Citroen CX Workshop Manual [PDF]

Zitiervorschau

LIST OF OPERATIONS APPEARING IN THE CHAPTER:

V

i..

°P7

VEHICLE CONCERNED

ENGINE TYPE

GENERAL INFORMATION

TEXTS

H-

General specification

vehicle identification

Petrol

Petrol

25 Petro/

/njectuof

25 Prestige

25 Petrol

Turbo

Prestige

25

Petrol

Diesel

25 Dese/

Turbo

Turbo

2%n Limousine

Petrol

Diese/

Turbo

25 Salan

Fambale

lnjection

2:r + Famihale

25 Salan

Desel

Ambulance

Turbo

829A5 829 AS

________

261 A 500

251659

25/659

25/662

__________ _________ __________ _________

25/662

251660

25/648

25/648

829 A

5

251659

251660

25/648

or

25/660

_________ __________ __________ _________

0

X

X

X

X

X

X

X

X

X

X

X

X

X

X

0

X

X

X

X

X

X

X

X

X

X

X

X

X

X

0

Jacking and towing points

22

0

OO(

/s

20

0

__________________ ___________________________________________________________________________________

SYMBOLS

OPERATION OPERATION NUMBER

1

L

Protection of the electrical units

A

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Recommended products

A

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Products to be used on the bodywork

A

x

X

X

X

X

X

X

x

x

x

x

x

x

x

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CX 25 Pallas D

(AM84)

(AM85)

TRD

D

pop

Pallas D

AD Turbo TRD Turbo

Limousine Turbo

AD

______

MM

MM

NB

ND

M25/660

M25/660

M2/648

M25/648

_

4

2,845 m

3,095 m

8

4,650

4,900m

C

1,360

1,375m

D

0,160m

E

A

E E

11,70m

12,50m

F

12,50m

13,40m

E

m

///L

E

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MA 000/1

(:1011:)

CX25 RD

Turbo

Limousine E

D

TRD Turbo

Turbo

420 kg 950 kg

435 kg 970 kg

460 kg 990 kg

1370kg

1405kg

1450kg

Pailas D RD

TRD

1300 kg Ill

685 kg

700 kg

725 kg

755 kg

790 kg

1155kg 1905kg

1160kg 1920kg

3190 kg

3205 kg

3220 kg

00

755 kg

1140kg 1890kg

80kg

100 kg

3190kg

3205 kg

3220 kg

12%

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CX2O

CX25D

CX 25 TRI

CX2ORE MR

NJ

5

CX 25 TRD Turbo

CX25RD

8

829 AS

5

M

4

MN

ri

5

25/659

8

M 25/660

5

4

Automatic

5

5

5

M

5 f+6

5

NC

25/648

5

_+) *+8mm

*

TRX

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000/1

CX2O

20 20

'

CX25

25

25 TRI

RE

D

25 TRD

25 RD

Turbo

530 kg

520 kg

510 kg

530 kg

860 kg

945 kg

965 kg

990 kg

1390 kg

1495 kg

1475 kg

1520 kg

///i

i::

1300 kg

''k

695 kg

730 kg

750 kg

750 kg

1030 kg

JIjIL

1065kg 2080 kg

2165 kg

1175kg 2190 kg

1175kg 2200 kg

3980 kg

3465 kg

3490 kg

3500 kg

1160kg

opp

80kg

100kg

3380 kg

3465 kg

3490 kg

3500 kg

o

11%

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MA 000/1

r Li -

CX 25D

CX2O

590 kg

585 kg

880 kg

990 kg

1470kg

1575kg

1065kg

1175kg

1030 kg

1030 kg

2080kg

2190kg

0

11%

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MA 000/1

1

2

VF7MANK0000NK0001

4( 0

6 'JIiiiptiiijIi''

0001

lo GkLJ

11

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©

2

'L5II1IIII)

IJ

ZF 3HP22

-

7/85

50 Km/h,

- 50 Km 7/85

-*

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EO

GENERAL INFORMATION

PROTECTION OF THE ELECTPICAL UNITS

*

*

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PROTECTION OF THE ELECTRICAL COMPONENTS

PRECAUTIONS TO BE TAKEN WHEN CARRYING OUT AN OPERATION ON THE VEHICLE

actions which may damage the electrica( or the e(ectronic equipment or create (with subsequent risk of fire or accident(. It is essentia( to avoid

a

short circuit

Battery: b

1

First disconnect cab(e c(amp from the battery negative terminal, earthed, then from the positive post. Before tightening the negative clamp to the battery (the negative lead shou(d be connected (ast(, ensure that there is no short circuit (bright sparks or arcs). Small sparks may occur due to the nterior (amp (door open(, door locking device, dock or components having ;--

a(

åns

C/)

remained in operation. Make sure that the terminals are properly connected. Clamps and termina(s should be c(ean and correct(y tightened. d ( When recharging the battery, disconnect the two clamps first. e( Do not reverse the negative and positive clamps on the battery. (This could destroy the alternator diodes(,

cl

Fuses: (

bl

Fit the correct type of fuses: use the fuses specified for the protected devices. Take the added accessories and the functions into consideration.

`ner

a

Charging circuit: Do not run the a(ternator unless it is connected to the battery. Do not disconnect the battery when the alternator is

(

e

1

o°°

(

d

Ensure that the regulator is correctly earthed. Do not interchange the leads connected to the regulator, (charge detection warning lamp and excitation are specific(. Do not connect a suppressor capacitor to the regulator without taking precautions or following proper mar-

c

..C

rotating.

---

bl

,-«

1

paj

,a

instructions.

fl

Do Oot use an electric welding equipment on the vehicle without having first disconnected the alternator, the regulator and the battery (insulate the two terminaisl. Do not « check» the operation of an alternator by short circuiting the positive and ground terminals, which may destroy the diodes.

-tom

Starting the engine: ,-+

Do not use a booster or a 24-volt battery. Only use a correctly charged 1 2-volt battery la higher capacity battery may be utilised(. Otherwise, risk of deterioration of the ignition module or any other electronic control units. If the starter is needed for starting the engine, without running it, it is necessary to disconnect datum and flywheel sensors on the All Electronic Ignition, or the primary lead of the coil on any other type of ignition.

Ignition: a) Do not connect

(l7

1

Q-6

1

r-:

,-,

a suppressor capacitor to the negative terminal of tho coil. Do not operate the module if ts radiator is not connected to the earth. c Fit the radio suppressor capacitors recommended by the factory. d) Never operate the ignition system while the HT circuit is open. Connect the HT leads to earth. e( Only use rev. counter having a HT sensor, (never puncture HT leads(.

b

Q.I. buib: al Never replace a 0.1. bulb with the headlamp switched on. If the headlamps have been in use, allow them to cool down. bl Do not touch a 0.1. bulb with bare fingers. Any fingerprints must be cleaned with soapy water and the bulb dried with a dry lint-free cloth.

0

Checks

919

al Preferably use a high resistance 1> 10 k 0 VI voltmeter or a battery-operated ohm-meter... bl Take care not to use instruments taking their power from the mains.

Electronic components:

O'>

al Avoid overvoltages duc to a badly insulated charger, electric arcing or connections to the coil. The units such as regulator, ignition module, tachometer, windscreen wiper timer, flasher unit, dock, radio, oil gauge unit, door lock control unit, etc. comprising electronic components may be deteriorated. bl The electronic components should not be placed or operated under a temperature exceeding 80°C. cl Always switch off nstruments or electronic control units before connecting or disconnecting them.

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RECOMMENDED PRODUCTS

-

CLEANING PRODUCTS

PRODUCT USE AND SPECIAL FEATURES

AND

SYMBOL

MARK

SUPPLIER

-

ZC

Gelified iquid designed for stripping sealing surfaces and non metal gaskets

ZC

r`:

SOLVANT FL.

Cold degreasing agent tor mechanical units specially designed to be used into cleaning tanks

9865832

D

U

1

R P

DECAPLOC

9865104

-cam

-

0)>

R.P. No.

D

D

U

D2 Aerosol can intended for unsticking and stripping non metal gaskets and sealing surfaces

DECAPJOINT ZC

9875077

R P

U

Carburettor ceaner ZC 9862011 U

cleaning product.

To be used pure.

D

D 3

RP.D

MARK

SUPPLIER

0

II -

SEALING COMPOUNDS

20C

- Carburettor

CDU

-

PRODUCT USE AND SPECIAL FEATURES

AND

SYMBOL

R.P. No.

-

-

Sealant for joint contact surfaces, screws and nuts. Clean with acohoI.

Hydrocarbon resistant product

CURTYLON

E

1

CURTY

LOWAC

E

2

S.E.B.I.S.

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2

RECOMMENDED PRODUCTS

PRODUCT AND R.P. No.

USE

AND SPECIAL FEATURES

TCO

Product for locking and sealing studs, screws and nuts with maximum effectiveness.

Sealer for housings: Aluminium based

arm

9865035

FRENBLOC ZC

9865033

9865037

U

C71

9865565

U

Sealant for joint contact surfaces. Remains flexible after drying.

Air intake casing heater tubes seaung compound

AUTO JOINT NOIR (black) ZC

9865038 C71

Paste for bonding door linings,

5

E

6

RP.D

FORMAJOINT ZC

E

U

POXY. MATIC ACIER ZC 9865559 U

windscreen, etc. Sealant for joint contact surfaces. Remains flexible after drying.

-

SCELBLOC ZC

ZC

Metal based

-

E4

U

POXY. MATIC ALU

Oro

-

9865036

E

7

E

8

E

d'1

Sealant for joint contact faces in replacement of traditional gaskets.

FORM ETANCH ZC

SUPPLIER

3

E

U

-lo

Bearings, nngs, bushes, liners, inserts, pulleys ocking products. Strengthening agent for splined and pinned connections.

9865034

C31

Sealant for joint contact surfaces, locking of screws, fixing studs and nuts. Sealant for joint contact faces and unions.

MARK

FRENETANCH ZC

9

E

10

E

10

E

11

Ets BARTHELEMY

E

12

FRAMET

U

AUTO JOINT BLEU (blue) ZC9865 103 U

FCO

-

Locking and sealing agent for removable threaded assemhUes.

Z^>

-

SYMBOL

Fire-proof mastic paste Ref. 1500 (CO LLAF EU)

Strengthener of fixed assemb(ies ,S3

-

SCELMETAL III

Aerosol can for rusted parts and seized assemblies

t!)

Anilha Recartilhada

o®o

oro

Fiachscheibe Fiad Skive

Arandela Piana Fiat washer

oja

Serrated washer

Piatte Ring

Anilha Piana

Rondelio Piate

fl

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Anzahl der Schraubelemente: Schrauben, Muttern. Stifischrauben usw

Antal dele

1

skruesamlingen

Canlidad de elementos de tornilleria: tornillos, tuerca. esparrago. etc.

Number of threaded components: screw. nut. stud, etc.

Z

Z

Numero di elementi di bulloneria. viti, dadi. prigionieri, ecc.

J

Aantal: bouten, moeren, tapeinden enz.

Nmero

0

de elementos de parafusos ou porcas. porca. perno. etc.

Antal förskruvningspunkter: skruv, mutter, pinnbult. etc.

Nombre déléments de visserie: vis, écrous. goujons.. etc.

Borgen of borg verwijderen

Sichern bzw, Entsichern opp

Travar ou destravar conforme o caso

Frenar o quitar el freno, segi'in el caso

Ls

Lock or unlock as appropriate

Ny del skal anvendes

Empleo imperatvo de una pieza nueva Use of new part esseritial

Uso obbligatorio di un pezzo nuovo

(/J

000

oro

i'

Schmieren

5J

SmØre

Aceitar

('

cup

Noodzakeik een nteuw onderdeel

Utilizaco imperativa duma pea nova ((0

Unbedingt Neuteile verwenden

(i')

Freiner ou défreiner suivant le cas

casi

000

Bloccare o sbloccare, secondo

fwfJ

eller avlägsna läsningen

..O

GB

Lse eller frigre

Ny del

mste ovillkorligen användas

Emploi impératif d'une

pice

neuve

Anolja

Oliare Oliön

Huiler

Olear

oro

Oil

Reinigen ...(je nach evontueller Markierung. siehe Tabelle der Klebe-.Schmier-und Dichtmittel)

(afhngig af evt. mrkning af produkt) siguiendo lo selado eventualmente, ver cuadro C:-

:ii":

Limpiar ...

(

de productos)

Clean

(according to symbol, if present, see table of recommendations)

Pulire

(

secondo eventuale riferimento. vedere tabella ingredienti) p..

zoals aangegeven, zie lijts met benodigdheden)

Reinigen ..

(

Limpar

(

conforme marca eventual, ver quadro ingredientes)

(

enligt eventuell märkning. se listan över olika produkter)

Reng6r

.

,.-,

'_.

FlengØre med ..

Nettoyer ...

(

suivant repére éventuel, voir tableau ingrédients)

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Mit

chmieren

gemäss Markierung. siehe Tabehe der Klebe-, Schmier- und Dichtmittel)

(

Overstryge med Untar con

)

GB Smear with Spalmare di

{

afifingig af referance produkt)

siguiendo lo sealado, ver cuadro de productos)

according to symboL see table of recommendations)

(

secondo riferimento. vedere tabella ingredienti)

(

Insmeren met

(

zoals aangegeven. zie lijst met benodigdheden)

Untar com ...

conforme marca, ver quadra ingredientes)

Bestryk med ...

(

Enduire de..

suivant repre, voir tableau ngrédients)

enligt mäkning. se listan över olika produkter)

o00

Gut C.7

God

OK

B ueno

Buono

Korrekt

Bom

Bon

Serviceable

(j

Siehe Se .. henvisning til

Ver ... dirigirse See

a

...

.

000

EII

Vedere ... riportarsi

a.

Se ... g

tillbaka

tIl

Zie ... verwijzen naar Ver ,. reportar- se

a..

Voir

.. se

reporter ä

refer to

d.'

Sichtprötung oder Pröfung mit der Hand Kontrollere visuelt eller manuelt Controlar visualmente o manualmente Check visually or physically

Controllare visivamente o manualmente

NL

Visuele of handmatige controle

Controlar visual ou manualmente ;(p

.]G

Gör en manuell kontroll eller en okulärkontroll

Contröler visuellement ou manuellement

Mit einem Messgerät prbfen

Controleren met een instrument

Kontrollere med mleinstrument

Controlar com um instrumento

Controlar con un instrumento

Kontrollera med instrument

Check with a measuring instrument

Controllare con uno strumento

Contröler avec un instrument

fl

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ann r

Mehrere Einbaumög li c hk e it en

a

______

(

iJ (

(

Flere monteringsmuligheder (1; 2; avi

Varios montajes posibles (1. 2. (!i

Severa! assembly possibilities

______

- 2 - 3

1

Diversi montaggi possibili

V ersc hill en d e moge li j kh ed e n

)

montage (1

3) 2,

(1

;

2

;

3...

Vrias montagens possives (1.

3...)

2.

3)

Hera monteringsutföranden förekommer

3)

(1; 2; 3)

Plusieurs montages possibles (1 - 2 -

3)

°_'

Markieren, Biem Wiedereinbau auf Zugehörigkeit der Teile achten Afmcerke. Ved genmontering skal delenes rette sammenpasning respekteres

Senlar. Respetar

el apareado de las piezas para el nuevo montaje

Mark. The parts must be kept paired for re-assembly Segnare. Rispettare faccoppiamento del pezzi per

__ -

1

I

Merken. Zorg bij montage avi

1

.

CII

dt de

il

rimontaggio

onderdelen bij elkaar komen

Marcar. Respeitar o acasalamento das

peas

Märk ut. Respektera a delarnas märkning vid

para armé- las

termonteringen

Repérer- Respecter rappariement des piéces pour le remontage

________

Einstellen

Regolaro

Justere

Mstellen

Regular

(j'

Ställ in

Afinar

Régler

Gioco

Spel

Adjust

Abstand. Spiel Spil

C!

Speling

0

Jeu

Folga

Juego Clearance

0

Einbau durch Pressen, Vorspannen oder genaues Einpassen `fl

paj

Montering med forspnding. prespasning eller itrykning Montaje con esfuerzo. precarga o apriete ajustado Assembly force fit. with preload or interference fit

(Ti

Montaggio forzato, precarico o accoppiamento serrato Montage onder spanning. voorspanning of klemspanning Armar om esforco, précarga ou encaixe apertado

Montering med förspanning. presspassning eller ihoptryckt (1'n

EII

...

Montage sous contrainte. précharge ou emmanchement serré

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Leicht anziehen

Aandraaien zonder vast te zetten

Skrue sammen uden fastspaending

Aconchegar sem apertar

Aproxmar sin apretar

Skruva

utan att dra

fl

t

Screw up wrthout tightening

Approcher sans serrer

Avvicinare senza serrare

Vorgeschriebenes Anziehdrehmoment

Tilspndingsmoment skal overholdes Par de apriete quo se debe respetar imperativamente

Observation of tightening torque essential

,

'"O

Coppia di serraggio da rispettare obbligatoriamente Voorgeschreven aanhaalspanning aanhouden a

respeitar imperativamente

Åtdragningsmoment som ovillkorligen

mste Sr.

Aperlo

respekteras

Couple de serrage ä respecter impérativement

\,

Löd

Hartlöten

Brasare

Lodde

Soideren

Soldar con metal

Soldar a metal

Braser

Cordone di saldatura

Svetssträng

SvejsesØm

Lasrups

Cord'o de soldadura

_'0

oro

(t

Schweissnaht

Cord6ri de soldadura

a,:

Braze

Cordon de soudure

_0)

Fiflet of weld

TJ

Lochpunktschweissen

Proplassen

Stubsvejsning

Soldadura por pontos

Soldadura por puntos de tapdn'

Pluggsvetsning

tampo"

Plug weld

Saldatura con punti

a

tappo'

Soudage par points

bouchon'

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Einen Gang einlegen

3. Gang)

z. B.

eks.:3. gear) eje mplo: 30)

`..

Stigear(f.

(

Ponor una relaci6n de velocidades

Engage a gear

(for example: 3rd)

lnserire una marcia

(

esempio: 30) (

Engatar urna velocidade

por exemplo: 30)

c`9

en växel

(

(till exempel: cp-

:c0

()

bijv: de 3 de)

Schalel een versnelling in

Lagg

(II)

(

Engager un rapport de vitesse

3

(

:

an)

ex.

:

38

() ()

Ein- oder Auffullen

Fylde eller efterfylde

(É

fl

GB

ED

)

Fyll eller korrigera nivån

Lienar o poner a nivel Ful

Vullen of niveau op hoogte brengen of bijvuUen Encher ou por a nivel

or top up to evel

Riempire o effecttuare il rabbocco

:1IiIII1

Z00

Gelenkwelle cz

Transmissidn

'a

Transmisso Drivaxel

Ofn

Transmisidn

Remplir ou effectuer a mise

Drive Shaft

Transmission

Trasmissi6ne

Nog

Styrtj Direccin

oro

000

('

6

/

Steo

,

tnrichting Direco Styrsystem

Direction

Motor

Motor

Motor

Motor

Motor

Motor

ED

Motore

Moteur

Zylinderkopf

Cilinderkop

7c-

Engine

Culata

Cabea Topplock

Cylinder Head Testata torn

000

oro (j

Topstykke

Z00

GB

(6k

0

ZON

____

C)

maj,

***'

Lenkung

Culasse

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lo

Getriebe

Versnellingsbak

Gearkasse

Caixa de velocidades

fl

Caja de velocidades

Gearbox (%)

BoTte de vitesses

Zwischengetriebe

Overbrengingstandwielen

Overføsels - gearhjul

Carretos de transferencia

Piones de transferencia

Överföringsdrev

II.

Scatola cambio

Transfer gear assembly Pignoneria di movimento

Pignons de transfert

Federung und Hadaufhängung

Vering

Ophngning eller affjedring

Suspensé

Suspensi6n

Fjädring

i

'j/

1

Suspension Sospensione

Suspenson

(J

Bremsen

Hemmen

Bremser

Travöes

E

ED

(c

Frenos

.

Brakes Freni

Freins

Hinterachse: Längslenker

Achterbrug: Draagarm

Bagbro: Brearm

Eixo traseiro:

Eje trasero: Brazo

Bakvagn: Bärarm

Brao

Hear axle: Arm Essieu arri'ere: Bras

Hinterachse: Radnabe

Achterbrung: Naaf

OND

Bagbro: Nav Eje

trasero: Buje

`L°

Assale posteriore: Braccio

Eixo traseiro.: Cubo

Bakvagn: Nav

Hear axle: Hub

Assale posteriore: Mozzo

Essieu arriére: Moyeu

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VOorbrUg

r

Vorderachse: Unterer Querienker

Forbro: Nederste Eje

Onderdraagarm

Eixo dianteiro:

brearm

Brao inferior

Framvagn: Undre länkarm

delantero: Brazo nférior

Front axle: Lower arm Essieu avant: Bras inférieur

Vorderachse: Achsschenkel

Voorbrug: Fusee

C(]

Assale anteriore: Braccio inferiore

oro

oro

,a«

Eje delantero: Pivote

Eixo dianteiro: Pivot

Framvagn: Pivot

Front axle: Swivel assembly

Assale anteriore: Pivot

Essieu avant: Pivot

Klasse

Klasse

Klasse

Classe

oja

_______

Z00

MEO

.S]

Forbo: Styrebolt

Klass

Clase Class

i

Classe

Ablassen

Aftappen

TØmme

oro TI

Vaciar

ED Spurgare

Bearbejde ,

Mecanizar

(!)

Z00

Bearbeiten

Ontluchten Purgar Lutta

000

Bleed

ni

()

Purgar

(JÉ

Töm ur

Vidanger

Svuotare

Udlufte 00:

Esvaziar

Dram

Entliften

_______

Z00

Classe

Purger

Bewerken

Trabalhar

a

maquina

Bearbeta, slipa, etc.

Machine Lavorare

Usiner

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LIST OF OPERATIONS APPEARING IN THE CHAPTER:

VEHICLE CONCERNED

ENGINE

ENGINE TYPE

c:::

OPERATIONS

20 Petrol

DESCRIPTION

______________________________________________________________________________

MA 124.0/1

Adjusting the valve clearances

MA 133.00/1

/\

Checking and adjusting the engine support brackets

Q_

,

0

Specification and part/cular features of the engine mounting brackets

MA 133.0/1

829 A 5 __

A

MA 180.00/1

Specification and particular features of the exhaust system

MA 180.00/2

Specification and particular features of the exhaust system

MA 180.00/3

Specification and particular features of the exhaust system

(3

MA 180.00/4

Specification and particular features of the exhaust system

0

(3

Carrying out work on the exhaust system

MA 220.0/1

Checking the engine

pressure

0

MA 220.0/2

Checking the engine oil pressure

0

MA 220.0/3

Checking the engine oil pressure

0

Specification and particular features of the cooling circuit

J

Specification and particular teatures of the cooling circuit

(3

Specification and particular features of the cooling circuit

(3

MA 230.00/1

.MA 230.00/2 MA 230.00/3

-

Petrol

J6T A 500

________ ________

25/659

25

Prestige

25 Petro

Turbo

25 Prestige

Petrol

Specification and particular features of the cooling circuit

Diesel

Turbo

25

DeseI

Turo

25

20 Safari

Limousine

Petrol

Desel

+

Turbo

Familiale

25/648

829A5

25 Safari

Petrol

Injecton

25 Safari Diesel

+ Familiale

25 Safari Diesel

Ambulance

Turbo

829A5 25/659

25/662

________

25/662

25/660

25/648

_________ _________ ________

25/659

_________ _________ ________

25/660

25/648

________ _________

or

25/660

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

A X

X

X

x

x

X

X

X

X

X X

X

X

X

X X

X

X

X X

X

X

x

x

X

X

x

x X

X

X

X

X

1

1

25

______ _____ _____ ______ _____ _____ ______ _____ _____ ______ ______ _____ ______

________ ________

X

MA 180.1/1

ou

25

Injecton

F-

230.00/4

Petrol

OJ

OPERATION No.

IVA

22

2

1

X

1

X

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LIST OF OPERATIONS APPEARING IN THE CHAPTER;

VEHICLE CONCERNED

ENGINE

ENGINE TYPE

20

DESCRIPTION

(1) >
-

MA 230.00/5

MA 230.0/1

Petro/

CI)

TEXTS

OPERATION No.

SYMBOLS

Petrol

22

r_-

OPERATIONS

3

x

x

x

x x

x

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OUf 50 6602

1

13815

L

T b

OUT 20 6323

r 5602 TJ

a

a

-,I

[our 106004

1

12827

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0U1 30 4O61

3312T1

rTj OIT

1T.

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829.A51 J6 RA 500 (AM 87

1[

x 4

)

1995 cm3

88mm E

0

1

82mm E E

c

V + V

9,2/1 (829A5) 9,5/1 (J6 RA 500)

V

SUPER 98 RON minh

- --

,-

-----

-

-

-- -------

-

-

40

-

- -

'

-

--

-

-

--

-- - -

---

16

-15-

1

+ii

*

j

I

1 1

1 1

1

1

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z

00

E

CA) m

E E

c)

9,3

z

LO

2

2 h.

z E

tco

J

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3

9,3

6

z SmdaN

1

MA

EI

829.A5

EEEJIII 0

0

01

(mm) = 66,668

Ø1(mm)

52,267

66,687

-

Ø2(mm)

52,286

62,873

maxi 0,005

a - b

3

100.00/1

62,892

maxi 0,005

b

1,846

1,852

1,878

.

1,884

T '

0,06 7

d

1

:

II

:

III

IV

74,5 mm

IC

lo

-

22,992

-

0,252

2,80 -, 2,85 2,85 -* 2,90 2,90 -* 2,95 2,95 - 3,00

75 mm

- 22,9961

lD22,996-23

1

lo D jo

jC

23,003 -* 23,0071 23,007

-

23,0111

PDF compression, OCR, web-optimization with CVISION's PdfCompressor

*

8531

9.

MA 100.00/1

829.A5

-4-- A -fr-fl--

Ø 88

87.9401

87,930

-

87,940 - 87,9501

88,020

D

88,020 -. 88,030

D

A Ø 88,010

-1-0-fr--- A Ø

-

- 88,010 0

Ø 87,950

-.

87j 0

1,800- 1,820 4,015

-

2,015

mm

2,035 mm

-

4,035 mm

-

69,35 mm E

68,75 E

6 0,30

-

0,45 mm

L'l MINI

6 gr.

MAXI

- 1,740

L'l

1,728

L'2

1,978 - 1,990

3,978

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MA

100.00/1

829.A5

_________ 0

0

®

Ii 0

1' 0

®

____

1

0

00

0

0

o

0 0

(SO

o

_ o

o

o

o

o

o

o

®

d

$

±O,5mm00 maxi 0,05 mm

0

Tr

0

0

*

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829.A5

0

4,25

ini

MA

10000/1

c

x 4,5

c

00

00\ 000

111,95

111,40

0

J-[j!H fl

0

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1

rrT2N 829.A5

'' '' 77

'

'

"t-

tH

!

_________________________________

0,8 bar

,:':

TOTAL XjX

J ____J 1

/

GTS Plus

10W40

__

5 L

+

GTI Plus

10W30

__

j

5,25

L

90°C

_

:::ars

L

= 101 mm

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*

8531

J6TA500

______

1[ TT

x 4

1[

2165 cm3

V+v ____ v

0

88mm

c

89mm

9,8/1 mm

SUPER 98 RON minh

*

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z m

E

m w

WIE:

3

zw M

6

z 00 CC)

9,3

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n*

h.

9,3mdaN

2

L5

z E

3

E

al

8mdaN

F3 2

5mdaN 1

MA

___

E1

J6 TA 500

0

0

1

1

Tr fl

ciHtijj419H

fl

66,687

0

56,286

2 (mm)'

62,871

maxi 0,005

1,836

Dit]

(mm) = 66,668

(mm)

56,267

a-b

1

62,880

maxi 0,005

1,876

1,841

1,864

____ ____

---

0,10

tt

lit IV

-

74,7 mm

C D

: : :

-

0,30

2,80 - 2,85 2,85 - 2,90 2,90 - 2,95 2,95 - 3,00

001001

0

0

10000I2

75 mm

0 22,992 0 22,996

22,996

- 23

+

1

145,5 ± 0,05 1

C

0 23,003 -

23,0071

1010 23,007 -* 23,011J

*

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'E1I A -1-fl-fl-- A

D

88,010

-

D Ø

88,020

-

88,020

88,030 0

Ø 87,930

-

87,940

0

-Ii-fl--

-. 88,010

Ø 88

0)0)0

-il-- A

J6 TA 500

87,940

-

87,950

87,950

-

87,960

0

ini

___

MA 100.00/2

0c0

4

IIID

E

E

0,05 mm

0,30 -. 0,45 mm

L'l MIN!

6 gr.

MAXI

L'l 111

L'2

1,728

-

1,740 mm

1,978 -* 1,990

-

F'1L3 -

3,978

3,990

UFLEX

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6 fl

1

J6 TA 500

0

0

® 0

0

® 0

0

0

0

0

0

0

0

__

__

®

MA OO00/2

00

0

0

® Q

>;

17°

5T 630

*

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6

MA 100.00/2

J6TA500

0

0

41

1200

0,8

4,8

+ 0,022

P

9OO)

pressure regulator and compressor holder nuts (1) (art conditioning option)

adjusting nuts (9),

all the shirns,

clutch control support screws (10).

`cup

and put them in place of the battery.

Uncouple the exhaust systern. Normally aspirated engine with

FFI.:

Rernove the 4 exhaust pipe nuts. Turbo with

FFI.,

Fig. II and Hl

Fully (nosen screw 11 21, then retighten it by two turns to prevent the speedorneter drive guide frorn being pushed out.

Disengage the twin outlet power take off 1111. Rernove oi( gauge (13).

Rernove: -

Uncouple the power take off with double outlet, Fig. V.

screw (2) and shirns (3), flexible pipe screws (7),

nuts and spacers 14).

Uncouple, Fig. V: -

Release exhaust pipe (8) downwards.

Rernove nuts

151

and tiexible pipe 16).

heater hoses (16) and (17), fast idle air duct (151,

-

petrol supply pipe (18),

petrol return pipe (14).

Disconnect, Fig. VII: connectors (20), fem'

-

- sensors (221,

- coils and suppressors (19), - gear shift link rods (211.

*

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6

REMOVING AND REFFTNG 1

)

IHE ENGNEIGEARBOX ASSEMBLY

Position on Inc engino, Fig. iså

sir g 251 7-T.bis

RH1 IT

1:

f INC

(as shown 00 illustration),

tthing

nt the engine crdnkcase water dram plug, fitted with new sea!: Tightening torque: 3 mdaN.

turbo with FFI: f it the bracket to the pressure relief valve outlet,

Place slirig 2517-T.bis, attachirig bracket 6031-T and tensioner 4061T; screw the terisioner fully in, Fig. and VI.

tensioner 4061-T (slack(.

,--

bracket 6031 -T natuially aspiiatcd engine with EFI: brackot to bo fil ted on the exhaust pipe, with one sorew,

a

1

'rom

-}y

0

`°-

(from the engine bearer, Fig.

III.

nut (31 and screws (41 from the gearbox mouriting, Fig. V (retrieve the shims),

screw (21 from the torque rod; slackeri the other screw, Fig. IV.

engine support hracket screw i-+

(1

Loosen tensioner 4061-T, Fig. II.

Ref it: (without tightening)

R emove:

screw

Engage the engine/gearbox assembly into its nom partment, Fig. VI. p_>

Place sling 2517-T.bis. under tension, tensioner 4061-T being loosened, Fig. II.

torque red screw

Il),

(71

gearbox support plate (together with iis shimsl.

Tighten: the engine bearer to 10 mdaN, Fig. III the torque rod to 9 mdaN, Fig. IV

Slightly raise the power unit assemhly.

the gearhox support plate fixings, Fig. V:

screws (41: to 3 mdaN not (31: to 16.5 mdaN.

(,A

Screw terisioner 4061-T fully, Fig. VI and remove the engine/gearbox assembly: --h

'-'

Insert the clutoh cable into its bat-joint Tighten clutch control support (51. Adjust the clutch Fig. VII.

Adjustment to be tested, (as per Op.® MA 133.0/11.

Locate, Fig. VIII. the dual outlet power take off (61.

f-+

`+°

Before refitting the power unit assembly: Check the condition of the engine mounting brackets. Replace them if needed.

the

ou

gauge.

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*

15

t

85360

v

II

____

-

7

lo 8

(

)

-

7

l)-_

---

\

-

--

--

-;_

v

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100.1/1

Reconnect, Fig. V and connectors (11),

Couple up the exhaust system

sensor (12) (with blue ident. mark), sensor (13) (with no ident. mark),

Tighten the (lange to 1.6 mdaN

HT coil (9) cyls

(with rio mark), cof (10) the suppressors, the reversing lamp switch wiring harness, the throttle spindle switch (141, knock sensor (181.

On the turbocharged engines with EF/, fitted with

NEW nuts and sea!s:

-

1

and II,

flexible pipe (2) to the pressure release valve outlet,

exhaust pipe pieces 151,

screw

16)

141

to the turbo, screws (3), distance

C31

3-1

Tighten, Fig.

1

and II:

flexible hose (2) screws 2.5 mdaN, 161

-

(31

-

and nuts (1) to

to 5 mdaN. -

Rofit: Fig. III

.-.

-0:c

the pressure regulator and compressor holder (air conditioning option) together with its shims; tighten nuts 171 to 5 mdaN.

Chock the oil levels. Top up if necessary. up the cooling circuit (with the heater open) and carry out the bleeding operation. (As per Op E MA 230.0/1). '-'

-

the pressure regulator accumulator, fitted with NEW sea!,

-

the HP pump outlet pipe, fitted with and its fastenings 181,

-

the pipe situated between the pressure regulator and the brake accumulator, fitted with NEW seals,

a

'''

the compressor belt and protection cover,

--0

the driveshafts, (See Op. ® MA 372 1/1) the radiator, the bonnet, the battery, the protection plate located under the spare wheel.

F1II

Vehicies with air-conditioning:

-

the water hoses, air circuit pipes 115), (16), (171, (20) and (211, petrol circuit pipes (191, gear shift hnk rods, the accelerator cable.

Fit:

turbocharger nuts (in the correctsequence), Fig. Il,

screw

Recouple, Fig. V and VI:

and adjusting shims.

There should be a 5 mm clearance at least between the exhaust pipe and the engine crankcase.

-

and 4 (with yellow ident. mark),

cy)s 2 and 3

HT

Refit: Fig.

1

9

V:

NEW seals:

On naturally aspirated engines with EFI, fitted with

a

NEW sea!

Bleed the front brakes. (Refer to Op. MA 453.0/1).

Check the gear change.

the HP pump rubber suction pipe, the horn.

*

MA

REMOVING AND REFITTING THE ENGINE/GEARBOX ASSEMBLY eka

r.

. Ki

Lower the vehicle to the ground.

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*

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ch::

122.0/1

Tum:

Rotating the crankshaft:

tha

twa rrrethod. 1 engago the highest geer, ut te the ) by mea ns of the road wheel,

ue

(

e r

ormaf

anksheft

ti ra sar ew accur og the or crnkshatt prrtey

and torr the crank haft

ri

the norrnai drrectrorr of

otatiori

Check:

Ad ju st

sin

_67

fl)

Remove, Fig.

1 va)ve clearance cleararrce should be of 0,30 to 0.75 mm.

cy)rnder No. Uhe

the contra) cab)e

raokshe)t throuqh a camp etc torr, in tf otatron.

dirc cPor of enqrnc

from

the cold start flap (1),

the valve clearance:

buse (2),

INLET

the accelerator control rad and cable,

EXHAUST

= 0.10 mm 0.25 mm

cyfinderhead cover (3). NOTE: This check can be carried out with shown on Fig. IV. .2T

Bring: the piston of cylinder No. 4 to TDC

a dra)

gauge, ss

(with the valves in the "rocking" position) Fit:

Make sure: that mark "a" on the f)ywhee) is facing the zero on the clutch bet housrng, Fig III.

Recouple: - the acceferator controf rad and cable,

Set: the clearance af cy)inder No.

150 mm,

the cylinderhead cover and rts gasket, )tighten to OM mdaN).

Fig II.

1

inlet valve (4) ta

the hases, the contra) cable ta the cald start flap.

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-

(;' 'T

i +

i

L)l 7-'

-

: : ,

__ r

p

A:! -

:

;

'i

85.614

=

25602 035

T

.1

-;'

-

____

03 Lr

>

85.615

PDF compression, OCR, web-optimization with CVISION's PdfCompressor

M25/659

VD

MA

M251662

RECOMMENDED TOOLS

1682-T

Support for the daLgauge osed to check the TDC

2437-T

Dia

1

-ndicato r

CHECKING THE

VALVE TIMING

*

8531 PDF compression, OCR, web-optimization with CVISION's PdfCompressor

®,;

Remove Co) 1682T,

NOTE:

Never et1erot to rot te thr renkshaft ht n edo the oroehaft puHe c amng nut.

of

Check and edjust the vd)ve ocker ole

Shift in the highest. geer. Move the crankshaft using the RH. med whenL "fl

cm

nlet = 0.15 mm Exhaust = 0.20 mm

Raise the vehicie front ond

Remove, Hg.

re r

Ref it: the cylinderhead sover the inlet pipes,

1:

the spark p(ugs Wghtening torque: 2.5 mdaN),

rn)et pipes (1),

the cyhnderhead cover,

Lower the vehic)e to the ground

the sparking p)ugs

cup

Bring cy)inder No. 4 piston to TDC (with the va/yes in the 'rocking" position) e--

Place too) 1 682-T fitted with cy(inder No. 1, Hg. II. Firid the TDC.

Adjust cylirrder No. 1.10 mm, Hg. Il.

1

a dra)

indicator in

irriet valve (2) ckarance to

Rotate the crankshaft through a complete norma) direction of engine rotation.

tum

in

the

Record the c(earance of cy)inder No. 1 irr)et valve. the figure should be comprised betweer

0.05 and 0.25 mm

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t.:

..I .

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M25/660 M25/648

1

MA 22O/3

1

CHECKING THE

VALVE TIMING

*

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MA

L

CHECKNG THE VALVE T

122OI3

Hacn iho venicrr RH sids on stands

1

Check, Flg.

fl

and Fig. ffi, opposite screw (2),

that mark A

SeIect the (ughest gear.

that there are 35 pitches between marks A and B passing around tensioner roller (1)

is

`f'

Disconnest the hattery negativc CaRle.

'-'

Remove: the road whee),

the filler plug,

fl-

-

Refit:

the wheelarch (ming, the belt protection covers, the engine ou fil(er plug.

thn timrng hell covurs,

Posflon:

the wheelarch (ming,

in the ''rockrng'' position the valves of cyhnder No. (look inte the cii filler neck), a(igned, Fig. 1. the f(ywheel, with marks 1

-

the wheel. Reconnect the battery negative cable.

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MA 122M13

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*

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{°e

MA

1221/1

REF

REMO VAL

ot

up tbc

TaKc off

cWcH

NOTE: Crankshaft otation, two possble mct( ods

Remove Hg. tF

4 t(

road whflH

1

the cor

P H

:

ol ca bIo from bO cchd ntart (la)) (1),

f!exble hose (2),

i(-1

accoler ator

c

onir 0 rod and cable

cylinderhead cover (3).

Loosen, Fig

II,

valve rocker adjustrnont scrows (4) so as to reduce thc strosses n the camshatt.

Fit: Hg, ffi, too! 6012-T, once the ergino tlywheel protechve plate has been removed

ngage the hglres1 gear and torn tho crank shaft by means of the road whoel or the w( co] bob a)

1

Hotate the crankshaft in the normal direotinn of engine rotacon usrng the crankshaft pulley fixing b)

ss rew

fitted with

a

distance pioce

Position: 0

Jack

fl TING

the pistons at mid point of their str oke

(with the crankshaft key placed horizoritally). Adjust the valve clcarance Inlet = 0.10 mm 0.25 mm Exhaust

-

Remove, Fig. IV: the RH wheelarch rubber sea)rng strip, the alternator beR and hoosing, 137

crankshaft pulley (5),

timing belt casing (6), too)

6012-T, Fig. Il!.

Slacken, Fig. IV, the two screws (7) and (8) securing the automatic tensioner by a halt torn,

Compress the tensioner spring arrd rotighten screws (7) and (8h R e move:

the timrng helt.

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MA

1221/1

1

24.

1,1

-;.__-

-

'

r kto

/ yta 1

5

85.61

*

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7 1

f

L9j

r

:

. .

,

1 1

«

,

r

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M25/659 M25/662

MA

1221/2

F?EMOVING AND REFITTING

A TIMING CHAIN, A CHAIN TENSIONER AND THE TIMING GEAR, ON THE VEH/CLE

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*

8531

"r i AND

12

J,

AH

GEAR, O

REMOVAL

v

REF TT N G

Jack up

ln

the ouci

W1

1

RE

A CHA!

ti 1

n

8 H

Hr

it

tm

run )\

1'

tt i im ii itt driv gear vtieu'i fP d witt Itu ni nj tu iii ,u that (tre ii ivung vde busnig tenu inre (1, ''b'' r sitrratu,d -

UJ

Ci)

tr

829 A 5

Q

_

________

25/659

J6T A 500

________

________ ________

1

fEl

25/662

25/662

X

\

X

WEBER carburettor specification

/\

SOLEX carburettor specification

A

WEBER carburettor specification

A

X

WEBER carburettor specification

\

X

General information on carburation

25/660

251648

________ _________ _________ ________

0

Tools

X

________

25/659

_________ ________

X

X

251660

251648

________

_________

X

X

or

25/660

X

X

X

X

X

X

X

X

X

WEBER carburettor checks and adjustments

0

X

X

X

SOLEX carburettor checks and adjustrnents

()

X

X

X

WEBER carburettor checks and adjustments

0

X

AntipoHution systern specification

M2/659

A

X X

engine fuel-injection systern specification

M25/659 engine fuel-injection systern: checks and adjustrnents

(J

X

X

X

X

X

X

M25/662 engine fuel-injection systern specification

0

M25/662 engine fuel-injection systern: checks and adjustrnents

X

X

X

X

Specification and particular features of the DIESEL fuel-inj. systern

X

X

X

X

X

X

Fuel-injection systern: checks and adjustrnents

X

X

X

X

X

X

Rernoving/refitting an injection purnp

X

X

X

X

X

X

X

X

Specification and particular features of the turbocharger

X

____________

0 _____ __________________________ 151.00/2 MA 171.00/1 MA 173.0/1

251659

Specification and particular features of the turbocharger Air circuit specification

.

J

X

X

X

X

X

x

1

Checking the fuel pressure

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LIST OF OPERATIONS APPEARING IN THE CHAPTER:

VEHICLE CONCERNED

FUEL AND AIR SUPPLY - CARBURATION

ENGINE TYPE

_______ _______

-

(1)

OPERATION No

DESCRIPTION >
5

J6T A 500

251659

251659

25/662

25/662

25/660

25/648

25/648

829 A

5

25/659

25/660

25/648

0 ______ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___

MA 175.00/1

Fuel circuit specitication

MA 175.00/2

Fuel-injection system specification

Q

MA 175.00/3

Diesel fuekinjection system specification

Q

Ambulance

Turbo

_____ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ 829 A

A

22

20

(/J

OPERATIONS

X

X

X X

X

X

X

or

25/660

X X

X

X

X

X

X

X

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MA

140/1

2437

T 1

OUT

106030T

T

:4

LIZ.

:

3089 T

OUT

106027T

j

OUT 20 6028 T

H

*

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CARBURATION

142MOOOI1

GENERAL FEATURES OF THE CARBURAT/ON

*

*

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MA 142.000/1

I=-

GENERAL FEATURES OF THE CARBURATION t0-

2

r-+

SOLEX and WEBER carhurettors are fitted with tampeNproof devices for the mixture adjustment screws. The SOLEX carburettor is fitted with protective caps for the throttle spindle stopscrew of 2nd choke and butterfly

adustment screw.

o-,

°'0ö

If the carburettor is not properly adlusted, the original protective plug (white on WEBEF? carburettors, black on SOLEX carburettors) will be removed, and after adjustment of the carburettor, will be replaced by a «REPAIR» protective plug (black on WEBEF? carburettors, and white on SOLEX carburettors).

L-2

The Replacement Parts Department supplies under Reference number protective plugs on SOLEX and WEBER carburettors.

,j]

TOOLS INCIUDED IN KIT 4029-T, Fiq.

1

4029-T

a

kit for removing and refitting the

et II:

A. Gun. B. Too) for loading the gun.

0

C. Too) for extracting the plug (a) protecting the sunken mixture adjustment screw (SOLEX). D. Tool for extracting the plug (a) protecting the sunken mixture adjustment screw (WEBER). E. Tool for fitting plug (a) and cap (b) (SOLEX and WEBER). F. Too) for breaking the head of cap (b) of the sunken mixture screw with collar (SOLEX). G. Tool for extracting cap (b) (SOLEX). H. Tool for fitting cap (c) protecting the stop-screw for the throttle spindle (SOLEX). This kit also contains a set of plugs for SOLEX carburettors: a) Protective plug for mixture adjustment screw. b) Protective cap for mixture adjustment screw with collar. c) Protective cap for throttle spindle stop-screw.

-

°-'

`-°

The Replacement Parts Department supplies caps in packets of 10, under the following reference numbers

Protective plug for sunken mixture adjustment screw SOLEX carburettor WEBER carburettor

No. 75 489 718 (white) No. 5489 716 (black)

SOLEX

No. 5 501 075

SOLEX

No. 5 507 643 (white)

C75

................................................ ............................................... Protective cap for mixture adjustment screw with collar carburettor ................................................ Protective cap for throttle spindle stop-screw and butterfly opening adjusting screw carburettor ................................................

-

-

U

(white)

UTILISATION 1.

REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MIXTURE ADJUSTMENT SCREW ON A SOLEX CARBURETTOR. REMOVAL. Fig. III, IV

et V:

0

1. Load gun A on too) B.

(Dv

vag

2. Pierce plug (a}r position too) C and hold it against gun A. position the gun and tonI assemb)y against plug (a) making sure that the nozzle of gun A is properly centred against the plug, and that the assembly is aligned as precisely as possible in the axis of the plug. actuate the gun, and remove it, leaving too) C on the carburettor. 3. Remove plug (a): - bad gun A. - screw too) C into the back of gun A. actuate the gun to remove the plug.

4. Adjust the level of pollution.

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1

142OOO/1

kizii

A

c

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76.1188

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,

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A

v

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MA 142.000/1

GENERAL FEATURES OF THE CARBURATION

FITTING. Fig.

1

and II:

-°O

°`°

5. Fit the tampec-proof protective plug (a): - !oad gun A. screw too! E onto gun A. - position plug (a) in its housing on the carburettors. - actuate the gun unti! the p!ug is proper!y !ocated.

'f1

II. REMOVING AND FITTING THE PROTECTIVE CAP FOR THROTTLE SPINDLE STOP-SCREW OF 2nd CHOKE (cap c), ON A SOLEX CARBURETTOR.

p_.

a

check and adjustment on

0

This operation is to be carried out only in the case of (L'POLLU 2000 type).

a

carburettor test bench

O'{

REMOVING AND FITTING THE PROTECTIVE CAP FOR OPENING ADJUSTING SCREW OF BUTTERFLY UNDER OPERATION OF COLD START DEVICE. REMOVAL. Fig. III: 1. Remove cap (c) using f!at-nose p!iers.

2. Adjust the butterf!y opening: Adjust the butterf!y opening using the test bench according to the specifications (sent upon request by the bench Maker to the users of carburettor test benches). FITTING. Fig. IV:

3. Fit cap (c):

-

p!ace the tool and gun assemb!y against the cap (c) and actuate the gun.

-

o-D

-

bad gun A, screw too! H onto the gun, f it cap (c) onto the throttbe spindbe stop-screw,

-

III. REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MIXTURE ADJUSTMENT SCREW ON A WEBER CARBURETTOR. REMOVAL. Fig. V: 1. Load gun A on too! B.

öms:

5cö

(L]

m:3 (1)

M--

C-0

2. Pierce piug (a): - position and ho!d too! D against gun A, - position the gun and too! assembby against p!ug (a), making sure that the nozz!e of the gun is proper!y centred against the p!ug, and that the assembby is a!igned as preciseby as possib!e in the axis of the plug. - actuate the gun, and screw the too! into the plug !L.H. thread!. - remove the gun, beaving too! D on the carburettor.

3. Remove p!ug (a), Fig. VI: - !oad gun A, - screw too! D into the back of gun A. - actuate the gun to remove the p!ug.

4. Adjust the !eve! of po!Iution.

*

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HITING. Fig.

CAJ

MA 142.000/1

6

GENERAL FEATURES OF THE CARBURATION

1:

CO-

c.,

5. Fit the tamper-proof protective plug (a): bad gun A, - screw tool E onto gun A, position plug (a) in its housing on the carburettor (make sure it is fitted the right way round Fig. II), - actuate the gun untib the plug is properly located.

EXHAUST EMISSION CONTROL ln order to

comply with current regulations, the checking and adjustment of the exhaust emission from vehicles petrol engine must, without fail, be performed after the following operations:

ENGINE REPLACEMENT. Il=

1.

a

`°?

with

II. CARBURETTOR REPLACEMENT.

III. WORK ON THE CARBURETTOR.

Ffeplacement of parts of the carburettor. Carburettor adjustment. Work on the carburettor controls.

u._

`-°

IV. WORK ON THE INLET MANIFOLD. Replacement or removal of: the inlet manifold, the air filter, - crankcase gas recirculation system.

v-


0,8


9

0 0

800±

3

____

50

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ANTI-POLLUTION

ioii

SPECIFICA TION AND PAR TICULAR

FEATURES OF THE ANT/-POLLUTION SYSTEM

*

*

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ELECTRONIC FUEL INJECTION

"LE Jetronic" System

*

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"LE JETRONIC" ELECTRONIC FUEL

MA

2

14400/1

INJECTION SYSTEM

M251659

"LE Jetronic" system

CL)

The

"LEJetronic" isa fuel injection system which injects intermittently petrol,

at low pressure, into the inletrnanifold.

The main characteristic of the device is to meter directly the air drawn in by the engine, which is the only reference for the fuel quantity to be injected. The fuel metering is carried out by electromagnetically triggered injectors. These are under a constant fuel pressure.

The quantity of fuel injected depends on how long the injectors remain open. The duration of opening is optimally determined for each engine operating phase by an electronic control unit, from data supplied by various electric sensors.

The "LE Jetronic" device is composed of:

COMPONENTS

MADE BY

REFERENCE

BOSCH

0280 000 300

z

No.

l42

Electronic Control Unit IEC,U.l

192

Throttle spindle switch

«

0280 120 301

280

Supplementary air control

«

0280 140

302

Flow meter

»

0280 202 021

345

Electrovalve

»

0280 141 011

576

Injector

»

0280 150 254

683

Electrical fuel pump

»

0580 464 008

731

Relay

»

0280 230 009

841

Water temperature sensor

»

0280 130 026

F

Fuel filter

»

0450 905 002

R

Fuel pressure regulator

»

0280 160 216

1

72

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700

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(2

ELECTRONIC FUEL INJECTION

14OI2

"LE Jetronic" System

*

*

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"LE JETRONIC" ELECTRONIC FUEL

MA 144.00/2

2

INJECTION SYSTEM

M251662

"LE Jetronic" system The "LE Jetronic"

is a

fuel injection system which injects intermittently petrol, at low pressure, into the inlet manifold.

The main characteristic of the device is to meter directly the air drawn in by the engine, which is the only reference for the fuel quantity to be injected. The fuel metering is carried out by electro-magnetically triggered injectors. These are under a constant fuel pressure.

The quantity of fuel injected depends on how long the injectors remain open. The duration of opening is optimally determined for each engine operating phase by an electronic control unit, from data supplied by various electric sensors.

The "LE Jetronic" device is composed of: No.

COMPONENTS

MADE BY

REFERENCE

BOSCH

0280 000 224

142

Electronic Control Unit (ECU.)

192

Throttle spindle switch

280

Supplementary air control

302

Flow meter

'>

0280 202 061

345

Electrovalve

'

0280 141 011

575

Cold start injector

576

Injector

'>

0280 150 200

683

Electrical fuel pump

'>

0580 464 008

731

Relay

0280 230 009

841

Coolant temperature sensor

0280 130 026

870

Slow thermal switch

0280 130 214

F

Fuel filter

R

Pressure regulator

0280 120 313


0450 905 002

0280 160 216

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M25/660

M25/648

ROTO-DIESEL DPA MA 300

D:-

*2/87 DPC MA 260

8443 A 1114

M25/669 (2/87) (J1

-2187

R0T0DlESEL DPC MAS 100

DPC MAS

or

ROTO-DIESEL

F

SL AC

ROTO-DIESEL

F

8361

200 88443 A 360 A B

SL AC

CAV 7111/796

CAV 7111/796

ROTO-DIESEL RKB 45 SD 5422

ROTO DIESEL RKB 45 SD 5422

ROTO-DIESEL RDNOSDC 6577B

R0T0DIESEL RDNOSDC 6751

BERU

0100 221 106

BOSCH

ROTO-DIESEL RDNOSDC 6850 C

BERU 0100 221 106

BOSCH 0 250 200 059

0 250 200 059

ROTO-DIESEL R53 56 501

+®

B

ROTO-DIESEL

Orange paint

R

5356502

R

White paint

M 25/660

53 56 503

C

Blue paint

M 25/648

M 25/669

By timing marks on cylinder block and flywheel

STATIC

SETTlNG2/87

4.32 ± 0.05 mm

22°

or

2/87--

3.58 ± 0.05 mm

BTDC

BTDC

19° Engine hot at

a

speed of 800 ± 25 rpm

10.30' ± 1°

9° ± 1° 800 ± 25 rpm

IDLING SPEED

ANTI-STALL

3.24 ± 0.05 mm or

4.71

DYNAMIC

TIMING

BTDC

DPA 800 ± 25 rpm DEC

800 ± 50 rpm

800 ± 50 rpm

MAXIMUM NO LOAD

4625 ± 125 rpm

4550 ± 200 rpm

4400 ± 125 rpm

SPEED

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122

bars

M25/648

137

bars bars C31

127

bars

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*

8531

FUEL SUPPLY

EL

CARBURATION

MA 146.0/1

RECOMMENDED TOOLS

2437-T.

DiaLgauge.

3089-T.F.

Dial-gauge.

3089-T.H.

Feeler.

4026-T-bis.

Injector test bench.

4059-T.

Right angled lever for dial-gauge.

5008-T.C.

DiaLgauge mounting fixing screw.

6027-T.

Set of 3 tools.

6030-T.

Dial-gauge mounting.

CHECKING AND ADJUSTING THE FUEL INJECTION SYSTEM

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MA

Pst

CHECKING AND ADJUSTING THE INJECTION SYSTEM 111

2

146.0/1

ADJUSTING THE INJECTOR SETTING PRESSURE (:i

1.

c

Test fluid:

Keep the equipment dean. The parts should be lubricated before assembly.

Deodorized petroleum or Kerdanne or Dilutine. Viscosity. to 2.5 centistoks at 20°C. Density: 0.770 to 0.810 at 20°C. 1

-

ln the injector-carrier body (3), place: -

injector

(41

and its nut 15), Q_)

Tighten to 6.5 mdaN Precautions to be taken: As the flash point of paraffin is low, it is essen tial to ensure that at safety precautions are taken before the test.

push-rod (6),

-

spring (71,

adjustment screw (2). -

Adjust the pressure:

n-+

Keep your hands away from the spray (use a transparent protective screen). The penetrating strength of these sprays is such that they could create serious injuries and cause blood poisoning.

-

arm.

M 25/660 Pressure

112

bars

setting

Checking the setting pressure:

Inlector

Actuate the pump lever slowly; record the pressure value measured by the manometer on opening the injector Icalibration pressure). Write the value down. The pressure setting is carried out using screw Fig. 1.

0 RDNOSD

6577

bars

0

B

RDNOSD

RDNOSD

68-50

6751

C

RKB45SD

RKB45SD

RKB45SD

carrier

5422

5422

5422

orange

white

blue

mark

-

+5

25/669

Fit seal (8) and cap nut (1). Tighten to 2 mdaN

Checking the spray: actuated with a brisk sharp action, the injector should produce a very fine and homogeneous spray. If the pump lever is

fl.

n-.

Injector setting pressure adjustment screw (21 is to be screwed in or out on the test bench 4026-T. bis only. The fuel pump lever must be operated continually to keep the needle and its seat lubricated and cleaned.

127

M

Injector

Paint

121.

M 25/648

Checking the needle seat for leaks: Test should be carried out with the injector in cal position.

a

verti-

'",

DISMANTLING To open an injector-carrier, place it in ped with lead vice grips.

a

vice equip-

fp'

.a:

Never tighten an injector-carrier alone in vice.

Wipe the end of the injector until dry.

actuating the pump lever, maintain a pressure 10 bars below the setting pressure. The injector should not drip within 30 seconds, By

Moistening should not be regarded as rejection.

a

reason for

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*

8531

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CHECKING AND ADJUSTING

MA 146.0/1

THE NJECTION SYSTEM

-

INSPECTION AND TIMING OF THE "ROTO-DIESEL" INJECTION PUMP

Raise the LH side of the vehicle and support it on stands.

Disconnect the battery negative lead.

Timing the injection pump: - set the engine to the initial

,-«

-C>

wheel.

tum

-

align marks on the flywheel and on the crankcase

the crankshaft back through

a

quarter of

a

torn

Slacken off the injector pipe connections and the 4 attachment points. Bring the pump to the injection point with the feeler at the base of V-shaped groove Itiming point).

"0"

mark on the dial opposite the needle on Set the the dial-gauge. Orientate the pump casing towards the engine.

Slowly tum back to the injection point Ineedle facing the "0" mark on the dial), by moving the pump casing away from the engine (in the opposite direction to engine rotat/on). -..

tum

Adjusting tho pump tim/og, Fig. III:

C/)

place cylinder No. 1 valves in the rocking position; the crankshaft by one tum in the normal direction of engine rotation. _5-

-

1

the crankshaft by 1/4 tum in the opposite direction to normal direction of rotation, then tum back in the direction of rotation to bring marks (--) and l--) opposite.

- tum

Engage the 5th gear. Rotate the engine by turning the

Set the No. 1 cylinder to the initial timing point, Fig.I. (look into the oil filter orifice).

timing point, Fig.

0.5

II.

Remove either the plug (with a 32 mm ring spanner) or the inspection plate depending on the type of the pump.

Tighten the pump fixing nuts to 2.4 mdaN. During +'_-

this operation, the needle should not move.

Refit, Fig

II

or III, according to pump:

Check the pump timing

-

the support for the dial-gauge.

Remove the timing tools.

-

the dial-gauge equipped with ts right-angled lever.

+"'

the feeler,

Refit the plug, (tighten to 2 mdaN), or the inspection plate.

,-t

Finding the pump internal timing point:

(/)

the crankshaft in the direction of rotation until the large pointer on the dial indicator starts moving in the opposite direction.

- tum

-

set

"0" mark on the dial-gauge in line with the large

pointer.

Reconnect the battery negative cable

0

E

t.1_

rotate the crankshaft by a quarter tum in the opposite direction to its direction of rotation. tum

Tighten the injector pipe connections to 2 mdaN. Switch on the ignition (electricai STOP solenoid cxcitationl and prime the tuel circuit using the manual pump 15) located on the filter.

Checking the injection pump timing: -

Seal the injection pump plug.

Fully depress the accelerator pedal to facilitate the engine bleeding and start.

back in the normal direction of rotation until the mark on the dial-gauge has been reached.

"0"

re-check the timing.

(--( should

be in line,

Note: the initial timing point corresponds to:

3.24 ± 0.05 mm BTDC: M 25/648 4.32 ± 0.05 mm BTDC: M 25/660 DPA pump 4.71 ± 0.05 mm BTDC: M 25/660 DPC pump L31

and

000

If not,

(--l

C'')

in that position, marks Fig. 1.

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CHECKING AND ADJUSTING

MA 146.0/1

6

THE INJECTION SYSTEM

m

III. - ADJUSTING THE ROTO-DIESEL INJECTION PUMP CONTROLS

DPA type pump from engine M

25/660, Fig.

L!')

25/648, Fig.

E

DPC type pump from engine M

1

II

ENGINE COLD

Set the engine speed to:

Checking the fast-idle control

0

v:3

(DPC pump)

(DPA pump) E

800 ± 50 rpm 800 ± 25 rpm

l--).

-f-)

Ensure that lever (7) is against ts stop, by pushing it in the direction of arrow If not, adjust tension of cable by means of cable end clamp (6). Complete tightening of cable using sheath tensioner (4)

by turning stop screw (5).

Remove the 3 mm dia, rod and the shim.

Adjust the idling speed to: 800 ± 25 rpm

ENGINE WARM

by turning stop screw (8).

1

Checking the engine deceleration:

Make sure that the cable is slack.

Accelerate the engine to 3.000 rpm, then release the accelerator lever sharply. - if the deceleration is too fast (engine often stalling), unscrew stop-screw (5) by 1/4 tum,

If not, check the operation of the thermal sensor (10) loca ted on the water out/et duct: the cable must operate over a range of 6 mm between its "ENGINE COLD" and "ENGINE WARM" positions.

+-'

Checking the fast-idle control

if the deceleration is too slow (poor engine braking), screw up stop-screw (5) by 1/4 tum.

ln both cases, checK the idling speed and adjust if

Adjusting the accelerator control

necessary.

Engine stopped: If the malfunction continues to exist, carry out the adjustments again.

Fully depress the accelerator pedal.

Check that lever (1) is against stop (2).

(3) of acce/era tor cable. Make sure that, at idle, lever (1) is against stop (5).

If not, move

pm

Check the efficiency of the mechanically operated STOP control (9).

t!1

Adjusting the anti-stalling device Engine running:

lnsert

a

1.5 mm thick shim (DPC pump, Fig. Il mm thick shim (DPA pump, Fig. II)

2

between lever (1) and stop-screw (5) at

"b".

+-+

(/)

Place a 3 mm dia. rod through the hole in lever (7) at "a" by pushing STOP lever (9) outwards.

Note: The setting figures are identical if the vehicle is equipped with air-conditioning and the adjustments are to be effected with the air-conditioning off.

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INI

FUEL SUPPLY

0

CARBURATION

MA 146.1/1

RECOMMENDED TOOLS

2437-T.

:

3089-T.F.

3089-T.H.

DiaL-gauge

Dial-gauge.

:

Feeler.

4059-T.

:

Right-angled lever for dial-gauge

5008-T.C

:

DiaL-gauge mounting fixing screw.

6027-T.

:

Set of 3 tools to check the timing.

6028-T. 6030-T.

:

Driving pinion extractor.

:

Dial-gauge mounting.

REMOVING AND h'EF/TTING DP.A. AND D.P.C. ROTO DIESEL INJECTION PUMPS

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2

REMOVING/REFITTING D.P.A. AND

DPC. CAJ

J MA 146.1/1

ROTO DESEL INJECTON PUMPS

,

. 1

REMO VAL Raise the RH. side of the vehicie and support it on

stands. Disconnect the negative !ead from the battery.

USED.

+-'

Engage the highest gear. Using the road wheel,

MANDATORY: TO AVOID THE PUMP BEING DAMAGED NTERNALLY WHEN REMOVING THE DRIVING PINION, PULLER REF. H AND ITS NUT J FROM TOOL BOX 6028.T MUST BE

tum

the engine. 1

cylinder to the initial timing point, Fig. +..

Set No.

1.

Slacken the nut of too! 6028.T until the injection pump drive shaft starts moving.

(look into the oj! filler hole) -

Bring cylinder No.

1

valves into the rocking position

by rotating the engine one -

Fit the nut and clamp of tool 6028.T, Fig. II.

Marks-and--should

tum

clockwise.

be aligned.

Disconnect the e(ectrical STOP solenoid. Uncouple:

-

the road wheel,

»

the whee(arch (ming,

-

the be(t upper protection cover.

Loosen: -

-

the accelerator cable,

-

the fast idling cable,

-

the fuel supp(y pipe,

-

the fuel return pipe.

`-'

Remove:

DPC injection pump, Fig. III:

Disconnect from the overfuelling circuit: -

the injection pump driving pinion nut,

the diese( fuel return pipe (2!,

the air pipe (1).

the helt tensioner nut,

`D-

compress the spring of the tensioner. Push the diese! fuel filter to one side.

Re move:

the pinion nut,

-

the injection pump driving helt.

-°-

-

Remove: -

the spring,

-

the injectors sets of feed pipes,

-

the pump fixing nuts (3) Fig. IV.

by means of a 13 mm A/F

open spanner

and a 6 mm hexagon Al/en key.

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INI /

/

/ 1r

MA

3

1461I1

iL:] r- -l

-

..

-

-

-

;

4r

1

Nid

114.40

III

(Q

6028 T 114.42

114.44

It

*

Iv

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2

REMOVING/REFITTING D.P.A. AND D.P.C.

MA 146.1/1

1

ROTO DIESEL INJECTION PUMPS

5

REFITTING

Remove the tools

Prepare -

MA 146.0/1).

the pump (see Op.

Refit: ter

either the p)ug ttighten to 2 mdaN),

Fit - the pump

with the mounting studs

the slots,

or the inspection plate. ,-t

Seal the injection pump plug.

the pump fixing nuts but do not tighten home. II)

-

-

in the middle of

Refit: -

1:

the belt upper protection cover, ."C-

E

Assembie, Fig.

- the

wheetarch lining,

- the

accelerator return spring,

the pump drive belt with the side opposed to the tension roller being without slack (take care not to rotate the pump).

- the

injector set of feed pipes.

,-r

the injection pump driving pinion (1); hand tighten nut (2), ,..,

..'

Tighten to 2.5 mdaN.

fl.

avi

Recouple: °_)

Unscrew, Fig.

1:

-

ute.

tensioner nut (3); et the tensioner bad the belt without assistance.

Retighten, Fig.

- the

accelerator cable,

- the fuel pipe, - the return pipe,

1:

tensioner nut (3) to 2 mdaN,

D.P.C. pump, Fig. III.

2

-

the fast idle cable,

- pinion nut (2) to 5 mdaN.

Connect to the overfuelling circuit, avi

- the diesel fuel return pipe (6), - the air pipe (5).

._.

Carry out the pump timing: the pump towards the engine to find the point of injection, (needle facing the "0" mark on the dial). Tum

Put the fuel filter back into place.

Reconnect: - the

Screw up, Fig. II, to 2.4 mdaN,

electric STOP solenoid,

- the negative cable

to the battery.

°_'

- the pump fixing screws (4); when tightening, the dial

gauge needle should not move.

Check the pump timing (refer to

MA 146.0/1).

Prime the fuet system using the manually operated pump located on the filter.

Adjust the injection pump controls and idling speed as explained in Op.

® MA

146.0/1.

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MA 151.00/1

GarrettTAO3

M

25/662

T3--M25/666

__ TAO3

:4l0mbar MAXI

T3

:440 mbar

flui _ 6-'I

5000 tr/mn

OOOH

_

1

MAXI

(1

_

\

/L\

_

P71

)7i10000C

1

0,025 _. 0,100 mm

[_0,7

_. 2,1 bar

0,080 _- 0,165 mm

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___

MA 151 .00/2 j

EI

fEI:j1

Garrett TAO3 -* M 25/648

T025

M

25/669

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CARBURATION

17/1

SPECIFICA TION AND PARTICULAR FEATURES

OF THE AIR SUPPL Y SYSTEM

*

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MA

SPECIFICATION AND SPECIAL FEATURES

171 OO/1

OF THE AIR SUPPLY SYSTEM

(J1

829A5

m

2

Engines types

and J6T.A500 are fitted with

a

device regulating the temperature of intake air.

ill

This device has been designed for maintaining a minimum temperature of the air drawn into the carburettor It consists of a thermal sensor and a vacuum capsule operating a flap.

Thermal source 0

The thermal sensor is located in the pipe connecting the air filter to the inlet manifold ol the carburettor. CD-

This bimetal type thermostat, is subjected to the inlet air temperature. It controls the opening of valves allowing passage

for

a

depression towards the capsule.

+-.

This depression is picked up by a union having a calibrated orifice, fitted to the pipe connecting the ou breather to the intake manifold of the carburettor, and by a Tshaped union situated near the carburettor base plate, 50 as to have an action over the engine bad. +-'

The thermal sensor allows the depression to circulate when the temperature is bebow temperature exceeds 25°C.

1

5°C and stops it when the

Vacuum capsule. The capsule, bocated in the inlet of the air filter, is subjected to the depression. When energised, it operates a flap which lets the heated air coming from a tapping bocated on the exhaust shiebd enter. At rest, the flap lets intake air coming from behind the grill enter.

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CARBURATION

MA 173.0/1

CHECKING THE PETROL SUPPL Y

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2

1

7I1

CHECKING THE PETROL SUPPLY

829.A5-J6TA5OO

1

Pump AC DELCO TYPE: PB3

Oms

CHECKING THE PETROL PRESSURE WITH APPARATUS 4005-T: Position apparatus 4005-T.

-

Disconnect the carburettor fuei return pipe; fit p)ug (2).

-

Unscrew tap ED by one

-

Start the engine.

,-,

-

tum

approx.

,,,

a) Check the petrol pressure at zero delivery: a

reading of more than 325 m.bar for the stabilised pli

screw up the tap; the pressure shou(d not show pressure.

- FuHy

b) Check the tightness of the pump delivery valve: Stop the engine: there should not be a sudden drop in pressure.

c) Check the tightness of the carburettor needle valve: -

-

0

'2n

-

Unscrew tap ; start the engine, leave it running for a few minutes. Stop the engine: there should not be a sudden drop in pressure. Remove apparatus 4005-T and f it the fue( suppy pipe and the fuet return pipe to the carburettor. (after plug (2) has been removed).

CHECKING THE PUMP FOR LEAKS: Close the pump detivery tube. B)ow compressed air under 800 m.bar pressure into the suction pipe. Immerse the pump in a container filled with c)ean White Spirit: no eak should be detected.

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8531

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MA

_____

17500/3

_______

M25/660 M25/648

99

/

ISNI

2

\//

CO

LO Cs,1

LJ t (0

co

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X

X

X

X

X

X

8531

El. the Checking

X

X

X

X

X

X

0

X

X

0

X

X

x

x

X

X

X

X

X

25/648

X

X

X

X

X

________

.

________ _________ ________

________ ________

X

X X

X

25/660

25/659

Familiale +

Injection Petrol

Satari 25

5 A

829

Familiale + Petrol

25/648

25/648

251660

Turbo

Safari 20

Diesel

Diesel

25

25/662

25/662

251659

Prestige

Petrol

Prestige

25

25

________ 251659

Injection Petro

5 A

_

829

adjustments and checks ignition: Transistorised

_Q (.1)

-

210.0/2 MA

210.00/3b MA

the of features Special

210.00/4 MA

the of features Special

(7/85 2500

210.00/3a MA

[EJ. the of features Special (7/83 2500

the of features Special

specification ignition Transistorised

A

A -

210.0/1 MA

210.00/4b MA

) (7/86 Turbo litres 2,500 sensor single with El. the of features Special

-.--7/86)

tEL sensor single with El.

7/86)

-7/85)

0.00/3 21 MA

the of features Special

[El. (-'--7/83) 2400 EL

ignition electronic integrated the on information General

A

ignition transistorised the on information General

X

________ ________ 500 A J6T

Petrol

20

210.00/2 MA 210.00/1 MA 210.000/2 MA

210000/l MA

_____________________________________________________________________________ _________________

w >
0,8 - 0,9mm
'N

VI

6

i?

r',, 14-

E J

41

83 26

1:

1

MP

IC

-

4M3

DM1

IM

1

2

*

3

4

5

6

1

8

9

10

Il

12

13

14

15

16

1

17

1

18

19

20

1

1

21

22

1

1

23

24 25

26

21

28

29

3Q

1

31

32

33

34

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MA

IIII

_,

the adjustment shim (6) found on dismantling, facing

forward.

:-"

pm

Uncouple ball-joint (3) from the anti-rofl bar link rod

Engage the spindle

using pu)ler 6320-T, Fig. Il.

;

place a new NYLSTOP out.

Tighten to 12.5 mdaN

Screw up the too! out in the bal/-joint stem. Fit the too! cross piece and pio. Recouple the upper ball-joint. Tighten the new NYLSTOP nut to 7 mdaN

p_)

Extract, Fig. III, - the not

from upper ball-joint (4). Reconnect the anti-roll bar link rod (wipe the bal/-joint fixing but do not use solvent).

Disconnect the upper bafl-joint.

Tighten the new NYLSTOP out to 4.7 mdaN ...

NOTE: 't''

-«,

the vehicie is fitted with the ABS, the removal of the upper ball-joint nut requires pushing back the transmission. if

Remove: - the pm, - the nut (ock, - the drive-shaft nut.

Fig. IV - nut (5),

Refit the suspension cylinder pivot and pm.

Vehicies equipped with the ABS: Fit the drive-shaft nut (with the faces and threads lubrica ted).

Tighten to 37.5 mdaN.

Replace: - the nut lock,

Fig. V - the spindle with extractor 6303-T.

-

the pm, the road wheel.

T1.

Remark: An adjustment shim may be found between the arm and the front face of the subframe.

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MA 412.1/1

;Sr

i:

V

VI

13.774

IV

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*

FRONT AXLE

MA 412.1/2

TOOLS TO BE USED

1671-T

3312-T

Inertia extractor.

Lower wheel arm ball-joint extractor

with bosses.

or 6323-T

Lower arm ball-joint extractor with or without bosses.

63O6T

Adaptor.

6312-T

Expandable element to secure the lower wheel arm fluid b!ocks.

66O2T

Set of three stands.

REMOVING AND REFITTING A LOWER WHEEL ARM

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*

REMOVING AND REFITTING

MA 412.1/2

A LOWER WHEEL ARM

REFITTING

Support the front of the vehicle on stands 6602-T

Note: the RH and LH arms are not alike.

Release the pressure in the hydraulic system.

If the wheel arm has been removed following an impact, it will be necessary to readjust the caster angle.

Set the height control lever to the

«

low

»

position

Withdraw:

Place the expander of too) 6312-T in the wheel arm, with screw A pointing rearwards, Fig V. C01

wheel,

-

the brake pad wear warning lamp harness holding clips,

-

the lower ball-joint nut.

Fig.

1

Take off: -

16)

into contact, Fig. V. ln order

to do so:

Uncouple the lower ball-joint from the arm using puller

3312-T or 6323-T, Fig.

Bring tubes (5) and

0(0

- the road

+''

REMO VAL

VI:

-

Grip the arm in

-

Tighten the expandable element by means of spanner B from tool 6312-T.

a

vice,

the plastic trim cover, nut

(il,

Fig. II,

with the help of inertia extractor 1671-T and adaptor 6306-T, Fig. III.

- spindle (2)

Mark adjustment shims (3) and (4) location, Fig. IV.

Remove the wheel arm.

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MA 412.1/2

Iv

v

G. -

t.i___ :L.....

-

.

t

:

1671T

*

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AVANT

ARRIERE

141.5

13.602

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A LOWER WHEEL ARM

Refit

Fig.

MA 412.1/2

LO

REMOVING AND REFITTING

5

1

the arm together with its adjustment shims (1) and (2) placed in the position they were found on dismanting.

Insert

spindle (3), Fig. Il.

Loosen

expander A with tool 6312-T spanner B.

Drift out

the assembly via shaft (3).

Tighten

the new NYLSTOP nut (4) to 14.5 mdaN, Fig VI.

Reconnect the (ower baU-joint to the arm (wipe the ball-joint fixing bot do not use solvent).

Tighten

the new NYLSTOP nut to 6 mdaN.

Reinstall

-

the brake pad wear warning lamp harness securing clips,

- the road

wheel.

Lower the vehicie to the ground.

*

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41/1

L1671

1

T]

OUT 30 6322 T bis

OUT 32 6335 T

1

t

*

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2

412.3/1

0

c,9

012mmJ

0

-

1J

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*

8531-8532

41/1

85,648

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III PDF compression, OCR, web-optimization with CVISION's PdfCompressor

*

8531-8532

6

4123/1

85.656

I

— 85.659

I

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(/

1

ILJ

MA 412.3/1

IN -1/87 X = e

= X

-

B-A 9,34± 0,08 mm AR

AV

1/87-- T.BCX®

N°2

85.718

85.651

*

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A

8412

r1J 9,34

9.341 10,04

G6

85.653

I

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0)

071

412.3/1

-

-;

.-'

p -

*

(N

c)

LO

8531-8532 PDF compression, OCR, web-optimization with CVISION's PdfCompressor 0

c-)

LO LO

*

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2

4i/2

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t

MA 412.3/2

/

WULkLWÅWÅW -

3

1

1

85,755

rL 85.750

--

,'

.

.

-p.

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MA 412.3/2

j

4

f

MAXI 1,2 t.

1w1J

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FRONT AXLE

41/1

TOOLS TO BE USED

Hub locking tool

3312-T.

Lower arm balkjoint extractor, with bosses .n°

6310-T.

or

6323-T.

Lower arm ball-joint extractor, with or without bosses Torque wrench (40 mdaN) Sleeve 35 mm A/F

REMOVING AND REFITTING A SWIVEL

*

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MA 413.1/1

2

REMOVING AND REFITTING A SWIVEL

ABS vehicies, Fig.

REMOVAL

$V

Support the front of the vehicie on stands. (1

E

0) securing the sensor.

II'

Extract the screw

Depressurize the hydraulic systems

CD>

avi

Disconnect the brake pad wear warning lamp

Remove:

harness.

-

the road wheel,

-

the pm, the nut ock,

-

the nut (35 mm AlF)

Withdraw: -

Lock the wheel hub with tool. 6310-T, Fig.

1.

the brake disc cooling plate, the harness screw and fixing bracket; release the harness.

Remove the lower ball-joint nut.

Fig. II: nut 11) and its washer; disengage the ball-joint from the swivel,

-

lock nut (6>,

-

nut

t-'

-

Uncouple, Fig. II and III

-

o

cup 141, connection 17).

Pull out the drive-shaft.

Take off nut (11) from the upper ball-joint, Fig. VI. -'^

-

c-0

avi

cable 12) from the contro) lever, spring 131,

III

151.

Uncouple the swivel lower ball-joint using extractor 3312 T or 6323 T, Fig. V, (avoid damage to the bal/-joint protection rubber).

Uncouple the upper ball-joint. Take off, Fig. ID, nut (8) together with its washer. Remove the swive).

Liberate f)exible pipe (9) from ts fixing bracket, Fig. III.

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ini

ini

MA 413.1/1

3

L63 1 OT 13751

1'

..,..'..

,

:l:11

L_1.

1

Ik ..:

-

$S7

{t.

3312Tou 6323 T]

1 86752

-

86.754

:

7>9

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t[1

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8531-8532 PDF compression, OCR, web-optimization with CVISION's PdfCompressor

-

ini

MA 413.1/1

Ii

-.

-

L

-

36.754

,a3

Iv

PDF compression, OCR, web-optimization with CVISION's PdfCompressor

MA

REMOVING AND REFITTING A SWIVEL

5

4131/1

Replace, Fig. IV:

REFITTING Wipe the bal/-joint fixings and location, do not use solvent.

-

flexible pipe (11) into its fixing bracket, washer (10).

Recouple the upper ball-joint with the swivel.

Tighten nut (9) to 2.2 mdaN.

Refit, Fig.

Recouple:

1:

-washer (1),

- Fig.

IV, connection

(1

2) provided with a new sea!.

not (2). -

Fig. V, the steering ball-joint.

Tighten to 7 mdaN (New NYLSTOP nut).

Refit: Introduce the drive-shaft end into the wheei hub (lubricate the hub sea! 1/ps).

-washer (13), nut (14) (New NYLSTOP one).

Couple up the lower ba)I-joint.

Tighten to 6 mdaN.

Tighten to 6 mdaN the new NYLSTOP nut.

Reconnect:

-cup (17), Reconnect the brake pad wear warning tamp harness.

Refit, Fig.

and III:

Adjust the handbrake (as indicated in

electrical harness fixing bracket (4),

©

454.0/1).

'LO

-

II

-spring (16), -cab(e (15).

pli

Cl)

- earth ead (5),

"-'

Put the drive-shaft nut into place. (Faces and threads lubricated).

screw (3), - metal panel (6). -

Lock the hub, utilizing too) 6310-T Fig. VI.

ABS vehicles, Fig. III: Tighten to 37.5 mdaN.

Reinstafl sensor (7) (spread MOBIL TEMP No. grease over the ou ts/de of the sensor.

Tighten screw (8) to

1

mdaN.

1

Bleed the front brakes (see @ 453.0/1).

Fit the wheel.

Lower the vehic(e to the ground.

*

853 1-8532

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FRONT AXLE

MA 426.1/1

TOOLS TO BE USED

3312-T.

Lower arm baIJjoint extractor, with bosses

or

6323-T.

Lower arm ba-joint extractor, with or without bosses

6310-T.

Hub locking toot

Torque wrench too! (40 mdaN)

Socket, 35 mm A/F

REMOVING AND REFITTING A FRONT WHEEL HUB

*

c3,

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REMOVING AND REFITTING A FRONT

MA 426.1/1

2

WHEEL HUB

c

REFITTING

Support the front of the vehicle on stands.

Introduce the wheel hub into the swivel.

--a

REMOVAL

Take off the road wheel. :3'

Withdraw, Fig.

Position the screws previously fitted with /ugged contact washers, Fig. III. Tighten to 2.7 mdaN. 1

the pm, -

the 35 mm A/F nut.

Insert the drive-shaft end into the wheel hub (grease the sea! contact face).

Couple up the lower bati-joint. Tighten the new NYSL TOP nut to 6 mdaN. (Wipe the ball-joint fixing and recess, do not use so/vent).

Remove the brake disc (as stated in chapter op.

MA451.1/3).

irr-

Lock the hub with tool 6310-T.

@,

Extract the swivel lower ball-joint nut

Refit the brake disc (Refer to

MA 451.1/3)

fl

Relocate, Fig. IV -

Uncouple the swivel lower ball-joint, Fig. II, using either puHer 3312-T or puller 6323-T (be careful not to damage the ball-joint protection rubber).

Liberate the drive-shaft.

Gli

the nut lock,

."r

-

the nut, use tool 6310-T to hold the hub in position, tighten to 37.5 mdaN, the out lock,

- the pm.

Bleed the front brakes (See

MA 453.0/1).

Take out, Fig. III Reassembie the road wheel. '-'

-

the screws, the hub.

Lower the vehicle to the ground.

.

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MA

426.1/1

/.

13.751

Ii'

II

13.750

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*

8531-8532

LIST OF OPERATIONS APPEARING IN THE CHAPTER:

VEHICLE CONCERNED

REAR AXLE

ENGINE TYPE

Petrol

25 2

Petrol

PERATION No.

DESCRIPTION

TEXTS

UD

UD

>


REMOVAL

Remove the road wheel. Release the pressure in the hydraulic systems.

Remove protection plate (11, Fig.

1/87 -* the thrust cups are identical and the adjustment is effected by means of shims facing the exterior of the vehicle.

1.

Vehicie having the A.B.S. fitted, Fig.

Il:

Return the shaft to its original location.

Withdraw sensor

13) and push aside the meta) panel and sensor, liberating the electrical harness from the retaining clips.

öö,

Remove suspension cylinder 15), Fig. III. (As explained in MA 433. 1/2).

Place nut (8), new NYSL TOP out, Fig. IV. Tighten to 13 mdaN.

Recouple the anti-roll bar, Fig. III. Add the screws (6) and (7) together with the adjustment shims and washers found at «a» and «b» on dismantling.

Take off fixing lug 14), Fig. III.

Tighten screws (7) to 6 mdaN and

16)

to 10 mdaN.

Uncouple: -

the anti-roll bar, Fig. III. ln order to do so, extract screws 16) and 17) and keep adjustment shims and washers «a)) and «b».

C13

Take off out

18)

24 mm A/F, Fig. IV.

Reconnect brake hose (2) Fig. sleeve sea!. Tighten it. 'f!

1,

61'

- brake hose (2), Fig.

1,

fitted with

a

NEW

Refit fixing lug 14), Fig. III.

Locate suspension cy)inder 15), Fig. IV. (See MA 433. 1/2).

®

+-,

Free the shaft and remove the arm.

ABS vehicle, Fig.

II:

'"'

Refit sensor (3), (grease the outside

of the sensor with

MOBIL TEMP No. 1).

Tighten the screw to

1

mdaN.

Reassembie: -

protection p)ate (1), Fig.

-

the road whee).

1,

Lower the vehicle to the ground.

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ini

MA 422.1/1

/

ir

85.603

Iv

3T

2(

142.5

II

v

sia

85.61

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*

8531-8532

VEHICLE CONCERNED

LIST OF OPERATIONS APPEARING IN THE CHAPTER:

SUSPENSION - WHEELS

-

a

.,...

MA 433.1/2

Removal/refitting of

0

a

rear suspension cylinder

MA 435.1/1

Removal/refitting of an anti-roII bar

MA 435.1/2

Removal/refitting of

front suspension cylinder

0

0

a

rear anti-roll bar

Special features of the wheels and tyres

A

Prestige

(-D

Turbo

Petrol

5

Diesel

Turbo

DseJ Turbo

25

20 Safari

Limousine

Petro!

Diesel

+

Turbo

Familiale

829 AS

25 Safan Petrol

Injecton

25 Safari

OJ + Familiale

25 Satari Diesel

Ambulance

Turbo

_____ ______ _____ ______ _____ _____ ______ _____ _____ ______ _____ _____ ______ ______ _____ _ ______ 829A5 829 AS

J6T A 500

25/659

25/659

25/662

25/662

25/660

25/648

25/648

25/659

25/660

25/648

___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___

or

25/660

X

X

X

X

X

X

X

X

X

X

X

X

X

X

0

X

X

X

X

X

X

x

`-'

Removal/refitting of

Injection

Petrol

Prestige

0

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

0

Specification and particular features of the suspension

Petrol

Petrol

5

5

x

0 0

A Q

Tools

MA 433.1/1

MA 471.00/1

0

>


QI

II IF11

F12

1

Lfi 0 '

721[

_721

H

Irc

255L

'-'

Gli

I1

---

--------------

1

BM

Vi

735

B

F13

vivT j532J

882

B

III

vi

Jl

RIN

-H----

Wi

1

Mi

TIT

B3

GR

B

1U12

VN

254

GLI

1115

JN

L+0r

IN

V Mv

vi

1I3

L

JF7

______

T

7-85

__________

=-j

mT3

-

cal

-

[

1_y

F8

GTI

1-Z

-CX25

J!

12

1

-CD

1

12345678915012345678916012345678917012345678 918012345678919012345678920012 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

`.'

..n

PDF compression, OCR, web-optimization with CVISION's PdfCompressor 151.176

ARRANGEMENT OF THE ELECTRICAL

STALLATION

REP.

c-n

51OO/1 CONNECTOR

LOCATION

DESCRIPTION

.

.

Circuit

Wiring

Front cigar iighter and (ighting

172-186

j5

10

Alternator

86 to 89

b6

44

Digital display

67 to 74

f5

45

Battery

2

b8

46

Instrument panel

63 to 108

g6

51

Ignition coii cyls

& 4

57-58

c6

52

Ignition coil cyls 2 & 3

61 -62

57

Fuel metering unit (optionl

60

__________________________________________________________ 1

Number

.

0

.

Channel-colour

1

HARNESS (or unitl

3B-l V

lic

&

1

lN

lN

H

M & CA

5V &

BA

lN

CP & CN

*

T

3N

Z

c6

3N

Z

47-48

j5

4B

0

Air conditioning control unit loptionl

12 to 15

h5

7B

0

81

Interior heating control unit

27 to 30

h5

LO

8N

K

84

Coolant level indicator und

76 to 78

e4

5B

D

89

Door locking indicator lamp unit

166-167

j5

5N

H

90

Door locking control unit

159 to 169

j5

9V

H

91

Remote control door locking unit

155 to 157

n5

8N

P

92

Interior lighting timer

152 to 156

iS

7M

H

93

Buib failure detection unit

191-200

s8

-Q7

,..,

CAD

0

1

o 83, 139-

*

3B 6B 6J

2xW

L &

g8 g6

5N

1

Flywheei datum sensor

60-61

c6

2M

Z

132

Flywheel teeth sensor

58-59

d6

281

Z

136

ignition vacuum sensor

59 to 61

e3

30r

CD

140

Mileage sensor (option)

50

e7

2B

0

141

(El

54 to 65

e8

142

Injection electronic control und

39 to 49

g3

25N

170

Boot light switch

171

s6

lM +

174

Boot door locking switch

166

tS

2M

C

180

Reversing lamp switch

33

d6

Stop lamp switch

139

h6

lN-lV lN-lM

0

185

190

Hand brake switch

90

k5

2M

H

192

Thrott(e spindle switch

45 to 47

b4

3N

IC

229

Ignition switch

38-130

h7

4M-4B

95

230

LIH front door switch

154

f9

lM

H

231

R/H front door switch

155

fl

lM

H

232

LIH rear door switch

157

k9

lM

H

233

R/H rear door switch

158

kl

234

Glove box switch

170

f3

235

Hydraulic fluid low pressure switch

81

e6

236

Hydraulic fluid leve) switch

80

e8

lM 2x lic lM lic-lM

G

237

Coolant low level switch

76-77

e3

3R

D

Side lamp audible warning

131

'-'

,,-

control und

*

5-27,

1

(ID

127

0-)

157-158

0)-03

*

--+

*

-,t

Junction/fuse box

LO

95

81

f,,

33-109-110,

.

,

5B-l SN

Z IC

1

E

H

H H G

Particular Specification

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ARRANGEMENT OF THE ELECTRICAL INSTALLATION

MA

1

510 . 00/11

CX 25 GTI

7/85 CONNECTOR

LOCATI0N

DESCR(PTION __________________________________________________________

Circuit

Wiring

Channel-colour

RSS

R/H front door lock switch

99

jl

28

H

239

L/H front door lock switch

98

j8

2B

H

241

R/H rear door lock switch

101

ql

2B

ED

242

L/H rear door lock switch

100

q9

2B

PC

243

Boot door lock switch

102

tS

2M

C

244

Bonnet lock switch

97

a5

2M

V

251

Height control switch

131-1 35

j5

2M & 4M

254

Lighting/direction indicator switch 192 to 198

g7

5B-4M-3M

T

125 to 129-142

g6

2B-4B-58

T

w`-

238

107 to 110-

608

H &

271

Air distribution switch

19 to 21

h5

4M

278

Blower motor speed control rheostat

23 to 25

h6

2B

0

29 to 31-103-104

h4

5B

K

38

b6

2N

IM

59 & 60

b6

2xlN

Z

143

c7

1MV-1N

A

tfn

Windscreen wiper/washer & horn switch

tid

255

Heater control & ighting

Supplementary air control (injection)

285

Ignition suppressors (radiol

295

Air horn compressor

300

Starter motor

302

Flowmeter

345

Fast idling electrovalve (air con option)

365

'-"

279

280

lN-lA

lN

3 to 5

bS

42 to 44

b2

5N

(C

14

d2

2xlV

V

Ashtray lighting

187

j6

28

H

370

Boot lighting

171

s4

lN-lic

F

375

Glove box (ighting

170

f4

1

N-l M

H

380

Engine compartment (ighting

185

c6

N

EC

385

L/H rear No. piate lighting

211

t6

386

R/H rear No. p(ate iighting

212

t4

lM-lIc lM-lIc

191

g7

2xllc

T

1

&

CP & CA

E

E

Air con compressor clutch

13

c6

lN

V

430

L/H front brake caliper

83-84

d9

2N & lN

U

431

R/H front brake caliper

85-86

dl

2N & lN

U

440

L/H front side (amp

184

a8

2M

G

441

R/H front side lamp

186

a2

2M

D

442

L/H rear side (amp

200

443

R/H rear side lamp

201

445

L/H rear lamp ciuster

t8

6G

F

446

R/H rear (amp cluster

t2

6G

F

457

L/H stop lamp

139

458

R/H stop lamp

140

460

L/H rear fog lamp

191

461

R/H rear fog lamp

192

462

L/H reversing lamp

33

tid

Steering (ock lighting

c--

390

410

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ARRANGEMENT OF THE ELECTRICAL INSTALLATION CX 25 GTI

REF.

DESCRIPTION

MA

51000/11

7/85

CONNECTOR

LOCATION

___________ __________ Circuit Wiring

463

R/H reversing lamp

470

Fuses

480

L/H front direction indicator

108

a7

a3

Number Channe)-colour

HARNESS (or unit)

34

*

g8

R/H front direction indicator

111

C`')

30r

481

D

482

L/H rear direction indicator

109

483

R/H rear direction indicator

110

486

L/H long range lamp

194

a7

2B

0

487

R/H long range lamp

199

a3

2B

D

488

L/H main and dipped beam

195-196

a8

3(c

G

489

R/H main and dipped beam

197-198

a2

3lc

D

500

L/H front loudspeaker connections

1

74

g9

1

501

R/H front (oudspeaker connections

1

76

g2

1

502

L/H rear loudspeaker connections

1

77

k9

28

PC

503

R/H rear loudspeaker connections

182

kl

2B

PD

506

L/H front tweeter connections

175

h9

2B

H

507

R/H front tweeter connections

1

75

hl

28

H

511

Rear fog lamp switch

191 to 193

g5

8 Bl

B

519

L/H window motor switch on driver's door

120 to 122

h9

5B

PC

520

R/H window motor switch on driver's door

115 to

11 7

)9

5M

PC

521

L/H window motor switch on passenger's door

120 to 122

hl

5B

PP

532

Heated rear screen switch

145 to 147

j5

5M

P

545

lnterior lighting switch

149 to 151

.-.

G

(31

:.p

30r

j5

5B

P

570

Hazard warning switch

110 to 113

g5

8N

8

576

lnjectors

41 to 44

c3

4x2G

IM

580

Fue) gauge

94 to 96

g6

600

Winscreen wiper motor

125 to 129

e4

58

608

Height control motor

132 to 138

j4

38

H

615

R/H front window motor

116

g9

30r

LV

616

L/H front window motor

121

gl

30r

PP

621

Air intake motor

17

e3

28

0

622

Air distribution motor

20

g4

28

0

625

R/H front door lock motor

160 to 162

j9

2M-3B

H

626

L/H front door lock motor

164 to 166

jl

2M-3B

H

627

R/H rear door lock motor

160 to 162

p9

2M-38

PG

628

L/H rear door (ock motor

164 to 166

pi

2M-3B

PC

629

Boot door lock motor

161

tS

28

C

transmitter

,

1

8 & B

&

1\R

H

1

H

M-l N-l J

J .

0

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*

8531-8532

C'3

ARRANGEMENT OF THE ELECTRICAL INSTALLATION

510

W11

_________________________________________________________

CONNECTOR

LOCATION

DESCR)PTIÖN

HARNESs

Circuit

Wiring

Channel-colour

162

s2

2B

X

Fuel flap lock motor

634

R/H engine cooling fan motor

9

a4

lM-lA

V

635

L/H engine cooling fan motor

9

a6

1

M-l R

V

650

Engine oj) pressure switch

79

d3

M

M

655

Blower fan speed transistorised module

25-26

f3

V-1 Bl

0

660

On-board computer

50 to 53

g4

.12N

0

680

Windscreen washer pump

130

el

2N

D

,-«

630

1

1

Fuel pump

45

g4

Central interior lighting

148 to 160

n5

lN, lM

695

Front interior spot lamp

148

n5

1

698

Headphone socket

178 to 181

k5

5B

H

700

Air con refrigerant pressure switch

13

c7

2x1)c

V

710

l2V supply socket

721

Radio connections 112V and )oudspeakers) («+»,- & H.P.)

731

f2°

683 690

&

B

1

& 2 x

N &

lN

FP-MP

1

lic

P

lM

P

lM

k5

k5

Fuel injection relay

38 to 46

a2

9N

lC

733

Engine cooling fan relay lair con)

12 to 14

b8

5N

V

735

Main beam relay

198 to 199

g7

5N

T

739

Height control re)ay

134 to 137

f7

5N

H

743

Air horn compressor relay

142-143

c7

5N

A

745

Blower motor fast speed re)ay

24 to 26

g4

5N

0

10-11

b8

5N

V

7 to 9

f8

5N

V

97

g6

4B

B

lA

&

H

& 4 x 2B

H

Engine cooling fan fast speed re)ay Engine cooling fan inverter relay

795

Lighting rheostat

810

L/H direction indicator repeater connections

107

'--

e9

2xllc

IV & MI

G

811

R/H direction indicator repeater connection

112

el

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the cubby hole (2) Uncouple speedometer cable 119). Disengage hydraulic fluid reservoir (20), but extract the 2 nuts (21). Withdraw the 3 screws located inside the vehicle. Remove the cubby hole, then disconnect: the electrical ou gauge, - the dock, - the electronic control unit for injection. 3

5. Removing

Örn

Q--

0a>

6. Removing

the glove box (6): 0--:C"

7,"

Q>)

Ca.

Take off: the 5 screws situated inside the vehicle (avoid slackening the 2 lock screws), - the 2 nuts positioned on the bulkhead, engine side (under the screen wiper motor and behind the screen washer bottle). Remove the glove compartment then disconnect: - the glove box lighting, - the cruise control unit.

the rear part of the console: Disconnect the handbrake switch. Withdraw the handbrake lever gaiter.

osv

7. Removing

front part of the console: ,..

8. Removing the

lake off: radio support bracket (3), air intake housing 14), oddment tray (8), - the 2 air vents (7), Disconnect: -

-

window motor switches (10), cigar lighter (9), map reading lamp (5),

....-,

- the centralised door lock control unit, - the door locking timer unit,

n"3

a._

Remove the air conditioning control switch (11) fixing nut. (Disconnect the white connector). Remove the console. E

9. Removing the heater unit:

.-+

.-r .-r

Uncouple the 2 pipes (23) from the air conditioning system lpaying attention to the 2 seals). Disconnect the 2 water pipes (121 and blank them off. lake off: - the 2 heating control bracket fixing screws, - the rear seat air duct (16), - the 2 air pipes (18), - the earth connection securing screws, the 4 heating unit screws (14), - the 3 wind sleeve fastenings (241, (2 nuts (13) under the instrument panel and 1 bolt on the engine side). Disconnect, at the point of attachment to engine: the feed wire and the earth lead (22) from the heater unit assemb)y, - the motor from the air recycling flap (2 channel white connector situated under the water header tank). Disconnect, from the interior: - the motor from the temperature regulation flap, - the feed wire from the temperature regulation device (1 channel mauve connector) - the potentiometer from the control lever, - the supply wire from the heater control (ighting, - the temperature regulation control unit (17). Remove the heater unit fitted with its controlling units (Push aside wind sleeve (24)). Retrieve the de-frosting gaiter situated at 115). (7l

1:!

-4.

,-e

"-'

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MA 641.1/1

/

/1r'j, ..1

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13.174

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83.122

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MA 641.1/1

1

, 2)

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REMOVING AND REFITTING A HEATING UNIT

1

MA

6411/1

X71

7/85

REFITTING: 1

"C*

C31

Refitting the heater unit: - Engage the unit in its ocation, - relocate the de-frosting gaiter (15), - secure the unit with the 4 screws (14)),

attach the wind sleeve (24) (2 nuts (13) under the instrument panel and 1 bott on the engine side). Reconnect, at the point of attachment to engine: - the feed wire and the earth lead (22) to the heater unit assembly (2 one channel mauve connectors), - the motor to the recycling flap (2 channel white connector under the water header tank). Reconnect, inside the vehicle: - the temperature regulation control unit (17) (8 channel black connectorl, - the supply wire to the heater control lighting 11 channel red connector), - the potentiometer to the control lever 13 channel white connector), - the feed wire to the temperature regulation device (1 channel mauve connector), - the motor to the temperature regu)ation flap (5 channel white connector), - earth terminal clamps Reposition: the 2 air pipes 118), - the rear seat air duct (16), - the 2 control brackot fixing screws. Reconnect: the 2 water pipes (12), - the 2 pipes (23) to the air conditioning system, fitted with the 2 seals. (CD

v(0

m_o

C/)

.-+

S17

2)-2

.-r

---

-

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6N0

(i)

t'6

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2. Refitting the front part of the console: Introduce the front part of the console in it location, white positioning the harness and connecting up: - the centralised door lock control unit, (9 channel black connector), - the door locking timor unit, - cigar-lighter (9) (3 channel white connector), - the cigar lighter lighting, the map reading lamp (5), - the window motor switches (10). Refit the air conditioning bott (11) (Reconnect the white connector). Secure the console. Put into place: - the 2 air vents 17), - cubby hole (8), - air intake housing (4), - radio support bracket (3).

3. Locate the rear part of the console, and reconnect the handbrake switch. Replace the handbrake lever gaiter.

,--r

=S3

+,,

4. Refitting the glove compartment (6). Fit the glove box, connecting the cruise control unit and lighting. Screw up: - the 2 nuts on the bulkhead, engine side, - the 5 screws, inside the vehicle,

7>O

Refitting the cubby hote (2): Place the cubby hole, reconnecting: .-r

.-.

the electrical oil gauge, the dock, - the fuel injection ECU. Reposition: - the 2 nuts 1211, engine side, - the 3 screws, inside the vehicle. Secure the hydraulic fluid reservoir, then recouple the speedometer cable (19).

6. Fit the steering lock cowling (1).

circuit with refrigerant a.+

7. Refill the air conditioning

(see the appropriate operation).

8. Attach the passenger seat. a..

9. Reconnect the battery.

*

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HEATING - VENTILATION AIR-CONDITIONING

641.1/2

REMOVING AND REFITTING A HEA TER UNIT

7/85 -+

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REMOVING AND REFITTING THE HEATER UNIT

MA 641.1/2

2

7/85

-

REMO VAL

Disconnect the negative battery lead. >-.

1

2. Empty the refrigerant from the air-conditioning system (see corresponding operation).

3. Remove

from the interior:

--. air-conditioning centre (11), control bracket (disconnect the contro(s(, -- the centre of the part of the -- the the glove box (6), the injection bracket (7), wheel, (10), -- switch fixing boxes -- storage dashboard fixing screw (8), unit support (19), duct (20). ,

The the

C/)

conso(e sides (5) and

(4)

part

conso(e (3), conso(e (2),

rear fue(

ECU

,-+

steering steering (ower panel, panel (9), 3 (1), L/H e)ectrica) pane) rear seat fl.

the tho the the the the the

4. Remove, from the engine compartment: The water header tank fixing (13) to move it clear, the ducting (12), the securing (2 nuts and 1 bolt) for the air intake tDwer (14), the 2 dashboard securing nuts (15) on the buikhead.

Disconnect, engine compartment: The yel(ow connector to the air-conditioning compressor c)utch, the 2 channe) connector to the air intake motor flap (under header tank), the 2 air-conditioning hoses (17) (be carefu) of the seals). '"''

--

veö

5.

C,__-

-

6. ln the engine compartment, clamp the 2 pipes (16) to avoid losing the engine coo(ant.

Disconnect, inside the vehicie:

-- the The blower motor speed control module (under the of the dashboard), connectors between the ventilation-air con and the interior harnesses, 4 channe) white connector situated at (22) channel clear connector ' - the connector between the heating and interior lighting harnesses, channe) white connector situated above the unit - the pipes (18).(supply, interior temperature sensor), paj

7.

,-:

arm

R/H side

`o°

>

f-:

avi

mag

1

2

>-p

(1)

air

2

8. Remove, the 4 fixing screws (23) from the unit.

9.

Remove the unit:

-- lift thethe intake tower (14) some 30 to 40 mm to the right (lift dashboard, -- disengage the heater ducts the upper part of the unit), remove the unit from inside the vehicle, - recuperate the situated Push

air

it to disengage the 2 studs),

(on

.,L

at (21(from the defrosting dram.

0

gaiter

NOTE: The units shown on the photographs opposite belong to L.H.D, vehicies, however, the remova//fitting operations for units be/onging to R.H.D. models are the same as on a L.H.D. version.

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8531-8532 PDF compression, OCR, web-optimization with CVISION's PdfCompressor

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REMOVING AND REFITTING A HEATER UNIT

7/85

-

1

MA

641.1/2

FITTING 1.

Refitting the unit:

the unit (ocation, position the harnesses, the defrosting gaiter -- connect the the upper part of the unit, the heater ducts - engage secure the unit with the 4 screws in its

Engage (ocate

(4),

dram

2 pipes (1),

on

(6).

2. Connect, inside the vehicie:

(1)

- The connector between the heating 2 channel

and interior (ighting harnesses,

white connector situated above the unit.

,-.

- The connectors between the ventUation-air con. and interior harnesses 4 channel white connector

situated at (5) 1

-

channe) c(ear connector

The b)ower motor speed contro( modu)e (urider the R/H side of the dashboard).

3. Connect, engine compartment: The yel)ow connector to the air conditioning compressor c)utch, the 2 channe) white connector to the air intake motor flap (under header tank).

-

4. Locate, and fix dashboard on the buikhead, engine side (2 nuts at (10)). 5. Refit, the three storage boxes (13). 6. Secure, engine compartment:

intake tower (9), -the ducting (7), - the water header tank. The air

Refit, inside the vehic)e: The rear seat air duct (3), the electrical unit support panel (2), the L/H dashboard fixing screw (20), the rear (14) and centre (15) part of the console.

--

ner,

7.

..J

8. Connect the contro)s of bracket (16) and refit it. 9. Refit, inside the vehicie:

-- the fuel injection(18), bracket (19), - the switch (21), -- the (22), steering the steering whee(, - the conso)e side (17) and (23). The g(ove box

0

ECU

pane)

whee( (ower pane( pane)s

10.

(n

the engine compartment, reconnect the two pipes (12) for the air conditioning (2 sea(s).

11. Remove the clamps from the two pipes (11). r-.

12. Refilt the air conditioning system (see corresponding operation). 13. Reconnect the battery. i-+

14. Top-up the coo)ant system.

*

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4

LIST OF OPERATIONS

I

Operation n umber

DESCRIPTION

MA 800-000

Overhauling the bodyshell Components sold by the Replacement Parts Department Il

III

Electrically zinc-coated or galvanized items Checking

a

damaged vehicle

MA 800-00

Preparation of the bodyshell

MA 800-01

Fitting and checking

MA 800-02

Exchanging the ongerons, with the mechanical components in situ (using CELETTE jig)

MA 800-10

Fitting and checking

a

bodyshell, stripped, on

MA 800-1

Fitting and checking

a

Satary bodyshell, stripped, on

1

bodyshell, stripped, on

MA 800-12

Checks on

MA 800-13

Checking on CAROLINER jig,

MA 801-1

Replacing

MA 801-2

Replacing the body fixed components

MA 802-1

Replacing

a

front wing

MA 802-2

Replacing

a

front wheelarch, complete

MA 824-1

Replacing

a

rear wing

MA 824-2

Replacing

a

rear wing, partly

MA 841-2

Removing/refitting

MA 841-3

Dismantling and rebuilding

MA 851-1

Replacing

a

..-

MA 851-2

Replacing

a

bonnet

MA 851-3

Opening

MA 853-1

Replacing

MA 853-2

Bonding the rear quarter glasses

MA 856-1

Replacing

a

CELETTE jig

a

(fl'

CAROLINER jig a

CARO)JNER jig

a

Safary bodyshell with the mech. components in situ

front unit, complete

side door

(fl

a

a

side door, completely '06

a

a

CAROLINER jig, with the mechanical components in situ

E

t7.

a

avi

a

front bumper

bonnet when the catch release fails to operate a

a

rear bumper

dashboard

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2

OVERHAULING THE BODYSHELL

8OOO

1.

PARTS OBTAINABLE FROM THE REPLACEMENT PARTS DEPARTMENT.

DESCRIPTION

REF. No.

OPERATION No.

812.1 825.1 825.1 825.1 831.6 831.5 831.5 831.5 825.1 825.1 825.1 825.1 812.2 812.3 812.2 812.2

Anti-recycling side baffte

32 33 34 35

Upper ctosing panet Lower sheet metal

36 37

Front wheelarch assembly Unit, comptete

38 39 40 41

Front box crossmember Lower scuttle Fuel tank bracket Steering mounting bracket

42 43 44

Centre box crossmember Centre box reinforcing plate Rear ftoor panel assembly

MA 831.1

Seat backrest upper spacer Sheet metal under backrest

8

Seat backrest lower spacer

9

Sun-roof rear crossmember Crossmember angte sheet Roat crossmember Interior lamp bracket Windscreen frame pillar Windscreen opening reinforcement Buikhead with windscreen opening cros'smember Louvre sheift Corner plate Header tank bracket Stay support bracket Air fitter special support (82 MY.>

1

2

13 14 15 16 17 18 1

9

20 21

22

Body fixed component Trim panel upper crossmember Upper anti-recycling baffie Gritte fixing bracket

Bonnet ock support bracket Lower crossmember inner panel Trim panel lower crossmember ,-,

C1]

CO)

Closing panel assembly Upper ctosing pane> Side ctosing panel

C.7

23 24 25 26 27 28 29 30

0

11

``n"

Ö..

10

Front wheelarch Front wheelarch, front section

C31

7

G31

6

t77

Rear sheif

t77

Roat panet with sunroof

5

ISA

4

2

Ill

3

t31

31

MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA MA

Windscreen frame Roat panel Rear screen pillar

1

812.3 802.3 802.3 802.3 802.3 802.3 802.3 801.2 801.2 801.2 801.2 801.2 801.2 801.3 801.2 801.1 801.1

802.4 802.4 802.3

.fl

801.1 801.1 801.1 801.1 801.1

`°3

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1

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0

0

7

45

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2 39

60

62 1.80.74 4L'08'1

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C)

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