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PEUGEOT 504 Convertible 1970, Workshop Manual

The PEUGEOT 504 Convertible 1970 Workshop Manual is a comprehensive manual for owners looking to maintain or repair their classic car. This manual covers all aspects of the vehicle's maintenance, ensuring that owners can keep their car in top condition. Download your free manual from manualshive.com today.

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Summary of Contents for 504 Convertible 1970

Page 1: ......

Page 2: ...s to be u d F1ttmg free expanding liners XM K F Gand KFS crig nes Fitting c omprossed linPrs IXM7 XNl and XN2 eng1rns FLYWHEEL Replacing the llywt eel Replac ing tt e staner rmg geaf TIMING Too s to b...

Page 3: ...n valves ln1cct1on pump removal rcf11t1ng ad1usting K F 6 ad1ust1ng KF 5 and XN 2 LUBRICATION Che mg the oil pressure WATER PUMP Re111uva1 rnf1tting Tools to be used Dismantling Reassembly Che k1ng th...

Page 4: ...n number c a letter followed by c gur11s an identification lern r d see table below WARNING In the event of replacement the new cv nj1 r b must be stamr id with the engine number 111 the space prov1dE...

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Page 6: ...ss 1 ENGINE REMOVAL REINSTALLATION TOOLS TO BE USED 8 0102 x Engine hoisting apparatus 8 0208 D Hoist beam E Front hook F Rear hook G Short hook Key for the clutch housing securing bolts 8 0125 Engine...

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Page 8: ...e radiator the ignition coil the starter the windscreen washer bottle Disconnect the heater hoses the fuel feed line the carburettor controls the Master Vac vacuum line the wiring On 504 Petrol Inject...

Page 9: ...using bolts J 0 4 Position the hoisting apparatus as shown opposite locate the hooks 1n the holes marked 404 Raise the apparatus unttl 11 is under load Remove the four bolts securing the engine mounti...

Page 10: ...he housing On 504 Automatic Remove the 4 bolts securing the convenor to the flywheel Disengage the convertor WARNING Never remove the engine with the convertor make sure that the convertor remains att...

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Page 12: ...the two components up exactly On 504 Automatic Secure the convertor housing to the cyh nder block Bring one of the openings in the flywheel to the bottom Rotate the convertor using a screwdriver engag...

Page 13: ...ting the engine check the oil level and top up 1f necessary slacken off the banio 1 with the engine being driven by the starter the 011 should flow freely On 504 Automatic Refill the transmission with...

Page 14: ...page 1211 Checking the cooling fan air gap I0 35 mm 0 014 Adjusting the engine idling page 1201 or 1211 2 73 __ _ _ _ _ _ _ _ _ _ _ _ _ _ __ SPARK PLUGS Carburettor engines For XM XM7 XM and XN 1 U S...

Page 15: ...00 ENGINE TUNING CHECKING THE DISTRIBUTOR Dwell angle 57 2 Dwell percentage 63 3 which corresponds to a points gap of approximately 0 40 mm 0 016 except in the case of S E V Marchal cassette points s...

Page 16: ...1500 2000 600 CENTRIFUGAL ADVANCE M74 L I I I I I I I j I I I I r1 H 2500 2500 17 f Lj I r 1111 I I f I I I I I I I I I is I I I I f i v I I i I 15 I o I I I f I 1 n II L _ __ I I i _ _ _ H I I I I 1...

Page 17: ...PLATE WARNING Make sure that rhe timing llate has not m 1c J It 1n doubt check the setting and 1d1ust as follows Position No 4 piston at T D C Move the timing plate to line the O up with the mark on...

Page 18: ...tension wire Switch on the ignition Rotate the distributor clockwise to fully close the 01ms anticloc wise until the points begin to open spark v1s1ble between them Lightly clamp the distributor Fit t...

Page 19: ...04 u 71 Standards Nl XN2 11 CV eng nes X 5 B T D C on 504 US 70 72 73 Stan dards X 100 B l DC j XM7 IOCV engines on b04 US G Standards or on engines with no timing plate until the mark on the flywheel...

Page 20: ...late Rotate the crankshaft clockwise until the 8 mm rod eng s m the flywheel Pos1tton the d1smbutor as shown oopos1te Conm ct the low tension wire a test lamp 5W bulb Switch on the 1gn1t1011 Rotate th...

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Page 22: ...g rear bearing cap seals C1 Diverse shim plates D 0 5 mm gauge GZ Dial indicator support with C J 7 mm x 100 pitch thread1 ng Apparatus for checking crankshaft end float consisting of 8 0110 GZ Dial g...

Page 23: ...inder liner extractor A or XM engines 0a 83 5 mm Jb 88 mm D or XN 1 XN 2 engines 0a 87 5 mm 0b 92 mm 0 0137 Chain tensioner retaining tool for KF 6 KF 5 md XN2 Cl 2 mm piano wife RECOMMENDED TOOLS Mak...

Page 24: ...ead WARNING Pivot the cylinder head so as not to disturb the liners when removing it Secure the liners using the screws 8 0104 D Remove the cam followers and set them aside in the order of removal the...

Page 25: ...4 Turn the arming screw clockwise 3 mm alien key On KF 6 KF 5 and XN 2 engines Use the pad retaining key Sedis tensioner 5 Turn the ratchet screw a anticlockwise Remove the timing drive components Re...

Page 26: ...l and remove the mechanism Remove the flywheel the crankshaft Recover 1he halt thrust washers 6 WARNING XM ZF XM 7 XN 1 and XN 2 engines are also fitted wtth two thmst washers in the rear main bearing...

Page 27: ...ghts are to be removed mark 1hem precisely before removing them If the cemering bush is worn remove 11 and its seal see class 2 WARNING This bush 1s self lubricating and in order to retain these prope...

Page 28: ...ly with engine oil Crankshaft Fit the counterweights respecting the mm s mad when dismantling tighten the bolts to 6 76 m kg 49 ft lbs bend up 1he tab waslie1s around thP boll heads Screw a 24 x 150 f...

Page 29: ...mly the appwprlate bearing shells and t mlSI washers a M 5 mm must be fitted WARNING 011 XM ZF XM7 XNJ and XN2 engines fit u 2 3 mm thmst washer 2 on each side of the rear bearing cap with the lubrica...

Page 30: ...ze washers Oversize washers thickness available 2 40 mm 2 45 mm 2 50 mm 1nstall the lateral seals 3 on the bearing cap and hold them 1n place using the apparatus 8 0110 W as shown opposite After lubri...

Page 31: ...g the gauge 8 0110 dS a guide Flywheel Clutch WARNING In the e ent of replacement of the flywheel 011 M XM 7 with 10 ignition advance flvwheel a for BA 7 gmrbox flywheel b for ZF transrrussion on XN I...

Page 32: ...stons Fit the liners following the method indicated on page 06 01 to 06 05 class 1 Connecting rods Big end shells original size e 1 812 to 1 818 oversize e 1 962 to 1 968 to be fined when crankpins ha...

Page 33: ...mark on the piston rings must be facing the crown of the piston Fit the piston nng clamp on the piston Insert the piston rod assembly without turning 1t making sure that the arrow is facing the front...

Page 34: ...t m irked AP or US at b is 10 bH used for 69 70 7l and 72 models Emission control standards and yellow valve springs arc to be fitted The camshaft marked XN1 at b and with a shoulder at cl is to be us...

Page 35: ...o the engine When ful ly engaged the slot should be more or less 1n line w ith the cylinder head bolt hole N 7 KF6 KF5 XN1 and XN2 Present the distributor drive as shown oppasite large side facing awa...

Page 36: ...rubber asbestos must be fitted on USA models with a11 alloy sump Fit the four bolts 7 alter smearing the 1hreads with normal holding LOCTITE Tighten them to 1 m kg 7 25 ft lbs Tighten the drain plug F...

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Page 38: ...he carburettor and seal it off the lead n 3 from the coil Drain the carburettor float bowl on XM engines by removing the choke jet on XN1 engines by removing the float bowl plug Lock the throttle flap...

Page 39: ...Decompress the gauge by pressing the poin1 on the tip of the rubber cone Raise the card to the 2nd position and carry out the same operation on N 2 cylinder Check the other cylinder in the same way Re...

Page 40: ...ylinder liner retaining screws 8 0106 z Spark plug spanner 360 mm long 27 5 mm outer diameter of the socket 8 0115 y Set of 2 cylinder head guides BZ Guide screws 8 0129 Double cylinder head bolt sock...

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Page 42: ...n opposite On KF 6 KF 5 and XN 2 engines remove the injector lines protect the delivery valves and injector unions with caps separate the air distribution chamber from the inlet manifold Disconnect th...

Page 43: ...t assembly Remove the push rods and lay them out in the correct order from 1 to 8 Remove the head guide from hole N 8 Pivot the head to separate 11 from the block and cylinder liners Remove the cylind...

Page 44: ...d check the cam followers Remove all burrs trom the face of XN1 XN2 and XM7 blocks Clean the face of the cylinder head 1he cylinder head bolts the push rods check them for distorsion Check the surface...

Page 45: ...sket out of its wrapping at the last moment and only handle it with clean hands XN 1 and XN 2 engines Make sure that the flats b are parallel on liners 1 2 and 3 4 Fit the guide screws BZ Position the...

Page 46: ...P rnckt r shr1ft s11pport n11ts There are rwo methods for tightening rile head On XM engines with free expanding liners Following the order shown opposite pretighten to 6 m kg 43 S ft lbs final tighte...

Page 47: ...socket by pushing on the lower prong of the spring Continue tightening until the pointer 11 is in line with notch 90 on the quadrant Repea1 this operation on N 2 bolt Place the double socket on the o...

Page 48: ...o ftt the inlet manifold 0 nng dry 011 XM and XM 7 engines to clean or replace the air filter element to leave 2 mm of dead stroke on the throttle cable to obtain 2 to 3 stretch of the I in llelt two...

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Page 50: ...t N 1 completely and retighten it to 2 m kg 14 5 ft lbs hold the wrench under tension place the pointer 11 on the 0 notch on the quadrant continue tightening until the pointer 11 is in line with the n...

Page 51: ...30 A40 E10 eu E3Q E D Exhaust ENGINE CYLINDER HEAD RETIGHTENING ADJUSTING THE VALVE CLEARANCES Follow rhe order shown opposite Gaps to be set with the engine cold Inlet 0 10 mm 0 004 Exhaust 0 25 mm 0...

Page 52: ...N B With the head in place Screw the plugs in without their springs to prevent dirt falling into the cylinders Remove the tubes using a mallet or the appropriate extractor WARNING If removed new tube...

Page 53: ...PARK PLUG TUBES Install the tools as shown opposite Drive the tubes in to obtain a protrusion of 72 mm as shown opposite N B With the head in place Blow all traces of dirt or dust out of the tubes bef...

Page 54: ...5 y Valve spnng compressor N B The lever 8 0105 Z can be converted to 8 0105 Y by fitting the hook 8 0105 8 the compressor 8 0105 C TOOLS TO BE REALISED 0 0136 Hinged rod for removing exhaust val spri...

Page 55: ...30 8 mm 66 kg 26 8 mm 33 5 kg since 1no BLACK 30 8 mm 62 kg 26 B mm 31 5 ka REPLACING A VALVE SPRING HEAD IN PLACE I INLET VALVE SPRING WARNING Turn the crankshaft in 1 t s direction of rotation Bring...

Page 56: ...rm from the exhaust valve as shown opposite Insert the hinged rod through the plug hole Turn the hinged rod through 90 Position the notch in the end in line with the valve stem Bring the piston to T D...

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Page 58: ...DER LINERS REFITTING TOOLS TO BE USED 8 0104 D Set of two cylinder liner retaining screws Dial Gauge indicator 8 0110 H Support block 8 1505 Dial gauge 8 0128 Liner compressor apparatus WVIW E CJ llCJ...

Page 59: ...ENGINES The components must be clean and free from impact marks WARNING Do not alter the piston liner pairing Fit the liners without their seals Check the protrusion which must be between 0 and 0 07...

Page 60: ...e flats a on the upper shoulders of liners 1 2 and 3 4 parallel on XN 1 and XN 2 engines Place the dial gauge and support on the block face Set the dial at 0 and 5 Check each liner at A C B and D noti...

Page 61: ...ER Without gasked from 0 036 to 0 06 from O Ql 1 to 0 035 from 0 to 0 010 Negative reading Reference GASKET TO BE FITTED Thickness 0 050 0 075 0 100 0 125 Fit the correct gasket on the liner carefully...

Page 62: ...tween the diametri cally opposed points A C and B D must be less than 0 07 mm If 1t is more find the reason Set the dial gauge at 0 on point 84 liner N 4l Place the dial gauge on point 03 liner N 3 Th...

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Page 64: ...XM KF6 KF5 and XM7 engines Ignition advance 10 with BA 7gearbox Flywheel a with ZF transmission Flywheel b On XN I XN2 engines Ignition advance 5 with BA 7gearbox Flywheel c with ZF transmission Flyw...

Page 65: ...e ring gear REMOVAL Drive the ring gear off away from the clutch thrust side REFITTING Mount the f lywheel on the base clutch side facing down Heat up the ring gear using a blow torch Position the rin...

Page 66: ...BE USED Apparatus for he kmg thr vah1c oi nmg 8 0110 GZ Dwl gauge support Al 8 0504 A 2 8 1504 Support rorl Support D1ill gauge with ll1Q 8 0126 D C feeler TOOLS TO BE MADE 0 0128 T1m1ng housing cente...

Page 67: ...1 Angle on XN1 XM7 Up to October 1972 Angle o Piston Flywheel IStroke mm 1 00 C l 009 36 00 75 440 33 00 76 310 5 30 0 243 1972 Piston XN 1 XM7 Since Oct 72 XN1 USA 1973 I Angle on Piston Flywheel Str...

Page 68: ...R F A or A O E the cylinder head must be removed Set the inlet valve gap on N 4 cylinder to 0 70 mm Install the dial gauges as shown opposite Set the dial gauge A at 0 on the inlet valve spring cup T...

Page 69: ...emove the protector plates and bloc the flywheel with a lever Remove the timing housing Neutralise the chain tensioner spring RenoId tensioner 1 on XM XM 7 and XN 1 engines rerr ve the pll q 2 1 1rr h...

Page 70: ...ng and that the oil galleries are perfectly clean Renold Tensioner KF 6 KF 5 and XN 2 remove the plug 2 lock the tensioner spring and withdraw the retaining tool turn the Allen key clockwise whllr hol...

Page 71: ...t and camshaft Fil a new tab washer on the camshaft sprocket Tighten the bolts to 2 25 m kg 16 ft lbs 81md the tab washer up around the bolt heads RenoId Tensioner Insert the filter Fit the tensioner...

Page 72: ...lable Fit the thrust washer where necessary the oil thrower cup a new l iming housing gasket Centre the housing with the tool 0 0128 and secure tt Fn the woodruff key the crankshaft pulley Fit a new t...

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Page 74: ...1 800 r p m bur by obta111ing an eng1no speed of 825 r p rn for 1969 504 1 carb11rettorl 860 r p m for 1970 504 1_ rt Jre1tors vt er di lf Q n 1h r p screw Z WARNING The setting of the screw situated...

Page 75: ...n a CD c Air Jet 210 on bowl 210 below 210onbowl 210 below 210 1n choke 210below 210 below 210below 210 below choke Lhoke choke choke choke choke Pump 1e1 50 50 50 50 Pump in1ector 45 45 50 45 40 50...

Page 76: ...pump adjusting nut a Correction jet Gg Main jet Gp Pump jet Gs Choke jet g Pilot jet H Acceleration pump valve and filter Pump injector K Choke tube Pr Acceleration pump S Choke lever t Fuel intake fi...

Page 77: ...E Hold the throttle flap open using a rod 1 of 3 mm 34 PBICA 5 for 34 PBICA 7 03 5 mm for 34 PBICA 9 ll4 mm for 34 PBICA 8 6 mm for 34 PBIC 8 6 5 mm for 34 PBICA 6 Slacken off nut 2 completely then ti...

Page 78: ...840 r p rn acting on he stop screw Z Repeat these operat ions until Lile maximum obtainable engine speed 1s 840 r o m Screw the screw W 10 until the engine speed drops to 800 r p m without upsetting...

Page 79: ...rol box to obtain the fast id ling WARNING Earthing of the lead N 83 will lead to immediate damage to the control box Remove the cap 1 Slacken the lock nut 2 Act on the allen screw 3 to obtain an engi...

Page 80: ...mp strok control cam cam cam cam cam cam Progressivity jet 110 100 120 110 100 120 120 120 120 120 Petrol bleed 55 55 55 55 55 55 Air bleed 80 80 80 80 80 80 Progress1v11y slot 7 lx0 6 12 7 1x0 6121 7...

Page 81: ...J 50 a Idling air bleed 80 80 c Idling iet 1n chokel 120 210 120 210 120 210 Jl Calibrated orofice 200 200 Idling air fCt 90 90 90 m Pump in1ec tor 40 40 40 40 1 P mp stroke control Pump n1ector 40 50...

Page 82: ...a Correc11or1 wts l 1xl dl b Ove1flow 1ets hxedl D Sprayers removable E Econost it 1e1 rernov ible gl Pilot 1et 1st cha o g2 Bleed 1et 2nd choke Gg1 Main 1e1 lst choke Gg2 Mnm 1et 2nd choki l H A cele...

Page 83: ...ver the gasket check and replace 1 nt Cessaryl Clean an blow dry t lie cover the idling air bleed holes the fuel filter Check the float level Place the gauge on the cover with tt1e gasket removed the...

Page 84: ...he flo Jt bowl plug W the mixture screw g1 the idl1119 1e1 g2 the 1dl1rig by P JSS Jf I H the accelerauon pump valve I the acct lerat1on pump in1ectors Gg1 he main 1et lst cho c small l Gg2 the main 1...

Page 85: ...opening of the flaps 1 he llCJp in t liP l 1 t hok shouId be open 2 3 mm r freck as sllown oppos11e Ad1ust 1f necessary by benchng lever 4 AIR FILTER 1 Nylon filter element Cti mgP tile element every...

Page 86: ...ADJUSTMENT Make sure that the idling is correctly ad1us1ed the nut 5 on the cam 6 is tight I 1 J Unscrew the screw 7 to obtain a gap at J Screw in the screw 7 until 1t 1ust touches the plunger 9 in or...

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Page 88: ...G Bie Battery A Pr Relay F3 Fuse l A D Ignition switch Feed lines Return lines HYDRAULIC CIRCUIT 1 Fuel tank 2 Fuel strainer 3 Pre filter 4 Electric lift pump 5 Degassing filter water trap 6 Injection...

Page 89: ...ENGINE FEED CIRCUIT KF 5 AND XN 2 ENGINES Feed circuit DESCRIPTION _ _ Feed lines Return lines IA D HYDRAULIC CIRCUIT 1 Fuel tank 2 Fuel strainer 3 Pre filter 4 Electric hft pump 5 Degassing filter wa...

Page 90: ...ic part A E G KF 5 and XN 2 engines Bosch pump 2 Characteristics Feed voltage 12 V Current absorbed 2 3 A Output 50 litres hour at 1 2 bars REMOVAL Disconnect the wires the fuel lines seal them ottl R...

Page 91: ...mp 2 Bracket 3 Support plate 4 Feed ltne 5 Pie filter 6 Line between pre filter and pump 7 Pump ou tlet line 8 rwo way union 9 Fuel return line 10 T union 11 Fuel return line Bosch pump mounting holes...

Page 92: ...line connecttons on the tank the pump feed voltage 12 V 0 1 the circuit for leaks the condition of the pre filter and the degassing filter cartridge Repeat the check and if necessary replace the pump...

Page 93: ...PETROL INJECTION ENGINE LIFT PUMPS Install the pump and realise the var1ousconnections Start up the engine Make sure that there are no leaks WWW EaCJ Cl OrG...

Page 94: ...re are check the tightness of the alien screws on the pump body If the unions leak replace the seals rather than lighten the screws Electrovalve Remove the electrovalve Refit the petrol feed unron Rec...

Page 95: ...B In the event of replacement only use the 2nd fitting filter Bosch BLEEDING Place a 1ec1pien1 under the filter Bleed tre filter through screw 3 WARNING If more than 10 c c of water are recovered remo...

Page 96: ...ocket for bl eding the delivery valves HZ T wrench JZ Pressure gauge K Puller L Feeler for KF 2 M Gauge for KF2 N Feeler P Retaining key R Gauge for ad1usting the pump throttle link S Gauge for settin...

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Page 98: ...class 15 A Nut lor installing thu OU bush B Draw bolt C Throttle spindle retaining nut D Guide for the 2nd bush E Drift for the 2nd bush F Dr1ft for the seals REPAIR KIT 1 Throttle spindle 2 Throttle...

Page 99: ...ion coil the air intake hose the throttle control drum the throttle flap On ZF engines remove the acceleration cable control quadrant Using the spindle 1 drive out the plug 2 and the bush 3 On ZF engi...

Page 100: ...ion und spotlessly clean Use all the parts in the repair kit Fit the bush 1 l on the throttle drum side T1ghten the draw bolt 8 unt1l 1t abuts WWW CJ Cl OrG Lock the spindle 2 using the nut C wllh th...

Page 101: ...tall the bush 4 with the spindle in place bearmg against a lead block Fit the spacer 5 the seal 6 Slacken the lock nut 3 Place a 0 05 mm feeler between the nut C and the housing Screw the nut C down b...

Page 102: ...e Remove the lock nut 3 and the nut Cl Make sure that the spindle rotates freely with an end float of approximately 0 05 mm Fit the nylon seal 7 Pos1t1on the spindle with the countersunk holes a facin...

Page 103: ...smearing weak holding Loctite on the threads Tighten the throttle drum nut to 1 25 m lcg 9 ft lbs I Carry out the various adjustments page 13 31 to 13 361 Refit the accessories On ZF engines F11 the a...

Page 104: ...Cl OrG Remove the in1ector Before checking flush the injector thoroughly by several rapid strokes of the pump Pressure Initial 30 to 38 bars Minimum 15 bars no possible adjustment Sealing No formation...

Page 105: ...3 continues to miss bleed the delivery valve BLEEDING A DELIVERY VALVE Remove the 1n1ector lines Slacken the nut of the delivery valve for the cylinder which is m1ss1ng Switch on the ignition and all...

Page 106: ...hydraulic head thoroughly to prevent dirt getting into the pump Remove the delivery valve Blow out the inside ot the valve recess and pour a few drops of oil in Fit the new valve fitted with its spac...

Page 107: ...new valve assembly valve body 0 nng filter thoroughly Lti1htly o I the O rtng 1 the thrt d 2 Fit the valve hand tighten only BLEEDING Operate the lift pump Sl 1cken off the suction valve until petrol...

Page 108: ...Remove the in1ectoc lines Protect the pump and injector unions Disconnect the fuel feed and return lines from the pump On KF S and XN2 Disconnect the return line from the degassing filter to avoid dis...

Page 109: ...fan belt and alternator drive belt the crankshaft pulley the timing cover the injection pump pulley with the drive belt in place the injection pump WARNING Never bend the belt once removed to form an...

Page 110: ...Secure the rear mounting bracket to the block while holding it up ll Jht against the rear of the pump Tighten to 2 m kg 14 5 ft lbs Fit the two suppart bolts 1n the rear of the pump Tighten to 0 75 m...

Page 111: ...hamber Corrector Atr chamber Air chamber Air chamber e d f 1 b c To j k I m g h n i The remov I of these lines i not euenttel Thermostat intake Thermostat outlet Identification Fast idling air intake...

Page 112: ...e pulley on the pump shaft Rotate the crankshaft backwards through one turn and then check by rotating it through one turn in the normal direction of rotation Tighten the pump pulley nut to 3 5 m kg 2...

Page 113: ...istance between them of 101 5 mm on KF 5 and XN 2 103 5 mm on KF6 T ghten the fuel feed union 5 to 2 m kg 14 5 ft lbs th ret im union 6 to 1 75 m kg 13 ft lbs ino 7 to 2 m kg 14 5 ft lbs the in1ector...

Page 114: ...ing of the various throttle flap positions Position A throttle open at 43 1st adjustment Position B throttle open at 94 fully open 2nd ad1ustment Position C throttleopenat 10 or 12 minimum opening 3rd...

Page 115: ...t the link Locate the rod 8 0112 BE 105 mm 1n the hole in the pump lever and the recess m the pump body Slacken the bolt 2 and remove the lever Insert the gauge 8 0112 S 1n 1hc groove 1n the bc1ttom o...

Page 116: ...e of 1 mm between the drum and the housing Withdraw the g iuge 8 0112 S nd th8 rod 8 0112 BE 2nd ADJUSTMENT MAXIMUM THROTTLE OPENING Engine switclwd off accelerator at end of stroke Slacken the lock n...

Page 117: ...p the reference tac C 10 w11h the lower face F of the b JOS on thi air chamber N B If the idling is not regular particularly with a new engine the mm1mum opening may beset at 12 orbetween 10 and 12 Ho...

Page 118: ...asing the flow of water around the thermostat by closing the tap slightly to stabilise the temperature at 50 C N B Never close the tap completely as the cooling down of the thermostat element will ren...

Page 119: ...Leave the feeler 8 0112 N m place Withdraw the key 8 0112 P Stop tf ie engine Close the tap 011 the thermometer ADJUSTING THE ENRICHENER Slacken the lock nut 9 8 mm spanner Slacken the nut 10 10 mm sp...

Page 120: ...3 Act on the air bleed screw 14 to obtain an engine speed of 800 to 850 r p m Screw it in to decrease the engine speed Screw it out to increase the engine speed Retighten the lock nut 13 WARNING The 0...

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Page 122: ...tion and setting of the ignition distributor spark plugs PREPARATION Disconnect the oil vapou1 recirculation line from the air tilti r lhe t1ir intake hose from the air chamber the water return hose 1...

Page 123: ...dge of the throttle flap is clearly visible Make sure that the nut 4 is tightened to 1 25 m kg 9 ft lbs Chec lung the 1st adjustment Engine stopped A small strip of light must appear as soon as the th...

Page 124: ...n the screw off slowly until the light 1ust disappears Screw it back in one tenth of a turn maximum to obtain a slight clearance the strip of light should just reappear Retighten the lock nut Make sur...

Page 125: ...acting on the air bleed screw St aside a 17 mm open end spanner for the thermostat valve a 10 mm open end spanner for the lock nut ttle key for holding the thermostat rod the gauge S acken the lock n...

Page 126: ...ained by acting on the following two screws air bleed screw 1 to meter the air enrichener stop screw 2 to meter the petrol N B By screwing 2 in the mixture becomes richer by unscrewing it the mixture...

Page 127: ...ure is too lean Screw in the stop 2 c ne qU Jrter of a turn If the engine speed is less than 1 020 Of 950 1 p m the mixture is too rich Unscrew the top 2 one quarter of a wrn WARNING The idling speed...

Page 128: ...p the pressure gauge A in place of the oiI pressure switch The check must be carried out with the oil at 90 C s1art1ng with the engine cold ambrente tempe rature 20 C run 1he engine al 3 bOO r p m and...

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Page 130: ...ing fan brush holder Remove the pump REFITTING WVIW E CJ llCJ OrG Clean the mating faces of the pump and head thoroughly Fit a new gasket Refit the pump and hoses in the reverse order to removal Fit t...

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Page 132: ...4 0 1 015 5 G 0 CIO TOOLS TO BE USED 8 0107 y Tool chest for the water pump AV Jaws for holding the pulley B Impeller extractor C AD seal extractor Tools to be realised 0 0107 Add1t1onal tools for wat...

Page 133: ...emove the pump hub nut Hold the pulley and tap the end of the shaft ro j1sengage the pump body WP RNING Do not lay the pulley on the bronze commutator ring Recover the key Remove the impeller Flemove...

Page 134: ...gs the AD seal and its bearing face 1 n the pump body Check the electro magnet on the fan pulley using an ammeter place the feeler inside the commutator ring so as not to scratch the hrush face clamn...

Page 135: ...11 the bearings on the shaft WARNING The unprotected sides of the bearings must be face to face Pack the space between the bearings with grease Fit the deflector 1 carefully Immerse the pump body in b...

Page 136: ...thP extremity of the shah and the AD seal bearing face Place the seal impeller as embly on the shaft with the splines engaging correctly Engage the as embly fully on the press Check the position of th...

Page 137: ...on a hub with two separate bearings Checking Chock the tan air gap which must be 0 3 mm 10 012 and adiust 1t 11 necessary using the 3 quare head screws 3 Check the operation of lhe fan on the work ben...

Page 138: ...en 1he 3 nuts on the manifold Pos1t1011 1111 front silencer and tighten the clamp 1 the mounting 2 on the torque tube Pos111on the rntt rmed1ate pipe and silencer the ri c11 p ipe Tighten in thP follo...

Page 139: ...Y Assemble the exhaust pipe w1thou1 tightening the nuts Tighten the nuts on the manifold and the clamp 1 Pos1t1on the front silencer and tighten the clamp 2 Pos1t1on the intermediate pipe and slli nre...

Page 140: ...rol REMOVAL REFITTING Tools to be used Removal and Refitting CLUTCH CONTROL Tools to be used Clutch thrust bearing Clutch fork Hydraul c control Supersedu the previous Ummory WWW c J Cl OrG Page 01 01...

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Page 142: ...4 0 1 mm free thickness after it hos been compressed by the mechanism 8 0 l mm compressed under a load of 450 kg t 0 15 mm 7 7 0 30 mm l Clutch housing 2 Flywheel 3 Clutch disc a clutch pressure plate...

Page 143: ...rs 504 AOl l 014 918 504 A02 l 012 920 beginning of series Moster cylinder 1without residual pressure valve and special spring 2 Clutch slave cylinder 4 with special cup 5 and internal spring 6 ensuri...

Page 144: ...I 0 w l J J w Cl CLUTCH REMOVAL REFITTING TOOL TO BE USED 8 0207 Clutch disc centering tool 12 69 I S persecl sheet doss 2 page 0202 504 Workshop Monuol Ref 1212 E www CJ orG...

Page 145: ...neces sary that the some metal thickness be removed on port b of the flywheel receiving the mecha nism in order not to alter the diaphragm tension Position the disc correctly flexible hub towards the...

Page 146: ...bleeding the clutch hydraulic system Thi s rubber comprises A One hose of 7 X 14 X 170 mm P N 1192 02 B One threaded union of the reservoir plug ARC 50 C Two clomps P N 1565 17 TOOLSRECOMMEHDED Descri...

Page 147: ...thrust bearing guide sleeve can be replaced as per procedure indicated in class 3 page 03 11 Removal Remove the thrust bearing by rotating it onti clokwise Re nstol lotion Smear the guide sleeve with...

Page 148: ...ing Pack the rubber cup 1 with grease SI ide clutch release fork 3 from the inside tow ards the outside of the housing Use a screw driver to raise clutch release fork bocking spring 4 Engage the fork...

Page 149: ...f the clutch hydraulic system con be carried out very quickly using ARC 50 and by proceeding as follows Connect the rubber union 0 0204 to the bleed screw and the ARC 50 supply pipe to union 0 0204 Ad...

Page 150: ...ting DISMAHTLIH G RE ASSEMBLY Tools to be used Dismontl 1ng Re assembly GEAR CHANGE COHTROLS Controls adjustment Column gear change lever Floor mounted gear change lever Supersedes the prev 1ous summo...

Page 151: ......

Page 152: ...ON AHO CHARACTERISTICS Speed Reduction ratios 1st 21 15 33 x 35 21 x 21 2nd 33 29 21 x 29 3rd 33 I 26 4th Direct drive 21 19 13 Reverse 33 31 x 19 WWW Ea c J J OrG Ratios 0 2727 0 4608 0 7098 1 0 2669...

Page 153: ...ector control 6 Speedometer drive worm 10 threads WWW iiCJ J orG 7 Reverse gear p1n1on 31 teeth 8 1st gear pinion 35 teeth 9 1st 2nd synchromesh cones 10 2nd gear pinion 29 teeth 11 3rd gear pinion 26...

Page 154: ...REMOVAL REFITTING TOOLS TO BE USED 8 0102 x Engine hoisting apparatus E Front hook G Short hook 8 0125 Engine or gearbox support base 8 0403 s Propeller shaft holding plate 504 Workshop Monuol Rei 121...

Page 155: ...WWW C J ICl OrG...

Page 156: ...cooling system Remove the starter motor securing bolts then free the starter motor without disconnecting it Recover the closure plate On 504 carburettor engine Remove the air cleaner to avoid damaging...

Page 157: ...dy Turn the steering wheel clockwise to disen gage the front pipe and let the pipe assembly rest on the rear crossmember Remove the heat dissipation plate P lace support base 8 0125 under the clutch h...

Page 158: ...he socket by about 10 mm Remove the fourth bolt 2 using a shouldered ol len key of 8 mm across flat Do not unscrew completely Remove both the Allen bolts used for securing the differential under the s...

Page 159: ...ylinder 1 without disconnecting the pipe Remove the counter lever 2 with its rods 3 Disconnect the reversing light switch leads 4 the earth lead 5 on the gearbox the speedometer coble 6 Remove the fle...

Page 160: ...r os possible in order to disengage the gearbox under the tunnel Insert o wooden block between the hoisting cross piece and the radiator in order to pre vent the radiator weight from damaging the hose...

Page 161: ...WVIW E CJ llCJ OrG...

Page 162: ...ion the gearbox and engage the engine drive shaft with the clutch disc without using too much force Secure the gearbox by means of three Allen screws equipped with new Grower washers The tightening to...

Page 163: ...I extension of 8 mm and the torque wrench equipped with a fork extension tighten the fourth screw 2 to 43 5 ft lbs 6 m kg Remove the support base 8 0125 Reconnect the earth lead to the gearbox the re...

Page 164: ...r Refit the exhaust pipe assembly and use a new metol loplas tic gasket Secure the rear attachment 1 to the connecting tube lug 2 as per drawing opposite Ensure that the rubber ring 3 does not turn wh...

Page 165: ...a reversal of the removal proce dure Using 2 pints 1 150 I of ESSO EXTRA MO TOR OIL 20 W30 40 fill the gearbox Tighten the filling plug to 20 ft lbs 2 75 m kg Ensure correct gear selector movement an...

Page 166: ...g J Extension dial indicator finger K Bar safety L Tool stoking M Drift plastic covered NZ Plate bocking hydroul 1c press P Wrench end mainshaft nut R Shells intermediate georshoft bearing re moving S...

Page 167: ...ted on drawing opposite by pressing support brackets 1 against the corresponding pods on the housing Firmly tighten screws 2 Remove clutch release fork 3 clutch housing reversing lights switch 4 Remov...

Page 168: ...the rear Remove al I seven housing securing bolts use wrench equipped with 13 mm long socket Facom J 13 L Remove rear housing using a mallet if re quired Remove all four Allen screws 3 on bearing loc...

Page 169: ...everse pinion using pliers H spring washer 2 intermediate shaft reverse pinion 3 bearing outer race 4 Remove front bearing using plate NZ half shells R Remove and recover front bearing and calibre ted...

Page 170: ...rom 3rd 4th speed synchro nizer without disengaging the dog gear Hold mainshaft in a vice Mork the position and direction of rotation of 3rd 4th speed sliding gear with respect to its hub 5 using a sh...

Page 171: ...upside down narrow s ide is turned upwards Secure safety bar K to shaft end using one of the rear housing attachment screws inserted into the centre hole of the safety bar Tighten to7 2 ft lbs 1 m kg...

Page 172: ...ing 6 needle bearing cage 7 mainshaft 1st speed pinion 8 1st 2nd speed synchroni ier without remo ving sliding gear 9 from hub 10 mainshaft 2nd speed 1l Remove grease from parts 9 and 10 and mark thei...

Page 173: ...utral 11 Engage 4th gear Remove cMecanindus pin from 3rd 4th geor shifting fork 3 RetJrn hift1ng fork 4 to Neutral Remove Locking plug 5 use a Smm Allen key type Facom J235 ET 5 1st 2nd gear fork shaf...

Page 174: ...stvck in the passage vse a 7 mm dia 230 mm long rod to free them Remover locking needle 1 from 3rd 4th speed fork shaft Use drift M to dislodge Spiro 11 pin 2 from reverse pinion shaft 3 and to force...

Page 175: ...ly NEVER USE EMERY CLOTH or CUTTING TOOLS The following ports must be replaced systematically snap rings used on shafts spring washers Mecanindus pins Spiral pin reverse shaft ma1nshaft nut moinshaft...

Page 176: ...lock of parallelism exceeds 0 10 mm Replacing the guide sleeve DISMANTLING Remove snap ring 1 from guide sleeve 2 using a screwdriver Remove guide 2 by forcing it out with a press if required use pla...

Page 177: ...sea I l using o tyre ever resting onbor K Removing the needle bearing Insert plug Al into bearing 2 Press out the Nodello bearing using a press and resting the housing on plate HZ covered with o shee...

Page 178: ...plate HZ covered with a sheet of cardboard drift A1 positioned as indicated on drawing opposite NOTE The rear bearing and the 01 seal must be replaced at each dismantling operation Installing the rear...

Page 179: ...s flush with the housing b Should the boll lock be inoperative remove the plug and check the spring and ball for proper condition replace al I defective parts At each repair operation remove the plug...

Page 180: ...5 w IJ w Q GEARBOX RE ASSEMBLY SCHEMATIC DIAGRAM OF GEAR CHANGE BALL LOCKS AND LOCKING PLUNGERS 504 Worksnop Monuo I Ref 12I2 E WVIW E CJ llCJ OrG...

Page 181: ...ow using drift M Turn the support base on its side so that I drain hole 5 is upwards I Install reverse gear pinion 3 together with shifting fork 4 Direction of fitment as shown on drawing opposite Ins...

Page 182: ...king needle 3 with tallow and insert it in the corresponding housing in 3rd 4th gear change fork shaft 4 Re install the gearbox support base in upright position Install the following inside the housin...

Page 183: ...ange fork 3 with a new Meconindus l pin Rest the housing on its R H side Insert o locking boll into passage 4 this boll must rest against 3rd 4th gear shaft 2 Insert lst 2nd gear shaft 5 until the ccN...

Page 184: ...ess the bearing onto the shaft until it bot toms MAINSHAFT Instol I the following on the mainshoft in the indicoted order mainshoft 2nd gear pinion 1 1st 2nd gear synchronizer hub 2 1st gear pinion sp...

Page 185: ...SHAFT Install the front and rear bearings using drift s Pos ition the following ports rear bearing outer race 1 reverse gear pinion 2 a new spring washer 3 a new snap ring 4 Engage the snap ring into...

Page 186: ...on support base 8 0311 turned upside down Engage drive shaft 1 into the corresponding hole Secure R H housing 2 to the clutch housing using the assembling bolts Tightening torque 14 5 ft lbs 2 m kg Po...

Page 187: ...ween drive pinion and front bearing The measured value should be rounded to the nearest 0 05 mm Example Dial indicator reading 0 58 mm Prepare a stock consisting of the following 1 deflector washer Th...

Page 188: ...gouge B 1n place of the intermediate georshoft front bearing Install the dial indicator finger on finger ex tension J and secure the finger extension to the dial indicator Positron the indicator supp...

Page 189: ...e value should be rounded to the nearest 0 05 mm Example Indicator reading 0 47 mm Prepare a 0 45 mm stock of shims and store it in the location provided in the cover of the chest Remove moinshoft and...

Page 190: ...front port of the gearbox facing upwards Place installing drift S on intermediate geor shaft front bearing and press downwards Rotate the shaft to position the bearings Install the clutch housing and...

Page 191: ...oft bore Rotate the dial indicator one complete revolu tion on the outer race of the rear bearing The out of parallel of the race with respect to the rear face of the half housings must not exceed 0 0...

Page 192: ...ng on beormg t Pre lood ROUND to 2 60 mm 4 52 mm 2 00 mm 2 52 mm 0 10 mm 2 62 mm Ploce the shim required in the location provi ded in the tool chest cover Colibroted odjustment shims ore available in...

Page 193: ...age 5 spacer bushing 6 ADJUSTMENT SHIMS 7 Adjustment N 2 rear bearing 8 with its snap ring towards the rear Bearing 8 shouId be instalied using the press and plate MZ CAUTIOM Do not exceed a force of...

Page 194: ...gear synchronizer hub 2 using the press as for the previous operation if required Clomp this ossombly vertically in a vice Install one new spring washer 3 new snap ring 4 using pliers H and then drift...

Page 195: ...3 page 03 19 Install spring washer 4 and snap ring 5 Place this assembly on the table of the press resting on spacer G SI de installing drift U over the drive shaft with the hollow section of the dri...

Page 196: ...g core that the shifting forks correctly engage the synchroniier rings Install mtermediote georshoft front bearing outer race 3 Lightly smear the mating surfaces of the ho If houstngs with HPerfect se...

Page 197: ...usings must not be out of flush by mor than 0 02 mm lns oll the four assembling bolts and nuts of the half housings Tighten these 4 bolts to 7 2 ft lbs 1 m kg Smear the mating surface of the rear hous...

Page 198: ...st 2 ond fill with greose coot guide sleeve 3 sparingly with Molykote grease Slide clutch release fork 4 from the inside towards the outside of the housing Use o screwdriver to raise clutch release fo...

Page 199: ...www CJ orG I...

Page 200: ...the splines of the control rod 2 should be mcrked An incorrect angular position of the lower lever in relation to the control rod could effect gear selection adversely Lower lever on the control rod...

Page 201: ...k 1 set at the length indicated above Inside the car place the gear change lever 1n the neutral position Under the car unscrew the nut 2 ensure that the selector lever 3 is in the neu trol position ma...

Page 202: ...rol link 2 Cleontheplosticboll joint sockets and make sure that they hove not been damaged at dismontl ing Replace oil defective port Lubricate the boll joints prior to refitting Check and adjust the...

Page 203: ...ink Make sure that the gear selector lever 5 is in neutral Connect the fixed boll socket on the link 1 to the selector jock lever 6 Push the link upwards as for as possible and check the al inement of...

Page 204: ...minimum gap of 10 mm between the console and gear change lever in all the gear positions REMOVAL Disconnect the battery Remove the front seats Unscrew the gear change lever bol I Remove the ashtray Di...

Page 205: ...central nut on the tunnel Check the freedom of the gear change lever in the console m al I the gears Correct the setting if necessary Set the rear of the console on the tunnel Drill the support to 2...

Page 206: ...sed Removal Refitting II DRIVE SHAFTS REMOVAL AND REFITTING Saloons Tools to be used Removal Refitting Convertibies Coupes Tools to be used Removal ReHiting DISMANTLING REASSEMBLY Tools to be used Dis...

Page 207: ...I...

Page 208: ...AL AND REFITTING 4 K1 TOOLS TO BE USED 8 0906 TooI chest for front and rear suspension Kl set of two rear cross member guide rods K2 set of two bors 8 0403 s PropeIler shaft holding plate 504 W orksho...

Page 209: ...e o jack under the cross member left hand support Remove the rear seat cushion Ur lock al I three securing nuts of the cross mnmber Remove the front securing nut Raise the tab lock locking washer Remo...

Page 210: ...move the four Allen screws securing the connecting rod to the gearbox Separate the tube from the gearbox by approx 20 mm Insert the p opeller shaft holding plate 8 04035 between them Using two Allen s...

Page 211: ...ximum warpi ng 0 05 mm P ropeller shaft Place propeller shaft between two centering pin s Usmg o dial indicator check the maximum out of true on the central bearing surface Maximum out of true 0 2 mm...

Page 212: ...ashers Tighten the three Allen screws 1 to 43 5 ft lbs 6 m kg The fourth one 2 should also be tightened to 43 5 ft lbs 6 m kg using the 8 mm male hex head socket and the Facom torque wrench equipped w...

Page 213: ...he floor Remove guide Kl Close the guide hole using the plastic plug Following the order given below install the following parts on the studs the flot washers o new tab lock the securing nuts must be...

Page 214: ...TO BE USED 8 0403 u Tool for fitting the centre bearing into the connecting tube comprising of AZ Impact puller K Puller assembly L Install ing stop M Plate N Adjustment sl iding ring P Guiding ring...

Page 215: ...tool so that the bearing can be pushed by a few centimetres thereby releasing some N01 E The above operation is of great impor tance because due to the relatively small con tact surface of the rockin...

Page 216: ...1mens1on o on the tool between centre bearing lubrication grrove 1 and plate M Bring sliding ring N against plate M ond tighten its attachment screw Us ing engine oil lubricate inside of connect 1ng t...

Page 217: ...I...

Page 218: ...chest for reor hub bearings A Hub retaining tool B Hub carrier extractor consisting of B1 long bolt B2 short bolt BJ thrust plate F Locking punch 10 ___________________________________________________...

Page 219: ...A on the hub Slacken the hub nut without removing it Remove the holding tool Remove the thrust spring 1 the retaining fork 2 the broke pods 3 Open the broke line retaining clomp 4 on the rear arm Remo...

Page 220: ...he suspension arm Use on extension fOf this operation and insert it in the hub hole provided fOf this purpose Remove hub steering knuckle dr1 e shaft assembly using screws 81 ond 82 tool chest 8 0521...

Page 221: ...DRIVE SHAFTS REMOVAL Remove the hub nut l Set aside the washer Remove the drive shaft from the hub knuckle us mg a press if necessary 4 IJ...

Page 222: ...Ensure perfect condition of lateral seal ring 4 on the differential housing Smear the gap between the seal lips with tallow or grease Grease the drive shaft splines Engage hub knuckle drive shaft ass...

Page 223: ...f fitment install the thrust spring in the broke pods arrow facing normal rotation direction of the disc Refit the broke pipe to the suspension arm Install holding tool A onto the rear hub I Tighten t...

Page 224: ...ool C1 Extractor bo It Gl Extractor plate G2 Reversible plate nuts 8 0906 z Tool chest for front and rear suspension J Set of 2 rods for positioning the rear arms on the cross member RECOMMENDED TOOLS...

Page 225: ...the rear arm D1 sconnect the coble from the rear broke end Remove the ont1rol I bar Iink pivot the nuts from the suspension arm pivots Drive the inner pivot out fitting the rod 8 0906 J 1n its place R...

Page 226: ...EFITTIMG e 1 l1J Remove the hub nut Withdraw the drive shaft using the extractor plate G1 secured to the wheeI studs with the nuts G2 and the extractor bolt Cl as shown oppo site if necessary 504 Work...

Page 227: ...at the splines on the wheel end of the shaft with Molykote 321 Engage the shaft in the hub Fit the washer 2 and a new nut 3 Greose the splines on the differential end of the shaft lightly Disengage th...

Page 228: ...r link using a new Nylstop nut without tightening it Fit the holding tool A on the hub Tighten the hub nut to 181 25 ft lbs 25 m kg Lock the nut using tool F Remove the tool A Refit the wheel and tigh...

Page 229: ...DRIVE SHAFTS REFITTING Tighten the antirol l bar link pivot to 33 ft lbs 4 5 m kg Check the oil level in the differential housing and if necessary top up using Esso Gear oil GP 90 WWW Ea llC l orG I I...

Page 230: ...OOLS TO BE USED 8 0403 u e 1J 1 R Propeller shaft tube suppo t Tools to be mode up in the workshop 0 0403 Spacer for removing the journal and bearing pocks 0 0404 Drift for positioning the journal and...

Page 231: ...t of the protector assemblies 5 and 9 can be envisaged after che cking the condition of the tulip 1 or 14 and the journal and bearing packs 4 In effect these con be damaged by the entry of water or du...

Page 232: ...cutters Disengage the cover by topping Iightly with o hammer Remove the tul ip by ra is ing 1t vertically Wheel side jc int Recover the spring and the thrust cup Lower the gaiter os for os poss ible o...

Page 233: ...e punch marks on the shaft as they will disap pear during removeI Remove the protector and the rubber ring Proceed in the some manner for the differen tial side ioint In the event of replacement of bo...

Page 234: ...ear or damage to the nylon stop 13 cut this away with a chisel Remove the retaining washer 12 through the cut in the nylon stop Remove the punch marks from the washer using a small stone Clean and blo...

Page 235: ...not exceed the fol lowing quanf1t1es Differential side 1oint 130 g l Wheel side joint 130 g P N 9 730 28 Direction of fitment Gaiter stop collar a of 10 mm width on the wheel s ide J oi nt cover s Whe...

Page 236: ...m jaws SI ide over the shaft The retaining ring The assembled protector Install the bearing pock on the shaft Drive it down until it abuts using the drift n 0 0404 and o hammer Check that the lower po...

Page 237: ...gr Spread the grease inside the tulip and the gaiter Remove the adhesive tape from the bearing pock On the wheel side cup and the spring should then be placed on the end of the shaft Fit the tul ip e...

Page 238: ...tain the dimension of 88 mm as shown oppos ile Remove the weIding rod without altering this position Differential s ide joint After having inserted the rounded welding rod under the gaiter insert the...

Page 239: ......

Page 240: ...O CHARACTERISTICS REAR HUBS AND HUB CARRIERS Saloons Tools to be used Removal Refitting Dismantling Reassembly Convertibles and Coupes Tools to be used Removal Refitting REAR CROSSMEMBER Tools to be u...

Page 241: ......

Page 242: ...Ratio 0 257 0 264 D1fferent1ol numbering as from 5 A 00001 504 802 504 C02 10 x 37 0 270 Lubricant ESSO GEAR OIL GP 90 Capacity Identification 5 for gear set 9 X 35 1604 AOl A03 4 for gear set 9 X 34...

Page 243: ...1 DIFFERENTIAL IDEHTIFICATIOH CHARACTERISTICS 30 www 3a a ors...

Page 244: ...04 to 7 33 mm 8 Tightening nut 9 Pressure release valve 10 Front oil seal support 11 Front oil seal 12 Pinion front beoring 13 Pinion rear beor mg 14 Spocer 15 Filler plug 16 Drain plug 17 Differentia...

Page 245: ...I WWW c J a OrG...

Page 246: ...02 01 1 doss S DIFFERENTIAL REMOVAL REFITTING 81 504 SALOONS TOOLS TO BE USED 8 0521 z Tool kit for rear hub bearings B Hub carrier extractor including B1 Long bolt 82 Short bolt 83 Thrust plate 504...

Page 247: ...o cor lift Raise the rear of the car and support from under the rear arms as indicated opposite Remove the left hand rear wheel Remove the broke pod anti squeal spring the retaining fork 2 the broke p...

Page 248: ...cket spanner inserted in the hole pro vided in the hub for this purpose Withdraw the hub corrier drive shaft assembly using the bolts 81 and 82 of the tool chest 8 0521 Z positioned diagonally and the...

Page 249: ...Remove the 4 nuts securing the connectingtube to the differential housing Remove the 2 Allen screws securing the differ ential housing to the suspension cross member using the 10 mm Allen socket Disen...

Page 250: ...ller shaft Secure the connecting tube to the differential housing using new Blocfor washers Tighten the nuts to 43 5 ft lbs 6 m kg Secure the differential housing to the suspen sion cross member using...

Page 251: ...0 ft lbs 1 75 m kg Reposition the ant i squeaI spring arrow pointing in direction of rotation of the disc Replace the brake hose on the rear arm Refit the wheel Tighten the wheel nuts to 43 5 ft lbs 6...

Page 252: ...04 CONVERTIBLES COUPES TOOLS TO BE USED 8 0906 z Tool chest for front and rear suspension J Set of two bent rods for positioning the rear suspension arms on the cross member 8 0403 s Propeller shaft r...

Page 253: ...ble from the rear arm and disconnect the coble from the broke Remove the ontirol I bar Iink pivot Remove the suspension arm pivots Disengage the arm from the crossmember using a lever Pull the arm dri...

Page 254: ...ws securing the differ entiol to the crossmember using a 10 mm Allen socket Separate the d1fferent1ol from the connecting tube and wi thdrow the unit until the studs ore op prox 1motely 15mm from the...

Page 255: ...tube to the differential placing new Blocfor washers under the nuts Tighten to the nuts to 435ft lbs 6mkg Secure the differential tothe crossmember us ing new counter plates and Blocfor washers T igh...

Page 256: ...d tighten the nuts to 43 5 ft lbs 6 m kg Fit the wheel trim Raise the rear of the car ond remove the chocks Lower the car and hove two people s1 tin the rear seats to position the flexible bushes neut...

Page 257: ...I...

Page 258: ...ter consisting of Kl Dial 1nd1cotor holder K2 Dial indicator extension rod K3 Long feeler L Apporotus for removing and refitting the drive pinion bearing outer roces including L1 bolt L2 thrust plote...

Page 259: ......

Page 260: ...ically in vice fitted with lead aws Slacken all bolts and assembling nuts of the 2 half housings Remove the front attachment screws of the differential bearing side plates the 6 assembling screws of t...

Page 261: ...slocken nut Turn wrench clockwise H B There is no need to unlock the nut Remove drive pinion holding socket M and pinion nut box spanner N drive pinion nut support plate D Drive the drive pinion out...

Page 262: ...or L4 Support plate D Turn bolt anti clockwise Recover od1ustmenl shims 2 thrust washer 3 Remove drive pinion front bearing outer race 4 using Bolt L1 Extractor L3 Support plate D Turn bolt clockwise...

Page 263: ...f the crown wheel Fit the extractor clomps Hl around the bearing 2 T ghten the Allen screws to 14 5 ft lbs 2 m kg using odoptor H4 Place press pod H2 on the crown wheel m the centre of the bearing Usi...

Page 264: ...pinion bearings Onduflex washers drive pinion nut differential assembling bolts drive pinion oil seal 0 rings ond oil seals of the differential bearing thrust plates Ensure that the front bearing slid...

Page 265: ...SEMBLY ADJUSTMENT DIFFERENT ADJUSTMENTS TO BE CARRIED OUT 1 Meshing distance od1ustment 2 Drive p1n1on bearings pre load adjustment 3 Backlash adjustment 4 Differential bearings pre load od1ustment WW...

Page 266: ...the boIt L1 thrust plate L2 and the nut LS Tighten and apply firmly the prescribed torque Tightening torque 101 ft lbs 14 m kg Oi I the bearings with ESSO EXTRA MOTOR OIL 20 W 30 140 with the exclusi...

Page 267: ...th the rear face of the drive pinion Place dial indicator in holder Kl Pos ition the latter so as dial indicator feeler guide rests on upper surface of feeler A2 Adjust height of dial indicator in the...

Page 268: ...r to be found on the pinion ts for the MESH SET 2 th 1s number is preceded by a letter and the some reference mark also appears on the crown wheel Write down reference marked on drive pinion Refer to...

Page 269: ...eler end onto extension K2 which tn turn should be secured to dial indicator Place dial indicator Kl on front face of drive p1n1on and make sure that exten sion tool K2 face s the marked spline and th...

Page 270: ...ghtening torque 7 2 ft lbs 1 m kg Rotate drive pinion 10 turns anti clockwise Repeat above operation several times unti I nut con no longer be tightened under 7 2 ft lbs 1 m kg With the some spline co...

Page 271: ...06 T hickness of shim 6 80 The shim to be installed in this instance must hove a thickness of 6 80 mm As a shim of this thickness 1s not ovo1loble use the 6 79 one Install pinion into the housing fin...

Page 272: ...necessitates the replacement of the complete oil seal housing F itting o new seal Fit o new oil seal in the housing using tool G Top the tool until it abuts on the housing 1 N B Dip the oil sea in eng...

Page 273: ...s 5 plonet gear shaft 6 with pin holes aligned fit o new Meconindus pin 7 flush with sur face of differential gear housing Loy crown wheel 8 flat on the work bench lnstal I in the fol lowing order the...

Page 274: ...of ESSO EXTRA MOTOR OIL 20 W 30 40 No other lubricant should be used Assembling the differential mechanism Place housing vertically in vice Apply Perfect Seal on machined surface of housing Apply oil...

Page 275: ...tightness of clomp P Tighten rear cover nuts Tightening torque 5 8 ft l bs 0 8 m kg Refit the d1fferent1ol rn the vice in its normal position Install bocklosh measuring tool R horizontally making sur...

Page 276: ...enough to moke 11 obut clockwise In this position the dial indicator indicates the bocklosh between drive pinion and crown gear Note this reading Repeot this operation ot three different points using...

Page 277: ...E SHIMS TO BE INSTALLED ON THE LEFT HAND SIDE 3rd od1ustment Ex Mini backlash 0 38 Thickness of shim 0 38 0 10 0 28 Which 1s 0 30 Remove backlash measuring tool R the dial indicator and the left hand...

Page 278: ...ter bearing race Make sure that micrometer does not rest on both housings Only on the front or the rear Adjust dial indicator setting so as to obtain 1 and O for example Place micrometer on machined s...

Page 279: ...dial indicator needles represents the height of the collar on plate Ex Measurement on plate l 00 Measurement on measuring surface 7 29 Height of collar 6 29 Compare number obtained when measurement on...

Page 280: ...and the housing Secure this housing with 4 bolts fitted with new Onduflex washers tighten to 5 8 ft lbs 0 8 m kg Proceed with final tightening of the eight bolts and four nuts in the sequence indicate...

Page 281: ...20 0 05 0 02 Fit the 6 assembly bolts fitted with new On duflex washers and tighten them to 7 2 ft lbs 1 m kg Refi t the differential on the car following the instructions given in class 5 page 02 05...

Page 282: ...3 Rear hub 4 Broke coliper 5 Broke disc 6 Suspension spring 7 Rear shock absorber 8 Anti roll bar 9 9 Rear suspension cross member 10 Rear cross member support 8 REAR A XLE CHARACTERISTICS In worldng...

Page 283: ......

Page 284: ...e assembling the hub and the bearing including Cl Bolt C2 Nut C3 Thrust pod C4 Extractor D Spanner heed for the carrier nut E Hub seal fitting drift F Punch RECOMMENDED TOOLS Standard FACOM tools Sock...

Page 285: ...DISMANTLING Remove the hub nut Set aside the washer Disengage the drive shaft from the hub carrier using a press if necessary Clamp the hub carrier assembly in a vice fitted with soft jaws Unlock the...

Page 286: ...ody the bolt Cl into the extractor C4 Tighten the bolt Cl until the hub 1s comple tely withdrawn Remove the extractor C4 Set aside the thrust pod C3 Remove the double bearing using nut C2 and the pres...

Page 287: ...uter races Grease the bearing with ESSO MULTI PURPOSE GREASE H H B All new bearings ore delivered by the Spare Parts Departement with a nylon ring 1 inserted to maintain the two parts of the bea ring...

Page 288: ...until it comes into contact with the bearing Thread the extractor C4 onto the bolt Cl Place the spanner head D on the knuck le nut Insert the bolt Cl fitted with the extractor C4 into the knuckle and...

Page 289: ...he hub in the knuckle using the bolt Cl and screw this down until the hub abuts on the bearing Coat the splines of the half shaft with moly kote 321 Insert the half shaft in the hub knuckle assem bly...

Page 290: ...Cl bolt C2 nut C3 thrust pod C4 extractor D Hub corrier nut spanner head E Drift for fitting the hub oil seals F Locking punch C1 Extractor piate C2 Reversible nuts RECOMMENDED TOOLS Standard Focom to...

Page 291: ...holding tool A Slacken the brake hose nut 1 and disengage the hose from the support lug Open the clamp retaining the hose on the arm Disconnect the hand broke cable from the rear arm Remove the anti...

Page 292: ...the hub disc assembly the thrust pod CJ the bolt Cl Leave the extractor C4 in place Remove the 4 Allen screws securing the hub carrier to the arm PIace the extractor pi ate B4 on the arm using two of...

Page 293: ...d the nut C2 as shown opposite Hold the nut C2 using a 40mm open end spanner T1ghten the bolt C1 untiI the hub abuts ogoinst the bearing Remove the nut C2 and the bolt Cl Refit the drive shaft class 4...

Page 294: ...MBER TOOLS TO BE USED 8 0906 Tool chest for front and rear suspension J Set of 2 bent bars for positioning rear arms on the cross member K1 Set of 2 guide rods for the rear cross member K2 Set of 2 ba...

Page 295: ...ct with it Remove the rear seat cushion Unlock the three nuts securing the cross member Remove the front securing nut Raise the tab lock and remove the plastic plug from the guide hole Screw into the...

Page 296: ...raighten the hand broke coble stop tongues on the relay arm Slide the coble sideways out of the arm Remove the lever arm assembly Remove protector covers and withdraw the broke cables from their respe...

Page 297: ...e the rear wheels Remove the inner rear arm articulation pivots Insert in their place the 2 bars 8 0906 J Then remove the outer articulation pivots of the rear arms Remove the bars 8 0906 J Disengage...

Page 298: ...ember so os to release the bors K2 maintaining the cross member suspen ded from the floor of the car Remove the bars K2 and the guides K1 Raise the bodywork until the guides Kl disen gage completely R...

Page 299: ...Engage the guides in their respective holes in the outer s idemembers of the car Raise the cross member in such a way as to enable the insertion of the 2 bars K2 in the guides Kl from inside the car...

Page 300: ...ab locks the six nuts must be tightened either at 29 ft lbs 4 m kg up to the serial numbE rs mentioned below or 47 ft lbs 6 5 m kg as from the same serial numbers 504 AOl 1 005 546 504 A02 1 003 649 5...

Page 301: ...hoses to the supports on the rear floor Refit the rear wheels Raise the reor of the car and withdraw the chocks Tighten the rear wheel nuts to 43 5 ft lbs 6 m kg Seat two people in the rear of the ca...

Page 302: ...osition a ock under the rear cross member support in contact with it Remove the rear seat cushion Unlock the three cross member securing bolts Remove the front securing nut Raise the tab lock and remo...

Page 303: ...member Remove the guide Kl Then remove the cross member support Remove the intermediate support in light alloy together with its rubber blocks If necessary replace the rubber blocks using new Ondufle...

Page 304: ...by bending the tab tongues over the nut Fit the guide Kl to the crossmember support Place o jock under this support and raise it unti I the three crossmember studs ore com pletely engaged Remove the...

Page 305: ......

Page 306: ...ds for positioning the rear orms on the crossmember 8 0907 Tool chest for front ond rear rubber bushes G Fitting and removing support for rear arm bushes H Fitting cup for rear orm bushes J Drift for...

Page 307: ...so that the shock absorber is not fully extended Remove the shock absorber Remove the flexible hose from the lug on the rear arm by slackening the nut on the hose Unclip the mounting 1 of the handbrak...

Page 308: ...REAR AXLE REAR ARMS Unscrew the rear arm pivot nuts Lower the jack carefully until the suspension spring is fully extended Remove the spring and its upper rubber cup Withdraw the rear arm pivots Remov...

Page 309: ...okes on the crossmember Retain the inner articulation using the bar 8 0906 J and insert the outer pivot 2 in its housing Then insert the inner pivot 3 in the correct direction of fitment Fit the new N...

Page 310: ...g nut Fit the shock absorber ithout t ightening the lower securing nut Tighten the upper shoek a Lsorber nut to 9 ft Ibs 1 25 m kg Lower and remove the jack Fit the rubber washer and metaI cup on the...

Page 311: ...eel trim Seat two people in the rear of the car to neutra lise the position of the flexible bushings T1 ghten with a torque wrench the lower shock absorber nut to 33 ft lbs 4 5 m kg the rear arm pivot...

Page 312: ...ear shock absorber rod holding tool 8 0907 Tool chest for front and rear rubber bushes G Thrust tube for rear arm rubber bushes H Cup for f1tt1ng the rear arm rubber bushes J Drift for removing the re...

Page 313: ...class 5 page 14 12 and 14 13 Place a jock under the arm and raise 1t until the shock absorber is no longer on maximum ex pansion Remove the shock absorber on Convertib les use the box spanner 91 and t...

Page 314: ...w Blodor washers T ighten the Allen screws ta 19 ft lbs 4 m kg Fit the hub in the carrier using the bolt Cl and the nut C2 as shown opposite Hold the nut C2 with a dO mm open end spanner Tighten the b...

Page 315: ...es correctly Fit the shock absorber installing new rubber washers and a new metal cup and Nylstop nut Tighten the upper nut to 9 ft lbs 1 25 m kg Fit the bottom pivot without tightening it On Converti...

Page 316: ...bushes neutrally Using a torque wrench tighten the arm pivot nuts to 47ft lbs 6 5 m kg the Ol ltiroll bar link nut to 33ft lbs 4 5 m kg the shock absorber link pivot nut to 33 ft lbs 4 5 m kg the nut...

Page 317: ......

Page 318: ...the bush with the cutter L Removal Cl 1np the rear am in o vice fitted with soft jaws Use the cutter L in a drill with a maximum speed of 600 r p m Cut the bush either dry or using broke fluid progre...

Page 319: ...und inside the support G REFITTING Smear the new bush and its housingwith tallow Place in order on the press base the support G in the opposite position to that of removal the new bush together with t...

Page 320: ...to be used 04 01 Removal refitting 04 03 Dismantling 04 04 Re assembly 04 05 FROHT TRIANGLE ARMS Tools to be used 06 01 Dismantling of the triangle rear arm 06 03 l Re assembly e f the triangle rear...

Page 321: ...www 3a a ors...

Page 322: ...k TOE IN CAMBER ANGLE CASTOR ANGLE SWIVEL PIN INCLINATION 2 CHARACTERISTICS Car in working order THEORETICAL STEERING ANGLE INNER WHEEL THEORETICAL STEERING ANGLE OUTER WHEEL 3 mm 1 mm 0 3a 30 2 40 J...

Page 323: ...I...

Page 324: ...o clomp nuts on the adjustable track rod l Hold the boll 1oint 2 in position with its two flats HORIZONTAL using o 14 mm open ended spanner Screw or unscrew the track rod l to obtain o toe in of 4 5 m...

Page 325: ...I...

Page 326: ...s 8 0803 Tool chest for disc brakes F Plug rod for the broke master cylinder 8 1101 Apparatus for hold 1ng the front mechanical components comprising of A Crossbar for holding the front tr iangle arms...

Page 327: ...I...

Page 328: ...rod 8 0803 F into the hollow master cylinder securing bolt and screw it in completely to prevent draining the broke flu id system Mork the rock pinion 1 opposite the bolt 2 on the flector col Ior Rem...

Page 329: ...oss member Raise the front of the cor carefully with a Pulley usmg o hoist chain mounted on the I jack guides unti I the four pivot holes of the front axle coincide with the holes on the appa I rat JS...

Page 330: ...an ces Free the pipes from the mounting lugs without disconnecting them Place the support opporotus 8 0125 on the side members Ensure the correct pos1t1oning of the lifting pod 3 under the clutch hous...

Page 331: ...lts securing the top spring mountings to the wing valances Raise the front of the car carefully to enable the withdrawal of the front suspension assem bly Link the front suspension springs using the c...

Page 332: ...Guide the upper spring mountings into their respective pos1t1ons Secure the suspension elements to the wing vo lances using new double toothed washers ond tightening the six bolts 1 to 7 2 ft lbs 1 m...

Page 333: ...m its mounting points Remove the holding apparatus A Secure the engine to the main cross member tightening the four bolts fitted with new Gro wer washers to 33 ft lbs 4 5 m kg Remove the engine gearbo...

Page 334: ...axle has been dismantled Reconnect to the 4 way union the mom fluid feed pipe the rear broke Imes Secure the broke flexi bi e hoses to the lugs on the front wing valances Reconnect the collar to the s...

Page 335: ......

Page 336: ...the outer race of the exterior wheel bearing 2 race thrust face 0 0601 B Thrust plate for removing the outer race of the inner wheel bearing 2 race thrust face N B The numbers 1 and 2 should be s tomp...

Page 337: ...0518 4 chamfered angle 1 618 0 N 2 46 1 __ __________________ chamfered angle 0 __ 5_ 6____ i 0 M 0 0601 D Hvb thrust block 1 thrust face for hub exterior 2 hrust face for hub interior 0 0601 E Drift...

Page 338: ...le shoulder Fit the washer the inner shoulder 2 against the inner race of the bearing Fit new nut 3 and pre tighten to 22 ff lbs 3 m kg Slacken the nut and tighten finally to 7 2 ft lbs 1 m kg Lock th...

Page 339: ...the outer race Place the hub on the block D on the side with the largest diameter Remove the bearing and oil seal using the dr 1 t C preferably in a press Outer bearing Insert the plate A in the hub...

Page 340: ...es os well os the boll cages ore paired and this pairing must not be altered Outer bearing Insert the complete bearing in the hub using the block D the drift E a press W1thdrow the 1nner race Inner be...

Page 341: ...I...

Page 342: ...ecuring nut N B The tools 8 0906 C D F N already xist for the 404 and Associated vehicles under references 8 0902 N M Al and K They re not delivered with this tool chest bvt a place is provided for th...

Page 343: ...I...

Page 344: ...lomp the assembly 1n o vice Remove the hub nut cop the hub nut Withdraw the hub broke disc assembly Remove the three bolts 1 Recover the grease nipple protector 2 the disc protector plate 3 the broke...

Page 345: ...l joint securing n1 it wrth the castled socket F Remove the triangle rear arm using the extrac tor B Romove from the arm the extractor B the protector boot and its spring clip the lower cup the steeri...

Page 346: ...ce d the steering swivel boll joint stem rubber protector 1 Spr ng clip 2 Upper boll joint cup 3 Steering swivel bol I joint head 4 if necesso ry Lower boll 1oint cup 5 Boll joint nut 6 Closing nut 7...

Page 347: ...ecuring nut to 33 ft lbd 4 5 m kg using the castled socket F Lock the boll head securing nut using the punch P Position the lower nylon cup white 10 mm thick on the boll head Fit o new closing nut Tig...

Page 348: ...5 m kg Lock the bolts with a punch mark on the threads protruding from the steering swive I Place on steering swivel the hub broke disc assembly Fit the washer with the inner shoulder against the inn...

Page 349: ...I...

Page 350: ...atus and recovell the si lentbloc REFITTING Smear with tallow the outer face of the silent bloc and the bore of the triangle arm Place on the bolt A the following the drift C as shown opposite the sil...

Page 351: ...upport side and on a parallel axis to 1 his In case of faulty positioning fit temporarily the triangle front arm tighten the nut and correct the position of the silentbloc using the arm as a lever On...

Page 352: ...ING THE TRACK ARMS Secure the gouge to the stub axle ond check horizontally the porollelrsm of the track arm eye wrth the gouge vert colly that the hole in the gouge lines up perfectly with track arm...

Page 353: ...I...

Page 354: ...ACK Tools to be used Dismantling Re assembly Adjusting Tools to be used Replacing the flexible bushes TRACK ROD BALL JOINTS Tools to be used Dismantling Re ossembly STEERING COLUMN Removal Ref1tt1ng W...

Page 355: ...I...

Page 356: ...ox 2 32 tooth rock 3 7 tooth pinion 4 R H track rod 11 5 l H track rod adjustable tn length 6 Cordon jointed steering column 7 Gear change control arm 8 Anti theft steering lock support 9 Steering whe...

Page 357: ...I...

Page 358: ...0 w IJ w Q STEERING GEAR REMOVAL REFITTING TOOLS TO BE USED 8 0703 w Tool chest for the steering gear E Trock rod ba 11 joint extractor 504 Workshop Monuol Ref 1212 E...

Page 359: ...ng the extractor 8 0703 E Remove the steering column flector assembly bolt the two AIlen type screws securing the s eering box to the cross member Insert a 6 mm centre punch 1 in place of the f ector...

Page 360: ...the steering box straight ahead position Connect the track rod boll joint on the oppo site side to the steering wheel temporarily Rotate the steering flector 1 4 of a turn to align the flector clomp w...

Page 361: ...ft lbs 1 m kg and lock by spreading the end of the bolt Reconnect the track rod boll joint on the stee ing wheel side checking the alignment of the 2 flats on the boll joint housing and the connectin...

Page 362: ...BE USED 8 0703 w Tool chest for the steering gear G Dial indicator mounting including Gl Dial indicator holder G2 Dial indicator feeler extension H Tool for replacing the pinion bush including Hl Dri...

Page 363: ...e stde to the pinion clomp the rock directly in the vice litted with aluminium 1ows to slacken the lock nut the rock plunger retaining plate with its grease nipple and nylon stop the plunger spring th...

Page 364: ...rts the pinion bearing the pinion bush the flexible bush together with its rubber rings nylon plunger spacer rock rubber boots and clips Replace at each dismantling the pinion nut the bearing sealing...

Page 365: ...p Insert in the housing in the opposite end to the pinion the inner thrust washer 1 he flexible bush equipped with its two rubber rings 2 the outer thrust washer 3 the circlip 4 Grease the rock and fl...

Page 366: ...re with the nut lock ing groove 1 facing owoy from the plunger housing Starting from the vertical pos 1tion of the pinion flange rotate it to the left through opp 200 Push 1 n the pinion unti I it abu...

Page 367: ...ted with soft jaws Fi o new nut and tighten to 11 ft lbs 1 5 m kg Lock the nut by topping the nut collar mto the groove on the pinion Grease the bearing housing with ESSO MULTI PURPOSE GREASE H Fit th...

Page 368: ...ial 1ndico tor and position it 1n contact w1th the plunger through the threaded hole in the plate Slide the rock from one side to the other of the steering box using the pinion The hands of the dial i...

Page 369: ...ated using od sting wos iers Use the smallest number of washers possible The e washers ore ovoiloble in 3 thicknesses 0 10 0 20 0 50 mm Final adjusting of the plunger Tf e rock plunger must hove a fre...

Page 370: ...n its hous ing in the steering box Secure the thrust plate assembly us ing the two 7 mm dio bolts equipped with new Blocfor washers Tighten the 2 bolts to 7 2 ft lbs 1 m kg Grease the plunger with ESS...

Page 371: ...y the rock C lo np the rock in a vice fitted with al uminium jaws Tighten the lock nut to 25 ft lbs 3 5 m kg ensuring the complete immobilisation of the eye Pos 1tion the yoke of the track rod on the...

Page 372: ...shape Pre adjustment of the pinion side track rod Adjust the distance between the shoulders of the yoke and boll joint housing to 180 mm Equalise the distance between the shoulders and the adjuster r...

Page 373: ...lange Centre the rack in relation to the steering box to the straight ahead position Fit the clamp to the fleeter using the reference mark made whilst dismantling In the straight ahead pos1t1on the bo...

Page 374: ...RACK TOOLS TO BE US ED 8 0907 Tool chest for front and rear flexible bushes M Removing refitting ba se for the steering rock s ilentb locs N Removing refitting drift for the steering rock eye silentbl...

Page 375: ...ift N with the smaller diameter facing the eye lower the press piston until the silentbloc falls into the bose M Refitting a si lentbloc Smear with tallow the outside of the silent bloc and the inside...

Page 376: ...RING GEAR TRACK ROD BALL JOINT F J TOOLS TO BE USED 8 0703 w Tool chest for the steering gear F Appo1atus for fitting ball 1oint spring clip including Fl Clamp F2 Drift 504 WorkshopManuol Ref 1212 E W...

Page 377: ...ll heod 2 th upper steel holf cup 1 RE ASSEMBLY Plo e the steel holf cup 1 in the bottom of the boll joint housing Place in pos1t1on th boll heod 2 the nylon holf cup 3 the new Bellev lle woshers 4 no...

Page 378: ...e control rod 1 the selector rod 2 from its lever Remove the bolt 3 from the flector Remove the lower shell from the steering column Move upwards the clip 4 which retains the pin assembling the gear c...

Page 379: ...i theft lock wires the 3 connectors on the steering column wir ng harness Remove the 2 bolts securing the handbrake lever support under the dashboard Remove the 4 bearing nuts of the column under the...

Page 380: ...ithdraw the lower bor of the steering column os for os possible ond disengage it towards the interiOI of the cor Remove the hond broke outer coble stop clomp to enoble the withdrowol of the hondbroke...

Page 381: ...ing the steering column closing plate to the scuttle Disengage the hand brake lever support from its securing studs to enable the freeing of the closing plate Remove the lower gear change control asse...

Page 382: ...nuts to 7 2 ft lbs 1 m kg Re connect the gear selector and change con trol rods to their respective levers ensuring the correct fitting of the nylon bearing on the boll head of the control rod Secure...

Page 383: ...mn Using new star washers fit and tighten the 4 nuts securing the steering column under the dashborad to 7 2 ft lbs 1 m kg Fit a new Mecanindus pin to assemble the gear change control rods Pos1t1on th...

Page 384: ...k 1t by spreading the protruding end of the bolt Secure the hand broke lever support under the dashboard Re connect the battery and reset the clock Check the operation of the lighting the 1nd1 cotors...

Page 385: ...I...

Page 386: ...and derivatives DISCS DRUMS Rect1ficat1ng of discs and drums Tools required Front disc replacement Rear disc replacement disc bolted to outer face of hub disc bolted to inner lace of hub 1st assembly...

Page 387: ...s Long models HYDRAULIC LINES Gland TI L link controlled compensator spring controlled compensator Instructions to be observed connections and layout flexibles hoses pipework HANDBRAKE Remove Refit ma...

Page 388: ...and high temperatures severe braking free1ing point llow Winter temperatures in cold countries Chemie illy inert inhibitors prevent corrosion of metals and the attack of Joints and seals For this reas...

Page 389: ...an axle MUST be replaced EVERY 6 000 miles 10 OOO km Adjust rear brakes long models Check and final adjust handbrake EVERY 12 000 miles 20 000 km 504 with rear drum brakes Dust out drum and shoes Chec...

Page 390: ...ressures and pressure drop A pressure gauge 8 union 1 security clip for use with union 2 P O 9787 07 RECOMMENDED TOOLING Testarc 50 apparatus for measuring low pressure and high pressure with 1 securi...

Page 391: ...n the fluid in the receiving vessel Install brake depressing fixture Screw the knurled nut a until the slots b are obsl ured and then continue screwing a further 10 turns Wait a few movements to allow...

Page 392: ...7 bars There should be no fall in pressure after an interval of 15 minutes If there is check for leaks around cups and seals Trace rectify and re check N B Leakage through the main cup of the master c...

Page 393: ...e the lJnion 1 inside which 1s a v lve CALIPER MOVEMENT Connect pressure gauge A to a bleed hole Replace the outer pad with a used pad 2 I Gently operate the brake pedal I Th calipers should operate a...

Page 394: ...lifting tackle including A Cross piece B Hool 8 0801 Key for adjusting rear drum brakes 8 0803 w Tool kit for disc brakes E Fixture fo1 actuating the pistons F Master cylinder plug G Key for positioni...

Page 395: ...by the cross member at the front by the rear 1ack1ng points Remove the wheels Slacken the hanrJ brake Drain the reservoir Remove the pads Retract the front pistons WARNING Ensure that the screw in fix...

Page 396: ...linders for leaks Shoes to be in position of maximum retraction 1 Long models 2 504 L Replace the drums Re drain the reservoir Drain the wheel cylinders WARNING Do not dram the rear wheel cylinders on...

Page 397: ...proportions Slowly refill the reservoir ensuring that the level 1s maintained during operation of the system Slacken a rear bleed screw P imp the brake pedal depressand releaseslowly until its complet...

Page 398: ...screw Slowly release the clutch pedal Repeat this o eration until the fluid runs clean Bleed the brake system see page 02 22 Adjust rear brake shoes of long models see page 02 32 handbrake it necessa...

Page 399: ......

Page 400: ...brakes of long models 8 0803 w fool I it tor disc brakes E fixture for movement of pistons G key for J oslt1oning rear disc brake pistons 8 1507 Rear ltftrng tackle including A Cross piece B Hook 18 4...

Page 401: ...kheed 55 Nafic FN3 Peugeot These fluids can be admixed in any proportions Procedure for bleeding valid in 111 cases Ensure there is sufficient level of fluid 111 the reservoir Release the handbrake Pr...

Page 402: ...nsert piston actuating fixture G in slot Actuate brake pedal several times the piston should travel to its maximum Bleed each wheel cylinder accordingly Replace pads see page 03 OG Proceed to bleed th...

Page 403: ...oes of rear drum brakes of long models see page 02 32 the handbrake if necessary see page 02 31 Check system for leaks fl Jid level in reservoir braking efficiency clutch operation Tightening torque b...

Page 404: ...ndbrake Slacken the equalising arm nuts Tighten ad1ust111g nut to give 1 to 1 5 rnm flexing or the spring w 1sl111r 3 Hold ad111st1rig nut in position and tighten lock out 11 Handbrake mounted between...

Page 405: ...only just revolves freely HANDBRAKE ADJUSTMENT WARNING handbrake must be fully released the system bled actuate firmly the brake pedal a number of times engine running the shoes should now be in adjus...

Page 406: ...506 8 1507 fa 8 0803JI _ 1 TOOLS REQUIRED 8 1506 Front lifting tackle 8 1507 Rear rifting tackle consisting of A Cross piece B Hook 8 0803 w Disc brakes tool kit E Piston actuating fixture G Key for p...

Page 407: ...the cross member the rear by the 1acking points Hemove the wheels Reduce fluid level in the reservoir to the minimum FRONT CALIPERS Remove pads P 1sh back pistons as tar as they will 1ravel WARNING En...

Page 408: ...at a Fig Ii Cahpcr MK Ill chamfered d a PRECAUTIONS TO BE TAKEN IMPORTANT To prevent the seal 1 being displaced by the piston 2 put into position used pad 3 Clean the caliper assembly anci d1sC with m...

Page 409: ...in place Ir necessary check caliper movement see page 02 08 Chuck condition of the disc If necessary check run out maximum O 0028 0 07 mm see ages 06 06 or 06 13 IMPORTANT Adjust the compensator if pa...

Page 410: ...k Ferodo 2430 pads can be used m place of NS 414 or F 737 or mixed pads always provided that the n ar and offside cahpers on any axle are fitted with the same grad of pad Protect the pads with masking...

Page 411: ...rodo EP 24 ID 5 clip 3 pressure spring 4 eturn spring 6 Rear calipers type MKlll chamfered at b pajs 7 clios 8 pressure sprinq 9 return srnng 6 Fit rhe pressure springs with arrow or hole towards the...

Page 412: ...ke pedal several times engine running until strong resistance is obtained FINAL OPERATIONS Check amount of travel of the brake pedal on 504 derivatives if necessary adjust the brake shoes amount of tr...

Page 413: ...www 3a a ors...

Page 414: ...ty is encountered when removing a 504 L drum Remove plug 1 Push the brake lever w11h a screw driver to release it from the stud 2 Shoes will then be fully retracted Dismantle the drum Use key LI for t...

Page 415: ...lever with return spring a 4 Leading shoe front ength 267 rn m 1 xtar V 643 lining width 45 m rn 5 Ad1ustm9 Pver 6 Pull off springs 7 r1wl 8 P 1wl spring 9 Shoe retaining sprrn JS 10 Hmdbral e cab e I...

Page 416: ...g 1 Wheel cylinder 22 m m dia 2 Pull of springs 3 qnk 4 Leading shoe front Lining Textar V 643 dgt 5 Lateral retaining clips 6 Segment retaining springs 7 Handbrake cable 8 Handbrake lever 9 Trailing...

Page 417: ...I...

Page 418: ...aced when its thickness 1 s less than 12 75 mm 11 25 mm 10 75 mm 2 Run out maximum perm1ssable in relation to hub fao i 0 05 m m NOTE After fitting to vehicle maximum run out is 0 07 m m 3 Variation i...

Page 419: ...I...

Page 420: ...s A Hub holding fixture m 2 parts C Device for rcrnovmy ttncJ refitting thP disc hub tornprismg C1 special bolt C2 special nut C3 thrust pad C4 Extractor D Spnnner head tor hub c irrier nut F LPt king...

Page 421: ...I...

Page 422: ...y Separate hub and dis Clean thoroughly Check the hub bearing before replacing REFITTING Assemble hub and disc ensure 1ha1 the mating surfaces are clean and free frorn burrs Assemble cacti bolt brushe...

Page 423: ...s shown opposite When rotated one complete turn maximum disc run out should not exceed 0 07 m m If his limit is exceeded rotate disc in relation to hub and re check for run out Locking of hub nut Rt t...

Page 424: ...G A REAR DISC depending 011the11 11e ofassemb l I fitting to Saloon I Disc mounted on the outside face ofhub I t fitting to Coupe Convertible U Discs filled to the inside face ofhub 2nd fitting au mod...

Page 425: ...he arms brakes pipes and flexible hose Remove brake pads Partially dismantle the caliper without disconnecting thC brake hose Remove the disc Thoroughly clean hub face a REFIT Fn the disc 1 to the hub...

Page 426: ...relation to the hub carrier and re check run out NOTE If run out is still in excess of 0 07 m m check the hub Clean the disc surfaces with meths Replace the caliper ensure mating surfaces contact and...

Page 427: ...ms brake pipe and flexible hose Dismantle the drive shaft 1 by disconnecting the redr cross n1embcr Hold the cross member temporarily in place by means of the tornrny bars J Rorrovc the pads Partially...

Page 428: ...Remove the hub disc assembly Check cond1t1on of oil seal 2 and flt hub nut Torque nut to 181 ft lbs 25 m kg Do not lock hub nut at this stage Dismantle the disc Salvage the deflector Thoroughly clean...

Page 429: ...ock washer a few drops of Loctite standard grade Torque bolts to 36 ft lbs 5 m kg I Replace the disc hub assembly The hub butting against the bearing leave in posi t1on the tools Cl C2 for checking ru...

Page 430: ...d clean with a new Blocfor lock washer a few drops of Loctite standard grade Torque nut to 31 ft lbs 4 25 m kg Replace pads Torque to 12 7 It lbs 1 75 m kg Replace drive shaft Torque nut to 181 ft lbs...

Page 431: ...EMOVE Raise vehicle at rear jacking points Disengage the brake pipe and flexible hose from the arm Remove brake pads Partially dismantle caliper without disconnecting the brake pipe and hose Remove sh...

Page 432: ...0 LJ J lJ J LJ J a BRAKES REPLACING A REAR DISC Remove bearing housing nut Remove hub disc assembly Remove the disc Thoroughly clean all parts Ref 1212 E...

Page 433: ...ipers type AH 12MK Jl Mount each bolt brushed clean with a new Blocfor lock washer a few drops of Loctite standard grade Torque bolts to 36 ft lbs 5 m kg Check the condition of the seals and bearing h...

Page 434: ...half turn in relation to the hub and re check run out Remove tools Cl and C2 Stake the hub carrier nut Coat the drive shaft splines with Molykote 321 Fit dnve shaft to hub Replace the assembly in vehi...

Page 435: ...NG A REAR DISC Replace the cal1per Mount the bolts brushed clean with a new Blocfor lock washer a tew drops of Loctite standard grade Torque to 31 ft lbs 4 25 m kg Replace disc pads Torque to 12 7 ft...

Page 436: ...uating front and rear pistons F Screwed rod for plugging rncister cylinder G Key for pos1t1on1ng the rear p1sto11s 8 1506 Front hoisting tackle I 8 1506 8 1507 Rear hoist1ng tad le cornpris1ng A r ros...

Page 437: ...vehicle by front cross member Block the master cyhn JC r inlet plug F Remove 1he wheels Remove the pads Disconnect from thP cal1per Naming light lead flexible hose R move the cahper A move the bleed s...

Page 438: ...ild Torque to 50 5 ft lbs 7 m kg Con11ect the flexible hose u rng new sc ihng washers make certain run of hose is correct Replace pads sue pag 03 01 Remove tho phiq F Bleed the system sec page 02 22 F...

Page 439: ...ody 2 Remove 1rotector retaining circlips protectors The two pistons from their cylinder The nylon spac r 3 Remove the seals With meths clean pistons and cylinders ensuring that all grooves are clean...

Page 440: ...ckheed Spagraph grease Locate tht seals in cylinder throat lightly coat the pistons with Lockheed Spagraph grease Insert pistons in ylmder body with the nylon spal r 3 caliper plat1 side Fit the rubbe...

Page 441: ...coat moving parts a with Molykote 321 Fit the caliper plate b with the aid of two pieces of 0 20 m m thick shim 6 Fit the thrust spring 1 As emble in place the pistons and caliper plate hand tighten t...

Page 442: ...stcr cylinder inlet plug F RemoVf the wheels Remov the pads 01sconne t frorn the cailper brakt warning hght lead fluid feed hose h mdbrr1kP Cdhle and outer casing Remove the caliper Remove the bleed...

Page 443: ...with cranked rod L 86 m m 5 master cylinder 20 6 m m dia 1 Girling caliper type AH 12 MKlll chamfered at bi Assembled with 2 12 m m thick disc 3 brake pedal with 102 m m axis 4 master cylinder with s...

Page 444: ...standard grade Torque bolts to 31 ft lbs 4 25 m kg Connect the brake hose handbrake cable and casing Ae lace the pads see page 03 06 Remove the plug F ftleed the system see page 02 22 Adjustment of th...

Page 445: ...HAULING A REAR BRAKE CALIPER DISMANTLING Rotate the piston 1 8 of a turn caliper MKI Fig I callper MKlll Fig Ill Return the pistons fixture E hand tight Remove the thrust spring 1 caliper plate 2 WWW...

Page 446: ...n spacer lift up the handbrake lever Remove the protector retaining c1rclips he protectors Remove the pistons Remove seals from cylinder body With meths clean the pistons and cylinder body ensure that...

Page 447: ...liper type AH 12 MKJ Assembled with I caliper plate rounded at a L _ 63 5 111 m 2 cylinder body l _ 63 5 m m 3 piston l 24 m m 4 piston L 32 m m ll Girling caliper type AH 12 MKlll Assembled with I ca...

Page 448: ...with Lockheed Spagraph grease Insert the pistons in their resoecuve os1t1ons as illustrated opposite Fit the r11bi Jer protectors retainino c1rcl1ps narrow d 1 6 J1sc side w1dP clip 5 cal1per plate si...

Page 449: ...mature plate with th d of 2 pieces of 0 20 m m thick shim steel b placwJ 1111der the thrust plates 9 1 11 the thrust spring Assemble pistons and cal1per plate hand t1gh11m 11xture E Pistons positioned...

Page 450: ...distance the rod protrudes engine idling after accelleration see page 10 06 No attempts can be made to repair a servo unit other than replacement of the valve 2 and adjust ment of the thrust rod If i...

Page 451: ...ling type AH 12 MKI rear ca ipers 504 derfrati11es 2 19 m m dia groved aI fitted to 504 with Girling type AH 12 MKIJJ rear calipers 504 L 3 20 6 m m dia Lockheed 30 m m tra11e not marked 4 20 6 m m di...

Page 452: ...vel f ured 20 replaceme lf for the preceding master cylinder on 504 derivatfres 7 19 m m dia Lockheed 35 m m tra1 el notmarked 8 19 m m dia Teves 35 m m travel figured 19 fitted to 504 I and as replac...

Page 453: ...r washers 18 x 23 x 2 5 II Lmkheed tandem master cylinder separate reservoirs the flats aI loc ated towards he rear WARNING TWO DIFFERENTASSEMBLES 1 U S A I Union screw 16 x 18 3 resen o1r hole 16 5 Q...

Page 454: ...Torque the nuts motJnted with new lock washers to 7 2 ft lbs 1 m kg Connect clutch feed hose Gently fill the reservoir When the fluid flows connect the pipe WARNING TWO DIFFERt NT CONNECTIONS FOR TAN...

Page 455: ......

Page 456: ...ch could be the cause of leakage or faulty operation of the cylinder cannot betolerated Look for scale scoring hurrs corrosion wear distortion Check in particular a cylinder bore b chreads c all orifi...

Page 457: ...the secondary cup and piston lip a towards the front Fit the sequence of components without damaging the cups the metal spring cup b bearing on the main cup 1 Fit the stop washer a new circlip 3 with...

Page 458: ...yltnder Tool steel heat to 830 C and quonch in 011 temper at 200 C OVERHAUL DISMANTLING Remove the stop screw 1 the circlio stop washi r E mact the primary piste r 2 Eject the secondary p1stor 3 using...

Page 459: ...t be tolerated Look for scale scoring burrs bruises corrosion wear distortion Check in particular a cylinder bore b threads c all orifices WARNING The primary and secondary piston sub assemblies shoul...

Page 460: ...tion of any of these parts cups pistons springs replace complete WARNING SIX DIFFERENT HODELSARE NVO VED 3 For Lockheed masrer cylmder 20 6 m m dia 30 m m rro11el b UJ J W 4 For Tei es master cylinder...

Page 461: ...master cyliJ1 der 10 6 m m dia 35 m m travel 6 For Teves master cvlinder 20 6 m m dia 35 m m travel numbered 20 7 For Lock teed master cylinder 19 m m dia travel 35 m m grooved a 8 For Pves master cy...

Page 462: ...econdary piston 3 Rt The stop wilshcr a new circl1p 6 and with a rounded end rod 7 force in the primary piston for a distance of approx 5 m m and fit the stop screw 1 I together with a new seal washer...

Page 463: ......

Page 464: ...hrust rod comprising K3 body K4 spindle 8 0804 Pedal depressor 8 1503 App ratus for heckmg pressure and pressure dror A Double readinq vaccum gauge cal1hrilted 76 cm Hg to 0 and 0 too bars 73 5 p s 1...

Page 465: ...s than 500 mm Hg Air lossi s ad1d nt ot the valve In p 1rt c uhr on 504 petrol abnormal air entry deteriorat1011 and or lack ot 1191 t S I the valve hoses and prpes carburettor mounting flange the air...

Page 466: ...ould engage freely in the notch 1 On all 504 LH drive saloon models Mastervac with cranked thrustrod 3 On 504 RH drive saloons equinped with a 20 6 m m dia master ylinder 2 On 504 LH drive saloon mode...

Page 467: ...ir WARNING With the pedal at rest there should not be any pressure in the system low pressure gauge re gistering zero If not then refer to the instructions at check V Free theservo unit five applicati...

Page 468: ...slots b are closed off Start the engine the pedal should descend and hydraulic pressure increase Re t1ghten the knurled nut a until slots b are just closed off Line up the two needles of the H P gaug...

Page 469: ...out d1sconnect1ng I the pipework If the pressure still does not fall overhaul the master cylinder WARNING Never pull thethrustrod 1 If the pressure falls to zero after removal of the master cylinder M...

Page 470: ...tools water 011 and petrol spare wheel in pi ice Locate vehicle over a pit or on a horizontal ram Vehicle at rest on 4 wheels Suspend an 11 lb 5 kg weight from the compen sator lever slot Push in the...

Page 471: ...ring al yellow flash d1mensio ns as 1flustraled Position the vehicle on a ramp and hoist the rear Rear wheels free of any load Press the lever 2 towards the torque tube Adjust and tighten the slot nut...

Page 472: ...int red signal flag ska1 Position the vehicle over a pit or on a horr1ontal ramp lnsi rt the wedge 0 0806 between hull and cliff hous1119 as illustrated WARNING Do not interfere with the adjustment of...

Page 473: ...paint red signal flag skai WARNING nvoDIFFERENTASSEMBUES REQUIRING DIFFERF NT ADJUSTMENT Ist assembly Compensator moutlted on bracket l al 45 mm a Restraining spring no identification mark dimensions...

Page 474: ...ion of torque tut e PLAY 1st Assembly J a b 1 2 to 2 2 m m 2nd Assembly J a b 2 2 to 3 2 m m ADJUSTMENT Slacken the slot nut 3 Measure b lever 1 pressed 1n direct ran of torque t 1bc Adjust caliper pr...

Page 475: ...WWW c J a OrG...

Page 476: ...es must be checked under maximum pressure by hard application of the brake p dal with engine running Hoses must be fitted without distortion as indicated below ensuring that there is no risk of con ta...

Page 477: ...I...

Page 478: ...good cond1t1on Assurn1 ng that all fastenings are tight ensure there 1s no vibrcttion or contact wtth metal parts when th steerinq rnech m1sm 1s in any ros1t ion or during any action of the suspension...

Page 479: ...inder Connection 1 to brake pressure warning light transmittor or 5 way union feeds front brakes 2 to brake pressure warning Iight transmittor or 5 way union feeds rear brakes Brake pressure warning o...

Page 480: ...ble tube 1 Saloons 2 Derivatives Lift the carpet and sound proofing at ge 1rhox tunnel On saloons Remove the mat anct sound 11roofing material from the rear left hand floor Uncl1p the cable beneath th...

Page 481: ...BRAKES HANDBRAKE DASHBOARD MOUNTED Remove the pulley 6 and collar 7 Push home the handbrake lever in its casing Unhook the cable Remove cable tube www 3a a ors...

Page 482: ...the aperture in the underbodv a Ftt the collar 7 to tlw cable c asing Hool the cable to the lever Aeploce the pulley 6 Fit the casing 4 and collar 7 Replace the shield 3 Clip cable casing to the fron...

Page 483: ...ndbrake off the operating lever 1 of the rear brake mechani n1 should seat on the nylon block 2 If necessary act on the nuts in order to obtain a flexion of the spring washer 3 between 1 and 1 5 m m O...

Page 484: ...spension spring 3 Spring upper seating cup 4 Upper flexible mounting 5 Safety cup 6 Anti roll bor 7 Anti roll bar connect ng link 12 69 ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

Page 485: ...s FRONT SUSPENSION IDENTIFICATION CHARACTERISTICS FRONT SPRINGS Coil Outer Height dio d10 of Free under in the lost Height load coil 1n mm 318 kg mm 1n mm in mm 225 to 230 500 230 to 235 13 163 214 to...

Page 486: ...disconnecting he flexible hose the track rod boll joint using extractor 8 0703 E the securing pivot of the anti roll bar con necting link on the rear triangle arm the rear triangle arm pivot by toppi...

Page 487: ...he cup the half silentbloc Then fit the arm thus equipped in the rear arm eye and mount in the following order the silentbloc second half a new nyIstop nut Engage the pivot 2 of the rear triangle arm...

Page 488: ...bs 7 m kg Refit the wheel Tighten the wheel nuts to 43 5 ft lbs 6 m kg Rest the vehicle on its wheels Push the car over a pit or onto a car lift Fit the rear articulation pivot 1 Using a torque wrench...

Page 489: ...I...

Page 490: ...suspension A Front ond reor springs compressor compris ing of A1 Lower clomp assembly A2 Upper clomp A3 Set of two operating screws E lower needle beoring seal fitting drift G Front shock absorber clo...

Page 491: ...the suspension spri g Alternate y tighten both operating screws unti I the spring upper holder comes into contact with the apparatus in a Hold the shock absorber rod using socket M and remove the nut...

Page 492: ...the shock absorber closing nut using socket G and on open ended spanner Pull rod slowly so that oil does not splash and remove rod and piston assembly Then removing the following from the rod support...

Page 493: ...TLING A SUSPENSION ELEMENT Remove the shock absorber froM the vice Remove the oi I from the shock absorber body Set aside the shock absorber cylinder 1 and the compensator volve 2 Remove the compensat...

Page 494: ...tess ports The fallowing parts must be replaced at eoch dismantling operation Shock absorber Valve compensator assembly 1 if necessary O seal ring of bushing 2 Rod seal 3 Rubber boot 4 NyIstop nut 5 U...

Page 495: ...er port F1t the rebound block 1 Insert compensator valve 2 in the shock absor ber cylinder 3 by topping gently with a mallet Blow carefully these ports os well as the inner port of the shock absorber...

Page 496: ...engagement of the upper bush 1 Face a must hove a clearance of three mm with regard the shock absorber body Fit the new O seal ring 2 tollowed Install the following on the shock absorber rod upper sp...

Page 497: ...rod rotation and displacement Pull the shock absorber rod fully out Fit clomp L on the rod os indicated on drawing opposite Tighten firmly using two screws Insto11 rubber boot on the shoek absorber ro...

Page 498: ...g down wards Shim 6 F it the following on the supporting element suspension spring 7 upper spring cup 8 upper holder assembled 9 Hold this assembly using compressor A Compress the spring by tightening...

Page 499: ...I...

Page 500: ...SUSPENSION IDENTIFICATION AND CHARACTERISTICS 1 Suspension crossmember 2 Shock absorber 3 Suspension spring 4 Anti roll bar 5 Anti roll bar connecting link Supersedes sheet cl oss 9 page 11 01 504 Wor...

Page 501: ...m coil in mm 318 kg in mm in mm 324 5 l yellow to and 5101 89 Saloon s 329 5 l green 504 AOl j as from 26 412 504 A02 beginning 329 S 1 blue 504 A03 of series I 5101 90 to and 334 5 l white 15 75 135...

Page 502: ...seating cup thickness 15 mm 2nd FITTING As from serial numbers 504 AOl 1 007 477 504 A02 l 004 863 The shock absorbers securing cups o are welded ottheupperportof the suspension crossmember l 2 Suspe...

Page 503: ...www 3aCJ a ors...

Page 504: ...TO BE USED 8 0907 Tool chest for front and rear flexible bushings M Fitting and removal tool for rear shock ab sorber lower si lentbloc N Fitting and removal drift for rear shock ab sorber lower sile...

Page 505: ...rubber washers the upper sheet metal cup the nylstop nut Fully extend the shock absorber rod Fit the fol lowing ports on the rod thrust cup 1 rod protector 2 centering cup 3 rubber washer 4 ny Ion sp...

Page 506: ...REFITTING Smear the silentbloc outer surface and the shock absorber eye bore with tallow Assemble the following on the press base plate fitting tool M shock absorber eye 1 new si lentbloc 2 with chamf...

Page 507: ...I...

Page 508: ...TOOLS TO BE USED 8 0906 Tool chest for front ond reor suspension A Reor spring compressor tool comprising of A2 Upper clomp A4 Set of two rods with nuts Kl Set of two guide rods for rear cross member...

Page 509: ...Slacken the rear arm pivot nuts Remove the petrol line rear securing clomp Place a jock under the cross member left hand loteroI braeket Remove the rear seat cushion Unlock the three securing nuts of...

Page 510: ...te disengagement of the springs Remove the springs and their upper rubber cup Remove the suspension cross member securing nuts from under the body Remove the sheet metal cups and the rubber washers Di...

Page 511: ...shock absorber upper nut of a mechanical a ssembly without first com pressing the spring Place apparatus 8 0906 A made up of clamp A2 and rods A4 Compress the spring by screwing alternately rod nuts u...

Page 512: ...4 Remove the spring compressor tool Ca_rry out the some operation for the opposite spring Remove both allen screws securing the dif ferential under the suspension crossmember Rest the differential con...

Page 513: ...f the car and position the springs in their upper cups F it the shock absorbers class 9 page 15 02 Do not tighten the lower securing nuts Install the wheels and tighten to 43 ft lbs 6 m kg Lower the c...

Page 514: ...m kg Smear Molykote G over the onti rol I bar bushes Fit and secure the anti roll bar under the body work Install the petrol line rear securing clomp Retighten the rear port of the exhaust pipe to the...

Page 515: ...ass 9 page 11 03 Place crossmember 5 on the mechanical as sembly Secure the differential under the crossmember using two Allen screws fitted with new Ondu flex washers Hand tighten the two Allen screw...

Page 516: ...THE FRONT FRAMEWORK REPLACING A FRONT PART OF THE BUTTRESS AND A FRONT FRAMEWORK REPLACING A COMPLETE BUTTRESS AND THE FRONT FRAMEWORK REPLACING A WING VALANCE A FRONT PART OF THE BUTTRESS AND THE FR...

Page 517: ...WVIW lllC J OrG...

Page 518: ...astening 4 PREPARATION OF NEW COMPONENTS 5 ADJUSTING AHO ASSEMBLY Adjusting Welding Finishing 6 PROTECTION AND SEALING Protective paint Sealing compounds 7 FINISHING CHECKING ADJUSTING Reficcing the d...

Page 519: ...CERNING THE CHOICE OF OPERATIONS As each acciden 1s a parcicular case typical operations treated individually here can be interchanged as required Example front Replacement of a w1ng by unfastening c...

Page 520: ...two guide rods for rear cross member K2 Set of two bars 8 1101 Apparatus for front mechan icoI components in eluding A Front triangle holding crossbar B Engine support bar C Front steering knuckle th...

Page 521: ...I www a orG...

Page 522: ...let manifold the wires from the alternator the oil pressure switch the ignition coil the thermostatic connector the starter rr otor the self disengaging fan switch the choke and throttle controls Remo...

Page 523: ...the battery cradle without disconnecting the supply hose Disconnect the gear change controls and re move the counter arm 1 Disconnect the reverse light wires 2 the gearbox earthing wire 3 from the bod...

Page 524: ...the guide hole plastic plug Fully screw in guide rod Kl in the hole thus exposed and tighten us ing bar K2 Leave bor K2 in the guide hole Remove the cross member rear securing nuts and thrust washers...

Page 525: ...ywork Recover the cups ond rubber washers Remove the broking compensator control lever bodywork side after having removed the cir clip ond the ort1culotion pivot Suspend the lever from its spring Remo...

Page 526: ...cting rod pivots 1 from the rear triangle arm Do not remove the flat wa shers 2 Remove the two nuts of the rear triangle arms articulation pivot nuts 3 from the main cross member Progressively raise t...

Page 527: ...four securing bolts from the main cross member the c 1x bolts of the front cross member Remove the six front suspension elements securing bolts from the wing valances Place a second hoist chain at the...

Page 528: ...BOD YWORK REMOVAL Using connecting bor D hold the front sus pension spring coils The mechanical assembly con thus be moved freely 504 Workshop Monuol Ref 1212 E WVIW a ICI OrG...

Page 529: ...I...

Page 530: ...cups 1 on the suspension crossmember making sure of their interchange ability Smear them with pure Teepol Install the hull on the mechanical assembly Remove the following connecting bor D holding bot...

Page 531: ...rs and the sheet metal cups on the suspension crossmember two se curing studs Fitthe nuts equipped with new Blocfor washers Tightening torque 23 5 ft lbs 3 25 m kg At the front F 1t he front crossmemb...

Page 532: ...nuts Tightening torque up to the fol lowing serial numbers 29 ft lbs 4 m kg and as from the following numbers 47 ft lbs 6 5 m kg 504 AOl 1 005 546 504 802 1 032 357 504 A02 1003 649 504 C02 1 009 769...

Page 533: ...ical components holding apparatus A Raise the car from the front using chain hoist until apparatus A is disengaged from the cor responding pivots Remove holding apparatus A Position the two new Nylsto...

Page 534: ...broke system completely refer to class 8 Fill the cooling system Check mechanical components oil level tyre infla tion pressure Check the front ond rear axle geometry Rood test the vehicle 504 Worksho...

Page 535: ...WVIW J OrG...

Page 536: ...en ome 4 Roof 5 Rear window lower frame cross member 6 Boot lid 7 Bonnet front panel 8 Front lower panel 9 Hull 10 11 12 13 14 15 16 17 18 WWW Ea lllC l orG Boot panel Rear lower panel Front wing Fron...

Page 537: ...HULL LIST OF THE MAIN PARTS USED IN REPAIR 504 Saloon 51 I...

Page 538: ...n ecting side member 41 Front half floor 42 Front web 43 Crossmember 44 Centre web 45 Rear web WVIW a ICI OrG 51 Gusset 52 Mud deflector 61 One piece side 62 Front hinge pillar 63 Side member 64 Trim...

Page 539: ...WVIW a ICI OrG...

Page 540: ...I HULL CLEARANCE OF THE MOVING COMPONENTS 0 w w Q offl flush 5 2 8 70 504 Workshop Monuol Ref 1212 E...

Page 541: ...HULL CLEARANCE OF THE MOVING COMPONENTS www 3aCJ a ors...

Page 542: ...rom the L H wing The 4 screws from the bonnet front p inel The 4 screws from the R H wing From the lower part The 2 screwsfrom the R H wing The 3 screws from the panel The 3 screws from the cross memb...

Page 543: ...elow Gop between wings ond windscreen frame 5 2 mm wings ond front doors front assembly and bonnet 2 mm 6 0 mm 5 2 mm 0 mm Check and set the level between wings and front doors 0 mm 1 front assembly o...

Page 544: ...nd the front frame d Plug the hole in the angle between the valance the wing and the frame from both sides Apply a strip of finishing filler at the joint e between the wings and the front punel EQUIPM...

Page 545: ...WVIW J OrG...

Page 546: ...5 90 ELECTRODES FOR INTERNAL WELDING OF THE FRONT WINGS WITH CROSSMEMBER AND FRONT PANEL These electrodes con be mode cold using 200 mm long straight electrodes These electrodes ore sold by the ARO co...

Page 547: ...PARTS Check and retouch the surface of the ports Point the inside of the new ports Bore the edges to be welded ALIHEMEHT AHO ASSEMBLY Position the wings vertically and hold them assembled on the cross...

Page 548: ...e cros smem ber if necessory PREPARATION OF THE NEW ELEMENT Check and retouch the surface of the panel if necessary Bore the edges to be welded ADJUSTMENT AND ASSEMBLY Adjust the level 0 mm 1 and secu...

Page 549: ...ET FRONT PANEL by unfastening on the car EQUIPMENT AFTER THE WORK CHECKING ADJUSTING Adrust the bonnet position level 0 mm 1 Refit the grille the headlamps the monogram Check the operation of the elec...

Page 550: ...adlamps the bumper the gri IIe INTERVENTIONS ON THE CAR t REMOVING THE PANEL Remove the 3 lower screws Cut the panel away flush with the wings Separate the spot weld points and smoothen the edges of t...

Page 551: ...wings l Spot weld and weld the assembly using o blow pipe from the inner edges S Secure the lower port using new screws PROTECTION AND SEALING Repaint the ports which hove been heated Apply o strip of...

Page 552: ...he top 2 at the bottom Cut the wing away flush with the bonnet front ponel a flush with the lower panel b Remove the wing Separate the spot welding points and smoothen the edges of bonnet and lower pa...

Page 553: ...ges a b _ Secure the top after checking the gap between c wing and windscreen frame 5 2 mm wing and bonnet 5 2 mm Secure at the bottom after checking the level 0 1 mm d 2 the gap 6 O mm WELDING Immobi...

Page 554: ...rip of filler on the edge of the mud deflector After positioning the wing a2 b2 Check the positioning of the filler and complete if necessary c Apply a strip of filler where the wmg joins the front fr...

Page 555: ...www 3aCJ a ors...

Page 556: ...ONENTS CHARACTERISTICS OF THE WELDING EQUIPMENT Reference of the assemblies used A 8 ELECTRODES straight 145 I 70 ELECTRODE HOLDER stroi ght bent Useful depth 120 250 Gap S1 andard gap WVIW a ICI OrG...

Page 557: ...I www a orG...

Page 558: ...orts There ore therefore no particular restrictions in repairing this port of the buttress SECTION 8 This section carries the mechanical ports and determines the characteristics of the front axle Two...

Page 559: ...I www a orG...

Page 560: ...oss piece supports Push bock the lower framework panel free the cross piece efill the holes smooth the framework panel and the cross p1ece supports Electrt c spot weld using the assembly c the cross p...

Page 561: ...I...

Page 562: ...ork upper cross piece Refill the holes and S llOOth the od1oinmg edges PREPARATION OF THE NEW COMPONENTS Clean the edges to be welded ADJUSTMENT AND ASSEMBLY Fit the cross piece Check its centering by...

Page 563: ...www 3aCJ a ors...

Page 564: ...f the valances d the cross piece supports e The lower cross piece Cut the lower brackets flush with f the wing valances g the buttresses h the framework Free the electric welded spots i on the wing va...

Page 565: ...sembly D 1287 t 2 Electric spot weld 1 with the assembly A m the side brackets n the fromewori panels to the front ports of the wing valances o the cross piece supports to the framework panels p the l...

Page 566: ...ning holes of the buttresses and the wing val onces Straighten out the distorted ports if necessary CUTTING Cut the framework panel as follows a the lower port of the front upper cross piece b the edg...

Page 567: ...the damaged ports of the components to be kept Refi II the holes on d S1 1ooth the adjoining edges PREPARATION OF THE HEW COMPONENTS Trace and cut at a right angle the buttress at 130 mm from the end...

Page 568: ...welding Place and fit the buttress sole plate With the assembly Electric spot weld e the inner port ond the end of the sole plate f the lower cross piece to the buttress Spot weld the end of the wing...

Page 569: ...In this case Torch weld the valance the buttress and the sole plates at the mechanical fastening rein for cement level p With the assembly IQ Spot weld the upper part of the battery supports q to the...

Page 570: ...damaged ports Check with the 1ock loose the progress of the operation by referring to the fastening holes of the butresses and the wing valances Check the ploy and the closing of the doors CUTTING Cu...

Page 571: ...e p on the front ports of the volonces q on the lower cross tece support Straighten and smooth the damaged ports of the co ponents to be kept Refill the holes smooth the ad joining edges PREPARATION O...

Page 572: ...he wing valances to the lower brackets h the lower cross piece i the cross piece supports to the lower port of the front framework j the front sole plate of the side member k the bulkhead front floor...

Page 573: ...bulk head leaving a space of 290 mm between them Tcrch weld r the lowe r port of the battery supports onto the buttress sole plate s the end of the sole plate to the bulkhead front floor 1oint On the...

Page 574: ...e points furthest away from the impact point Straighten the damaged ports Check with the 1o ck free the progress of the operation by referring to the fastening holes ofthe buttresses and the wing vala...

Page 575: ...plate m cut at right angles the port of the buttress to be kept Cut the rest of the sole plate UH FASTENING Free the welded spots n on the port of the buttress to be kept o at the base of the bulkhea...

Page 576: ...than 1 mm gap between the parts to be welded Clean the edge of the components to be welded 0 1nclud1ng the plate ADJUSTMENT AHO ASSEMBLY Fit the front port of the buttress on the bench Place the plat...

Page 577: ...diagonal reod1ngs between the front and rear fastening holes of the front assembly D 1287 2 With assembly Spot weld h the connecting bracket to the wing valance i the side brackets j the framework pan...

Page 578: ...o 290 mm spoce between them Torch weld r the lower port of the battery supports On the buttress so le plate s the end of the sole plate to the bulkheod front floor 1oint PROTECTION SEALING Apply a coo...

Page 579: ...rts of the s ide of the bulkhead 9 on the lower port of the mud deflector NOTE Before fitting the connecting bracket make sure the pfoces mentioned in the paragraph Protection sealing ore sealed Weldi...

Page 580: ...ad threading it through the ventilator hole OUTSIDE Apply a strip of sealing compound to c the windscreen frame lower gusset d the lower front door frame e the tube d with the connecting bracket NOTE...

Page 581: ...WVIW a ICI OrG...

Page 582: ...THE PART TO BE REPLA CED Smooth down the 3 sides of the poneI to cut away the bent bock edges Stone away the welding Ori II outthe spot welding and remove the panel Smooth the edges of the lining to o...

Page 583: ...l of the hinges c the lower edge d the top edge NOTE Use boll electrodes or a palette to avoid marking the panel Bend over and crimp the edges B Wed e and f at the joint between window frame and the u...

Page 584: ...le patterns one for tracing thequorterponel one for tracing the lower rear window frame crossp iece A I QUARTER PAHEL PATTERN A Bearing face To ovoid the cutting being effected on the original welding...

Page 585: ...A REAR WING TOOLS TO BE MADE IN THE WORKSHOP jl co 111 PALETTE ai 0 0 D Material copper N NOTE This tool enables one to avoid marking l on the door side when spot we lding the quarter 150 i panel to...

Page 586: ...channel trim the rear bumper INTERVENTION ON THE CAR ST RAIGHTENING OUT where necessary Straighten out the damaged panels NOTE Replace and od1ust the detachable damaged ports before straightening out...

Page 587: ...ing following c the water drip channel angle d the reor window I1n1 ng angle e the boot lid hinge support f the edge of the rear panel g the lower edge of the one piece side h the angle of the wing wi...

Page 588: ...ves as a stop for the quarter panel and aids the centering of the wing Stone owoy welding on the boot panel o Block the holes and smooth down the edges PREPARING THE NEW WING Check and touch up the su...

Page 589: ...panel against the water drip channel and the rear window lining The front port should rest against the rear door buttress The lower edge should rest on the whe I edg have the same curve and rest on t...

Page 590: ...of the wing 0 mm 1 c spot weld at the bottom pf the wing Adjustthepositionofthe wing to obtain a clea rance of 5 mm 2 at the boot lid d Spot weld at the extremity of the gusset e Hold the boot panel...

Page 591: ...nd the roof Smooth the welding Braz ing Braze the front port of the wing to the door buttress filling the holes l To ensure the waterproofing run the brazing 1 along the base of the water drip channel...

Page 592: ...the base of the wing and the one piece s1 de a A A A pply a strip of finishing filler b on the 101nt between the wing and the buttress smooth the filler c on the joint between the water drip chan nel...

Page 593: ...etween the boot panel and the rear light housing rear light housing 2 boot panel 3 rear wing 4 filler EQUIPMENT AFTER WOR K CHECKI NG ADJUSTING Refit the electrical installation the rear bumper the wa...

Page 594: ...ine the damaged deta chable ports before straightening out the body work CUTTING AWAY Cut away the wing panel along a opproximo te ly 70 mm from the line just above this NOTE The final cutting will be...

Page 595: ...ce Bore the edge to be welded Drill a number of 6 mm holes P at 60 mm apart on the front port of the wmg for wel ding Drow a straight line i 50 mm under the upper ridge on the panel curved at the end...

Page 596: ...when raising the wing for smoothing drill a 4 mm hole at T Before engaging the bottom edge of the wing apply o strip of filler M for spot welding along the inside of the wheel arch The door odj usted...

Page 597: ...nd the wing with a strip of damp asbestos t 2 along the base of the front port of the wing 3 along the rear bose of the wheel arch 4 along the base of the boot panel 5 along the upper angle of the win...

Page 598: ...een the wing and the boot panel and one piece side y between the rear light housing and the boot panel Point the ports bored by the welding EQUIPMENT AFTER WORK CHECKING ADJUSTING Refit the lectricol...

Page 599: ...I...

Page 600: ...plate trim the rear bumper INTERVENTION OH CAR Straighten out the damaged ports if necessary Cut away a the boot panel b the lower panel along the floor the one piece side extensions c the rear cross...

Page 601: ...s along 35 mm Bore the edges to be welded ALINEMENT AND ASSEMBLY Position the crosspiece under the floor and centre it in relation to the right hand edge of the hole Spot weld it to the fl oor _ _ the...

Page 602: ...he rear wings A Spot weld the gusset p Using a torch weld the inside of the panel to the wings in successive lines Brase to waterproof 1 the upper angles of the wings 2 the lower angles of the panel 3...

Page 603: ...rear light housing and the boot pa ne l f the gussets and the panel and rear wings EQUI PMEHT AFTER WOR K CHECKING ADJUSTING Ref1 t the electrical equipment the boot lock the spore wheel carrier and...

Page 604: ...arrier and lock the badge the number plate trim the rear bumper INTERVENTION ON THE CAR Cut away the boot panel along a up to the level of the rear Ii ght hou sing b the inner edge of the rear I ight...

Page 605: ...he edges Check and if necessary touch up the surface of the panel ALINEMENT AND ASSEMBLY Hold the wings spread to 1 230 mm Position and centre the panel and draw the c uts to be made f at the top g at...

Page 606: ...at the joint j between the rear Iight housing and panel k between the gussets and the panel EQUIPMENT AFTER WORK CHECKING ADJUSTING Refit 1 the electrical equipment the boot lock the spare wheel carri...

Page 607: ...WVIW a ICI OrG...

Page 608: ...F ENS 128 no longer manufactured To be used only for 504 Sa loons ENS 128 bis Complement for the 128 assembly Usable for 504 Saloons Convertibles Coupes ENS 128 01 New assembly Usable for 504 Saloons...

Page 609: ...tunnel G Supports for checking the front guide holes 1n the front floor H Supports for checking the position of the one piece sides J Cross piece for checking the reor bulkhead guide holes K Cross pie...

Page 610: ...EQUIPPED FOR 504 SALOON 0 EHS 6010 Universal extension EHS 128 A B C D E F G H J K M N 0 P Q R S POSITION OF THE SUPPORTS ON THE JIG m11 J Red 8 70 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...

Page 611: ...floor guide holes H Supports for checking the position of the one piece sides J Cross piece for checking the rear guide holes in the bulkhead K Cross piece for supports M M Supports for checking the r...

Page 612: ...128 A B C D E F G H J K M N 0 P Q R S ENS 128 b1s A bis DZ E bis N bis UV W A Abis J Ebis N Nbis LOCATION OF THE SUPPORTS ON THE BASIC JIG Red Light beige Light beige a u R V ENS 6010 9 10 _ _ _ _ _ _...

Page 613: ...ont floor guide holes H Supports for checking the position of the one piece sides J Cross piece for checking the rear guide holes in the bulkhead K Cross piece for supports M M Supports for checking t...

Page 614: ...OL BENCH EQUIPPED FOR 504 COUPE CONVERTIBLE EHS 128 EHs 128 b1 5 A b1s D1z E bIs N bis u v w L ight Beige L ight Beige A Abis E Ebis J Ebis K Ebis N Nbis Q U R V 0 0 0 LOCATION OF THE SUPPORTS OH THE...

Page 615: ...nnel G Supports for checking the front floor guide holes H Supports for checking the position of the one piece sides J Cross piece for checking the rear guide holes in the bulkhead K Cross piece for s...

Page 616: ...O CHARACTERISTICS CONTROL BENCH EQUIPPED FOR 504 SALOON ENS 6010 Un1versol extension ENS 128 01 A B C DZ E F G H J K M NOl O P 001 ROl SOl U V W LOCATION OF THE SUPPORTS ON THE BASIC JIG E J Red ENS 6...

Page 617: ...tunnel G Supporis for checking the front floor guide holes H SupPorts for checking the position of the one piece sides J Crosspiece for checking the rear guide holes in thebulkhead K Crosspiece for su...

Page 618: ...ICS CONTROL BENCH EQUIPPED FOR 504 COUPE CONVERT BLE A ENS 128 01 A B C DlZ E F G K M NOl 0 QOl ROl SOl U V W A E J K No1 0 0 0 0 LOCATION OF THE SUPPORTS ON THE BASIC JIG WVIW a ICI OrG 4D1111 Dork B...

Page 619: ...WVIW a ICI OrG...

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