl fl 0 0 2 z c E 0 0 0 L0 PRESSURE REGULATOR L 14 12 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 115: ...m e n t a r y a i r c o n t r o l 6 I n j e c t o r r e s i s t o r s 7 D o u b l e r e l a y 8 E l e c t r i c p e t r o l p u m p 9 C o l d s t a r t i n j e c t o r 1 0 T h e r m a l s w i t c h 1 1 A i r H o w s e n s o r w i t h a i r t e m p e r a t u r e s e r i s o r 1 2 W a t e r t e m p e r a t u r e s e n s o r 1 3 T h r o t t l e b u t t e r f l y s p i n d l e s w i t c h J q n i t o ...
Page 116: ...ance advance curve proper grade of plugs 0 0 6 Remove the E C U before putting the vehicle through a paint stoving oven c 7 Check the conditions of the various connections 2 8 Never disconnect the E C U while the ignition is on 0 z 9 When checking compression disconnect the positive terminal of the coil in order to stop the injection signal E 0 10 When carrying out a check requiring an ohmmeter us...
Page 117: ... OPERATION N MA IE 144 0 Jnckiug and a jusIing ihe L Jciron c elecironic flici iiijcciion SVSt m THE ENGINE DOES NOT START OR IS DIFFICULT TO START P T O PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 118: ..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 2 b a r n 2 9 P r e s s u r e i s o v e r 2 b a r s 2 9 p s i P r e s s u r e r e m a i n s u n d e r 2 b a r s T h e f u e l p u m p i s h e a r d t o R e p l i r n e t b c f r e l 2 9 H R e p l a c e t h e p r e s s u r e r e g u l a t o r 1 1 1 1 o p e r a t e C i r e r k t h e f r e i y i t e r r r f u e l p r r m p f ...
Page 119: ...z OPERATION N MÅ lE 144 0 huki i 1 1 1 a Ijt s LJ Ir mlC f Iro i Op MÅ lE 144 0 3 i I j CIWJ svsI m 2 THE ENGINE STÅRTS THEN STOPS o PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 120: ...u r e r e m a i n s c o n s t a n t a t 2 b a r s 2 9 p c i a n d t h e e n g i n e S e e p a r a I I I O p 3 P a g e 1 5 S t o p s R e p l e c e t h e E C U C h e c k t h e e l e c t r i c a l f u n c t i o n s c h e c k i n g f o r m e c h a n i c a l a n d e i e c t r i c a l f a u l t s 1 S e e P a r a I I I C h e c k t h e e n g i n e f o r m e c h a n i c a l M o v e t h e w i r i n g h a r ...
Page 121: ...4 OPE RATION N MA lE 144 0 ckin a I ac jiisI 1J Irwiic l C rO iC 1 1 1 01 SVS I 1 1 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 122: ...144 0 ncki g 111 1 l fjUSti g tI L J tro ic l CtrQ liC Op MAJ E 144 0 5 u i f cIio I S St ll 3 NSTABLE OR INCORRECT IDLING SPE EXCESSIVE FUEL CONSUMPTION P T O PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 123: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ T H E E t G N E O O E S _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ h e p r e s s u r e i s o v e r 2 b a r s t O S T R T O R t S O t F F t C U L T 4 2 9 s i T O S T A R T R v p t s c e t h v E C U B H 0 C h e c k c o n t i n u i t y o f t h e f u e l o v v i l i n e t h e f u e l f i l t e r t h e t a n k f i l t e r a n d t h e...
Page 124: ...6 OPERATION N MA I E 144 0 heckiug and adjusting the L Jetronic eleetronic Jiie in cclii systern PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 125: ...ATION N MÅ 1 E 144 0 i cki Hd a l s iJ t L JHI O C H1HC rOH C Op MÅ lE 1 44 0 7 fl Hl i jHcIion SVS H l 4 THE ENGINE MISFIRES AT ALL SPEEDS PT O 1 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 126: ... a n d o p e n t h e n e n s o r f l a p b y h a n d u n t i l t h e p u m p o p e r a t e s A f t e r o p e r a t i n g t o r 1 m i n t h e q u a n t i t y d e l i v e r e d m a s t b e c z p p r o x 2 l i t r e s T h e c o r r e c t e m o t i n t f r a s n o t b e e n d e l i v e r e d T h e f u e l f i l t e r r n u t t n o t b e b l o c k e d c h e c k d i r e c t i o r t o f f i t t i n g T h...
Page 127: ...8 OPERATION N MA IE 144 0 Ieki i au l j1 S i IC I cIr J ic JiiI Iio SVSI PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 128: ...0 0 OPERATION N MA IE 144 0 ick aH I 1 Ijf S1iJ 1 cIro c Op MA IE 144 0 9 tiOl VS I 1 5 LACK OF POWER PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 129: ...the cenditinn o the battery the igrritton the spark at the plugs the advance the pluqo See ANNEXE A Check the air circuit connectiorio and it5 crir tiqhtesezs aning compressed air and snopy wOter Clean the hiltr See ANNEXE Bl The carreat quantity ha been deh vered Replace the pressure regulator and The correct quantity check the delivery not been dehivered Check the hud pressure See ANNEXE Cl Make...
Page 130: ...10 OPERATION N MA IE 144 0 ecki 11 1 l IjI SIi I u L J IrO liC I CIJ iC J1I 1 j IiW SS ll PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 131: ...nsor 1 ara n co 9 Co1dstart injector and thermal switch Diagram 9 10 Switch on throttle butterfly spindle idling speed function Diagram 10 z 11 Switch on throttle butterfly spindle maximum power function I iagram 11 12 E C U Diagram 12 ANNEXE A Checking the ignition Page 25 Page 26 B Checking the air circuit Page 27 C Checking the fuel system and the fuel pressure Page 28 D Adjusting the idling sp...
Page 132: ... 1 and 5 of the E CU operate the starter the voitmeter must register the ignition impulses If it does not check the ignition ANN EXE A 2 Fuel pump feed on operating the starter DIAGRAM 2 Disconnect the E CU Switch on the ignition On operating the starter the fuel pump secured aiider the iehicle 1 ear the R Il rear 11 eei must be heard to operate by someone standing close by If not switch off the i...
Page 133: ...818 1 ADD z 0 OPERATION N MAIE 144 0 Ickh and ldj ISI 1 tb LJ trO iC nI CIlO C Op MA IE 144 0 13 i CtiQ SVSI i1l DIAGRAM 1 0 c 0 0 z 0 0 E 0 0 0 Id DIAGRAM 2 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 134: ...TION N MA I E 144 0 heck ug au u f sIi t the L J etronic clcclro iic ud u1 dCIl SS1cni DIAGRAM 3 DIAGRAM 4 Battery 1 2L Lf IIII1II1I1I1I1I1I1I1I1 III PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 135: ...inal is not connected to the E C U The res istance between terminals 86 b and 85 on the relay box r h L H hu1 amp must be between 52 and 78 Q 4 Supplementary air control DIAGRAM 4 Disconnect the E C U Check that the supplementary air control is properly connected arrow on the casing If it is fitted the wrong way round the port may be blocked The resistance betweeri terminals 34 and 48 on the suppl...
Page 136: ...circuit for air tightness 6 Resistors and injectors A dirty injector may cause a lock of power or an unstable idling speed It is possible to test the functioning of the injectors with the engine idling by disconnecting each injector in tum the engine rpm should decrease each time Disconnect the E CU The resistance of an irijector is 2 to 3 Each supplementary resistance is 5 to 7 ft The volume deli...
Page 137: ...N N MAJ E 144 0 hcki i and adji stin tbc JnIronic n nctro ic Op MAJ E 144 0 17 fu ni i fn db s s In DIAGRAM 5 rOO L DIAGRAM 6 3332 I IH TI I LLi I i IL I i r 33 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 138: ...L i r 18 OPERATION N MA I E 144 0 hcking and adjusling t u LJtronic electrw ic J I 1 ii Chou S S1 COl DIAGRAM 7 rT LL L_ DIAGRAM 8 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 139: ...sconnect the ECU Using the ohmmeter test the continuity of the circuit and measure directly the resisitance using the sensor 10 C R7to l2k 20 C R2to3kQ 80c C 250 to 400 Q 0 0 c 0 E 8 Air temperature sen sor DIAGRAM 8 0 Disconnect the E C U Usinq an ohmmeter test the continuity of the circuit and measure the resistance of the sensor between terminals 6 and 27 10 C R8to 11kg 20 C R2to3kQ 50 C R 750 ...
Page 140: ...e must be 4 2 l at 20 0 Connect the injector to the thermal switch If the water temperature is below 350 0 on operoting the starter motor the cold start injector must supply petrol for the following amounts of time 7 5 secs for a temperoture of 20 0 5 i0 0 3 0 0 1 20 0 On operating the storter terminal of the ECU terminal board must be energized voltmeter between terrninalS 4 and 10 Switch on thro...
Page 141: ... Pil OPERATION N MA I E 144 0 cki l jl SIi I J 1 ro c Op MAJ E 144 0 21 ii 1 ju f u I o S S ul DIAGRAM 9 0 0 co co 0 0 0 z E 0 0 DIAGRAM 10 L 1 LIII H HHHHHHHI L_ J PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 142: ... 11 IH 1 IL _L _I_ iIiIiiiiiiIi ir4JJI L DIAGRAM 12 Switch on throttle 4 ___ Frequency Enrichment of divider Wave iorm warm up mixture shaper _______ J Stading switch Magnetica ily triggered distributor Air temp Water temp sensor sensor PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 143: ...meter check there is no resistance between terminals 3 ond 18 of the multiple connector board with the accelerotor pedol fully depressed 12 E C U DIAGRAM 12 Visually check the condition of the terminals male corinectors on the EC U and female connectors on the multiple connector socket With the engine running top lightly on the ECU to detect ony possible defect in the soldering dry joints PDF comp...
Page 144: ... Battery Ignition 0 24 OPERATION N MAJ E 144 0 ckiu 111 1 a Ius Ib I J trOu C I C TO l1C u1 h jccIi system ELECTRICAL CIRCUIT aj 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 145: ...lE 144 0 Ch kiuc ac jusIhi Ih LJeIrO iC CIrO l c Op MÅ lE 1 44 0 25 J I III fe ci On svs fern ANNEXE A CHECKING THE IGNITION THE ENGINE TURNS BUT DOES NOT FIRE PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 146: ...f r o m t h e m o d u l e g m u s t b e 9 6 0 t o 1 1 4 0 f l I t _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L _ J n i u z t b e i n s u l a t e d f r o m t e a r t h z R e p i m n e t h e m o k i T h e r e s i s t a n c e 1 n o t C D r r C c t T h e r e s i s t n r r c e i ...
Page 147: ...26 OPERATION N MÅ JE 144 0 cki i 1 1 1 j1IsI I iiJ C W S S fll ANNEXE B CHECKING THE AIR CIRCUIT L 1411 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 148: ...the pressure regulator the reguloted pressure must be 2 5 bars 36 1 4 ps If one of the readings is incorrect check condition of the flexible vacuum pipe for the pressure regulator as weil as its aspect If it is satisfactory replace the pressure regulator after making sure th0t its vacuum pipe is not blocked totally or partially at the manifold end With the engine stopped the pressure must remoin s...
Page 149: ...clusively a high tension tachometer do not damaqe the HT lead of the ignition wiring hamess ADJUSTMENT 1 Check that the butterfly is not jammed in position when it is restinq against its stop 2 Wait for the electric cooling fan s to cut in 3 Use screw 1 to adjost the idlinq speed to 850 to 900 rpm 4 Check the exhaust emission The resulting amount of CO C02 corrected CO reading must be below 4 5 In...
Page 150: ...engine rpm Minimum output ln litres per hour Minimum pressure in mbars 500 45 88 3000 65 170 5500 69 5 192 INSTALLATION OF PETROL PtJMP Fitted on the crankcase with one Phenoplaste P12 spacer 6 0 1 mm thick two SOCOID puper gaskets fitted dry Tightening torque for petrol pump nuts 21 mN 2 1 m kg 15 1 4 ft Ib CHECKING THE STROKE OF THE PUMP PUSH ROD a With the pump removed and using a depth gauge A...
Page 151: ...ssue c Check the proper sealing of the carburettor needle valve Unscrew knurled plug B and stort the engine Let it run for a few minutes Stop the engine There sliould be no sudden drop in pressure Remove appartus 4005 T and fit to carburettor the tank supply and return pipes after having removed plug A CHECKING HE PUMP FOR LEAKS Ciose the pump return pipe Blow compressed air under pressure of 800 ...
Page 152: ...wise Contact pads pressure for information purposes i 440 50 g Distance between contact pads 040 mci Closing angle of cam 55 2 30 DWELL ratio 61 3 Angular gap between the four opening points symmetry of the cams 1 max Capacity of condenser 030 0 03 F Minimum resistance of condenser 5 MQ Centrifugal advance ref n of curve LA 2 LA 4 Vacuum advance correction curve advance LD 2 z Stotic advance 10 en...
Page 153: ...nce at 20 C 7500 1000 6000 5 Q 7500 10 H T LEADS Manufacturer Reference All ich des 1 1975 ELECTRIFIL Bougicord 400 RTF 33 Description of leads Length in mm Resistcince of leads a 20 C Coil to distributor 570 to 580 625 to 1025 Distributor to N 1 cylinder 400 to 410 420 to 645 Distributor to N 2 cylinder 520 to 530 555 to 850 Distributor to N 3 cylinder 540 to 550 580 to 880 Distributor to N 4 cyl...
Page 154: ...n the module the earthing is carried out via the fixinq bracket for the coil and module assembiy 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 primary circuit which causes a High Tension current in the coil secondary circuit The module is located in the distributorreplacing the contact breaker unit in a co...
Page 155: ...iii aku aud thu lv u 0 spark pln lo Usu cousull Ihu luchuicaf Bul clius 0 1 1 5 suh1ccl uhich fru iijhlishc rutuIar r 0 6 to 0 7 mm Spark plug gap 2 to 2 5 daNm Tightening torque cylinder head cold 14 5 to 18 ft lb spucar tbc thrcacl lihilr with NO BIN IGNITION COIL ÄND TRANSISTORISED MODULE ASSEMBLY AC DELCO Manufacturer Reference N 210 0 48 0 61 Resistance of coil primary circuit at 20 C 8500 to...
Page 156: ...rk b It must be lo i before T D C v wr mark If not slacken nut 2 and rotate distributor to ohtain this condition Tighten nut 2 from 1 9 to 2 1 daNm 13 5 to 15 ft lb Stop the engine b ts og a d rigous ir and d i s1i Rs heuc TECALEMIT Model Tecamcitic 30 SOURIAU models 1615 01 1625 0 1 or 1256 61 RABOTTI model Rabofast 103 These models are mentioned in the Equiprnent and Repoir Materials manua1 or i...
Page 157: ...r torque converter the advance point must remain within 2 tsiu 1Ia o5tic tSth ich The start of openinq 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 arm or the contact breaker back plate are faulty The distributor must be reconditioned or replaced II CHECKING AND ADJU...
Page 158: ...ots are produced outside the four normal positions at speeds under 3000 rpm make sure the contact points are dean and if necessory make sure the test bench batteryis 1 ully charged before repiacing the contoct breaker unit the spring of which may have weakened 3 Checking the spark regulurity Whatever the speed of rotation the angulor difference of the f our opening positions of the points must not...
Page 159: ...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 1O mark b of the engine flywheel 1 opposite the fixed mark a b Fit the distributor Remove the distributor cap Insert the distributor inta its housing see position on the diagram below Water pump 1i 2S 4 Vacuurn capsule removed 4 Vac uu m capsule in place 1 ___ LII LONG1TUDIN...
Page 160: ...ributör until the exact moment when the indicatior lamp liqhts up At this point the distributör is at the static advonce point Switch off the ignition Tighten out 1 from 19 to 21 mN 1 9 to 2 1 rn kg 13 1 2 to 15 ft lb Fit distributor cap and secure it Fit sparking plug in cylinder No 1 2 C1 eckinq the ignition timing using a strobosopic lamp or a test beneh See chapter page 1 PDF compression OCR w...
Page 161: ... mast be 25 before TDC Q k c 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 2 to 15 ft Ib Stop the engine b 5 I a diag osiie test be el This method is recommended for its speed its precision and the ease with which it is carried out Connect the l2 pin plug of the test bench to the corresponding socket on the diogno...
Page 162: ...distributor timing properly adusted 25 ut 2500 rpm the advance poirit must not vary by more than 2 on the four cylirxlers II d The impuise must not vary by rnore thon 2 for the f our star points II CHECKING AND ADJUSTING THE DISTRIBUTOR ON A TEST BENCII PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 163: ...nts must full within the shaded area of the curve b To a certain extent it is possible to correct the advance curve by altering the tension of the springs for the o centrifugal weights To obtain this condition slightly bend in ihu appropriale dirciio the securing brackets for the springs or replace thern 0 0 0 0 z c 3 Checking the symmetry of the star points 0 The angular positioning of the 4 star...
Page 164: ...1 opposite fixed mark b visible throuqh opening a b Vit the distributor Remove the distributor cap insert the distri butor inta its housing see position in diagram und photagraph on this page Provisionally position fixing clamp and moderately tighten nut Position distributor cap and sedure it Vit spark plug to N 1 cylinder 2 Ådjust distributor timing using either strobe lamp or test bench 250 at 2...
Page 165: ...copp r 0 t r 2 uni r c r scrcu IoFw Tighten union screw 3 6 Start engine With ou temperature at 1000 C pressure should be at 2000 rpm 3 bars mrn 43 5 ps 014000 rpm 4 to 5 bars 58 to 72Spsi TOTE 4diusfin tt 1 0 tu e oJ putu ut 1 tn c S trit is no fo h1 O flfJfflh IIS htt t ttt f S tII 7 Remove union 6304 T and pressure iauge Fil pressure swi Ich 1 ut ith eoppi r u lsI r 1 Tightening torque 30 to 35...
Page 166: ...rough pipes with compressed air 0 0 02 0 0 0 0 0 z 0 5 E 5 0 0 0 14 757 3 Filling the gauge WARNING This operation is to be carried out with great care so as ta ful the gauge with LHM Fluid which is not emulsified Oisconnect tilibe 2 from the unit sa as to get to the filler arifice b Undo completely the calibrating screw marked with arrow to allow the gauge to be adjusted on completion of the oper...
Page 167: ... 3 from the gauge ta the filler on f ice b B ÅDJUSTING THE GAUGE Two methods are possible Adjusting the gauge using an engine sump simulator Adjusting the gauge on the vehicie Ad iisting il e gauige sing tf e sim ala to 1 Prepare a jar as per diagram an page 2 NOTE This simulator is also suitable for adjusting o qauge on a CS Birator vehicle 2 Connect the rubber tube 2 unmarked to the tube labelle...
Page 168: ...n the gauge IJ ffSf 130 lc e ln the 0 j f0 1 Refit the pneumatic gauge and map pocket unit onto the vehicie making sure that the pipes are fitted correct ly according to their colour marks 1 h s op e TIll on m es ho carriecl out 11 ih i 3 0 3 Ole 03 fl 010 horizoij slIr lice 11 1 0 II Ih e en iu 0 su di ed off at oas it e mine les b orI 3a id 2 Check the ou level using the monual gauge 3 Calibroti...
Page 169: ...z COOLING OPERATION N MA 230 00 7 aracirisIics lud specitil caturcs o Op MA 230 00 c co i svsIdn P T O 1 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 170: ...stige torque converter air conditioning 23 dm2 356 5 sq in NOTE Radiators originally fitted to the vehicies differ occording to the type of vehicle on which they are fitted 0 in the material used for the coolant channels and the distance between the cooling fins c 0 0 3 Radiator cap or pressure relief valve calibration cap screu ecl On 1 bar 14 5 psi c 0 0 4 Thermostat Make CALORS TÄT Reference N ...
Page 171: ...400 GTi except optional towing equipment 1 23 dm2 356 5 sq in radiator CX 2400 ond Prestige with optional torque converter and air conditioning and CX 2400 Gti with optional towing equipment 2 10 blade fan 5 blade fan 5 blade fans lO blade fans lO blade fans lO blade fan lO blade fans 10 blade fan lO blade fans The electric cooling fans are controlled by a thermal switch on the rad ator Power rati...
Page 172: ... and heater system open 1 Electric fan Hot coolant 2 Radiator 1 3 De cerating pipe Cold coolant 4 Header tonk expansion chomber 5 Thermostat 2 6 Heater unit 7 Inlet manifold 8 Cylinder head outlet tank L ___ 3 il 8 1 ____ 1 7 Hl H Partial view F 1 111111 Thermostat closed PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 173: ...mostat and heater unit open Hot coolant 1 Electric fan 2 Radiator 1 3 De aeratiny pipe Cold coolant 4 Header tank 5 Thermostat 6 Heater unit 2 7 Inlet manifold 8 Cylinder heod outlet tank 8 1 jj 11111 1 Partial vuew F ____ il j L 6 Thermostat open PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 174: ... a 2 2 litre and 2 4 litre engines c veu co er er air coaditioning a n ziei injer on Thermostat closed and heater unit open 1 2 iii liii 0 0 0 H II 8 7 Parhal view F Partial view F 1 6 L 5 Tliermostat 6 Heater unit Thermostat closed Hot coolant 7 Inlet rnanifold 8 Cylinder head outl et tank Cold coolant PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 175: ...lc CO fl f r a rr tIo Jr 1 Hl iiv j CIiO Thermostat and heater unit open 0 0 4 co co 0 0 c 0 0 z c q E 0 0 0 0 vo 1 Radiator 2 Electric fan s 3 De aerating pipe 4 Heacier tank 5 Thermostat 6 Heater unit 7 Inlet nionifold 8 Cylinder kead outlet tank Partial view F Therrnostat open Partial view F Hot coolant ______ Cold coolant PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 176: ...mostat and heater unit open Parti al viewF 4 1 10 1 3 8 1 fl 7 4 1 Raciiator 9e9 1T 2 Electricfan s OK j L 3 De aerating pipe 1 5 4 Header tank 5 De aeration chamber 6 Thermostat 7 Heater unit 8 Dram top lcorel uic fan s Thermostat open PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 177: ...ON N MÅ 230 00 r aruc v st cs bj S tc il Cfuru 0 Ile rrjo svs n Op MÅ 230 00 7 COOLING SYSTEM 2 4 litre engine fuel injection Therniostat and heater unit open PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 178: ... L Hemove spare wheel 2 O en heater control to fullest extent inside vehicie 3 Unscrew the twa bleed screws 1 and 2 Place a transparent tube 200 mm in length over each screw in order to avoid the escape of the liquid 4 Disconnect the heater outlet hose and pour in approximately 0 6 litre of cooling liguid Reconnect tube 4 5 Ful remainder of circuit slowly through the header tnk and ciose bleed scr...
Page 179: ... PARTIAL FILLING Same operations as for total filling except that the heater unit is not filled by outlet tube 3 to the radiator III FILLINC AND DE AERATING THE AUXILIARY HEATER UNIT ON CX AMBULANCE VEHICLES Before connecting the auxiliary heater unit water system to the main system the followinq must be carried out Vill up the auxiliary heater unit and its hoses with heater control open with 1 6 ...
Page 180: ... rto 1 Ot 1 tt l Ittudltt St ii fl t tf jo 1 NOTE Aligning the alternator pulley is carried out by placing shirns behind the pulley Tightening torque for nut 4 for the alternator pulley 4 dciNm 29 ft Ib t 1icIt 5 tflIt tt j t t stott pu p 3 Ahgning the high pressure pump a Tiqhten pump on its support plate b Place device 3C85T on the camshaff pulley c Brinq its rod inta contact with the groove of ...
Page 181: ... 3Sto4Okg 77to88lb Run in helt 200 to 225 N 20 to 22 5 kg 44 to 50 lb Vnh c es jitI d ulih air condiiiouing Compressor bett 400 to 450 N 40 to 45 kg 88 to 99 ib New belt 250 N 25 kg Ss Ib Run in helt 150 to 180 N 15 to 18 kg 33 to 40 lb Toothed bett for water pump NOTE Insufficient tension reduces considerably the reliability of the toothed helt Tension in excess of 180 N 18 kg 40 Ib will cause wh...
Page 182: ...chanism _____ 235 DBR 490 1 1975 Prestige 8 76 235DBR490 215 DBR 410 235 DBR 410 3 1975 CX2400 Injection Type 235 DBR 450 1 1976 Prestige 8 76 All CX 2400s 235DBR450 ________________ ___________________ except Injection DIs __________________________________ 62957 3 225 mm 1 75 Ref VERTO 62838ff 0 136mm 63266 225 mm 3 75 63571 3 228 6 mm 63550 if D 142 mm 63571 fs 228 6 mm 1 76 PDF compression OCR...
Page 183: ...RTO disc ref n 63571 ci 228 6 mm With 235 DBR 410 rnechanism fit a VERTO disc ref n 63266 225 mm Replacing the mechanism Replace the 235 DBR 490 and 235 DBR 410 mechanisms by a 235 DBR 450 mechanism with a VERTO disc ref n 63571 2286 mm Thrust bearing self centering III SPECIAL FEATURES Clearance between thrust bearinq and diaphragm 1 to 1 5 mm PDF compression OCR web optimization with CVISION s P...
Page 184: ...r a p Adjust the c Iutch free play Remove spring 3 Loosen lock nut 1 Tiqhten nut 2 until the thrust bearing is in contact with diaphragm bord point NOTE Clutch pedal should be in contact with its upper stop ot a Unscrew mil 2 twa turns ond o halt to obtain o cleorance of 1 to 1 5 mm between thrust betning and diaphragrn Tighten lock nut 1 Fit spring 3 PDF compression OCR web optimization with CVIS...
Page 185: ...ype 2 8doNm j 8to9daNrn 20 1 4 tIs 58 to 65 ft Ibs ___ __________ 8to9daNm 58 to 65 ft Ibs LOCTITE FRENETANCH _____ ___ 0 0 cxD 0 0 0 z c 5 5 a a II SPECIAL FEATIJRES Adjustments Contact gap in electric switch unit controlling the electro valve NOTE The gap for the 2nd 3rd gear contacts must only be ad usted once the selector shaft stop screws have been adjusted See Op MA 33000 0 8 to 1 1 mm Gap a...
Page 186: ...ectro valve a dozen times Tightening torques 2 8 daNm 20 1 2 ft lb Electro valve fixing screw 3 to 3 5 daNm 21 1 2 to 25 1 2 ft lb Union screw for ou pipe 3 5 to 4 daNm 25 1 2 to 29 ft Ib Suction filter 0 2 to 0 3 daNm 1 1 2 to 2 ft lb Contact fixing screws 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 reverse opé...
Page 187: ...on filter control relay OPERATION N MA 32OOO r c cri s 1 1 1 S CI i I i of I r u oi r 0 Op MÅ 32OOO 3 III OPERATIONAL DIAGRAM OF TORQUE CONVERTER Engine running gearlever in neutral 0 0 0 0 0 0 z 0 c E 0 0 0 IIIIIIII1 r _ i _______ g _ _ __ 1n ______ 1 2 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 188: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ S u c t i o n f i l t e r S w i t c h u n i t O i l c o o l e r o n g e o r b o x R e t u r n 1 C i l c o o l e r b y p a s s v a l v e J 2 P r e s s u r e r e l i e f v a l v e h l c 0 0 0 0 0 0 Q 0 0 0 D F n I 0 z z 3 c b f l PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 189: ...adjust it proceed rn exactly the same manner as for 3rd gear Checking and ad usting the contacts 1 Remove cover 3 from the switch unit controllinq the electro vaive 2 Check adtustment o contact gaps Proceed in the same way for euch of the 4 contacts a Engage 0 geer WARN1NG In order to obtain correct opening of a contact the corresponding geer must be fully engaged otherwise the adjustment would no...
Page 190: ...mph ist 12 38 3 1666 1 15 1022 1 7 82 4 89 2nd 18 33 1 8333 1 8 7434 1 13 51 8 44 3rd 30 34 1 1333 1 13 62 4 7691 54049 1 21 86 ______ 13 66 ________ 4th 35 28 0 8 1 38153 1 3097 19 36 Reverse 1341 3 1538 1 15 0411 1 7 85 4 90 Speedometer drive ratio 5 12 b Econorny option gearbox on CX 2000 J75 Gears Gearbox ratios Final drive ratio Overall ratios Speed in km h at 1000 rpm mph ist 12 38 3 1666 1 ...
Page 191: ...justing the 3rd gear stop urho v IQVIO Smear thread of stcp screw 1 with sealinq compound Engage 3rd qear with 3rd 4th qear slidinq pinion restinq aqainst 3rd qear idlinq pinian Brinq the stop screw inta contact with selector shaft then screw it in ene tum in order to obtain a cleorance between the selector shoft and the face af the qroove of the slidinq pinion Tiqhten locknut 2 Ad ju sti ny the 4...
Page 192: ... for gear selector shoft Bushnut for dipstick guide Assembling the gearbox casings 3 5 to 4 5 daNm 25 1 2 to 32 1 2 ft Ib 28doNm2D 2ftlb 5daNm36ft1b lit ol2daNrn 79 l 2to87ftlb 3to4daNrn 21 12to29ftlb Sealing Smear the contact faces of the gearbox casings and the rear cover with sealing compound MANUAL 4 SPEED GEARBOX Tightening torques PDF compression OCR web optimization with CVISION s PdfCompre...
Page 193: ...z OPERATION N MA 330 00 aracIriIic 5 7 1 17 11 S oJ earbo v MANUAL 4 SPEED GEARBOX Adjustment shims PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 194: ... NC MÅ 330 00 harac rislics l ciaI t I 11rS I C dr X v Op MÅ 330 00 5 GEARBOX Gecir sequence L 33 1 a ist gear 2nd gear 3rd geer 4th geer 1Ij1 I1U11 Reverse geer PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 195: ...9 273 1 12 75 7 97 2nd 30 34 1 133 1 5405 1 21 90 13 69 13 62 ___________________ _____________________ _________ _________________________________ 4 789 1 3rd 35 28 800 1 3815 1 31 19 38 Rev 18 43 2 388 1 11 393 1 10 40 6 50 Speedometer drive rotio 5 12 Lj bricotion TOTAL FLUIDE T Type of ou 5 5 litres 9 7pts opprox Total copcity inciuding converter 2 to 3 litres 3 5 to 5 3 pts deperiding Drainin...
Page 196: ... with CURTYLON Engage 2nd qear with 2nd 3rd gear sliding pinion resting aqainst 2nd gear idlinq pinion Bring stop screw inta contact with selector shaft then screw it in 1 2 a tum in order to obtairi a clearance of 0 4 to 0 7 mm between the selector fork and the face of the slid ing pinion groove c Tiqhten locknut 2 Adju sting the 3rd gear stop cmi hc carricd out ujih crbo v io itu Proceed as abov...
Page 197: ...0 OPERATION N MA 330 00 dractj Ii 1 1 1 Rcj l l 1 t 5 0 I ar 0 GEARBOX Longtudinal section PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 198: ...1 to 155 1 2 ft Ib 2 8daNm 20 1 2 ft Ib 8 1 to9daNm 58 1 2 to 65 ft Ib Gearbox casing assembly screws and nuts dia 8 mm 2 3 daNrn 20 1 2 ft lb 5 daNm 36 ft Ib Fina1 drive casing assembly nuts dia 10 mm Bush nut for selector shaft lita 13 daNm 79 1 2 to 94ft Ib Suction filter 35 to 4 daNm 25 1 2 to 29 ft Ib 3 5 ta 4 5daNm 25 i 2to32 1 2ft Ib Drairi and filler pluqs 3 to 3 5 daNm 21 i 2to25 1 2 ft l...
Page 199: ... J OPERATION N MA 330 00 rI Ii 1 cial Ra i r I arbov TORQUE CONVERTER GEARBOX gear sequence REVERSE GEAR 2ud GEAR ist GEAR 3rd GEAR PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 200: ...18 1 ADD z 0 z o OP ERÅTION N MÅ 330 00 harachristcs a d s chi fci urcs o tbc carbov Op MÅ 330 00 11 GEARBOX LOCKING DEVICE FOR PARKING 0 0 0 0 0 0 z 0 E 0 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 201: ...EQUENTLY THE CONVERTER Ful up the gearbox Capacity 2 3 litros 3 1 2 to 5 1 4 pints according to draining time Check the leve1 with the dipstick 4 Top up the gearbox O to tu Crld o le o bta o e cr rrrrI ooc tr ctl a to lo i o Immobilise the front wheels and put the hand brake on b Run the enqine at idling speed and engage a gear 3rd gear for exarnple Slightiy mov the geor lever to actuate the elect...
Page 202: ...n km h mph ist 12 38 3 1666 1 15 1025 1 7 82 4 89 2nd 18 33 1 8333 1 8 7435 1 1351 8 44 3rd 28 35 1 25 1 13 62 5 9615 1 19 82 12 39 4th 33 31 0 9393 1 4 769 1 4 4801 1 2638 1649 5th 45 33 0 7333 1 3 4974 1 33 79 21 12 Rev 13 41 3 1538 1 15 0414 1 7 85 4 90 Speedometer drive ratio 10 20 Lub jcotjon Type of ou Total capacity Capacity after draining Difference between min and max on dipstick Gear con...
Page 203: ...of stop screws 1 and 2 with sealinq compound Enqaqe 3rd gear with 3rd and 4th gear sliding pinion resting against 3rd geer idling pinion Bringstop screw 1 into contact with selector shaft and screw it in ene tum to oblain the correct clearance between the selectorfork and the sliding pinion groove Tighten lock nut Proceed in the same manner to adjust stop screw 2 for Sth qear Adjusting 4th gear st...
Page 204: ...0 0 3 5 to 4 5 doNm 25 1 2 to 32 1 2 ft Ib Filler plug and main plug 2 8 daNm 20 1 2 ft Ib Final drive casing ossembly nuts din 8 mm 5 doNm 36 ft Ib Fianl drive casing assembly nuts din 10 mm lita 12 doNm 79 1 2 to 87 ft Ib Selector shoft bush nut Assernbling the gearbox casings Sealing Smear the contact ces of the casings and the cover with sealing compound PDF compression OCR web optimization wi...
Page 205: ...hims L 33 5 1 41 1 46 1 51 1 56 1 61 1 66 171 0 1 41 1 46 1 51 1 56 1 61 1 66 1 71 2 44 2 47 2 50 2 53 2 56 2 59 2 62 2 65 2 68 1 37 1 40 1 43 1 46 1 49 1 52 1 55 1 58 1 61 1 64 1 67 29 shims from 4 25 to 5 65 in steps of 0 05 1 52 1 58 1 64 1 70 1 76 1 8 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 206: ...Manual 818 1 z i 0 OPERATION N MA 33OOO iracl isfics 7 ni R lai a aIur af 11 arI r v Op MA 330 00 17 FIVE SPEED MANUAL GEARBOX gear sequence PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 207: ...ar lever NOTE Should it be irnpossible to effect adjust ment 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 dinul axis YY of the veh cle If not Adjust selector shaft hall joint 4 to obtain this position NOTE When adjusting hall oints 4 or 5 it is imperative that the flats on eac...
Page 208: ... 343 5 mm 4 sp qearbox X 378 5 mm S sp qearbox RIGHT HAND DRIVE SHÅFT 0 0 co co 0 0 0 z 0 5 E 5 0 L 37 2 7 to9doNm 50 1 2 to 65 ft Ib 35 to 40 daNm 253 to 289 ft JI 0 7 doNm face ond threod 5 f Ib greased Y 423 mm 4 sp gearbox Y 388 mm 5 sp gearbox 1 CHARÅCTERISTICS 1 constant velocity ball joint at wheel end 1 tri axe joint at gearbox end II SPECIAL FEATURES Lubrication TOTAL MULTIS MS grease PDF...
Page 209: ... m p r e s s u r e r e g u l a t o r a n d f r o n t a n d r e a r c o r r e c t o r s 5 S u c t i o n l i n e f o r H P p u m p 6 F i l t e r o n s u c t i o n l i n e f o r H P p u m p 7 D e f l e c t o r 8 O v e r f l o w o n d r e t u r n l i n e f i l t e r 9 L e v e l i n d i c a t o r f l o a t N O T E T h e r e s e r v o i r a n C X 2 0 0 0 a n d C X 2 2 0 0 v e h i c l e s p r o d u c e d...
Page 210: ...inder pump operated by an eccentric machined on camshaft 1 cycle 2 engine revolutions Operating ratio 14 mm Piston diameter 10 0 10 mm Piston stroke erotrfc lift 1 07 cm3 per cycie By nay of indication output under bad of 175 bars 1 gud al 60 SPECIAL FEATURES Adjustment 0 05 to 0 09 mm Clearance between pump bady and plug he ore iighlenin 0 05 0 10 0 15 0 20 mm learancc ohlained by iusing shiuns o...
Page 211: ...I CHARACTERI STICS It differs from the single cylinder pump fitted up to 10 1976 only in the two pump breather unions Reciprocating single cylinder pump driven by an eccentric machined on the camshaft Operating ratio 1 cycle 2 engine revolutions Pis ton diameter 14 mm Piston stroke ecceatric lift 10 0 10 mm Fot infonnation output under pressure of 175 bars 2531S psi and with fluid at 600 C 1 07 cm...
Page 212: ...pecial Jcalurcs of tbc source an 1 res eric of rc ssure H ydraulic svs fern DIAGRAM OF BREATIIER CIRCUIT FOR SINGLE CYLINDER PUMP Salooii i ein nie s ni ih naniinl sten ring 10 1976 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 213: ...Hr rW L__Jr M 6 __ LJ _ 7 1 Control shaft 4doNm 2 Oscillating plate 29 ft Ib 3 Piston connecting rod 4 Piston 5 Sleeve 6 Pump valve 7 Pump body CHARACTERISTICS The pump rotates at haif engine speed Output for each pump cycie for ivformation Valves 6 ou tight up to 2 cm3 150 bars 2175 psi SPECIAL FEATURES Piston connecting rods Iength in ste of 0 1 mm 28 8 to 30 5 mm Clearance between crown of pist...
Page 214: ...2 899 29 psi 10 145 SPECIAL FEATURES Pressure regulator 0 30 mm Thickhess of adjusting shims 0 30 mm For cut out 0 30 and 0 70 mm For cut in approx 3 bars 44 psi One 30 mm shim brings about a change in pressure by approx 7 bars 102 psi One 70 mm shim brings about a change in pressure by Tiitening torques 1 8 daNm 13 ft lb Pressure regulator fixing screws 2 5 to 4 5 daNm 18 to 32 1 2 ft lb Main acc...
Page 215: ... DIAGRAMS OF OPERATION CUT IN fo y u 1 c rc uit Li 000 Å J ry 1 14jÄUjJJ Hv HP 1 i JV rjfjjk JVLL inlel 1 Ii 1 1111 ___ 2 9 H ___ ____________ 1 1 0 0 al 0 0 0 0 z 0 0 a 0 0 LO CUT OUT H vdroLoicLocji A CL L 00 y Y 1 T T Ui k 1 HP j 1 2 in le t fl yF nI t 1 To 7 L K PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 216: ...OR s or c bl CI S CHARACTERISTICS Brake occumulator Capacity Identification mark on filler plug Calibration pressure tor chcckii Tighten ing torque Accumulator onto its mounting 0 400 litre 0 70 pts 62 62 32 bars 899 464 psi SPECIAL FEATURES 3 daNm 21 1 2 ft lb PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 217: ...Nm 8 to 8 2ft Ib HP supply Brake valve supply dia 3 5 mm A Manual steering vehicle Steering system supply dia4 5 mm Powersteering vehicie z CHARACTERISTICS Calibration pressures for slide valve return spring Increasing pressure Decreasing pressure Pressure for checking exfectiveness of slide valve seal Pressure switch Calibration pressure Mark 1 on pressure switch SPECIAL FEATURES Thickness of adj...
Page 218: ...suspension Sofety valve J Rear Brake valve 1 Rear Front brakes b Pou er steering vehicles HP supply _________ _______ rake ____ Brake accumulator Supply to front brakes valve 3way un SuppIy to steering governor Safety valve Front suspension 1 Rear suspension Brake _____Supply to volve rear brakes Steering Supply to control slide vaive and operating cylinder PDF compression OCR web optimization wit...
Page 219: ...spension Safety valve Reor suspension Brake valve 0 co co 0 0 0 z 0 E 0 0 Front orokes Brake pressure limiter 1 Rear brokes d Ista 1j 5 1 iii 011tr SI ti I ____ 1 J7 Source of pressure Brake icumulotor Brake volve Front brakes Supply to 3 woy union steering governor Brake pressure Iimiter Safety 1Frontsuspension Rear brakes Rear suspension Steering supply to slide volve and operating cylinder PDF ...
Page 220: ...pension Brake vaJve Brake pressure limiter It Front brakes f IsIciIe ch c CS with polter sie ri 9 1 97o Source of pressure Rear brakes Brake cccurnu1ator Brake valve Front brakes ______ 1 3 woyunion Supply to steering governor Brake pressure limiter Safetyvalve Front suspension Rear suspension Rer brakes Steering supply to slide vulve and operating cylinder PDF compression OCR web optimization wit...
Page 221: ...w return Breather OPERATION N MÅ 390 00 Lhqracieristics alul spcia1 fea ures o the source Op MA 390 00 13 and reserve of pressurc Hvdrau ic S1 Ste fl 2 Assembfy diagram a Saloo i 1 ehic es viii Ffl cliii cii sieer 0 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 222: ...r e s s u r e s u p p l i e d b y s t e e r i n g g o v e r n o r P r e s s u r e s u p p l y t o s u s p e n s i o n c y l i n d e r s P r e s s u r e s u p p l y t o b r a k e s R e t u r n t o r e s e r v o i r O v e r f l o w r e t u r n S u s p e n s i o r i c y l i n d e r b r e a t h e r s 0 o m I 0 z z 0 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 223: ... z nig OPERATION N MÅ 390 00 1 r lc r sIics 1 1 1 sfci l afurs 1 1ir Op MÅ 390 00 15 11 1 V S rl of rsI1r IIVc r u syI c LS I 1 it 11 11 11 11 s ri JO Illr r Q u 0 w W U GJ 0 0 w ID 1 ID D 0 ID 0 0 2 2 U 1 Ii 1 11 1 1 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 224: ... l i e d b y s t e e r i r i g g o v e r n o r P r e s s u r e s u p p l y t o s u s p e n s i o n c y l i n d e r s u p p l y t o b t a k e s R e t u r n t o r e s e r v o i r O v e r f l o w r e t u r n S u s p e n s i o n c y l i n d e r b r e a t h e r s L i L i 1 f f r i r I r i I I i 0 0 m l 0 z z 0 b 0 5 5 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 225: ...nsion cylinder z z 0 OPERATION N MÅ 390 00 Iydrac tristics dUi s ftic1I frdIiirs o I sm rc Op MÅ 390 00 17 aucf r s r o rsucc tIVc rduhiC sys em e LsiaI 1IJ c1 s u t 11 a IclI sIccri l lOi 0 co co 0 J 0 0 0 z 0 ci E ci 0 a 0 cD 111111 rD j J TIiI_ PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 226: ... p p l i e d t o s t e e r i n g g o v e r n o r P r e s s u r e s u p p l y t o s u s p e n s i o n c y l i n d e r s P r e s s u r e s u p p l y t o b r a k e s R e t u r n t o r e s e r v o i r _ _ _ _ _ _ _ O v e r f l o w r e t u r n S u s p e n s i o n c y l i n d e r b r e a t h e r s o 0 n i l 0 z z 0 b PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 227: ... ben cath tbc tehicie 1 F irst ensure that hydraulic reservoir filter is dean that hydraulic fluid is at normal running tempe rature arr out a road test first t ehicfe is cold 2 Draining the circuits Place manual height control lever in ou prsitiwi Slacken pressure regulator bleed screw 1 3 Fitting pressure gouge A Disconnect the tube 2 HP outlet from pressure regulator Connect the following assem...
Page 228: ...sure must be egual to 170 5 bars 2466 73psi When the cut out pressure is obtained allow the engine to run for a few rninutes 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 inpressure exceeds 10 bars l45psi check seal of plug D and repeat the test suence If the result of test is the same the pressure regulator i...
Page 229: ...urn pipe to safety valve L Secure safety valve screw 1 7 Checking the safety valve slide valve a Remove plug from rear suspension ouUet on safety valve at b b Disconnect contact breoker lead on coil and tum engine using starter fluid should start to run through the opening d when pressure reaches 110 to 130 bars 1585 to 1885 ps c Slacken pressure regulator bleed screw Connect contact breaker lead ...
Page 230: ...lize Stop engine Examine pressure gauge and note pressure drop during a period of 3 minutes tf it exceeds 10 bars 145 psi check once more If the result is confirmed check the following components to determine which one is leaking either the front corrector om the suspension cylinders one or both Testing the 3 components should be carried out by eliminating each ene in tum a lesting the front heigh...
Page 231: ...rop in pressure persists the front riqht hand cylinder is defective 0 u ca D c 0 z E a 3 J t I Y 1 Åtk ___ r jr Replace or repair it 11 Checking the rear uspension Slacken pressure regulator bleed screw Put mrinual height control in be pui oo Remove plug E Connect rear suspension supply pipe to safety valve Disconnect rear brake supply pipe 4 from bruke valve Plug oritice of pipe using plug D Tigh...
Page 232: ...Castor adjustahle by dispiacing loner ann 0040 to 1 Castor angle for optical appliance reading Camber not adfustahle 13 0 Camber angle ignment 1 to 4 mm Toe in IMPORTANT Checking of readings given above should be made with vehicie empty engine running and in normal running position with heights maintained at 165 mm at the front and 215 mm at rear Saloons or 228rnm Estates See Op MA 410 0 NOTE Cast...
Page 233: ... cup Thickness 9 34 mm 12 to 13 daNm 87 to 94 ft Ib Castor adjustment washer Thickness 0 5 to 6 mm in steps of O 5mm Thickness 0 5 to il mm in steps of 0 5 mm II SPECIAL FEATURES Upper wheelarms Stress on bearings h scl cliou of Irolli ih ust eu 500 N 50 kg Lateral play of arm before tightening screw 1 by s Idio ol rus flOre asher 0 to 0 9 mm Wheel balancing dynamic balancing to within 10 grams mi...
Page 234: ...der to avoid any mistakes due to the expanding of the fluid bioc bushes Checking ond adjusting the castor angle using tool 6309 T Assemble the components of toni 6309 T ond place checking pm A in the qroove of pcid C Slacken screw D and tilt pad C so that bush B is squarey in contact with it over its entire contact face and tighten screw D Measure distance L It must be between 49 and 50 5 mm NOTE ...
Page 235: ...EPAIRS 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 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 236: ...ip of adhesive paper at a and b and mark a locating point on each strip Measure the distance Li when vehicie is at a heiqht of 165 mm at the front and the distance L2 when the vehicie is at a height of 165 mm at the front and the distance L2 when the vehicie is at a height of 215 mm at the rear Sa oo ec e cs or 228 mm Ls aI i Note values Li and L2 which will simplify the following checks 3 Check t...
Page 237: ...rate the zero setting of the tum tables must correspond exactly to the sIrai b inc position of the vehicie 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 i re 1 Clii 1 il L Po S Ii OI Check measurements Li and L2 c Hem ove turntable locking pins E Focus beams on gratuated rules sa that illu min...
Page 238: ...l pm inserts NOTE In the case where the eccentric travel 2 is insufficient ______ _____ Place eccentric at the centre of its traveL Slacken screws 2 and rotate steering shaft 3 until pm inserts ln the case where this last operation is urisuccess _____________ ful it is necessary to move the steering clamp on 3 the rock control pinion 2nd case The values indicated on reor grac u ated rules ai e cli...
Page 239: ...el Cc mber angle must be between 00 13 29 lv CHECKING AND ADJUSTING THECASTOR ANGLE IMPORTANT For precise results from this check it is imperative to set the vehicie heights as foliows 165 mm at front and 215 mm at rear SaiGmis or 228 mm Lzsiates 1 1 Setting the vehicie height a Check ineasurements Li and L2 see d apter 1 b Release pressure in suspension system 2 Setting control oppartus Place the...
Page 240: ...l 6312 T class 2 which is required for fitting lower wheelarm on front axle oj Remove wheel lower arm ond castor angle adjusting shims 3 b Determinirig 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 fitteci must corres pond to the total thickness of shims found on dismontling in order...
Page 241: ...d perpendicular to the lonqitudinal axis of the vehicie and the overall distance between them is exactly 2 48 meters The rods need not necessarily be at egual distance from the axle but the spacing between them is essential 4 To make the test Pivot ann of the twa projectors towards the front rad find read off on the graduated rule the value indicated by the lurninous mark Then pivot prajector towa...
Page 242: ...Ib Ceck the adjustmnerit TMPCRTANT The length at a of the visible ead on the L H and RH trackrods nusi be i el tu ni line mm 0 0 D o 0 z 5 0 0 0 A 3 1 5a 20 1 i 1 l p Sce1 col uIs Turri sleeves 4 a fraction of a tum at a time to obtain correct setting NOTE Tum each sleeve the same amount in order to retain the alignment with the rear axle urjit arne tu ing on eac1 side on graduated rIes 4 One comp...
Page 243: ...ixed object which will indicate the initial positioning of the vehicle 3 Meosure the variation in the wheel alignment wheel by wheel as a functionof the height of the vehicie a from th JIJ ffifil IT 1 l rJ Si Ou to Ih o 1 iI uosi ir o Ilr uocI With vehicie in uornii dr ring pos it on engine running and position marked in relation to ground Mark position of luminous spot on front graduated ru le Pl...
Page 244: ... 6 Slacken nut 5 and sorew 6 securing the wind screen crossmember on the side to be moved Slacken the upper fixing nut on the opposite side as weil in nrrin u fr riun I rfj 1or jn Ibo u r s snu e nibnu 1 7 Move the crossmember in the direction decided by using as a mark extremity a of screw 3 NOTE t molnm nI oj 1 mm 0 1 in u rossmrmhnr rrurrns 1 rr fl s fr 1 1110 no 01 11 0 ipin 1 i n 1 tI 7 n si ...
Page 245: ...NG Vuhi ulus f thd f jf r u r stÉ riug This operation is to be carried out on a level road in the absence of any wind The vehicle puils to the right Slacken both nuts 1 rotate eccentric 2 towards the left Tighten nuts 1 The vehicie puiis to the left Slacken both nuts 1 rotate eccentric 2 towards the riqht Tighten nuts 1 0 NOTE In case the movement of eccentric 2 is not sufficient see para 3r sub p...
Page 246: ...m ________ 976mm 990mm lOO4mm 1 _________ Inner thrust cup LL Thickness 9 34 mm _____ _____ IL 1 7 to 9 daNm 1 _ LL 50 1 2 to 65 ft 1b2j 1 DESCRIPTION 1 to 4 mm Alignment oot aduslablo Front toe in oc_ Camber not adjustable Max difference between the two sides 12 Il eights to be adherod to dur og this check At front 165 mm At rear 215 mm Saloons 228 mm Esta os PDF compression OCR web optimization ...
Page 247: ... daNm r lii iuaaNm 253io325 8ft Ib 2ftlb II SPECIAL FEATURES preloud of 500 N 50 kg Tightening of wheelarm spindle bearing NOTE Beorings and ear arm adjustment cups are identical to those of front wheelarms TOTAL MULTIS MS grease Greasinq of hub and arm joints Wheel balancing dyr balancing to within 10 g max PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 248: ...3 REAR AXLE Lstate jehi cfns L 4 5 Outer thrust cups Thicknesses 934 mm 9 48 mm 9 62 mm 9 76 mm 9 90 mm 10 04 mm 10 18 mm 10 32 mm 10 46 mm EEECT1 Inner thrust cup Thickness 9 34 mm 0 0 4 0 0 0 z c E 0 0 1 t 65ftJ t H 12 to 13 daNm 7 87 to 94ft Ib Face and thread greased PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 249: ... S of t rear a v e jiflil REAR HUB L St lI l hiCl S L 42 3 4 daNm 24 1 2ft Ib face and threa g rea sed 1I1 1 4 I 1 _ I II ffi 1 1 daN 8 ft Ib 55 to 65 daNm 398 to 470 ft Ib face and thread grea sed PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 250: ...1 on the vertical centreline of each front wheel b Fit the projector unit on ach rcdr iuh r I c 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 diference in the readirig between Ieft hci d and right hand sides 2 Checking wheel alignment 3 3 248m Place...
Page 251: ...e 1 BEM MULLER 665 Juriior Proceed a for front wheels IF ibI fl t r1jj cu n is fnj bc s ru uInius rn5fJ ItI I r ibis c c ck at front 165 mm at rear 215 mm Sa oaus or 228 mm Esiates Value o the camber angle 00 0 24 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 252: ...0 0 0 0 z 04 SUSPENSION OPERATION N MA 430 00 baracler stics and sfecial feati res of the suspension Op MA 430 00 0 0 co co 0 D c 0 0 z c REAR SUSPENSION FRONT SUSPENSION PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 253: ...MA 430 00 lr lCf rIsI c 1 1 1 7 11 qf rs o 1 CHARACTERISTICS 9 1 A1 L 43 6 HEIGHT CORRECTOR SUSPENSION CYLINDER All Saloon vejiicles SUSPENSION CYLINDER Estate vekicies PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 254: ...3 MANUAL HEIGHT CONTROL 14567 0 L co 3 D 6 z 4 E 6 6 6 3 Monual heiqht control quadrant 1 High position IT Inermediate high position lIT Normal driving position IV Low position Assembly diagram for manual height control L 43 2 Seen along Fl ___ PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 255: ... Identification mark on filler plug Calibration pressure or d ick ii FRONT HEAR 5 1 0011 1 1 1 1 i L 75 40 35 2 bars 40 2 bars 35 2 bars 27 10 1088 p 1 580 ps 1 508 psi 392 D ampers They are incorporated in the pneurnatic units NOTE The front and rear dampers are different on CX 2400 GTI vehicles and therefore the pneumatic units are specific ______________ _______________ Suspension cylinders Dia...
Page 256: ...G Ii th un or f p j 1 c jj 10 10 1 Tiqhtening torques 3 daNm 21 1 2 ft lb Bush nut Anti roll bar link rod on upper wheelarm NYLSTOP nut 4 5 to 5daNrj 32 1 2to 36ft lb 4 5 to SdaNm 32 1 2to36ft lb Link rod on cinti roli ber 2 7 dciNm 19 1 2 ftib Screw securing front anti roll bar beoring 1 3 daNm 9 1 2 ft lb Clarnps for adjusting pre load on front anti roll bar 1 5 daNm 11 fL lb Ciamp for height co...
Page 257: ...nd point of contact of wheels with ground AT REAR Between under face of point b subfrome ond point of contact of wheels with grou n d 1 Check tyre pressures 0 z E 0 D 2 Remove corrector protectors and make sure the manual controt rods are not exerting pressure on levers 1 ond 2 3 Sliqhtly loosen automatic control clamp and adjust to obtain Front height 165 8 mm Rear height 215 8 mm Saloons 228 8 m...
Page 258: ...icie by hand Release when weight becomes too great to support Vehicie wil l drop then risc again and stabilize itseif Note front height b Push vehicie down by hand Release when resistance becomes too great Vehicie will rise again then drop and stabi lize itseif Note front height again c Take the average of these two measurements which should be between 157 and 173 mm inciusive At rear Proceed in t...
Page 259: ...et grippers 6401 T as shown in photograph and unscrew clanp screws 5 c Position anti roli bar so that an identical distunce of L is obtainetl on both sides to within 2 mm d Tighten alternately left and right hand grippers 6401 T nuts A e Compress spring 4 so that spirals touch then loosen nut A 1 2 tum f Tighten fixing screws of clamps 5 to 1 3 daNm 9 1 2 ft lb g Check distance L identical on hoth...
Page 260: ...z STEERING OPERATION N MÅ 440 00 harcictristics 111 1 S CI i faturs Of I Stcen i Op MÅ 440 00 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 261: ...NUAL STEERING 1 CHARACTERISTICS STEERING RACK 0 c 0 0 z c 0 E 0 0 0 1 STEERING COLUMN 9 1976 1 44 S il J2 is obtained by moving flange 1 0 long steering pinion and spacer 3 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 262: ...t adjustable outside wheel 32 50 Turning circie between walls between kerbs Steering ratio REPAIRS 11 80 m 12 70 m Sa1oon ts ats lO 9O m 11 80 m 24 5 1 The spring on the flange side can be fitted to a pre September 1976 vehicle as long as the following are also fitted the new steering shaft with spring ceritering guide the increased calibration spring 3 on the fixed support side the Delrin spacer ...
Page 263: ...ointing verticaily downwards Angle of universal joint 17G to the left approx with steering wheel in straight ahead position Tightening torques Flange for universal joint on steering skaft Fixed steering wheel tube attachments Coupling f or steering pinion flange steering shaft Flonge on steering pinion Steering pinion securing flange Steering rack bali joint rczck lock ed Track rod lock nut Rock k...
Page 264: ...ween walls 1180 m d 2200 SaI s between kerbs 10 90 rn between walls 12 70 rn L SI f 1 1 1 Ir II between kerbs 11 80 m 1 Steering wheel 2 Anti theft device 3 Control unit 4 Steering shoft 5 Coupling flange 6 Eccentric for adjusting straight line running 7 Clump for coupling hydraulic pipes x 7 2 A 6 r Section A N Ji J2 obtained by moving clamp 5 along steering pinion 1 STEERING COLUMN AND HYDRAULIC...
Page 265: ...IC RACK CONTROL UNIT OPERATING CYLINDER a Hydroulic rock control unit operafing cylinder The rack is connected to the hydraulic control unit operating cylinder Assume Sas the piston in chamber 1 and S 2 Its surface as dcsincd iII d an bl r 2 The steering is balanced when forces F and Fl exerted on each face of the piston are equal therefore 5 X Fl HP HP operating pressure of hydraulic circuit 1 rc...
Page 266: ...ud mc chuica1 v liokod lo tho s orio Pioiou Rockers E tilt ard cause s1idevalve C to movealong 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 Roluro lo osi ioi 0 orjiiil briim Movement of rack causes movement of its contral pinion piniori B and pinion D Pinion F being then locked in posi tion pin...
Page 267: ...h 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 haft A iIct 0J tccvvtric Pressure exerted on piston F 1 a iablo prvs s11r sup plivd by s fr iivg go lomor Straight cihocu position Pressure of piston F is being exerted in the hollow on cam H which tends to maintain the steering in the straight ahe...
Page 268: ...nder the effeet of centrifugal force couse lever B to tilt Vari able position of slide valve A ollows the pressure exerted on the com cylinder piston to be varied NOTE ln order to make possible the powered return function the steering governor supplies a pressure of 20 r5 bars 290 73 psi when the vehicle is stopped uith the euiue r000ing POWERED RETURN The powered return is a combinotion of the tw...
Page 269: ...reaches the hollow part of cam H ro IdI o al lo rcj I is ca ri The steering is then in the straight ahead position NOTE Pressure supplied by the steering governor is applied to piston F via a variable output regulator in order to slow down the return of the steerinq to the straight ahead position b Variable output reguafor Wl o I crior return of piston F causes the fallowing Expulsion of fluid thr...
Page 270: ... 3 Return 4 Control skaft Backlash 6 0 0 OPERATION N MÅ 440 00 barcic istics and sfcial alurns oj the sIr n Op MÅ 440 00 9 CROSS SECTION OF CONTROL UNIT L a cc 0 D 0 0 0 z 0 0 E 0 0 0 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 271: ...0 z 0 z z 0 10 OPERATION N MA 44OOO c1ctritics cijij s cial Jcaturs o hc stc i g CROSS SECTION OF STEERING GOVERNOR L 44 16 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 272: ...e In the straiht ahead position the steerinq wheel spoke must point vertically downwards e Tiglitening torques dl Positioning the collars on the wheel iIignment adjustment sleeves 6 to 8 daNm 45 1 2 to 58 ft lb Steering wheel fixing nuts Screws securing control nut on body shell 2 1 daNm 15 ft lb 2 7 daNm 19 1 2 ft lb Screws securing steering shaft to coupling flange Nuts securirig fIexibe black o...
Page 273: ...wards 1 CHARACTERIST1CS Main braking system at the front S aloou s Disc brakes on all four wheels with Fult la ed 1 Ses front and rear I slah s 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 The front braking system is supplied by the main accumulator Ich rlF s ititI nianii1 sIcerlI c or by the the...
Page 274: ... 00 harac ris cs 11 1 spcia d IrS of I f rakin s FRONT BRÅKE UNT L 45 1 6 to 6 SdoNm 43 1 2 to 47 ftlb L 45 3 3 5 daNrn 2 3 to 2 5daNm 25 1 2 ftj 16 1 2 to l8ftib PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 275: ...rac ris ics I f s c il cd ur i brakin S S m Op MÅ 4500O 3 REAR BRAKE UNIT Scjfow s L 42 4 2 to 4 7 daNm 30 1 2to 34 ftib face and threod q rea sed 0 0 co co 0 D 0 0 z 0 0 E 0 0 0 co PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 276: ...III lip 4 OPERATION N MÅ 45OOO arac riIic 1 1 1 h a haI r 1 l rakii REAR BRAKE UNIT I JaI L 42 6 5 to 7 daNm 47 to 50 1 2 ft Ib face and thread qreased ___________ g 1 1 II iL II PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 277: ...r brakes and vice versa b Vch id c in ib c no rio al dr iii o 5 1 01 7 0 action on brak p cdal 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 aliows flow of fluid from brake valve to rear brakes and vice versa c Vc ii din in 77 0 tio iiiIh Ii brak c r al an nainni Fluid from the front brak...
Page 278: ... Si 1101 ti i ih no act ou ou tho brak u pudal Force F exerted by the rear suspension fluid under pressure is qreater thon force RI produced by the spring The slide volve is in the position shown on Fig 2 which aliows fluid to flow from the brake volve to the rear brakes ond vice versa c 1 ch cl ic iiiot ou uith the brak e pedal be og acizialud Fluid flowing from the rear brakes exerts a force Fl ...
Page 279: ...1 818 OPERATION N MÅ 450 00 haracterisi cs and spcc aI eaIurcs of iI hraking svsIm Op MÅ 450 00 7 HÅNDB RAK E Emergency Brake VIEWAT F 1 5 doNm 11 ft Ib PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 280: ...m 42mm 3Omm 4Omm 55 cm2 8 52sq in 24 cm2 3 72 36 cm2 5 58 sq in sq in ll5mm l2mm l2mm Checking the flatness of a disc take a reading in 8 different points the resuits should be the same ta within 0 02 mm TYPE OF BRAKE PAD LINING Front linings incorporating warning lamps leads AUTHORISED REPAIR FITTINGS VEHICLE FRONT REAR All Salowi Viic s CX 2000 MA series MB TEXTAR T 254 FERODO 748 CX 2200 MA ser...
Page 281: ...in Area of one pad Adjusting the pcxds the pads must just contact the disc at its highest points Tightening torques 3 6 to 4daNm 26 to 29 ft lb Flexible brake pipe on front brake unit tube 2 1 to 2 4daNm 15 to 17 1 2ft lb Nut securing front broke pipe on subframe 1 8 daNm 13 ft lb Brake valve securing point 0 5 daNm 3 1 2 ft lb Pedal ossembly securing point 0 cx 0 0 0 z c E 0 0 PDF compression OCR...
Page 282: ...d d 12 mm thread pitch 1 25 length 30 mm Ex Crown wheel securing screws on s D vehicies REAR BRAKES Method 1 Raise vehicie ond assernble equipment as shown above Tighten the three screws to approxima tely 70 mN 7 m kg 50 1 2 ft lb 2 S dial gaii o d as t idi rala as p0 id fr tf sf frC The run out thus regi stereci must not exceed 0 2 mm If thi condjtjon cannot be satsfied the disc must be changed P...
Page 283: ...emove bleed tubes Check the bleed screws for leaks by depres sing brake pedal to fullest extent Stop engine Vit rubber protectors over the bleed screws d Replace front wheels and lower vehicie to the ground B REAR BRAKE BLEEDING 3 Release pressure in circuits a Set manual height control to lao osiiiou b Slacken pressure regulator bleed screw 1 c Wait until vehjcle has reached its lowest point Rais...
Page 284: ... ln iv 1 prc SSt d b Tighten release screw on pressure regulator and let fluid flow until there are no more air bubbles in the bleed tubes Then tiqhten the bleed screws c Release brake pedal and remove bleed tubes d Iii air ehci nher 1 a t er bce u b rju ii fl Il can c i o Iii r n res s d alr e Check bleed screws and air chamher 1 are properly sealed by fully depressing broke pedal Stop engine Pla...
Page 285: ...aIor cicItidIc i c a so ds lo Fc cds III rcss I in l brok c dc 1 fl 1 idlo b Depress pedal three or four times to move the contra1 slide valve to the end of its stroke and ensure that pedal returns freely to its stop There should be no variation of clearance i as initially set Tighten pressure regulator bleed screw IV ADJUSTING THE STOP LAMP SWITCH 1 Check adjustment of free play on brake pedal se...
Page 286: ...ads just contact the disc at point of maximum run out Tighten screws 4 from 6 to 6 5 daNm 43 1 2 to 47 ft lb En 511 Te il eli erren tel es do 7101 TO tate Check correct contact of pads Screw down stop scmew 3 until it contacts the bmake unit housing 1 tigI tc n iis lock out 3 Adjusting handbrake control cabies On tc brak e noll Ensure that the sleeve and its stop 8 are comrectly positioned Full al...
Page 287: ...5 daNm 11ft lb 4 Checkurig ihe handbrake Operate handbrake lever severa1 times Check that adjustment does not change and that locking system operutes satisfactorily 5 Refit front wheels Tighten screws from 6 to 8 daNm 43 1 2 to 58 ft Ib Lower the vehicle to the ground PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 288: ...r the last group of identification marks four cases may occur CO Oh 1 I Sl l 01 7 lead 1 le co our oj ubich is rrclcian 1 morks on diagrams Bc Bl Ve Gr I O s ccl e 01 7 lear 1 Ja CO OUT o ithici series as idel ti lcatiol mark marks on diägrom F Gr F Ve F Bc co ozired sleete ou a lear the co our of iihicl series as ideij tificatiou mark as mcli marks on diagram FN Bl F Ve Bc 11 idel Ii fied Icao it...
Page 289: ... Red 1 Instrument panel terminal Lighting ___ Windscreen wiper switch Horns Heating relay coil Window winder relay eau Interior lamp Boot lamp Cigar iighter Positive battery 16 A Green Clock terminal Hazard warninq lamp Voltage regulator Lighting Reversing lamps switch L____ Rear window heater Ashtray lighting Lighting for cigar lighter Heating control lighting 10 A Yellow Dashboard lighting Side ...
Page 290: ...9 F G r Gr By Bl M By Bl FV Fr l r PMr BcBl 3 ci ARAR BE Mr FMr Bl V667j1 1 Mv TE FMr Bl ic _______ 4r Jf Ii TE t rl 4 Mv R BE By 1 BE r 4TBTBTBE r J Gr Mr F MrBc T T B T1B TB TBTB r J Gr R Mr F MrBc Mv FR FNFBC 1 R Mr j R Mv R Mn AR 111 1 FR N F BcFGr j d By 533 266824L Lif TE 1 1 1 1 1 1 1 1 1 1 1 i 1 23 56789101234567892012345678930123456789401 PDF compression OCR web optimization with CVISION ...
Page 291: ...G LG LG LG BTB r 1 1 R rBc 3 Bl Bl Ve flMvFRFNPBc H 1 MrT T n1 H4R NGr Mn LJ r25L1 1 6761 34 BcBc 21 Mr ______________ ______ y F G r EJ Mvj 32 Ve 27 KTT EMrR H 4HD 38 38 13 JT Fb0 TB LriJ r4TBTB EL Bl Bl F Ve F VeM l 94755 fl fln TB TB 8 EVe EVe 8 jr_ t 2 EVe EVe r AR R EVevlvF IeR e Mr 6 67 01 1 2 _ o v_O 1141 ri H p6 I8 22 M ax 6564 Mr 1 1 1 1 1 l 1 1 1 1 56789401234567895012345678 i ___J PC 9 ...
Page 292: ...2 34 21 Windscreen washer pump 36 Hydraulic pressure warning lamp 31 22 Piug for diagnostic operations 65 Warnirig lamp for hazard warniag 17 23 Engine ou pressure switch 34 Sidelamp warning lamp 70 24 Idle cut off 60 Direction indicators warning lamp 23 25 Engine ou temperature switch 35 Headlamp main beam warning lamp 77 26 Engine coolant temp switch 30 60 Left hand control panel 27 Top dead cen...
Page 293: ...eversing lamps 2 Front side lamps and rear lamps 4 BA 15s 19 12 V 5 W R 136 13 Number plate lamps 2 Interior lamp 1 Festoon 12 V 5 W R 13614 Boot lighting 1 Dashboard lighting 5 BA 9s T 8 2 12 V 2W R 13634 Glovebox lighting 1 Warning lamp 13 Lighting for cigar Wedge base 12 V 1 2 W lighter 1 Ashtray lighting 1 KEY TO CIRCUIT DIAGRAM SYMBOLS Wiring con nector Capacitor Connection bock Motor electri...
Page 294: ...Supplement 1 818 1 L a m L 818 WIRING HARNESS Colour Code White Bc Blue Bl Grey Gr Yellow J Brown Mr Mauve Mv Black N L1 J PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 295: ...3w3 1 2 III _S1 f1 z b7 III fem RNESS J 4 J 7 5 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 296: ...roup of identification rnarks tour cases may occur Coloured si ie oi a lead the co our of il ch is irreleta 1 Marks on diagrams Bc Bl Ve Gr f 4o siee e on 1 lead ih e colour oj u iich series as ide Ii ficatioi mark Marks on diagrams F Gr F Ve F Bc olo ired sie le 01 a lead the co our of uhich se vi es as i fel tificatio iiiark as ueli Marks on diagrams FN Bl F Ve Bc ide tified lead Its position ca...
Page 297: ...pad wear warning lamp Fuel gauge Ou pressure warning lamp Hydraulic fluid pressure warning lamp Water temp warnirig lamp Interior lamp Boot lamp Cigar li ghter Clock 16 Amps Green Hazard warning lamps Voltage regulator Ignition Reversing lamps switch Rear window heating element Hondbrake warning lamp R H Switch R H window winder Window winder relay 16 Amps White L H Switch L H window winder Ashtra...
Page 298: ... LITMv 6r FV AR Mr Mr N Mtr66 F Mr fMr F 69 L_ J Bl Ti FV 614 TB 1 1 j Gr Mr FMrBc j r R MrflFMrl I GGr 1 Bc GrGrGrGr 1 Bc Rri4ir1r Mr Bc M hIiI Mr 56 1 jJ3 M1r251 rLi r 26143 Fv li 3623 B TB rhi ii L Iy 63 BBc flB y y y yTrCO BeBI RMv F BI FMr Bl J TB TB co T BT B FVPEN Mv 16I cp Bc COr l GrF BcF N ER c Bc Ir F 1 i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12345678910123456789201234567893...
Page 299: ...N 1 Ft __ Ilv Ve rLi LII 3oI 4 i fl 1 63 jk i 1 IM _____il 27 yy yy Il II Bc Bc r LG r LG 16 141 TIW VeBI nI ii _ ILGLGLGLG iH 1 t Ve Bl Bl Ve Il tJ1rr M L 47 42j6 Tr Bl 1 FG lC 62 1e AR VeMvFVeR VeVe J PC 1 1 1 i 1 1 1 1 1 1 1 i 1 1 1 1 i i i 1 1 78940123456 89501 23456 8960123456789701234557 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 300: ...l temperature 35 22 Socket for fault finding daagnoslic 65 Warning lomp f or water temperature 29 23 Oil pressure switch Red STOP warning lamp 31 33 Warn ing lamp for hydraulic fluid presssure 31 24 Idle cut off 60 Warning lamp for hazord worning 17 25 Ou temperature switch 35 Warning lomp for sidelamps 70 26 Coolant temperature switch 30 Warning lamp for direction indicators 23 27 T D C sensor 63...
Page 301: ...n 12 V 5 W E 136 14 _________________ Lighting for tachometer 2 BA T 8 4 14 V 4 W and speedometer Lighting for glove box _______ 1 BA 9 s T 8 2 12 V 2 W FL 136 34 Warning lamps 14 Lighting for cigar lighter 1 Wedge buse dia 5 12 V 1 2 W Lighting for ashtray 1 Lighting for pneumatic ou gauge 1 Lighting for instrument 3 Wedge base dia 10 12 V 2 W panel ________ ____________ __________ ___________ __...
Page 302: ...Supplement No to Manual 818 1 ADD 1v_ WIRING DIAGRA 1 1975 7 0 0 cX 0 D 0 0 0 0 z 0 0 E 0 0 0 D 1 5 R b B 4 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 303: ...0 r IRING DIAGRAM 1975 7 1975 L 51 4 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 304: ...ur olourcd slc eie on a lead the co our of uhic i is irrlccant Marks on diagrams Bc Bl Ve Gr No Sl c lc on a lead thc colour of uhich scr es es idcntification mark Marks on diagram F Gr F Ve F BC oloured sleeve on a lead the co our of u hich ser es as identification mark as jiell Marks on diagram FN Bl F Ve Bc Unidc ntificcl inad Its position cannot give rise to any confusion IMPORTANT Identificat...
Page 305: ...l gauge Ou 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 Voltage regulator Reversing lamps Ignition Heated rear window element switcn Haridbrake warning lamp Relay for window R H switch RH window winder 16 Amps White winder switch LH window winder Ashtray lighting Liqhting for...
Page 306: ... TBcr Mr 1 R r1i ___ 6 L j BCI JEJ Mv Bc Bl Bc Bi PC N 66r1 h ri1 L J Bl FN F N Bl EV 67O 4 L ljB TB rh 63 N L rf Lf 63 Bl B T Bc Bl R Mv FBI FGrrJ T B T B 1 c T BIT B j Gr F Mr F Mr Bc 1 1 1 1B TB T1B 1B T BTB 1 r J Gr R Mr FMr Bc 1 I I r F BcF NF RMv 1 J Gr R MrFMrI rLj A R A GrGrGr r Bc FGrF BcN gR F yl 1 Ic rrtT JII M r1uI Mr 56 1i Tt 1 M r25 h Bc UFrii 261e 23 EGr Mr 36 ___ LL 1 1 1 1 1 1 1 1...
Page 307: ...R r R L FMi CP Mr Ji Bc COr l L___J L J 47 70 64 L LJ Bc 34 Iri F Gr i 1 4 Mr 274 38 II J D71 Ve F1 r F G r T B r AR FBI FN T1B N GrTB J rh 38 8 11C2 FVe TB TB ii T1BTB Bl Ic F V F VeMv TB 1 T1B Ve 1 FJ 1 L J yF Bl FVe FVe Bl F G Bl CT 44 __i 13 1 1 lGr 1 J R F eMv F Je R Ve je Ic Ic Mr r1 rL pI 67 I t FGrFGrMr Li PC I Mv Mv 22 6766 Pc 1 1 1 1 1 1 1 1 1 1 1 1 1 i i 1 1 1 1 678940123456789501234567...
Page 308: ...on indicators 23 26 Coolant temperature switch 30 Warninq lamp for main beam 77 27 T D C sensor 63 Warning lamp for handbrake 16 28 Switch for reversing lamps 8 63 L H control unit 30 Relay for windowwinder 49 Direction indicators and hazard warning 31 Relay for heater unit 45 lamps 19 32 Relay for electric fan 58 Horns 41 33 Front RH brake unit 28 Windscreen wiper motor 38 34 Windscreen wiper mot...
Page 309: ... Festoon 12 V 7 W R 136 05 Baot lamp 1 Festoon 12 V 5 W R 136 14 Lighting for tochometer and speedometer 2 BA9s T8 4 14V 4W Lighting for qlove box 1 BA 9 s T 8 2 12 V 2 W R 136 34 Warning lamps 14 Lighting for cigar lighter 1 Lighting for oshtray 1 Wedge base dia 5 12 V 1 2 W Lighting for pneumatic oil gauge 1 Instrument panel lighting 2 12 V 2 W Wedge base dia 10 Liqhting for odometers 1 24 V 3 W...
Page 310: ...Supplement N Manual 818 1 ___ III 1 818 WIRING DIA J975_ 2 5 1 3 _ rift F BV 34 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 311: ... A 56 NJ73 LL 64 ic75 4jJ II cUT11 II TLt r fl FR 1 kl I Mv lJC 1PBI P 1 utft FBI kQIiL IrMtr i i 71 j F 1 1 Ic ________ 1 3 J L4LL 53 ft N 61 tJ LJ__ Gf1 1 gI Ei _____ 62 F V 69 Mv 1M T3N L My PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 312: ... may occur Z oloured siec ic ou a iead the co our of oh ch is irrelu an marks on diagrams Bc Bl Ve Gr No sie te 01 Cl man tbc co our oj oh ch serles nis idel Il iCCltiOl mark marks on diagrams F Gr F Ve F Bc oloured sleevu on a h ad the co our of uhich serces as identificalion mark as och marks on diagram FN Bl FVe Bc Unideutified mcd Its position cannot give rise to any confusion IMPORTANT Identi...
Page 313: ...eft Reversing lamps Green 16 Amps device Heated rear window Hundbrake warning lamp on instru ment panel Glove box lighting Centre and rear interior lamps Bonnet lighting Boot lamp Accessory terminal radio Front window winder relay White 16 Amps LH ftH switches L H RH wiridow winder Map reading icimp 5Amp in line fuse Liqhting for heater controls Liqhting for ashtray and cigar lighter Lighting swit...
Page 314: ...B F2H _TB T ii i 1 Bc I NFVe Gr N ic 8 h r j 1 TT L R Mv Mv Bc Lii 1 86 38 L 1 Bl le rtiri 1 RI R LJ r I 62 94 88 N F VeEVeJ BI EMv Mv EN i6A A46 Bc Mv F J FJ Bl V 56 u LJ JMvl RJv rhil34 i rF BIBc 72 jJ N RF VIJ rh ri 53 Bl 7i Bc Bl Bl 9488 II 1 1 1 1 1 i i i i i i i 1 1 1 1 1 1 II 1 il i i 1 23 5 7890123456789201 234567893012345678940123456789501234 PDF compression OCR web optimization with CVIS...
Page 315: ...TBITBTB nnn M ________ _________ 1 EJ Mr R JMvEJMv 1 r i 3j137 1 L1J Il p ir 9587 N Mr N Gr F 4FVe R Bl F Gr Bc c IclBc IJV 1 ______ L C R rkBc Id N R PRBIVP ___ d 1 241 73 PRPR 76 1 r PC PC PD PD R T M F Gr II Lii 1 BIV BIV I lI 1l r Mr Bl 13 L _ 1 1 ___ PGPD TBL R Ic l N Bl Mr R R 67Ev PRPC il Ii 1 1 II 1 1 14 i 1 1 N N EV Mv RVe9Ve Mv I Il 1 L__J L___ ttJI I ii 96 84 L 1 1 c PGPD Bc FMrVe EMrL ...
Page 316: ... lamp for eng ou pressure 26 25 Air conditioning compressor clutch 51 Emergency STOP warning lamps 23 25 26 Relay for compressed air horn 8 Test button for STOP warning lamps 27 Windscreen washer pump 15 21 23 25 28 Fast idle electrovalve 49 Warning lamp for hydraulic fluid press 24 29 Engine au pressure switch 26 Worning lamp for hazard warfling 30 30 Idle cut off Warning lamp for converter ou te...
Page 317: ...3605 Map reading lamp 1 Festoon 12 V 5 W Fl 136 14 Rear interior lamps 2 Lighting for speedo 2 BA 9s T8 4 14V 4W and tacho Glove box lamp 1 BA 9 s T 8 2 12 V 2 W Fl 136 34 Warning lamps 15 Lighting for cigar lighter 1 Lighting for ashtray 1 Wedge base dia 5 12 V 1 2 W Lighting for ou gauge 1 Lighting for instrument 2 12V 2W panel Wedgebase dia H0 ________ ________ __________________ Lighting for o...
Page 318: ...c 0 E 0 0 0 0 2 3fr Colour Code Wlrtc Bc Blue Bl Grey Gr Colourles Ic Ycilow J Bro we Mr Mauve M Black N Red R Grece Ve 5J___ 6jFGJ 7 p r U S 16 JB1 1 4j L LJo FBI 18 27 N EVe Evcfl EUH 1 FMr EJ Bc F Ve 47 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 319: ...__ 86 1i 1 1 __ ____ PR 1 7e 75j L SM t173 Im74 N I oV NiV 78 N M M 91 Nifi M 1 J jTF i _____ tc Mv TIEEEIJ 7 J R G f JIEIIIIIIITj 4 N IDI N FM ii TI JJiY N ______ Bc G f _ ___ ___ ___ ___ 68 F4 11 i 3 FM LBI 3 J 97 k Lj v F R13 v t II 80 r PG R v PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 320: ...g sleeve NOTE For the last group of ideritification marks four cases may occur Co oured sleele ou a icad the co our of ul ich is irrclc ant marks on diagrams Bc Bl Ve Gr No Sleene on cl lead the co our of uhich ser es dS ide tijication mark marks on diagrams F Gr F Ve F Bc Unideutified lead Its position cannot give rise to any confusion IMPORTANT Identification murks for components and wiring harn...
Page 321: ...g lamp Fuel gauge Oil pressure warning lamp Hydraul fluid pressure warn lamp Wcxter temp warning lamp Tchometer STOP warning lamp Interior lamp Boot lamp Cigar lighter Clock Hazard warning lamps 16 A Green Voltage regu ator 1 Reversing lamps Ignition Heated rear window switch _ Handbrake warning lamp Rear screen washers and wiper R H switch ft H window winder Window winder relay 16 A White L H swi...
Page 322: ...i63JtL F Lr F N 63 RL L l M2 9 1 J N VeBcBI TBI __ __________ Bc Bl 1 Gr TBcri 1 1BTB Ié _ _1RDIT N R F i didi FJ___ 69 1 ____ L __ T B J4J9J r T B 1 Mr F Mrc B j TB 1IB T B TB 1B TBTB 1 Gr R Mr FMr c 1J J FCNI Mr J r MrflFMrI Bc Bl N Bc Bl R GGr 1 Bc rhLjJrhrhF _JL R H64 R D UF Mr HHH fEr Bi T Bc N IE J E Bc r1 1 IJH RD Il ll i MJL1 Bl I68 RD rF Mr ML25 L J L J pi F N B LFN r1i Pr1 2610 6 L 73 FV...
Page 323: ...c 1 Pi FGrF LG r 1 N FJ F VeFN Pi 30 29I JLjJ HkrJ r FN Mr FBI LG M LGBC rLG Pi54 Pi Pi FbFi LO hIT 414 1 4 i L T341rH Y e Bi v It 1 1 Ir LGL6LGLG R l 1 Bl Bl L J t 46 40 FGrFGr 73u N I41 R 1 Mv I j M 3trru1 0 IVe Li 24 27U4 37 T1B N Pi L TB Ve 37 TB TB TB FJ FJ ri1 TB Je t ___ Fy V F VeR VeV 1 71 Il 1 l 1 1 89401 2345678950123 456769601 23456769701 23456789C2 PDF compression OCR web optimization ...
Page 324: ...5 24 Idle cut off 65 Warning lamp for direction indicators 28 25 Ou temperature switch 40 Warning lamp for mcrin beam 82 26 Coolant temperature switch 35 Warning lamp for handbrake 21 27 T D C sensor 68 63 L H coritrol unit 28 Switch for reversing lamps 8 Direction indicators and hazard warning 24 29 Relay for window winder 54 Horns 46 30 Relay for heater unit 50 Windscreen wiper motor 43 31 Refay...
Page 325: ...36 14 Liqhting for tachorneter 2 BA 9 T 8 4 14 V 4 W and speedometer Light ing for glove box 1 BA 9 s T 8 2 12 V 2 W R 136 34 Warning lamps 14 Lighting for cigar liqhter 1 Wedgebase dia 5 12 V 1 2 W Lighting for ashtray 1 Lighting for pneumatic 1 gauge __________ __________ _______________________ Instrument panel _________ ____________ ___________ 2 12V 2W lighting Wedge base dia 10 _____________...
Page 326: ...1 25Bc ColourCode 27 M Yellow IL II R 34 Brown Mr fl 1 i D Gr JBC Mr Mr o Mauve Mv ________ 2 Black N f 1 Red R _______ N BI GrIBc Mr Green Ve 12 IMivl Z Colourles Ic _______________ 35 __ 14 28 361111 1 1 _____ ___ AV ____ __ I37 Ve LLr __LJ CO Mr BIfE lJ L 1 ____FMR1 38 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 327: ...0 WIRIP4G DIAGRAM ides r ch t1arkt 1 1976 L 51 11 40 Bl cC 72 M11 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 328: ...ion W indsyreeni w oshers Mv B c Rear fogi amp swrtch BLACK RH d rection Horn F Bl Bl indicators contaytfor 2 6 reloy for compressor Red fuse Mv J E Mr horn 3 7 Taxi alorrn system Directiori indicators BcrF Gn J F Gr Swedish mark et headlomp wipers Direvt 1 supply through green fuse F Ve Ve iBM Converter oH temp to dock an hozard fr Warnifly NO COLOUR Earth F Gr b R W Woriling lamp N 3 Trarler dir...
Page 329: ... Relay for electro volves 3 Ignition and starting contact 4 Electro valve contra11 ing fast idle 5 Electro valve controlling clutch 6 Gearbox switch housing 7 Control relay for electric fan N FVe 21 EJ FMr F Gr F Ve jI 1 MvorBI EJMV0rBI N JMr 8 Thermal switch con trolling the electric fans 9 Electric fan 10 Relay controlling supplementary elecfric fan 11 Supplementary electric fan 12 Warning lomp ...
Page 330: ...b rranim 0 h cIricaI is cl aI ou Op MÅ 510 00 b 15 Ironi 9 97 5 tf LX 2400 i fCI S f ii ilb oplio ia CONVERTER AIR CONDITIONING J2 1976 4 T O CIRCUIT DIAGRAM PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 331: ...1 170 _____ _____ te10 R Mv FGr FJEL II F1 L i TB EN EMr FN 12j EBIEN N 25 EN Mv Mv Mv fl4 67 FR R Tj r ii Li II Bc MrMr EVe 1 Bc FR EJ FVeI Bc Bc N L Ve Mr Mr Bl 1 CM t4 r1r Li l I Ii 17 CM L R Bl FMr EJ E 20Bc Bc R ___ 7 1 r r 0 0 0 c 0 0 z 0 0 0 a PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 332: ...I rco r iIi0 16 Air conditioning switch 17 Pressure switch on de watering tank Ciro n Iioui 18 Compressor clutch dircoJ c io io 19 Control relay for LH supplementary electric fan 21 ai coiiJiIiwiig 20 Control relay for electric fan 21 cooli ol ridi aio r Idlcr 21 Supplementary electric fan for condenser airco di iooio and water radiator cooliu 22 Control relay for RH electric fan 24 cooIin 23 Ther...
Page 333: ...le 5 High pressure switch on de watering tank 6 Eiectro magnetic clutch for compressor 7 Control electro valve for fast idle and recycling ram WEBER electro valve 8 Control relay for supplementary air conditioning electric fan 9 Control relay for electric cooling fan 10 Ignition coil 11 Idle cut off an carburettor 12 Electric cooling fan 13 Thermal switch for electric cut in on radiator 14 Supplem...
Page 334: ...em is operating This relay with its u i contact cuts off supply to electro valve 9 which therefore produces fast idle DESCRIPTION OF COMPONENTS 1 Heater relay 5taudarcf 2 Air blower Standard 3 Speed control for blower Standard 1 4 Regulating thermostat 5 Air conditioning switch 6 Pressure switch ou d uaI riu tauk 7 Compressor clutch 8 Control relay for fast idie electro valve 9 Fast idie electro v...
Page 335: ... wirinq harness t 1L i F Mr EN riiL ML LI___ Mv _____________________ 11 Mv R 1 Lii EN r i 2 EN Ej EVeER rr 3 1 EN i L j Bl 1 Il Mr Ve FVe R EVe EN EN Bl Bl EJ rh r 4 i r 41 6 r IJ I 1 ii 9 1 _ L_ L Y 8 10 12 14 Ve EMr Bc EMr EJ EJ Bc Bc R Bc Bc rh t4 r Ic y 15 7_ 11 13 Mr Mr I Mr _8 7777 77 7_ 77 77 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 336: ...ni 0 WIRING DIAGRAM FOR THE AIR CONDITIONING SYSTEM j L64 o 8____ EMr IF Ve FMr R FJEN BcFVe II 1 BcBI BcFJFNBI 1 iH 14 12 2 Mv i _______ rl JJ 3oR H 0 co co D 0 0 z c E 0 D J PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 337: ...z 0 18 OPERATION N MA 510 00 b rraun iI 0 f tb fctriudf i S dlfdl 0 from 9 19 5 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 338: ...t front window winders and horn compressor Hcizard warning lamps Stoplamps Clock Winding for relays for front and rear foglamps Front and rear L H and R H sidelamps warriing lamp Number plate lamps Lighting for instrument panel battery meter dock odo 10 Amps Yellow meters Lighting switch Fl Lighting for ignition switch ciqar lighter ashtray water temp gauge and heater controls Map reading lamp and...
Page 339: ...12 V 5 W FL 136 14 Map reading lamp 1 Lightinq f speedo tacho 2 Lightinq for anti theft 1 BA 9 s T 8 4 14 V 5 W switch Lighting for qlove box 1 Liqhting for coolant 1 BA 9s T 8 2 12 V 2 W R 136 34 temp gauge ____________ __________ ___________ ________________________ Instrument punel __________ ____________ warning lamps 16 Lighting for cigar lighter 1 Wedge base din 5 12 V 1 2 W Liqhting for ash...
Page 340: ...r and lighting 4 112 18 Pressure switch 40 65 Ashtray lighting 19 Double relay for irijection control 7 ta 27 66 Radio equip locat f aerial 83 to 85 20 LH electric fan relay nir conditioning 38 67 Handbrake flasher unit housing 97 98 21 Rear foglamp cut out relay main beam 104 to 105 68 Electroriic control unit injection 8 to 25 22 Front foglamp relay 106 107 69 Lighting for pneumatic ou gauge 72 ...
Page 341: ...re 71 Foglomp 105 Coolant temperature 77 Reversung lamp 95 Direction inducator 65 Engine ou pressure 73 Stoplamp 51 Emergency STOP and test button 74 76 78 Sudelomp 105 Hydraulic fluidpressure 75 103 RH number plate lomp 114 Hazard warning lamps 63 104 L H number plate lamp 113 Sideiamps 106 105 Boot lamp switch 86 Direction indicators 69 106 Rear LH lamp cluster Main beam 99 Foglamp 104 Handbrake...
Page 342: ...2 rrr L 15 33 32 14 13 R 1111 1 IM IM IM IM IM C IM IM CICIcJ 34 2 18 3 1 1 1 1 1 15 33 32 14 1 13 5 lC I I lic I Ic lic I C Lic i _L1J liLLLJ I I_ 27 6 7 8 9 10 15 33 32 14 1 131 _1 4 4 2 18 3 20 68 JK 5 16 171 L Bl 1 Di Lft 1 lBc II 1 1 FVe 35 118 ____ LJ 1 If III 31 24 is 24 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 i 1 i 1 i 1 1 1 1 i 1 1 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 920 1 2 3 4 5 6 7 89 301 2...
Page 343: ...EN EN r LJ Ve Bl EJ LJ 58 Ve ___ rTB 11 FBI 74 91 1 J EBcEtr tjj LJ HJJ EJ 1B Ic Bc Bl N J 1TB ri lp J EBIIOI ö64 Jl Bl Mc R Bl Bc R CO CO TB TB TB TB TB TB II IH EN F Ve Mc ER EN EBc 5i ER EN EBc RO Tco 54LL J 1 83i 1 Li_ J L II 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 30 1 2 3 4 5 5 7 8 9 40 1 2 3 4 5 6 7 8 9 50 1 2 3 4 5 6 7 8 9 60 1 2 PDF compression OCR web optimization with CVISION s ...
Page 344: ...rVe _ TB Ve By Bl L 1I1I TT BL DN BN Bl nPriiirr 1i06I02T 1 101 TB TB NI R h By RMr 88fr FV Mv T RADIO 1 L TB jrj M 3to R N LN T 1 Gr N J 1 TB TBTB fl NI M LM UFUF PR By Mr Mr ri 1 4210 40 56 ffl r Gr 1 R 4IJ jtl 3 4 5 6 7 8 9 7Ö 1 2 3 4 5 6 7 8 9 80 1 2 3 4 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 345: ... LJ 3J N t6U iL Ic Ic 06 c3 Bc6 80 ii _____ c N Mv N rnh 841 o85 t 4TB R TB TT TT N Bl M By L_ J T L 73 3 8 r Mv Mv 02 Bl 23f F Ve BG 3 OGe 8 7 1 R 63 LJ 1 NMr OVe OVe ML oj 4 Mv 3 Ve 3 Ve 8 R 861 LjJ Mc 81 FBI FBI fl OVe EVe rhrfi 6465 eflve R Mv Mv 51 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 901 2 3 4 5 6 7 8 91001 2 3 4 5 6 7 8 9 1101 2 3 4 PDF compression OCR web optimizatio...
Page 346: ...OPERATION N MA 510 00 I trrI n t of I o cIr cdl jo dllIio 9 195 Op MA 510 00 b 23 24 WIRING DIAGRAM 9 19 T O 1 CIRCUIT DIAGRAM PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 347: ...z 24 OPERATION N MÅ 510 00 b rr ni f lit itt Irit 1 Iti lqliaIio 4G DIAGRAM 1977 L 51 35 104 00 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 348: ...ARIS RHONE A 14 R 11 0 0 0 0 0 0 z 0 E 0 0 CHARACTERISTICS 7584B 510 2 A 14 R 3 510 4 A 14 R 11 Voltage 14 V Direction of rototion Sco 20 2 fri c d Anti cl ockwise Maximum power from 000 illor Otor 211 740 W 1050 W 1050 W 1120 W Maximum power consumption 3400 W 3600 W 3600 W 4480 W Cut in speed at 14 V 1100 Alternator rpm Resistonce of inductor 4 5 0 3 2 4 5 0 3 2 4 ro 4 0 2 Nominal length of brus...
Page 349: ... 6 1975 and CX 2200 jehicies to temperate climates Belgium France L K Ireland famn ed japan I1ollad Rejin on taly 1976 12 V 45 Ah 225 Amps L 2 type battery 3 All ich des for West Germanv Uislria reece Su tzerland Poland and Yugoslatia 12 V 60 Åh 300 Amps L 3 type battery FULMEN AS 311 M 4 1 i ch ch s co ci climates orua Stieden De n ark and Finland Air co dit o ii ii 0 it on Pc tro IA 1 t e A iiib...
Page 350: ... A 6236 and 450 A D 9 E 1 6 b Current consumedwhen starting at 200 C 150 to 170 A c Current consumed with no bad starter removed 50 A maximum BENCH TEST Use a 12 V 200 40 Ah fully charged battery MEASUREMENTS DUCELLIER 6236 PARISRHONE D 9 E 16 Average torque at 1000 rpm 0 85 daNm 6 1 ft lb 0 83 daNm 6 ftlb Correspondin current 300 A 270 A Torque locked 015 daNm 1 08 ft lb 0 l55daNm 112 ftlb Corres...
Page 351: ...m Cleorance 32 25 mm Nominal diameter of commutator Minimum diameter of commutotor after 30 25 mm rectifying 0 5 mm End float fl exible washer Brushes 680 568 Positive brush reference 680 567 Negative brush reference Maximum force of springs on new 1 5doNm 11 ft lb brushes 15 mm Nominal length 8 mm Minimum length after wear Solenoid 680 592 Reference 0 37 0 02 Resistance of pull in coil Hoat V cf1...
Page 352: ...9 mm Diameter of armature 0 5 mm Clearance 36 5 mm Nominal diameter of commutator 35 5 mm Diameter after rectifying End float flexible washer 2 2 mm Brushes 52 R 92 550 N Positive brush reference Negative brush reference 92 550 N Maximum force of springs on new brushes 1 5daNm 11 ft lb 14 mm Nominal lerigth Minimum length after wear 8 mm Solenoid 0 ED 509 95 631 U Reference Resistance of pull in c...
Page 353: ...375 rpm engine 78 Amps at 6000 rpm alternator 2750 rpm engine 80 Amps at 8000 rpm alternator 3670 rpm engine 2 12 V 53 Amp alternator DUCELLIER 7584 and MOTOROLA 510 2 Cut in speed under voltage of 14 V 1100 rpm olternator speed Output under voltage of 14 V 21 Amps at 1480 rpm alternqtor 680 rpm engine 46 Amps at 3300 rpm alternator 1510 rpm engine 51 Amps at 6000 rpm alternator 2750 rpm engine 53...
Page 354: ...he ignition and immediately switch it back on in order to demognetize 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 of regulated tension and check that the values obtained ...
Page 355: ...f the pinion and the stop 8 This reading should equal c 0 5 to 1 mm If not reset adjusting nut 11 To do this Remove the 3 fixing screws 2 of solenoid 3 and draw it backwards to its maximurn extent in order to prevent the core from turning by means of a screwdriver set in notch a Measure the distance c efter fitting the solenoid 3 each time using the 3 fixing screws 24 Disconn ect battery from sole...
Page 356: ...4 is normally in free position Measure the distance d between the flange of the starter nose at b in the bore of the motor housing and the extremity of the starter pinion This reading should egual ci 30 5 mm maxi If not recondition the starter Connect the inductor supply wre 7 Refit plastic plug 5 see page 3 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 357: ...e hold in winding which is prefe rable smaller current but in this case the care of the solenoid has to be n s in mcfnllrl Iv until it is h d in it In tti v B With the pinion in the forward position iba inp betweeri the extremity of the pinion and the stop 4 must be 0 5 to 1 mm If not actuate screw 3 in order to obtain this conditjon Disconnect the battery from the solenoid _ 3 Check the pinion in...
Page 358: ... brokeri line Euro pean dip type Set the intersection point of this line on the vertiaol point of the screen by turning odjusting knobs 1 and 3 Equalize adjustment sarewing and unsarewing knabs 1 and 3 by the name arnount Vertical adjustment Switah on dipped headlamps Tum the adjustment knob 2 no that the broken line coincides with the upper line of the shaded area on the screen European dip type ...
Page 359: ... lb Correspondinq current 5 5 A max Torque at 20 rpm and 13 5 valts 1 07 da Nrn 7 74 ft lb min Correspanding current 13 2 A max 0 u 0 0 0 z c ii E 0 0 UD 2 Second speed Nominal power 15 watts Speed under no bad at 13 5 valts 70 rpm Carresponding current 2 3 A Torque motor locked at 13 5 valts 1 5 da Nm 10 85 ft lb min Corresponding current 21 A max Torque at 60 rpm and 13 5 valts 0 2 da Nm 1 45 ft...
Page 360: ...b 1 ia7ra n lur 1 s luft 1 ADJUSTMENT OF REAR SCREEN WIPER ARM 76 289 With the wiper motor in the automatic stop position position wiper arm sa that its outer edge is at o distonce of 40 10 mm from the rear screen rubber 7 iv renT SCW N tiiper palle ni ic is synie trka y di idud in e alion lo lite Ion7itiidi ial I vis of lite hody si e 11 corres Jonds lo an angle oj 1150 Tigten wiper arm nut to 0 ...
Page 361: ...FROID 15 or FROID 20 type The air is blown around the channels of a radiator supplied by water fram the engine cooling systern co co 0 0 0 REFRIGERATION 0 1 CHARACTERISTICS ASPERA FRIGO type HG 700 or Compressor SANKYO type SD 508 De watering tank SINGER Condenser CHAUSSON Evapoxator blawer SOFICA Flexible hoses STRATOFLEX and RANCO Refrigerating fluid R 12 Weight of refrigerating fluid 1 kg 2 2 l...
Page 362: ...cessive pressure in the return circuit a pressure switch 6 opens the supply circuit to the compressar dutch Condenser 7 Monufacturer CHAUSSON It aliows the fluid to condense and to release its latent heat to the outside air circulating around the fins It is secured to the front LH side of the engine cooling radiator At the condenser outlet the fluid is in the high pressure liquid state The fluid f...
Page 363: ...n centre console S5 De niisting ond de frosting of windscreen S6 Centre outlet on dashboord Distribution of regulated air Vi Distribution flap between outer and inner air intakes controlled by 0 1 V2 Flap for cutting off outlets S3 S 4 S5 SS controlled by C 2 V3 Distribution flap between outlets S3 S4 and S5 SS controlled by C 2 V4 Distribution flap between outlets S5 and S6 controlled by a lever ...
Page 364: ...mospheric pressure but under the action of the vacuum and flap V 1 via the pneumatic piston blonks off intake E 1 the air drawn in comes from the passenger campartment recycling position NOTE Identification mark for fittinq the one woy valve the outer diameter is reduced on the side of the 3way union V FAST IDLING SPEED CONTROL This cantrol allows for a faster idling speed when the compressor is o...
Page 365: ...oling fan 2 Control relay for air blower 3 Ambient thermostat lacated on evaporator 4 Air conditioning switch on centre console 5 High pressure switch on de watering tank 6 Electro magnetic clutch for compressor 7 Electro valve controlling fast idling speed and pneumatic recyclinq piston WEBER electro valve 8 Control relay for supplementary electric fan for air conditioning 9 Control relay for ele...
Page 366: ...rmal switch 13 controlled by the coolant temperature in the radiator is off Supply to supplementary electric fan 14 olone This is carried out by contacts in relay 8 when its energizing wind ing is supplied The relay winding is supplied when ignition is On uir conditioning switch 4 is off contact on the ambient temperature thermostat 3 is closed Supply to the electro magnetic clutch for the compres...
Page 367: ...s relay with its open contact cuts off supply to e1ectro valve 9 whih 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 Standard 3 Speed control for blower Standard 4 Regulating thermostat 5 Air conditioninq switch 6 Pressure switch on de natering tank 7 Compressor clutch 8 Control relay for f...
Page 368: ...ONTROL 7 1976 L 64 EVe EJ 1 LJ1i I iifii F Mr EN 1 LTJ KEY Standard wiring harness Air conditioning wiring harness 2 I f 4 EVe ER 3 II LJ Mr Ve EVe R EVe EN EN Bl Bl EJ rir 1 r 1 T1 6 1idIsj_4EtJ Je EMr Bc EMr EJ EJ Bc Be R Jc it 1 L1 11 13II 15 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 369: ...ITIONING SYSTEM 0 0 0 z E 0 0 I 71976 10 8_____ FMr1 F Ve EMr R FJEN BcEVe L _____________________ _ 11 1 rijc _ Li JI 1 BcBI BcFJFNBI II liii 14 12 1 2 0 _ Vr ___________________________ i ___ _______ 4 3 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 370: ...ched off The fast idling speed is adjustable by rneans of adjusting screw located on top of the vacuurn capsule on the car burettor NOTE In case the fast idle is impossible to obtain the vacuurn capsule may be moved slacken both fixinq screws on carburettor in order to reduce the clearance at the fixinq point of the rod controuling the first choke butterfly opening 3 Adusting the pulleys Camshaft ...
Page 371: ...OGEV equipment IT IS IMPERATIVE before driving the vehicie to another workshop equipped with the special equipment to carry out the following To leave the blankng 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 temporarily Todrsconnect the supply lead to the electro magnetic compressor clu...
Page 372: ...he refriqerotinq circuit d Never switch on the air conditioninq system if either of the cooling fans are disconnected 1 Dram the circuit NOTE This operation must be carried out in a weil ventiiated room The refriqeratinq circuit must be drained before any work can be carried out on it a Remove piug 7 from compressor intake valve and connect in its place at a flexibie pipe 4 b Flemove pluqs 1 prote...
Page 373: ...n the circuit to eliminate by evaporation any trace of water which would hinder the operation of the refrigerating system In the case of replacing the compressor fully unscrew screws 2 and 3 then screw in screw 2 two turas af ter having connected 1 lexible pipe 4 to the intake valve In other cases see paras 1 and 2 a Connect flexible pipe 4 to the intake valve and flexible pipe 6 from the vacuum p...
Page 374: ...the noise stops when the refill is empty this can be confirmed by shaking the refill NOTE In certain cases heating the refili with ones palms may be insufficient The operation must then be 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 coid and maximum ventilotion positions Switch on the engin...
Page 375: ...tery terminal d Rotate the clutch in order to line up mark a i sih1 ii ro h ii ilI r 0 i i du d lo a cl roi Ibr carn p1at 1 with the axis of the filler opening Then make a mark on the clutch and the compressor casing and then rotate the clutch by approximately 110 clockwise seen from pulley end Disconnect the supply lead from the battery terminal e insert gauge 6009 T into the freed off passage Th...
Page 376: ...ating system consists of the following device to heat the inlet air Kdevice to increase the heating in the pussenger compartment A wuter 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 PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 377: ...e carburettor C Adevice for heating the inlet air by means of the exhaust by having a take off on the exhaust manifold shield ASSEMBLY DIAGRAM C arbu retto r Calibrated orifice for Thermal sensor ir fIter A VACUUM CAPSULE Ii Position of capsule when not under vacuum flap open dos ing plate clas ed L2 Position of capsule under vacuum L 2 L 1 flap closed closinq plate open Flap Closing plate PDF com...
Page 378: ... 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 aliows the supply of warm air to the air filter When the effect of the vacuum ceases the capsule returns to length Li Diagram 2 the flapopens allowing supply of cold air and the clos...
Page 379: ...ion 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 190 C the bi rnetallic 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 190 0 the positions of valves and bi me...
Page 380: ...er distribution box to side vents III WATER TEMPERATURE GAUGE The presence of cx water temperature gauge entails modifyinq the following components water pump spacer oddition of o temperature sensor steerinq column surround location of temperature gauge engine horness for warning lamp senders oddition of lead from temperoture sensor to front wiring hcirness additiori of a temperature sensor and cx...
Page 381: ...1 MOUNTING OF BODY SHELL TO UNDERFRAME L 71 1 0 u c 0 z 0 E 0 0 0 SPECIAL FEATURES Pointz and are guide holes Tightening forques Body shell fixng nuts 1 on rubber pads 2 5 daNm 18 ft lb Rubber pad fixing screws 2 on sidemeinbers 3 daNm 21 1 2 ft lb PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 382: ... max Clearance between boot hd und rear luinp cluster 34 6 2 5 rom Clearunce between team bumper und lower edge of boot hd 35 10 mm ÅDJUSTING THE BODY SHELL COMPONENTS Cleurance between wings und bonnet F 2 5 1L mm 1 Difference between left und right hand sides 2 Smmn mux Difference in hevel between wings and bonnet 2 mm max Flush lit tolerance between wings and bonnet L1 2 mm mux Longitudinal adj...
Page 383: ...indow frames 2 mm max Clearance between side window frames and roof edge J5 7 2 mm Difference in level between window frames and roof 2 mm max Clearance between door and rubber seal fixings 16 14 2 mm FIush ittoIerances Protrusion of eoch component in relation to the one immediately 0 to 2 mm max behind it 2 mm max Continuity of the light line Difference R 7 4 mm Recess of side door window frames ...
Page 384: ...ght adjustments 2 _______ 4 ______ rr i 3 Loosen hinge fixing screws Move the door vertically in order to obtain a cleararice of il 7 2mm between the upper part of the window frume and the roof edging Check the continuity of the light line und the difference in alignment between door and front wing Inset of front door in relation to front wing maximum of 2 mm Tighten the hinge fixing screws and fi...
Page 385: ... 4 2 Trcinsversal and height adjustments Check clearance between upper edge of window frame and edge of roof il 7 2mm Check also continuity of the light line and the recess of the rear door in relation to the front door 2 mm max Laos en upper and lower hinge fixing screws Adjust door to obtain positioning as above Tighten fixing screws of these hinges Secure distance strap by its two screws 3 3 Ad...
Page 386: ...ide trim of ear window on il ur sic c Slacken screws 3 und odjust boot Ud in order to obtoin ot u b a clearance of 0 3 mm ciccironce between reur window und boot Ud J2 6 5 4 mm deaconce between boot Ud ond ear bumper 13 mm by woy of indicution Tighten screws 3 Fix trim and trim fixing screws 2 i tu sidc 3 Ådjustment of lock Loosen acrews 4 and mdcc verticul adjustment to lock in order to obtuin co...
Page 387: ...um diffe ad ust also to obtain clearance between front edge of wings ond bonnet 0 L 0 3 1 i ________ l 3 Adjusting the strking plate Laosen screws 3 Centre striking plate in relation to lock Tiqhten screws 3 4 Adjusting the safety catch Loosen screws 4 Adjust safety catch sa that With borinet resting on caich the lcttter must engage under weight of bonnet oboe Tighten screws 4 5 Adjusting the lock...
Page 388: ...s not crttached to the catch or the cable is broken Introduce tool MR 630 84 21 into the lower front ventilation grille Shiiu a lighi on t c bounni lock Ihrough the radi a or grille Engage the point of the tool inta the lock protection housing 1 from the rear and exert pressure in the direction of arrow F on the catch of the tock in order to unlock PDF compression OCR web optimization with CVISION...
Page 389: ...epartment 1 Repair kit ZC 9 855 128 U This SECURIGLACE outfit inciudes 1 Bottle of abrasive cleaning powder 1 Small bottle of conductive enamel 1 Tube of adhesive 1 Tube of hardener for adhesive 1 Small 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 for ...
Page 390: ... to dry at ambient temperature for approximately 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 weil using the spatula Apply the resulting paste on the conductor enamel deposit overlapping on both sides by 1...
Page 391: ...nq the ou filter cortridge 6401 T Set of 2 grips for adjusting anti roll bor 6501 T _______ iF Tool for hanlbrake eccentric nut 6004 T Union for checkinq nu pressure 6451 T Set of 2 tools for positioning steering orossinember 6009 T Dipstick for checking oil evel on SANKYG Comp ressar PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 392: ...0 bar 0 145 psi Pressure gauge 3085 T Pulley aliqnement rad consisting of the following a 2279 T pressure gauge ci meta1 union A dia 6 min taken rom kit 31 12 T 1 Dial auge mounting Assembly for checking petrol pressure PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 393: ...t to Manual 818 1 ADD 0 MÄNUFACTU RING DRAWINGS FOR TOOLS NOT SOLD Electric system Air conditoning system MR 630 73 15 0 0 0 0 0 0 D NI 2 qrooves PDF compression OCR web optimization with CVISION s PdfCompressor ...
Page 394: ...0 0 1 818 civ MANUFACTURING DRAWINGS FOR TOOLS NOT SOLD Bodywork 1 MR 630_84 21 35 r 6 360 0 0 w 0 0 0 0 z 0 E 0 0 0 0 Red paint SteeL drawn serni hard Developed length 63 PDF compression OCR web optimization with CVISION s PdfCompressor ...
