Citroën DS (1965) manual

DTAV ( TECHNICAL ASSISTANCE) REPAIR MANUAL NO814 VOLUME I MARCH 1974 D VEHICLE (D vehicles all types produced since september 1965) CHARACTERISTICS ADJUSTMENTS CHECKS PRINTED IN FRANCE SOCIETE ANONYME AUTOMOBILES CITROEN CAPITAL 600 000 000 F - HEAD OFFICE 117 to 167. QUAI ANDRE CITROEN 75015 PARIS - R C SEINE 64 B 5019 DTAV (TECHNICAL ASSISTANCE -[...]

USING THE MANUAL PRESENTATION To facilitate the use of the Manual we have arranged the repair operations into two volumes : - Volume 1 contains : - the CHARACTERISTICS - ADJUSTMENTS - CHECKS necessary at all repair work- shops for adjustment or simple repairs. - Volume II contains the operations of: - DISMANTLING and ASSEMBLING. - RECONDITIONING. -[...]

b) a number with three figures indicating the unit or unit component. c) a figure indicating the nature of the section. - figures 0 0 0 indicate the characteristics of the vehicle - figures 0 0 indicate the characteristics of the unit - figure 0 indicate checks and adjustment - figures 1 4 7 indicate the removal and fitting - figures 2 5 8 indicate[...]

LIST OF OPERATIONS SHOWN IN VOLUME N o 1 OF MANUAL814 Vehicles D «all types» , except IE DESCRIPTION CHARACTERISTICS General characteristics (general dimensions, various capacities) Protection of the electrical units Work on the hydraulic sys tem (precautions) Ingredients recommended ENGINE - CARBURATION - IGNITION Engine characteristics Adjustin[...]

LIST OF OPE RATIONS SHOWN IN VOLUME No 1 OF MANUAL814 Vehicles D o all types, Operation Number DESCRIPTION GEARBOX @ Characteristics and particular features of the gearbox. Checking and adjusting the gear control (Vehicles with hydraulic gearchange I - Adjusting the gear engagement stroke - Checking a clutch re - engagement lock - Adjusting a clutc[...]

LIST OF OPERATIONS SHOWN IN VOLUME N o 1 OF MANUAL814 Vehicles a D B All types, except IE Operation Number F DESCRIPTION BRAKES @ Characteristics and particular features of the brake system Checking and adjusting the brake units Checking and adjusting the brake control - Bleeding the circuits - Pedal gear control ('411 types except DV.DT) - Co[...]

LIST OF OPERATIONS SHOWN IN VOLUME No 1 OF MANUAL814 DS 21 vehicles with Electronic Fuel Iniection(DX.1E and DJ.IE) The operations for this type of vehicle alone have been covered. For operations that do not appear on the list below, refer to the list of operations relating to "Dm vehicles all types. Operation Numbers DESCRIPTION CHARACTERISTI[...]

OPERATION NO D. 000 : General characteristics Op. D. 000 1 :TERISTICS Official Commercial I. GENERAL CHAR. General Symbols ENGINE Fiscal rating Cubic capacity Gearbox ratios TYPE - BRAKE HORSEPOWER - TORQUE Bore - Stroke (french) I Introduced Symbols DS 21 DS 21 Ct l0/1965 Hydraulic 10/1972 DX 4 10/1968 ~DX 2 (21 N) b 10/1968 100 CV DIN AT 5500:RPM[...]

OPERATION W D. 000 : General characteristics Op. D. 000 Official Commercial General Symbols I synboIs 1 symbols ENGINE Cubic capacity Gearbox ratios - . -1sca1 rotin! (French) MAXIMUM TORQUE DS 19 DS 19 Serie A Hydraulic DY 84 CV DIN AT 5250 RPM 14.6 MKG 1106 LBSl AT 3500 RPM (DIN) 1,985 cc 86 X 85,5 mm I 4 gears DY 2 4 10/ 1971 DY 3 (17 N) I-+ 10/[...]

OPERATION No D, 000 : General characterisr~cs Op. D. 000 3 Types of tyres and wheel rims : D, ALL TYPESlexce~t D.IE I 4 lo/ 1968 A L L T Y P E S ) D Y - D T - D V - D L - D X 1 180 380 XAS 1 DJ - Safari - All Types - DP - Front 180 HR 380 XAS - - .............................. D.IE ALL TYPES. I 185 HR 380 XAS 155 HR 380 XAS 165 HR 380 XAS 180 HR 38[...]

4 OPERATION No D. 000 : Ceneral chnmctprisrirs Ground clearance : Low position Normal position 1 st intermediate position D. All Types (except Safari all Types). ............ 2 1/ 2 Ins (0.065 m) Safari All Types 3 Ins (0.075 m) ........................... D. All Types (except D.IE and Safari All Types ....... 6 Ins (0.150 m) D.IE All Types .......[...]

OPERATION No D. 000 : General characteristics Op. D. 000 5 Ill. DIVER CAPACITIES .................................................. - Petrol tank. 65 litres (14 Galls Imp) ........ i .............................. . DX-DJ All Types ( 10/1972) - D.IE All Types 13 litres (23 Pts Imp) Cooling system DX - DJ All Types-DP 10.8 litres (19 Pts Imp) ......[...]

OPERATION N o D.0 1 Protection of the electrical units . Op. D.01 1 PROTECTION OF THE ELECTRICAL UNITS PRECAUTIONS TO BE TAKEN WHILE WORKING ON A VEHICLE Certain actions must be avoided at all costs as they would damage some of the electrical components or cause the electrical system lo be short-circuited. (Fire risk) 1. Battery : a ) Disconnect th[...]

2 OPERATION N o D.01 Protection of the electrical units . c) Never strike a spark to check the continuity of a lead. d) Never start a vehicle with a voltage exceeding 12 volts. e) Never force a connector onto the unit concerned. Take note of the inhibitor chamfers. f) Only withdraw the connectors by taking hold of the sides and never by pulling on [...]

OPERATION N o D.02: Work on the Hydraulic system . Op. D. 02 1 CARS WITH SYNTHETIC HYDRAULIC FLUID. L.H.S.2 The D vehicles produced up to September 1966 use a red fluid of synthetic base in their hydraulic circuits (Fluid L.H.S.2) The main reservoir, steering unit, HP pump ( 7 pistons ), suspension spheres and accumulators are painted black. The ge[...]

2 OPERATION N o D.02: Work on the Hydraulic system . CARS WITH MINERAL HYDRAULIC FLUID. L.H.M D vehicles produced since September 1966, with the exception of certain models for export markets, use a green fluid of mineral base in their hydraulic circuits (fluid L.H.M. ). The main reservoir and the hydraulic units are printed green or bear green ide[...]

OPERATION N o D.0 2 : Work on the Hydraulic system . Op. D. 0 2 3 VEHICLES ALL TYPES WORK ON THE HYDRAULIC SYSTEMS To ensure correct functioning of the hydraulic systems it is essential that the hydraulic fluid and all the component parts shall be perfectly clean. The most stringent precautions must be taken when working on the car and for the stor[...]

4 OPERATION No D. 02 : Work on the hydraulic system 3, PRECAUTIONS AFTER DISCONNECTING THE UNIONS. Close the open ends of all pipes For the metal pipes use screwed unions. For pipe assemblies protect the union flanges with self - adhesive masking - tape. Protect plastic pipes in the same way. For rubber pipes use cylindrical plugs : diameter = 8 mm[...]

OPERATION N o D.0 2: Work on the Hydraulic system . Op. D. 02. 5 NOTE : All sealing sleeves must be renewed-after each dismantling operation : 1) Place a sealing sleeve « a » on the pipe. This sleeve should be set back 2 mm from the end of the pipe. 2) Centralise the pipe in the bore by aligning it with the axis of the bore. MOST IMPORTANT : Make[...]

6 OPERATION N o D.0 2 : Work on the Hydraulic system . 8. PRESSURE GAUGES. When carrying out checks or adjustments on hydraulic units of the car, the use of pressure gauges is essential. In just the same way as precision tachometers are necessary for accurate checking and adjustment, so it is necessary to use sufficiently accurate pressure gauges. [...]

OPERATION No D. 02 Work on the hydraulic system Op. D. 02 7 DRAINING THE HYDRAULIC CIRCUIT. ( Fluid LHS 2 or LHM) DRAINING. 1. Position the vehicle on a pit or car - lift. 1627 2. Place the manual height control in the e low + position. 3. Unscrew the bleed screw on the pressure - regulator 4. On vehicles with power - steering: Move the steering to[...]

8 OPERATION D. 02 : Work on the hydraulic system REFILLING. 8: On uehicles produced since September 1967. - Place the plug ( 1 ) on the flexible pipe (3 ). Insert the flexible tube ( 3 ) into the spring - clip ( 2 ). 9. Clean the reservoir filter - with alcohol for the I,.H.S.2. fluid. - with petrol or white spirit for the L.H.M. fluid Blow it thro[...]

OPERATION No D. 02 : Work on the hydraulic system. Op. D. 02 9[...]

10 OPERATION N o D.02: Work on the Hydraulic system . REPAIRING A PLASTIC PIPE NOTE : a ). This operation can be carried out by sleeving the pipe. b ). A pipe cannot have more than two sleeves which must be approx. 800 mm apart in order to preserve its flexibility. C ). The glue to be used is RILSAN cement sold in 60 cc bottle by : Société BOYRIV[...]

OPERATION N o D.03: Approved pastes, glues and solvents . Op. D. 03 1 APPROVED PASTES, GLUES AND SOLVENTS PRODUCTS POLYCLENS ADEXOLIN 56 RILSAN GLUE PROTOJOINT CURTYLON DEVCON LOCTITE AUTOFORM METALIT SILASTIC 733 RTV MOLYKOTE 557 USES Grease remover for mecha- nical assemblies when cold. Can be in pure or diluted form. Rinse off with plenty of wat[...]

2 OPERATION N o D.03: Approved pastes, glues and solvents . PRODUCTS METOLUX A OIL AND GREASE REMOVER ROCOL ASP GREASE GSI 160 ARALDITE MASTI-JOINT HD 37 PLATE-LOWAC PLASTISOL D.C.O. 625 HEXYLENE GLYCOL MASTIC GLUE Ref. 1500 (COLLAFEU) USES Sealing porosities in casings Grease remover for mechani- cal units when cold Grease for water pump Silica gr[...]

OPERATION No D. 100 - 00 : Characteristics and particular features of engine. Op. D. 100 - 00 1 VEHICLES ALL TYPES I. GENERAL CHARACTERISTICS 1. Engine type DX, DJ, DXF, DJF. -1 10/1972 (Inlet manifold external, distributor at front) - Fiscal rating (French). ............. 12 CV .................. - Number of cylinders 4 in line ...................[...]

2 OPERATION No D. 100-00: Characteristics and particular features of engine. 4. Engine type DV (Inlet manifold internal, distributor at rear 4 1011968 (Inlet manifold external, distributor at [ront +e 10/ 1968 - Fiscal rating (French). ....................... .ll CV ............................ - Number of cylinders 4 in line - Cubic capacity. ....[...]

OPERATION No D. 100 - 00 : Characteristics and particular features of the engine. Op. D. 100 - 00 3 ENGINE CROSS SECTION[...]

OPERATION N o D. 100-00 : Characteristics and particr~lar features of the engine. ENGINE LONGITUDINAL SECTION[...]

5 OPERATION N o D. 100 - 00 : Characteristics and particular feulures of the engine. Op. D. 100 - 00 II - PARTICULAR FEATURES 1. Housings. a) Cylinder block. - Crankcase and crankshaft bearing caps are matched. - The crankshaft bearing caps are marked from the front - Bore of crankshaft bearings ................................. - General out - of [...]

6 OPERATION N o D. 100-00 : Characteristics and particular features of the engine. - Big end bearings : . Bore (two possibilities) ................................................ 54 and 53.5 mm + 0.100 Width.. ............................................................................. 25 - 0.150 mrn t 1.200 . Outside diameter ...................[...]

OPERATION No D. 100 - 00 : (.ltaracteristics and porticulur leurtcres of the engine. Op.D.lOO-00 7 b) Piston rings : ' NOTE : For pistons of <,6 93.5 rnrn, the thickness of the oil control ring is 4 - 0.010 - 0.022 rnrn. Piston ring Compression ring (3) Scraper ring (2) Oil control ring (1) NOTE : Certain engines are fitted with simple oil [...]

8 OPERATION No D. 100 - 00 : Characteristics and particular features of the engine. C) Changing and positioning the guides : Use instrument 3079-T. d) Tightening torques : ........................... 1st tightening 30 mAN (3 mkg) (23 ft lbs) - Cylinder head screws ........................ Final tightening 60 to 65 mAN (6 to 6.5 mkg) (43 to 47 ft Ib[...]

OPERATION N o D. 100 - 00 : Characteristics and particular leatures of the engine. Op. D. 100 - 00 9 e) Camshaft drive chain : c) Setting : Clearance between tensioner and limiting device.. ...... fl. 1 to r1.5 mm. Theoretical valve clearance .................................................... Inlet opens BTDC .....................................[...]

ENGINE OPERATION No D.IE - 100 - 00 : Churucteristics and features of the engine. 0p.D.IE-100-00 1 I. GENERAL CHARACTERISTICS D. IE VEHICLES - ALL TYPES The engines of vehcctes wcth electronic fuel differ lrom those o/ other vehlcles only in the following poinfs : 1. Engine (type DX) 4 10/1972 - .................. Fiscal rating (french) ....... 12 [...]

2 OPERATION No D.IE - 100 - 00 : Characteristics and particular features of the engine. ENGINE LONGITUDINAL SECTION[...]

OPERATION No D.IE-100-00: Characteristics and particular features of engine Op. D.IE-100-00 5 ENGINE CROSS SECTION[...]

4 OPERATION N º D.IE- 100-00 : Characteristics and particular features of engine OIL CIRCULATION DIAGRAM D.22-2 NOTE : The cooler is no longer fitted to DJ.IE vehicles 1970 Engine oil gallery Piston crown Piston crown Piston crown Small end Small end Small end Big end Big end Piston crown Small end Big end Big end Front bearing Main bearing nº 2 [...]

OPERATION No D. 112-0 : Adjusting the valve rocker clearances. Op. D. 1 12 - 0 1 ADJUSTING THE VALVE ROCKER CLEARANCES VEHICLES ALL TYPES ADJUSTMENT EXHAUST 1. Place the auxiliary clutch control in the engaged position. (Hydraulic ,gearchange vehicles only). 2. Disconnect the earth cable from the battery. 3. Remove the cylinder head cover : Disconn[...]

2 OPERATION No D. 112 - 0. Adjusting the valve rocker clearances. 5. Fit the cylinder head cover with its gasket. Make sure that the gasket is correctly positioned. Tighten the bolts 7 mAN (0.75 m.kg 5.4 ft.lbs). (Copper washers under the heads of the securing bolts). 6. Connect up the plug leads and the battery earth lead. 7. Put the hydraulic cir[...]

OPERATION No D. I E 112 - 0 : Adjusting the valve rocker clearances Op. D. IE 112 - 0 1 ADJUSTING THE VALVE ROCKER CLEARANCES 5850 INLET D.IE VEHICLES ALL TYPES 1. Place the auxilary clutch control in the ((engaged)) position (only on vehicles with hydraulic gearchange) 2. Disconnect the earth cable from the battery. 3: Disconnect the inlet air man[...]

2 OPERATION No D. IE 112 - 0 : Adjustin g the valve rocker clearances 10. If valve rocker noise persists after adjustment, proceed as follows : - Remove the battery - Slacken the alternator and the H.P. pump moun- ting bolts. Disengage the belts from the drive pulley. - Engage the parking brake - Remove the nut securing the drive pulley ( 1 ) and w[...]

OPERATION N o D. 133 - 0 : Adjusting the engine mountings Op. D.133 - 0 1 ADJUSTMENT OF THE ENGINE MOUNTINGS ( Engine out of car ) 3388 VEHICLES ALL TYPES ADJUSTMENT NOTE : The adjustment of the rear flexible moun - tings must be made under load; the engine comple - te, in running order and resting on its four support points. 1 Place the engine - g[...]

OPERATION No D. 142 - 00 : Characteristics and particular features of the carburettors Op. 142 - 00 1 I VEHICLES ALL TYPES CARBURETTORS CHARACTERISTICS AND PARTICULAR FEATURES[...]

2 OPERATION No D. 142 - 00 : Characteristics and particular features of the carburettors. WEBERCARBURETTOR D . 14-1[...]

OPERATION No D. 142 - 00 : Characterisiics and particular feaiures oj the carburettors. Op. D. 142 - 00 3 WEBER CARBURETTORS 1 - Characteristics : Introduced Vehicles with hyd-gearchange Vehicles with man - gearchange Vehicles with Borg - Warner 28 X 36 DDE 28 X 36 DDE A1 28 X 36 DLE 28 X 36 DLE A1 28 X 36 DM 2 28 X 36 DMA 4 28 X 36 DMA 5 DLE AS Se[...]

4 OPE RATION N o D. 142 - 00 : Characteristics and particular features of the carburettors SOLEX CARBURETTOR D. 14 - 50[...]

OPERATION No D. 142 - 00 : (.hurac.teribtlc,s unti puticulur feuiurea of the c't~rt~urrtlr~rs Op. D. 142 - 00 5 II - SOLEX CARBURETTORS 1. Characteristics : a) Vehicles DV. Carburettor types Introduced Items I Key Mark on choke lever ............. Choke tube ..................... Main jet ...................... Air correction jet .............[...]

6 OPERATION No D. 142 - 00 : Cf~arncleristics and parlicular fenrures of he car41crettors NOTE : Since February 1970 a certain number of DT zlehicles have been fitted with SOLEX carhurettors, 28 X 36 SFIF. Carburettor Types Items ........................... Choke tube ............................. Main jet Air correction jet .......................[...]

OPERATION N o D. 142 - 0 : Adjustin g carburettors and controls. Op. D. 142 - 0 1 BASIC ADJUSTMENTS. OBSERVA TlONS : - The basic adjustments are to be carried out when the vehicle gives an uncomfortable ride or when the engine stalls frequently. - They consist of six separate operations which must of necessity be carried out completely and in the o[...]

2 OPERATION No D. 142 - 0 : Adjusting curburettors and controls NOTE : The use of an electric tachometer (2436-T), is essential for the following operations. This tachometer is connected to the outlet terminal (red sleeve of the coil). The electric tachometer has to be checked periodi - cally according to amount of use. The electric tachometer must[...]

OPERATION N o D. 142 - 0 : Adlusting carburettors and controls. Op.D.142-0 3 VEHICLES with MANUAL GEARCHANGE VII. ADJUSTING THE IDLING SPEED. NOTE : This adjustment must be made with the engine hot. Use of a tachometer is essential. It must be exact and easy to read from 0 to 1500 r.p.rn. The reading is rendered incorrect during the time that the H[...]

4 OPERATION No D. 142 - 0 : Adjustin g carburettors and controls. VEHICLES ALL TYPES. VIII. ADJUSTING THE ACCELERATOR CONTROL. 16. Check the measurement (( a )); it should be : a = 135 mm. If it is not, move the hooking plate for the accelerator return springs to obtain the measurement : a = 135 mm. 17. a) With the accelerator pedal held fully down[...]

OPERATION N o D. 142-0 : Adjustin g carburettor. Op. D. 142 - 0 5 D. VEHICLES ALL TYPES - September 1972 ADJUSTING THE IDLING SPEED IMPORTANT NOTE : 4 On no account must the throttle stop screws (2) and (3) of the primary.and secondary throttle butterflies be 4 altered, as these have been micrometer set by the manufacturer. 4 43 ADJUSTING THE IDLIN[...]

OPERATION No Dbw. 142 - 0 : Adjustin g the carburettor Op. Dbw. 142 - 0 1 DBW VEHICLES J ADJUSTING THE IDLING SPEED NOTE This adjustment should be carried out with the engine warm. The use of a tachometer is indispensable. It should be accurate and easily readable between 0 and 1500 r.p.m. While reading the tachometer make sure that the H. P. pump [...]

OPERATION N o Dh. IE - 142 - 0 : Basic adjustments. Op. Dh. IE - 142 - 0 1 E.F.I. VEHICLES with HYDRAULIC GEARCHANGE BASIC ADJUSTMENTS. 7046 NOTE : It is essential to proceed in the following order : I. ADJUSTING THE ACCELERATOR CONTROL AND THE THROTTLE VALVE. 1. Adjust the throttle closing : a) Detach the spring (1) from the throttle housing at (([...]

2 OPERATION No Dh. IE - 142 - 0 : Basic adjustments. Ill. CHECKING THE CLUTCH CLEARANCE. 6. Check that the fork release spring is in good order and correctly fitted. - Reduce the pressure in the clutch cylinder by means of the auxiliary clutch control. - Check that the fork is free. - If.it is not, recommence the clutch clearance adjustment which w[...]

OPERATION N o Dh. IE - 142 - 0 : Basic ad~ustments. Op. Dh.lE - 142 - 0 3 V. ADJUSTING THE CLUTCH DRAG SPEED. IMPORTANT : This ad~ustment must be made with the engine hot and the oehicle placed on a flat, horizontal surface. 10. Switch on the engine, engage first gear and accelerate very slowly. Clutch drag should begin at 850 + 25 rpm 11. If it do[...]

OPERATION No Dm. IE - 142-0 : Adjusting the idling speed. Op. Dm. IE - 142 - 0 1 IDLING SPEED ADJUSTMENT VEHICLES with MANUAL I GEARCHANGE NOTE : This adjustment must be made with the engine hot. Use of a workshop tachometer is essential. Do not use the dashboard tachometer. 4 I w 1. Connect the electric tachometer onto the terminal ((Rup H or N- n[...]

OPERATION No Dbw. IE - 142 - 0 : Adjustin g the idling speed Op. Dbw. IE - 142 - 0 1 ADJUSTING THE IDLING SPEED 10 388 DBW. IE VEHICLES NOTE : This adjustment must be made with the engine hot. Use of a workshop tachometer is essential. - Do not use the dashboard tachometer. 1. Shunt the electric tachometer onto the terminal NRUP )) or ((--H of the [...]

OPERATION No D.IE 144 - 0 : Checking the electronic fuel injection system Op. D.IE 144 - 0 1 (CITROEN 1494 Tester) D.IE VEHICLES ALL TYPES CHECKING THE ELECTRONIC FUEL INJECTION SYSTEM BY MEANS OF THE CITROEN 1494 TESTER, A VOLTMETER, AND AN OHMMETER 7898 NOTE : The 1494 Tester allows each one of the components of the iniection system to be checked[...]

DIAGRAM D.IE 511-00 ELECTRONIC FUEL INJECTION SYSTEM (D.Y./E vehicles produced up to March 1970) (see operation D.1.E 51 1 - 00) Colour Code White Bc Yellow J Brown Mr Mauve Mv Black N Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 8 St[...]

2 OPERATION N o D.IE 144-0 : Checking the electronic fuel injection system . ( CITROEN 1494 Tester ) WARNING : Certain actions must be avoided at ail costs as they would damage the components of the electronic fuel in- jection system, in particular the electronic control unit : 1) Never use a rapid charger, and never carry out arc or spot welding o[...]

Manual 814 - 1 0 'P rn n b 1 9 Z, P - rn I f b sz 2: 0 S. has 2, ;;; 2- 2 2; & - 2 E 2. D 2' h s. L. D C) C. 0 a h Y - ; 0 ? P - rn I 4 k b tu n ORIGINAL EQUIPMENT REPLACEMENT COMPONENTS (essential fitting) DATE CONTROL UNIT PRESSURE SENSOR 1) CONTROL UNIT ONLY 2) PRESSURE SENSOR ONLY from September 1969 No mark Standard - Fit a contr[...]

2b OPERATION No. D.IE 144 - 0 : Checking the electronic fuel injection system Op. B.IE 144 - 0 (CITROEN tester 1494) IDENTIFICATION OF COMPONENTS : the control units and the sensors (pressure and temperature) always bear the supplier's reference number. NOTE : 1. A pressure sensor No DX. 144.119 A (1 green dot) has been fitted as a repair on a[...]

OPERATION No D.1 E 144 - 0 : Checking the electronic fuel injection system Op. D.IE 144 - 0 3 (CITROEN 1494 Tester) FIRST PART The following checks are to be carried out with the electronic control unit disconnected. Remove the electronic control unit. Disconnect the harness terminal block from the electronic control unit and check, by the sleeves [...]

4 OPERATION No D.IE 144 - 0 : Checking [he electronic fuel injection system ( CI TROEN 1494 Tester ) Operations to be carried out b) The u - )) at terminal 1 1 of the tes - ter ( earth ). The (( +N at terminal 24 of the tes. ter. Voltmeter should read 11 to 12.5 volts. Switch off the ignition (connect the lead to the coil ) 2. Check the starting vo[...]

OPERATION No. D.IE 144 - 0 : Checking the electronic luel injeclion system (CITROEN TESTER 1494) DJ.IE VEHICLES manufactured since 26th April 1971 On these vehicles, the starter motor and impulsion relays are no longer fitted (for the identification of the leads, refer to the diagrams showing the principles on the following page and to operation DJ[...]

4b OPERATION No D.IE 144 - 0 : Checking the electronic fuel iniection system iClTROEN TESTER 1494) DIAGRAMS SHOWING THE PRINCIPLES OF THE STARTER MOTOR CONTROL D.IE Vehicles all types DJ.1E Vehicles produced up to April 1971 DJ.lE, manufactured since April 1971 The starter motor and impulsion relays are no longer fitted[...]

OPERATION NOD.IE 144-0 : Checking the electronic fuel injection system ( CITROEN TESTER 1494) Op. D.IE 144 - 0 5 Operations to be carried out Additional checks to be carried out if the value specified is not obtained 3: Check the insulation of the pressure sensor scale ) a) between terminals 11 and 7. b) between terminals 11 and 8. Pointer must rea[...]

6 OPERATION No D.IE 144-0 : Chec.klng (h(4 electronic /riel inler.(~on sjsterrc (CITROEl TESTER 1494) I Operations to be carried out T Additional checks to be carried out if the specified value is not obtained b) Secondary winding : - between terminals 8 and 10. read 350 R Check !.dentical to a), b), c). d) If (he ohmmeter indicates a resistance co[...]

OPERATION No D.IE 144-0 : Checkin g the electronic fuel injection system ( CITROEN TESTER 1494) Op. D.IE 144 - 0 7 Operations to be carried out Additional checks to be carried out if the specified value is not obtained I 7. Check the throttle - s p indle switch ( 10) Connect the ohmmeter (OF NE CESSITY ON SCALE 1 M Q min. ) Between terminals 17 and[...]

8 OPERATION No D.IE 144 - 0 : ChecXing fhc elecfronic fuel in~ection system ( CITROE$ TESTER 1#9#) I Operations to be carried out T Additional checks to be carried out if the specified value is not obtained OHMMETER : must read -. d) Refit the connector on the switch and adjust the switch ( 10) as in 5 a above. e) If the ohmmeter still indicates m [...]

OPERATION No D.IE 144-0 : Checking the electronic fuel injection system (CITROEN TESTER 1494) Op. D.IE 144 - 0 8 a D.IE VEHICLES ALL TYPES (produced since 5th April 1971) The electronic fuel injection control has been modified as follows on these models : - Addition of an air temperature sensor fitted on the air filter. - Modification of the electr[...]

OPERATION No D.IE 144 - 0 : Checking the electronic fuel injection system (CITROEN TESTER 1494) Op. D.IE 144 - 0 9 Operations to be carried out 10. Check the full - load switch. Connect the ohmmeter (OF NE - CESSITY ON SCALE 1 M Q min.) Between terminals 2 and1 1. Should read 0 Withdraw the connector of the full - load switch. Should read W. Refit [...]

10 OPERATION No D.1 E 144-0 : Checking the electronic fuel injection system (CITROEN TESTER 1494) Operations to be carried out Additional checks to be carried out if the specified value is not obtained 11. Check the fuel - feed pressure : - First remove the cold start injector ( 9) from the induction air manifold, and disconnect the fuel pipe ( 1 )[...]

OPERATION No D.IE 144-0 : Checking the electronic fuel injection system Op. D.IE 144 - 0 11 ( CITROEN TESTER 1494) Operations to be carried out I ) Press button (( Pn briefly ;AUGE : hould register a rapid pressure rop to 1.2 bars ( 18.5 psi ). Wait pproximatively 30 seconds, the ressure should not drop visibly ny more. Additional checks to be carr[...]

12 OPERATION No D.IE 144 - 0 : (,herklng the elcrtron~r /urzl rrrlec /loo in I CI LROEN TE CTER 1491 i Operations to be carried out Additional checks to be carried out if the specified value is not obtained C) I/'the pressure drops to 0 : - Check the fuel tightness of the cold - starting injector. Look to determine whether fuel is escaping. If[...]

OPERATION No D.IE 144-0 : Checking the elec~ronic fuel injection system Op. D.IE 144 - 0 13 ( CITKOEN TESTER 1494) Operations to be carried out Additional checks to be carried out if the specified value is not obtained I 13. Check the action of the cold - start iniector and of the time - dela y thermal switch. - Switch on the ignition - Pressurise [...]

OPERATION No D.IE 144 - 0 : Checking the electronic fuel injection system Op. D.IE 144 - 0 15 (CITROEN TESTER 1494) 1. SECOND PART The following checks are carried out without the Tester 1494, the electronic control unit being connected as normally. 14. Check the movement of the triggering contacts in the distributor. Put the intermediary wiring ha[...]

16 OPERATION No D.IE 144-0 : Checkin g the electronic fuel injection system Op. D.IE 144 - 0 (CITROEN Tester 1494) 16. Check the full - load switch (16). Withdraw the wiring connector from the full - load switch. Remove the full - load switch from the chassis leaving the rubber pipe on the full - load switch connected to be air - inlet manifold. 1)[...]

OPERATION No D.IE 144 - 0 : Checking the electronic fuel injection system (CITROEN TESTER 1494) Op. D.IE 144 - 0 17[...]

Manual 814 - 1 Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 8 Starter mtr cntrl rela. 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 1[...]

OPERATION No D . IE . 144 - 0 : Checkin g the electronic fuel injection system Op . D . I E . 144 - 0 19 (CITROEN TESTER 1494) D . l E VEHICLES (All Types) produced between March 1970 and April 1971 Wiring diagram D . IE 511 - 00 a differs from the wiring diagram D . IE 51 1 - 00 only in the following points : 1) Wiring harness in two parts : a 12 [...]

OPERATION No D. IE - 144-0 : Checkin g the electronic fuel injection system (CITROEN TESTER 1494)[...]

v26 Colour Code Blue BI White Bc 17 Grey Gr Yellow J Brown Mr Mauve Mv Black N U L----+ Red R Green Ve I Violet Vi Cold start time delay /thermal swltch Cold start Injector Throttle spindle sw. COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 6 Thermal sensor I I 11 Cyllnder 1 Injector 12 Cyllnder 2 Injector 13 Cyllnder 3 Inject[...]

20 OPERATION No D.IE 144 - 0 : Checking the electronic fuel injection system (CITROEN Tester 1494) D.IE VEHICLES (all types ) poduced since April 1971 The wiring diagrams DX.IE 511 - 00 and DJ.IE 511 - 00 of these vehicles differ from wiring diagram D.IE 511 - 00 only in the following points (vehicles introduced before March 1970) : 1) The wiring h[...]

22 OPERATION N o D.1 E - 144 - 0 : Checkin g the electronic fuel injection system (CITROEN tester 1494) I. Air filter 2. Pilot valve 3. Throttle housing 1. Full load switch 5. pressure sensor I I I 5. Supplementary oir control d I DJ.IE VEHICLES + 9/1972 " DECEL" circuit : Vehicles DJ.IE released Since Se p tember 1972, To comply with[...]

OPERATION No D. IE - 144-0 a : Checkin g the electronic fuel injection system Op. D. IE - 144 - 0 1 (BOSCH EFAW 228 - S 10 Test Unit) I D. IE VEHICLES ALL TYPES CHECKING THE ELECTRONIC CONTROL UNlT USING BOSCH EFAW 228 - S 10 TEST UNlT EFAW 228 - S 11 : Markings in French EFAW 228 - S 10 : Markings in English E FAW 218 : Markings in German NOTE : T[...]

Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time dela) /thermal swltch 8 Starter mtr cntrl reli 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 12 Cyllnder 2 Inj[...]

OPERATION No D. I E - 144 - 0 a : Checking the electronic /uel injection system (BOSCH Test Unit EFAW 228 - S 10) VEHICLES D. IE ALL TYPES I IMPORTANT : Certains actions must be avoided at all costs as they would damage the components of the electronic fuel injection system, in particular the electronic control unit itself. 1) Never use a rapid cha[...]

Manual 814 - 1 ORIGINAL EQUIPMENT REPLACEMENT COMPONENTS (essential fitting) DATE CONTROL UNIT PRESSURE SENSOR 1) CONTROL UNIT ONLY 2) PRESSURE SENSOR ONLY from September 1969 No mark Standard - Fit a control unit : No ZC. 9.851.101 U (Ref. BOSCH No 0.280.000.042) (or the Standard Change control unit No 5.417.266 B) - Keep original pressure sensor [...]

4 OPERATION No D. IE - 144 - 0 a : Checking the electronic fuel injection system (BOSCH Test Unit EFAW 228 - S 10) IDENTIFICATION OF COMPONENTS : The control units and the sensors (pressure and temperature) always bear the supplier's reference number. NOTE : 1. A pressure sensor No DX. 144.119 A (1 green dot) has been fitted as a repair on a f[...]

a) Switch B : in position "voltoge 1" Switch on the ignition OPERATION No D. IE - 144 - 0 a : Checking the electronic fuel injection system 0p.D.IE-144-0a 5 : (BOSCH Test Unit EFAW 228 - S 10) TURN THE SWITCH TO THE " MEASURE " POSITION Precautions : - It is necessary to switch on the ignition to carry out the following checks. [...]

6 OPERATION No D. IE - 144 - 0 a : Checking the electronic fuel injection system (BOSCH Tester EFAW 228 - S 10) Operations to be carried out Further checks to be carried out if the specified value is not obtained 2. Check the starting voltage at terminal 87 of impulse relay (5). - Switch B : in " Starting volta g e w position - Operate the sta[...]

OPERATION No D. IE - 144 - 0 a : Checkin g the electronic fuel injection system 0p.D.IE-144-Oa 7 (BOSCH Test Unit EFAW 228 - S 10) DJ.IE VEHICLES PRODUCED SINCE 26th. APRIL 1971 The starter motor and impulsion relays are not fitted on these vehicles (refer to the diagrams on the following page and to opemtion DJ.IE 511 - 00 to identify the markings[...]

8 OPERATION No D.IE 144-00 : Checking the electronic fuel iniection system (BOSCH EFAW 228 - SlO Test Unit) DIAGRAMS SHOWING THE PRINCIPLES OF THE STARTER CONTROL D.IE Vehicles all types DJ.IE Vehicles produced up to April 1971 DJ.IE Vehicles produced since April 1971 The starter motor and impulsion relays are no longer fitted.[...]

OPERATION No D. IE 144 - 0 0 : Checking the ~l~ctroni~. fuel inlcrtlon ajste~rr Op. No D. lE 144 - 0 a ( HOSCH Tester EFAW 238 5 10) Switch B : in position ((Adjust m 11 Pressure sensor. - Adjust the tester (ohmmeter) to position m by turning the ((Adiusf - 11 control. - Press button marked (( Earth Operations to be carried out OHMMETER : pointer o[...]

10 OPERATION No D. lE - 144 - 0 a : Checking the electronic fuel injection system (BOSCH Tester EFAW 228 - S 10) Operations to be carried out Additional checks to be carried out if the specified value is not obtained 5. Check resistance of secondary windin g of pressure sensor (17) : Switch B : in position (( Adjust pressure sensor )) Press (( Seco[...]

1 I OPERATION No D. lE 144 - 0 a : Checking the electronic fuel injection system op. D. IE - 144.0 a ( BOSCH EFAW 228 - S 10 Test Unit) 8. Check resistance of the contacts of the throttle - spindle switch ( 10) : I Operations to be carried out Additional checks to be carried out if the specified value is not obtained 1) Accelerator pedal released I[...]

12 OPERATION No D. IE 144-0 a : Checking the electronic fuel injection system ( BOSCH EFA W 228 - S 10 Test Unit ) Operations to be carried out Additional checks to be carried out if the specified value is not obtained I 9. Check the resistance of the thermal sensor (6) Switch B in position (( Temperature Sensor I I ,) - OHMMETER : must read 0.3 to[...]

OPERATION No D. IE - 144 - 0 a : Checkin g the electronic fuel injection system Op. 6. IE - 1144 8 1.2 a (BOSCH Test Unit EFA R. 228 - s 10) D.IE VEHICLES (All types) produced since 5 th April 1971 The electronic injection control of these vehicles has been modified as follows : - the addition of an air temperature sensor - modification of the cont[...]

OPERATION No D. IE 144 - 0 a : Checking the electronic fuel injection system Op. D. IE - 144-0 a 13 / ROSCf! EFAW 228-S 10 Test Unit ) Operations to be carried out I Additional checks to De carried out if the specified value is not obtained 1. Check the fuel - feed pressure : - First remove the cold start injec - tor (9) from the induction air ma -[...]

14 OPERATION N o D.IE 144 - 0 a : Checking the electronic fuel injection system (BOSCH EFAW 228-S 10 Test Unit) Operations to be carried out Additional checks to be carried out if the specified value is not obtained I b) If the gauge registers a higher or lower pressure than 2 kg/cm2 (28.5psi) The fuel - pressure regulator is maladjusted ; it must [...]

OPERATION No D. IE 144-0 a : Checking the electronic fuel injection system ( BOSCH EFA W 228 - S 10 Test Unit ) Op. D. lE - 144 - 0 a 14a Operations to be carried out Additional checks to be carried out if the specified value is not obtained 12. Check the action of the iniectors : Switch A : in position *Injector check a Pressurise the circuit by b[...]

OPERATION N o D. IE 144-0 a : Checking the electronic fuel injection system Op. D. lE 144 - 0 a 15 ( BOSCH TESTER EFAW 228 S-10 Test Unit ) II. SECOND PART With the terminal block (1 ) of BOSCH tester EFAW 228 S - 10 still connected to the terminal block (2) of the iniec- tion system harness, CONNECT THE ELECTRONIC CONTROL UNIT (3) to the other sid[...]

16 OPERATION No D. IE 144 - 0 a : Checkin& the electronic luel inlection system ( KOSCH TESTLR EFAW 228 S-I0 Test llnit ) 3) Snap open the throttle : the needle must me7-e smartly between the two values indicated previously. /[the needle only drops sloud) : - Disconnect from the air inlet manifold the flexible pipe leading to the switch (16) : [...]

OPERATION No D. IE 144 - 0 a : Checking the electronic fuel injection system Op. D. l E 144 - 0 a 17 ( BOSCH TESTER EFAW 228 S-10 Test Unit )[...]

Manual 814 - 1 Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 8 Starter mtr cntrl rela 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 12[...]

OPERATION No D . IE . 144 - 0 a : Checkin g the electronic fuel inlection system Op . D.lE . 144-0a 19 (BOSCH EFA W 228 S 10 Test Unit ) D . IE VEHICLES (All Types) produced betweenMarch 1970 and April 1971 Wiring diagram D . IE 511 - 00 a differs from the wiring diagram D . IE 511 - 00 only in the following points : 1) Niring harness in two parts [...]

OPERATION NO D. IE - 144-0a : Checkin g the electronic fuel injection system (BOSCH E FAW228-S 10 Test Unit ) DIAGRAM DX.IE - 511-00 ELECTRONIC FUEL INJECTION SYSTEM DX.1E Vehicles produced since April 1971 (See Operotion DX.IE - 51 1 - 00)[...]

Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 12 Cyllnder 2 Injector 13 Cyllnder 3 Injector 14 Cyllnder [...]

OPERATION No D.IE . 144-0 a ; Checkin g the electronic fuel injection system Op . D.IE . 144-o9 (BOSCII Test Unit E F.4 A 218 . S 10) D.IE VEHICLES (All Types) produced since 'lpril 1971 The wiring diagrams DX.IE 511 - 00 and DJ.IE 511 - 00 for these vehicles differ from the wiring diagram D.IE 511 - 00 only in the following points : 1) The ha[...]

22 OPERATION No D.IE - 144 - 0a : Checking the electronic injection system (BOSCH Test Unit EFAW 228 S-10) I I 1. Air filter 2. Pilot valve 3. Throttle housing 4. Full load switch 5. Pressure sensor 6. Supplementar y air I I I control I DJ.IE VEHICLES 9/1972 " DECEL " circuit DJ.IE Vehicles released since September 1972. To comply[...]

OPERATION No. D. lE, 173 - 00 : Characteristics of the petrol feed Op. D. I E. 173-00 1 I D.IE VEHICLES, ALL TYPES 1. CHARACTERISTICS OF THE FUEL PUMP - Electric fuel pump - Reference number. ...... BOSCH OF 525 H - Output : ............. 60 - 80 litres/hour (13 gal. 2 pt - 17 gal. 5 pt (Imp.) /Hour) - Regulated pressure : ..... 4 bars (58 psi) - P[...]

OPERATION No D. 173 - 0 : Checking and adjusting the petrol pump Op. D. 173 - 0 1 VEHICLES ALL TYPES I. ADJUSTING THE PUMP OUTPUT NOTE : This operation is to be carried out if it is noted that the petrol feed is not correct or after the replacement of a spacer, push - rod guide, cylinder block or engine. It is not carried out if a pump alone has be[...]

2 OPERATION N0.D. 173 - 0 : Checking and a&usting the petrol pump II. CHECKING THE FUEL PRESSURE USING THE 4005 - T TESTER (on vehicle). 1. Place the tester on the vehicle : a) Disconnect the fuel conduit from the carburettor, and connect it to the fuel tester (2) on (tc n. b) Connect the cofiduit ((a)) from the tester (2) to the manometer. c) [...]

IGNITION CENTRIFUGAL ADVANCE OPERATION No D. 210-00 : Characteristics and particular features of the ignition. Op. D. 210-00 1 VEHICLES ALL TYPES. listributor advance CENTRIFUGAL ADVANCE 500 1000 1500 2000 2500 Distri - - 5 CENTRIFUGAL ADVANCE c3 - - "! I Distributor advance I Distributor advance 20 15 10' 5 0 500 1000 1500 2000 2500 Dist[...]

2 OPERATION No D. 210 - 00 : Characteristics and particular features o[ the ignition - References : DUCELLIER 3941 A SEV - MARCHAL N4C-FG/ LB CENTRIFUGAL ADVANCE LOW - PRESSURE OPERATED ADVANCE Dl m ID -2 1961-W!, 19t11 IDistributor advance 1 Distributor advance ,-. CENTRIFUGAL ADVANCE References : DUCELLIER 3941 B Distributor r.0.m. Distributor ad[...]

OPERATION No D. 210 - 00 : Characteristics and particular features of the ignition. D. 210-00 3 : DUCELLIER 4155 B SEV - MARCHAL A 147 SEV - MARCHAL 850 a 1000 g DUCELLIER 700 a 850 g SEV - MARCHAL .............................. 59' f 2' .................................. DUCELLIER 57' f 2' : DUCELLIER 4169 A SEV - MARCHAL A 158[...]

4 OPERATION No D. 210 - 00 : Characteristics and particular features of the ignition. CENTRIFUGAL ADVANCE c9 CENTRIFUGAL ADVANCE c 10 CENTRIFUGAL ADVANCE c11 DX - DJ - DXF - DJF h 10/ 1968 --t( 9/ 1972 DP +9/1972 - References : DUCELLIER 4253 A et 4253 B SEV - MARCHAL A 222 NOTE :Since February 1972, SEV - MARCHAL distribu - tors are litted with a [...]

OPERATION No D. 210 - 00 : Characteristics and particular features of the ignition. Op D. 210 - 00 5 CENTRIFUGAL ADVANCE c 12 Type of vehicle DX - DJ DXF - DJF DY - DL - DT DYF - DLF - References : DUCELLIER 4254 B 4254 C SEV - MARCHAL A 252 NOTE : Since Februar y 1972, SEV - MARCHAL distribu - tors are litted with a cassette. The curued marks and [...]

OPERATION No D. 210 - 0 : Checkin g and adjusting the ignition Op. D. 210 - 0 1 I I = PRE - S ETTINC OF STATIC TIMING 1. Check the gap between the contact breaker points (cam angle). 2, Find the position of static timing on the engine : a) Release the pressure in the clutch cylinder. To do this operate the manual clutch control (Vehicles with hyd. [...]

2 OPERATION No D. 210 - 0 : Checking and adjustin g the ignition. T.T. VEHICLES 7/1971 NOTE ; On a vehicle fitted with a 5 - speed gearbox, raise the front, L.H. side of the vehicle so that the wheels are off the ground. Engage 5th. gear and turn the front L.H. wheel so as to turn the engine. II. PRE - SETTING OF STATIC TIMING As from 1st July 1971[...]

500 1000 1500 2000 2500 tr/mn allumeur[...]

fig 3 Tracing the mark on the drive pulley, engine stopped, timing pin in place in the engine flywheel : Mark " a " opposite the " zero " of the gauge. fig. 4 With the engine turning at 2000 r.p.m., the position of the mark on the pulley when the distributor is set correct b 4' distributor fig 5 With the engine idling, the [...]

OPERATION No D. 210 - 0 : Checking and adjustin g thc ignitlon Op. D. 210 - 0 3 NOTE : It may be noted on figure 2 that when the engine turns at a speed 6f less than 700 r.p.m. approximately the advance point read on the stroboscope is less than 12' When the engine is idling it is possible for the mark on the drive pulley to take the position [...]

4 OPERATION No D. 210 - 0 : Checking and adjustin g the ignition. TABLE OF VALUES FOR ADJUSTING THE STATIC IGNITION TIMING - Column A : engine speed at which the timing must be carried out - Column B : total angle of spark advance in crankshaft degrees in relation to the T.D.C. - Column C : anqle of advance in relation to the static iqnition timinq[...]

OPERATION N O D. 210 - 0 : Checking and adjusting the ignition Op. D. 210 - 0 5 IV. ADJUSTING THE STATIC TIMING VEHICLES ALL TYPES (With a stroboscopic lamp) If the distributor has been removed, pre - set it so that the engine can run (see same operation 5 I) Connect the tachometer. Fit instrument 3078 - T onto the alternator bar ( 3 ) so that the [...]

6 OPERATION No D. 210 - 0 : Checking and adjusting the ignztion I VEHICLES ALL TYPES V. ADJUST1 __ 7/ 1971 (With a strobc NG THE STATIC TIMING ~scopic lamp with dephaser) 1. If the distributor has been removedpreset it so that the engine can run (see same operation 5 I) 2. Connect the tachometer. 3. Fit instrument 3078 - T onto the alternator bar ([...]

OPERATION No D. 210-0 : Checkin g and adjusting the ignition Op. D. 210 - 0 7 VI - ADJUSTING THE STATIC TIMING 1014 I VEHICLES ALL TYPES 1. If the distributor has been removed, pre - set it so that the engine can run (see same operation,•˜ 11). 2. Bring the piston of the first cylinder to TDC (see same operation, 5 11). 3. Make sure that the mar[...]

8 OPERATION No D. 210 - 0 : Checking and adjustin g the ignition VII. TEST BENCH CHECK OF A DISTRIBUTOR. The curves and characterislics of lhe different types of distributor are shown in operation D. 210 - 00. 1. Check the condition of the contact breaker points and adjust the contact gap. 2. Position the distributor on the test bench and connect t[...]

OPER A TIO N No D. 210 - 0 : Checking and adjusting the ignition Op. D. 210-0 9 IX - CHECKING AN IGNITION COIL 1. Check the insulation of the primary circuit. Check the insulation of the primary circuit usinq an ohmmeter connected between the primary terminal marked (x or BAT) and the housing. Resistance must be infinite This check may also be carr[...]

OPERATION No D. IE. 210 - 0 : Checkin g and adjusting the ignition. Op. D. IE. 210 - 0 1 I I. ADJUSTMENT OF THE DISTRIBUTOR AT THE STATIC SETTING I D. IE VEHICLES ALL TYPES 7/1971 NOTE : Ensure that the distributor is properly poeitioned, the connector (4) of the triggering contact mast be on the opposite side to the engine. 1. Check the contact - [...]

2 OPERATION No D. IE - 210 - 0 : Checking and adjusting the ignition D. IE VEHICLES ALL TYPES 7/1971 II. PRE - SETTING THE STATIC TIMING NOTE : Make sure that the distributor is properly positioned, the connector of the triggering contact must be on the opposite side to the engine. Since 1st. July 1971, the engines have been modified. - The notch o[...]

OPERATION No D. IE. 210-0 : Checking and adjusting the ignition Op. D. lE. - 210 - 0 3 Ill. TEST BENCH CHECK OF A DISTRIBUTOR D. 21 - 68 tributor advance 20 15' 10' 5 " 0 500 1000 1500 2000 2500 trlmn CENTRIFUGAL ADVANCE CURVE FOR BOSCH ZV 11/7A 3 A DISTRIBUTOR 1. Check the condition of the contact breaker points md 6. Check the odiu[...]

4 OPERATION N o D.IE. - 210 - 0 : Checking and adjusting the ignition on. D.IE VEHICLES ALL TYPES -. 7/1971 I IV. ADJUSTING THE STATIC TIMING (With a stroboscopic lamp) NOTE : The distributor must be timed, with the engine running at 1800 r.p.m.. Ignition advance must be 22' ( crankshaft degrees in relation to T.D.C. ) 1. If the distributor ha[...]

OPERATION No D. lE - 210 - 0 : Checking and adjustin g the ignition Op. D. IE - 210 - 0 5 NOTE : The distributor must be timed engine running at 1800 r.p.m. Ignition advance must be 22' (crankshaft degrees in relation T.D.C. ) V. ADJUSTING THE STATIC TIMING 1. If the distributor has been removed set it at the static setting so that the engine [...]

1. If the distributor has been removed, pre - set it so that the engine can turn over (see this operation, chap. 11) 6 OPERATION No D. I E - 210 - 0 : Checking and adjusting the ignition. 2. Bring the piston of cylinder 1 to TDC (see same operation, chap. 11) D. I€ VEHICLES ALL TYPES 7/1971 3. Make sure that the mark on the drive pulley (1) (yell[...]

OPERATION No D. 220 - 0 : Checking the oil - pressure on the vehicle Op. D. 220-0 1 VEHICLES ALL TYPES CHECKING THE OIL PRESSURE CHECKING 1. Run the engine until the oil temperature is about 60•‹C Stop the engine 2, Remove the lubrication screw from the cylinder head. Connect a pressure gauge graduated from 0 to 10 bars (0-150PSI). Link this to[...]

OPERATION No D. 230 - 0 : Checkin g the cooling system Op. 0. 230 - 0 1 Reference of regulators CL. 35-3800 V. 28 Ref. 5950 V. 28 - Ref. 6153 VEHICLES ALL TYPES CHECKING A THERMOSTATIC REGULATOR Date Types of vehicles * DX A.T. (except BW)DJ A.T. DY A.T. 4 l0/1972 1 DV - DT - DL DT - DLF - DV DP + 10/1972 Start of valve opening DX A.T. and Dl A.T. [...]

OPERATION No D. 236 - 0 :Adjustin g the pull(~ys and belts. Op. D. 236 - 0 1 VEHICLES ALL TYPES 1. ALIGNMENT OF THE PULLEYS NOTE : The adjustments are made starting from the water pump pulley which is fixed on its spindle. 1. Adiustment of the drive pulley : Place tool 3082 - T, or 3085 - T, in one of the grooves of the water pump pulley. The rod m[...]

2 OPERATION No D. 236 - 0 :Adjustin g the pulleys and belts. 4. Adiustment of the centrifugal re g ulator pulley: Place tool 3082 - T, or 3085 - T in the groove of the regulator pulley. The rod must centralise in the first groove of the high pressure pump pulley. Decrease or increase the thickness of the packing pieces at (a) to obtain correct alig[...]

OPERATION No D. 236 - 0 : Adjusting the pulleys and belts Op. D. 236 - 0 3 6. Tension of the centrifugal re g ulator belt. ( Vehicles with h y draulic gear change only) Unscrew : - the clip ( 1 ) - the tie - rod ( 2 ) - the mounting spindle ( 3 ] Tension the belt using the hooked tool MR. 630 - 66/ 11b. This hook passes round the regulator body beh[...]

4 OPERATION No. D. 236 - 0 : Adjusting the plleys and belts 8. Tension of compressor drive belt iuehicles with air conditioning) NOTE : To perform this operation correctly, a GATES 150 tension - meter, sold under No. 1688 - T, MUST be used. a) Fit the meter 1688 - 'I' on the belt as shown in the illustration opposite, the scale bl against[...]

CLUTCH OPERATION N o D. 312 - 00 : Churacteristics and checks on the clutch Op. 0. 312 - 00 1 VEHICLES ALL TYPES except D.lE 4 10/1972 SPECIAL FEATURES Tighten the screws securing the clutch mechanism to the flywheel to 21 to 28 mAN (2.1, to 2.8 mkg) (15 to 20 ft Ibs) After resurfacin g : the distance between the disc thrust face and the clutch dri[...]

2 OPERATION No D. 312 - 00 : Characteristics and checks on the clutch. Checkin g the mechanism : - Fit the mechanism onto instrument 3108 - T - Using a depth gauge, measure the distance ((a)) between the upper part of the toggles ( 1 ) and the bottom c(bj) of assembly 3108 - T. + 1.5,, - This distance must be (tan = 39.8 - Move the clutch up and do[...]

OPERATION No D. 312 - 00a : Characteristics and checks on /he ciutch Op D. 312-00a 1 VEHICLES - ALL TYPES b 10/1972 SPECIAL POINTS 4 4 Clutch type 235 DBRI 490 : No operation is possible on the clutch mechanism except for the mechanism check. r-4 03 - S e 2 - Tighten the screws securing the mechanism on the flywheel (recessed hex - head screws of 6[...]

2 OPERATION N o D.312-00: Characteristics and checks on the clutch . Clutch plate Type of engine ø Exterior of the plate DY.3 DX.2 (17 N) (21 N) 225 mm DX.4 DX.5 (19 N) (29 N) 228,5 mm Mechanical clutch control (Manual gearchange vehicles): a) Height of the pedal measured from the underside of the pedal plate to the floor panel : - on PA. vehicles[...]

CLUTCH OPERATION N o D.IE 312 - 00: Characteristics and checks on the clutch Op D.1 E 312 - 00 1 D.IE - VEHICLES - ALL TYPES - 10/ 1972 except BW SPECIAL POINTS 4 u 5 G s Clutch type 230 - DIB 440. No operation is possible on the clutch mechanism except for the mechanism check. - Tighter1 the bolts securing the mechanism on the flywheel (grower was[...]

2 OPERATION N o. D.IE 312-00: Characteristics and checks on the clutch . Mechanical clutch control (Manual gearchange vehicles): a) Pedal height measured from the lower face of pedal to the panel of the floor : - on PALLAS vehicles (rubber pad in place) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 ± 1 mm - on[...]

OPERATION N o Dh. 314-0 : Checks and adjustments on the hydraulic clutch Op. Dh. 314 - 0 1 control. VEHICLES with HYDRAULIC GEA RCHANGE I . BASIC ADJUSTMENTS. (See operation D. 142-0) I1 . CHECKING THE CLUTCH CYLINDER FOR LEAKS - 1. Use test bench 2290 - T for vehicles with L.H.S. fluid or test bench 3654 - T and its accessories 3655 - T for those [...]

[...]

OPERATION No Dh. 314 - 0 : Checks and adjustments on the hydraulic clutch control. Op. Dh. 314 - 0 3 IV. CHECKING THE CLUTCH DISENGAGEMENT. 12. Put the vehicle in the a low N position. Slack - en the bleed screw on the pressure regulator. 13. Disconnect : - the lead from the negative terminal of the battery, - the fuel feed pipe on the fuel pump, -[...]

4 OPERATION No Dh. 314 - 0 : Checks and adjustments on the hydraulic clutch control. VI. CHECKING THE PRESSURE SUPPLIED BY THE 22. Prepare the test bench. a) Disconnect the pipe H from the pressure gauge M1 and from the test bench pump. b) Connect the pressure gauge M2 (200 bars) (3000 PSI) to the test bench pump D by means of pipe H. 23. Tighten t[...]

OPERATION No Dm. 314 - 0 : Checks and adjustments on the clutch control. Op. Dm. 314 - 0 1 I VEHICLES WITH MECHANICAL I GEAR SELECTION September I968 I - ADJUSTING THE CLUTCH CONTROL 1. Check the hei g ht of the pedal : Standard Vehicles : The height should be L = 142 + from the underside of the pedal plate (with the rubber pad removed) to the floo[...]

VEHICLES WITH MANUAL GEAR SELECTION, ;~n~duced ,.!nc? Sel,iernher i% ? Option : P.A./ -[...]

OPERATION No Dm 314-0 : Checks and adjustments on the clutch control. Op. Dm. 314-0 3 I VEHICLES WITH MECHANICAL II - ADJUSTING THE CLUTCH CONTROL (Pedal gear with overlood spring.) GEAR SELECTION 1-w - September 1968 5. Adjusting the height of the pedal : a) Standard Vehicles The height must be : L = 142 2 mm from the under side of the pedal plate[...]

4 OPERATION No Dm. 314 - 0 : Checks and adjustments on the clutch control. 3332 - 1 8. Adiust the clutch clearonce. Using a rule, measure the clearance (( J a given above. An assistant should depress the clutch pedal by hand up to the point where resistance is felt when the thrust face comes into contact with the toggles. Again measure the clearanc[...]

TORQUE CONVERTER OPERATION No. Dbw 320 - 00 : Characteristics and particular features of the torque conl~erter Op. Dbw 320-00 1 I DBW. VEHICLES All types 1. DESCRIPTION - The "DS 21 " vehicles (carburettor or electronic fuel ~njection) may be optionally fitted with a BORG - WARNER fully automatic gearbox " type 35 " . - Principa[...]

2 OPERATION No. Dbw 320 - 00 : Characteris tics and particular features 01 the torque converter Converter - hydraulic coupler. w Brand : FERODO 250 I (transmission 1680) Licence : BORG WARNER. It is composed of a leakproof housing filled with oil and containing three bladed wheels : - Two of these are mobiie . the impellor and the turbine. - the th[...]

4 - SPEED GEARBOX OPERATION No. D. 330 - 00 : Characteristics and special points on the gearbox Op. D. 330-00 1 DX - DL - DV - DT ALL TYPES VEHICLES DJ + 9/1970 1. CHARACTERISTICS. 1. Gear ratios : NOTE : The speeds are given for vehicles fitted with 180 - 380 XAS, 180 HR. 380 XAS and 185 HK. 380 XAS types for which the rolling circumference is : 2[...]

2 OPERATION No. D. 330 - 00 : Characteristics and special points on the grarbor e) Vehicles DV and DT 91 1971 Gear 1 2 3 4 REV. 2. Oil capacity of gearbox : Gear 1 2 3 4 REV' - Capacity : ..................................................................................... 2 litres (3 112 pts. imp) - Oil : .....................................[...]

OPERATION No D, 330.00 : Charuc~trristics und sp~cial points on the gearbox. Op. D. 330-00 3 GEARBOX (Mechanical gear selection) DIFFERENTIAL D. 34 - 1 Left hand side kd Right hand side[...]

4 OPERATION No D. 330 - 00 : Characteristics and special points on the gearbox. FIRST GEAR SECOND GEAR THIRD GEAR REVERSE FOURTH GEAR II. SPECIAL POINTS 1. S p eedometer drive : - Torque of 8/35 : ....................................... - lo = 0,4761 2 1 - Torque of 7/ 34 : ....................................... 7 = 0,4375 16 2. Adiustments (Gearb[...]

OPERATION No D. 330-00 : Characteristics and special points on the gearbox Op. D. 330-00 5 3. Tightening torques : - Dog nut (main shaft) ....................................................... 150to 170mAN (15 to 17m.kg) (110to 123 ft lbs) - Bevel. pinion shaft nut .................................................... 200 to 220 mAN (20 to 22 m.kg)[...]

OPERATION No Dh. 334 - 0 : Checkin g and adjustin g the gear change control Op. Dh. 334 - 0 1 VEHICLES WITH HYDRAULIC GEAR CHANGE I - CHECKING AND POSITIONING THE HYDRAU - LIC SELECTOR 1. Put the gear selector lever in the first speed position 2. Remove rubber plug from locating hole " a " 3. Insert alignment rod q5 = 3,94mm (2429 T) : it[...]

2 OPERATION No Dh. 334 - 0 : Checking and adjusting the gear change control 10 . Check the position of neutral for reverse : Determine the end float of the reverse fork shaft when in neutral. Engage 3rd or 4 th. gear. Free the gauge 3183 - T (or 3188 - T) Push the reverse fork shaft towards the rear of the gearbox and measure, by means of a depth g[...]

OPERATION No Dh. 334-0 :Checking and adjusting the gear change control Op. Dh. 334- 0 3 b) Adjust the stroke of second geor : Pull on the shaft to engage 2nd gear fully. Make sure that gear is fully engaged by checking the shaft projection (for example 55,3 mm as determined in 5 9 line b) . Remove screw or threaded T fitted on the end of the shaft.[...]

4 OPERATION No Dh. 334 - 0 : Checkin g and adjustin g the gear change control 16. NOTE Ill. CHECKING A CLUTCH LOCK 2549 9/ 1966 - Use test - bench 2290 - T (painted grey ) the accessories bear no markings 9/ 1966 - Use test - bench 3654 -T (painted green) the accessories bear green markings 17. Connect pump outlet ctcn to pressure gauge M2 and to c[...]

OPERATION No DM 334 - 0 Checking and adjusting the gear change control (4 and 5-speed gearboxes) Op. Dm. 334 - 0 I I VEHICLES WITH MANUAL GEAR CHANGE N.B. : This operation applies for both 4 and 5 speed gearboxes 1. ADJUSTING THE STROKE OF FOURTH GEAR 1. Remove the gear box cover 2. Engage fourth gear, the sliding sleeve for 3rd/4th gear in contact[...]

2 OPERATION No DM 334 - 0 : Checking and adjustin g the gear change control (4 and 5 - speed gearboxes) b) Gear shift travel (movement F2 - F3) Adjust the control rod length (1) so that gear change lever does not touch the surround in any selected position. To do this : a) Slacken nut (2) b) Disconnect control rod (1) from c) Operate ball pin (3) d[...]

5 SPEED GEAR BOX r5PE FATION 1.1 ' 340-CG . Characterlstl( s unti piuticulur feulures of 5 ,,wed gear hoi Op. D 340.00 1 I VEHICLES : DJ all type. + 99/1979 I. CHARACTERISTICS 1. Gear ratios : rJO'IA Speeds Jre given for 7:ehicles fitted with tyres 180 HR 380 XAS or 185 HR 380 XAS whose mllinq cirixmiererice i.s 2,07 m. I E 1.4 Ins j, und[...]

2 OPERATION N o D. 340-00 : Characteristics and particular features of 5 - s p eed gearbox, GEARBOX D 33-130 DIFFERENTIAL D. 34 - 1[...]

Ill. DIAGRAMS OF GEARS S. 33 - 2 b 1st GEAR 3rd GEAR 5th GEAR 2nd GEAR 4th GEAR REVERSE GEAR[...]

AUTOMATIC GEARBOX OPERATION No. Dbw 350 - 00 : Characteristics and articular features of the automatic gearbox. Op. Dbw 350 - 00 1 I DBW VEHICLES - All types BORG - WARNER AUTOMATIC TRANSMISSION BORG-WARNER automatic transmission, type 35, can be fitted as an option on aDS 21 n carburettor or electronic injection vehicles. 1. GENERAL DESCRIPTION. T[...]

2 OPERATION N O . Dbw 350 - 00 : Characteristics and particular features of the automatic gearbox. 111. PRACTICAL OPERATION 1. Gearbox controls The driver has two methods of controlling the operation of the gearbox : a) The selector lever : This has 6 positions : (( P )) - t( R ), - tt N )) - a D ), - tt 2 s - tt 1 n. The positions (t D )) and (t 2[...]

OPERATION NO. Dbw 350-00 : Characteristics and particulur fecrtures of the autornatic geurbon Op. Dbw 350 - 00 3 5, POSITION (( B)) : Automatic changing of the three forward gears (drive), This position is used for the normal runninq of the vehicle : a) Acceleration of the vehicle, stadrcg start : - When starting the firs.t gear is always used - Th[...]

4 OPERATION No.. Dbw 350 - 00 : Churn,.teris~ics illlll purticulnr lentures 01 [he automutic geartor 6- POSITION ((2)) : Automatic changing of the first two forward gears. This position is used for town traffic or motoring in mountainous areas. In this position the operation is identical to that of position ((D)), but only the first two gears are u[...]

OPERATION No. Dbw 350 - 00 : Characteristics and particular features of the automatic gearbox Op. Dbw 350 - 00 5 IV. CHARACTERISTICS 1. Gears : Vehicles fitted with 180 - 380 XAS, 180 HR 380 XAS and 185 HR 380 XAS whose rolling circumference is 2.07 m (81.4 ins) 1 I Gearbox 1 Crownwheel ratio I and pinion Total I Speed at 1000 rpm demultiplication [...]

FRONTBRAKE b. _ Brake band Adju EPICYCLIC GEA CENTRIFUGAL G O V E R N O R - Valve chest CAM stable stop EPICYCLIC GEAR[...]

OPERATION No. Dbw 350.00 : Charc~cteristics and purticulur 'catures of the autona tir gearbox Op, Dbw 350-00 7 Y, DESCRIPTION OF GEARBOX 0. 35 - 49 Forward drive v IY / I I run gear Rear J'roat Fret wheel ~w&e drive clutch clutch @* 9- The gearbox comprises - A train of epicyclic pinions giving three forward gears ar,d one reverse gea[...]

OPERATION No. Dbw 350 - 00 : Characteristics and particular features of the automatic gearbox. VI. DlAGRAMATlC VIEW OF GEAR TRAIN D. 35 - 49 1 2 3 4 1 st GEAR COMPONENTS : Conductors I 1 6 4 2nd GEAR[...]

OPERATION Noo Dbw 350-00 : Characteristics and particular leatures of the automatic gearbox 1st GEAR (Positions (( 1 D, a2tb, or u D))) - Rear clutch (1) operating : it connects the forward movement sun gear (5) and the torque convertor. - When the selector lever is in position (( 1 n the front bmke (3) immobilizes th planetary gear holder (4) whic[...]

OPERATION No. Dbw 350 - 00 : Characteristics and particular features of the automatic gearbox Fixed REVERSE[...]

OPERATION NO. Dbw 350 - 00 : Characteristics and particular features o/ the automatic gearbox Op, Dbw 350 - 00 11 THIRD GEAR (Position (( Do) - Rear clutch (1) operating, it connects the forward movement sun gear (5) and the torque convertor. - Front clutch (8) operating, it joins the two sun gears (5) and (7), thus locking the epicyclic gear train[...]

12 OPERATION No. Dbw 350-00 : Characteristics and particular features 01 the automatic gearbox VII. PARTICULAR FEATURES 1. Selection lay-out of ranges of operation : It is this which, in conjunction with the locking mechanism of the hydraulic selector, holds the lever in each of its positions. To change from one position to another, pull the lever [...]

0fPUT)OI W1 D. bw 35440 : Working principles of hydraulic gecdage cond. Op. 8. kr 3- 1 a I 0. bw V-LES ALL TYPIM BORC-WARNER GEARBOX HYDRAULIC GEARCHMCE CONTkOL I - BASIC DIAGRAM. w ,, II - DESCRIPTION. - Gearchanges are controlled by multiple disc clutches and brake bands. These components ure ' hydraulically operated, hydraulic power being s[...]

CONVERTER CLUTCH CLUTCH BRAKE REAR BRAKE FRONT[...]

OPERATION N o D. bw 354-00: Aorking principles of hydraulic gearchange control Op. D. bw 354 - 00 3 The hydraulic control unit consists of : - The prinrary and secondary regulator slide I~I-es : They control the pressure of the oil supplied by the pump and permit it to feed the converter and the lubrification circuit. - The manuall) operated r-ontr[...]

OPERATION N O . Dbw 354-0 : Checkin g and adjusting the gear controls Op. Dbw 354 - 0 1 DBW VEHICLES All types I. ADJUSTMENT OF BRAKE BANDS 1. Loosen the lock - nuts. 2. Tighten the screws (1) and (2) to 7 mAN (0,7 mkg), then loosen then 3/4 of a turn. 3. Hold the screws, and tighten the lock - nuts to 45mAN (4,5 mkg). II. ADJUSTMENT OF KICK - DOWN[...]

2 OPERATION No. Dbw 354 - 0 : Checking and adjusting the gear controls Ill. ADJUSTING THE SELECTOR 1. Adiust the selector cable : a) Remove the coupling pin (3). b) Place the selector lever in position "1" and pull the cable using the fork end (2) until it reaches the last notch of the locking mechanism. c) At this point, the holes for th[...]

OPERATION N O . Dbw 354 - 0 : Checking and adjustin g the gear controls IV. ADJUSTING THE SWITCH FOR THE STARTER MOTOR AND THE REVERSING LIGHTS. Use an ohmmeter or a check lamp. 1. Place the selector lever in position "Dm " 2 " or " 1' 2. Tighten the switch (1) until the current no longer passes between the two narrowest te[...]

4 OPERATION Ne. DLw 3546 : Checking md adjusting the gear controls V. ROAD CHECKS A) Cbeckine switch on gurbo~. Place the relector lever in the following pmitions : - In positions "P" or "Nu : the.starter motor can be operated. - In positions " R, D, 2 or 1 " : the starter motor cannot be operuted - In position "R"[...]

OPERATION No D.bw. 354-0 : Checking the oil pressure in the gearchange circuit. Op. D. bw 354-0 5 4z REMOVAL. I DBW. VEHICLES - ALL TYPES VI. CHECKING THE OIL PRESSURE IN THE GEAR CHANGE CIRCUIT Remove the spare wheel Disconnect the headlamp control Remove the spare wheel support bar and radiator ventilation duct assembly. Remove the plug of the hy[...]

TRANSMISSION OPERATION N o D. 372 - 00 : Characteristics and purticular /earurt.s o/ driveshalts Op. D. 372 - 00 1 I VEHICLES OF ALL TYPES PARTlCU LAR FEATURES 1. Tri - axe a) vehicles-3/197L A shim of 2.5 mm is placed between the protection plate and the tri - axe housing Note : When carrying out a repair on a vehicle produced between March 1970 a[...]

2 OPERATION No D. 372 - 00 : Charactercstics and particular features of driveshafts - Left hand side - - R ight hand side - Angulac posirion of half rings in relation fo each other not important I I MARK RI DESCRIPTION COULEUR I MARK R RH Block Blue with I I I LH Block Yellow without I 2. Vibration dampers : (on DX, Dj, DXF, DJF W lo/ 1968) - Mount[...]

OPERATION No D. 372-0 : Checkin g and adjustin g the drive:shafts Op. D. 372-0 1 I - ADJUSTING THE CROSS - HEAD END - FLOAT NOTE : .-!pi1 1967. The cross - head end - float is adjusted by using needle - cup circlips ( 2) The spare parts department supplies circlips of seven different thicknesses indicated by cuts en - graved on the curved end piece[...]

SOURCE AND RESERVE OF PRESSURE OPERATION No D. 390 - 00 : Charac~eristics and particular features of source and Op. D. 390 - 00 I reserve of pressure for the hydraulic circuit. I. HYDRAULIC CIRCUITS - BASIC DIAGRAMS. VEHICLES ALL TYPES 1. DX/ DY vehicles ( - 12/1967) Power steering high pressure t Source of -Three way union -Three way union - Hydra[...]

2 OPERATION No D. 390 - 00 : Characteristics and particular features of source and reserve of pressure for hydraulic circuit. 6. I.E. vehicles Source of - Brake accumulator - Front brakes high pressure I ( - Front suspension Priority valve s ear suspension --Rear brakes Hydraulic gearchange control (DX.IE Vehicles) Seven - cylinder H.P. pump. D. 39[...]

OPERATION N o D. 390 - 00 : Characteristics and particular features of source and Op. D. 390 - 00 3 reserve of pressure for hydraulic circuit. II. CHARACTERISTICS. 1. Hydraulic circuit : 4 9/ 1966 red fluid L.H.S. 2 t--t 9 i 1966 green fluid L. H. W. ....................................... - Capacity of circuit 6 litres (10,s pts) 2. Reservoir : - [...]

OPERATION No D. 390 - 00 : Characteristics and special features of source and reserve of pressure for hydraulic rircuit Pilot Valve Dressure requlator. D, 39 - 53 Pressure distributor. Vehicles with hydraulic gear change o. 34;7 Front suspension Hiqh pressure Rear suspension Vehicles wilh manual change D. 39-8 Front suspension High pressure Rear su[...]

OPERATION N o D. 390-00 : Characteristics and special features of source and Op. D. 390.00 5 reserve of pressure for hydraulic circuir. Ill. PARTICULAR FEATURES, 1. Seven c y linder high pressure pump : - tension for belts ................................. 40kg. (88 lhs) ............ - piston push rods : (lenghs : in steps of 0,l mm.) 28,8 to 30,5 [...]

6 OPERATION N o D. 390 - 00 : Characteristics and particular features of source and reserve of pressure for h y draulic circust. 5. Priority valve : ......................... Thickness of adjusting shims 0,9 mm Tightening of plug screw ............................ 12 mAN (1,2 m.kg) (8,68 ft. lbs) ................................ Tightening of plug [...]

OPERATION No DV 390 - 0 : Checking h y draulic components on the vehicle Op. DV 390 - 0 1 CHECKING HYDRAULIC COMPONENTS ON THE VEHICLE I VEHICLES DV - DT - DP In order to carry out these checks, the following must be used: - 2 - 3 - way unions ( HY 453 - 134 ) - 2 link pipes ( DV 394 - 122 ) - ( ALD ) rubber seals (NN 394 - 87a ) - (green marking f[...]

2 OPERATION N O DV 390 - 0 : Checkin g hydraulic components on the vehicle 8. Checking pressure regulator : Block end - piece ctd n of 3 - way union and openings ((a )) and ((c )) of front and rear suspension feed pipes. a ) Cut - out. Start the engine, with the pressure regulator bleed screw tightened and the vehicle in low position. Observe the p[...]

OPERATION NoDV. 390 - 0 : Checking the hydraulic components on the vehicle Op. DV. 390 - 0 3 10. Checking the slide - valve of the security valve. By means of plugs block : - the end piece ccc~ of the three way union - an opening ((a )) of the suspension feed pipe Tighten the pressure regulator bleed - screw Switch on and activate the starter to al[...]

4 OPERATION N O DV. 390 - 0 : Checking the hydraulic components on the vehicle 12. Checking a brake pressure switch. a) By means of plugs stop the openings of the feed pipes for front suspension ((a )) and rear suspension (( b~. Connect the brake control valve feed pipe to end piece (( c )) of the three - way union. Tiqhten the pressure regulator b[...]

OPERATION No DV. 390-0 : Checkin g hydraulic components on the vehicle Op. DV. 390 - 0 5 d ) To check the height corrector block the sus - pension cylinder feed pipes by means of plugs. The leakage observed is that of the height cor - rector, and should not bring about a drop in pressure of more than 10 bars ( 150 psi ) in three minutes. 14. Checki[...]

6 OPERATION N O DV. 390 - 0 : Checkin g hydraulic components on the vehicle 2' ) On vehicles c-) 3/ 1967. Block rear brake feed union ( 3 ) To check rear right cylinder, block union ( 2 ) To check rear left cylinder, block union ( 1 ) To check height corrector, block opening ct a )) 15. Checkin g the power assisted steering. a) Block, by means[...]

OPERATION No D. 391 -0 : Checking a suspension sphere or a brake accumulator Op. D. 391 - 0 1 I VEHICLES ALL TYPES CHECKING THE INITIAL PRESSURE OF A SUSPENSION SPHERE OR A BRAKE ACCUMULATOR 4 NOTE : To carry out this operation make use of test ' bench 2290T for vehicles using synthetic hydraulic 2 a fluid LHS2 (Red marking) and bench 3654T fo[...]

OPERATION No D 410 - 00 : Characteristics and particular features of front axle Op. D 410 - 00 VEHICLES ALL TYPES 1. CHARACTERISTICS (on vehicles) 1. Caster Caster angle.. ........................................................................................................... 2. Camber .. ............................... ..................... Dif[...]

2 OPERATION No 410 - 00 : Characteristics and particular features of front axle. II. PARTICULAR FEATURES. PIVOT Do not clean the pivot assembly by immersion The pivot bearings can only be replaced by using a special tool. Tightening Tightening Tightening Tightening torque torque torque torque for nut of upper pivot ball on arm: ....... 85 to 100 mA[...]

OPERATION No D. 410 - 00 : Characteristics and particular features of front axle Op. D. 410 - 00 3 HALF AXLE 1. Removal The suspension piston rod can only be freed when the pin holes in the rod and the lever are in line. To bring them in line it is necessary to press on the arm. Tighten the screws holding the half - axle to between ............. 70[...]

OPERATION No. D. 410 - 0 : Checking and adjusting the front axle Op. D. 410 - 0 1 VEHICLES ALL TYPES 1. ADJUSTING THE CAMBER 1. Check the heights (see the corresponding operation) 2. Put the vehicle on a flat, horizontal surface. Put the height control in the normal road position. Start the engine and keep it running for the whole operation. 3. Put[...]

2 OPERATION N o D 410 - 0 : Checks and adjns~rnrn~s on lron~ axle Ill. CHECKING THE CASTER 1. Case 1 : using luminous projection or level tool : Follow the makers instructions; /hc! c-aslrr should he : 1~30' 2. Case 2 : using tool 2321-T a) Fix the two track gauges A and B onto the arms of the axle in such a way that the machined dovetail at ![...]

REAR AXLE OPERATION No D . 420 - 00 :Characteristics and particular features of rear axle Op, D. 420 - 00 1 1. CHARACTERISTICS 1. Camber (not adjustable) VEHICLES OF ALL TYPES - Difference between L.H. Side and R.H. Side .......................... ... .... . ... . . ....... . 1mm - Angle ..................................... . ..... . . . .........[...]

2 OPERATION No 420 - 00 : Characteristics and particular features of rear axle 4. Wheel arm bearing housing II. PARTICULAR FEATURES : 1. Hub : - Length of conical spacer for hub bearing ............................... 72.78 + 0,02mm - Adjusting shims for hub bearings (25.1 ~31.8) . thickness in steps of 0,04mm ......................................[...]

SUSPENSION OPERATION No. D. 430 - 00 : Characteristics and particular features of suspension 0p.D. 430 - 00 1 1. CHARACTERISTICS. 1. Spheres a) Inflation pressure : Saloon : front = 59 + bars (860 + 28 psi) - 15 - 220 Safari : front = 59 + bars (860 + 28 psi) - 15 - 220 D VEHICLES OF ALL TYPES rear = 26 + bars (380 + 28 psi) - 10 - 150 rear = 37 + [...]

2 OPERATION No D. 430 - 00 : Characteristics and particular features of suspension 4. Tyre pressure : See Op. 0.000 ..................................... Tightening torque of wheel nuts : 43 - 58 ft lbs (6 - 8 mkg) 5. Adiusting the heights : NOTE : The hei g hts are measured between the under - face of the anti - roll bars and the plane on which th[...]

SUSPENSION OPERATION No D.IE 430 - 00 : Characteristics and particular features of the suspension Op. D.IE 430 - 00 1 I D.IE VEHICLES - ALL TYPES The suspension of the cars equipped with electronic fuel injection system is similar to that of the other vehicles with the exception of the followin g points ; 1') Size of tyres : Front and rear ...[...]

OPERATION No D. 430-0 : Checking and adjusting the suspension and its controls. Op. D 430-0 1 I VEHICLES ALL TYPES I - PRE - ADJUSTMENT OF THE FRONT HEIGHTS 1. Connect the height control rod ( 2) to lever ( 1 ) and to fork end ( 3 ) on the corrector control bar, the manual height control lever being in the low position. 2. Place the manual height c[...]

2 OPERATION No D. 430 - 0 : Checking and adjustin g the suspension and its controls. 111 - ADJUSTMENT OF THE HEIGHTS In order to carry out this operation, the vehicle must be in running order. Place the height control lever in " normal " posi- position. 6. Check the tyre pressures : See Op. D. 000 7. Place the car on a lift or over a pit.[...]

OPERATION No D. 430 - 0 Checkin g and adjustin g the suspension and its controls. Op. D. 430-0 3 d) Lower the car by pressing on the rear bumper. Let go when resistance is felt. The vehicle rises then lowers and stabilizes. c) Lower the car by pressing on the front bumpers. Let go when resistance is felt. The car rises then lowers and stabilizes Me[...]

4 OPERATION N o D. 430 - 0 : Checking and adjusting the suspension and its controls Note the distance between the underside of anti - roll bar and the plane on which the wheels stand, for example : 342 mm. Take the average of the figures : This measurement must lie between: - 335 and 345 mm for D vehicles all types (except IE) - 355 and 365 mm for [...]

OPERATION No D. 430 - 0 Checking and adjusting the suspension and its controls Op. D. 430 - 0 5 IV - ADJUSTING THE FRONT ANTI - ROLL BAR 13. Adiust the lateral position of the anti - roll bar a) Remove the lateral and lower mudshields. b) Measure the distance ( h ) between the stop clamp ( 1 ) and the inner face of the right hand ball pin securing [...]

6 OPERATION No D. 430 - 0 : Checking and adjusting the suspension and its controls V - ADJUSTING THE MANUAL HEIGHT CONTROL X. 55 18. Position front linkage rod ( 6 ) correct1 in relation to relay lever (9 1. Determine in the rod the corresponding hole ((a)) to obtain a clearance j = 7,s + 115 mm - 0 If no adjustment is possible by using the holes i[...]

OPERATION No D. 430 - 0 : Checking and adjustin g the suspension and its controls Op. D. 430 - 0 7 In the low position the suspension spheres must be free. In the high position the rubber stops are compressed. The distance between the base of rubber stop and thrust face of sheet - metal buffer must be : d = 6 mm maximum at the front e = 8 mm maximu[...]

STEERING OPERATION No D. 440-00 : Characteristics and particular features of the steering Op.D.440 - 00 1 I VEHICLES ALL TYPES A. STEERING WITH HYDRAULIC RACK CONTROL Vehicles all types (optional on DV and DT vehicles 1. CHARACTERISTICS ................................................... - Toe - in 2 to 4 mm ........................................[...]

OPERATION No D. 440 - 00 : Characteristics and particular jeatures of the steering 111 - IMPORTANT POINTS 1. Before doing any work on the hydraulic control of the steering, make sure that the steerins track rod ball joints are in good condition. To do this : Disconnect the outer track rod ball pins from the pivot levers (use ball pin extractor 1964[...]

OPERATION No D. 440 - 00 : Characteristics and particular features of steerin g Op. D. 440 - 00 3 VEHICLES DV - DT B. STEERING WITH MECHANICAL RACK CONTROL I. CHARACTERISTICS - Wheel alignment. ......................................... toe - in 2 to 4 mm- - Steering reduction ratio ..................................... 1/ 20 - Steering radius .....[...]

OPERATION No D, 440-0 : Checking and adjusting the steering Op. D. 440 - 0 1 I VEHICLES ALL TYPES ADJUSTING THE LATERAL STEERING POSITION. 1. Put the front of the vehicle on stands. ( Support 2505 - T ) Disconnect the negative battery terminal. 2. Remove : - the spare wheel - the front wings - if the battery is on the left, remove the battery, the [...]

2 OPERATION No D. 440 - 0 : Checkin g and adjusting the steering Ill. ADJUSTING THE WHEEL ALIGNMENT. 8. Pllt the vehicle in normal running position -" ------- ~ ". with the engine running. 9. Use an ordinary commercial track gauge. Measure at wheel - centre height the distance between the wheel rims at the rear. Mark the points with chalk[...]

OPERATION No Do 440-0 : Checking and adjusting the steering NOTE : When the wheels are at maximum lock, there must be a clearance between the tyre and the lateral protection shields for the suspension mechanism. If necessary reduce the lock angle. VI. ADJUSTMENT OF THE CROSSOVER PRESSURE. (Power assisted steering only) NOTE : Use test bench 3654 - [...]

OPERATION No Dm 445-0 : Adjustin g the straight - ahead steering position for vehicles with power assisted steering ADJUSTING THE STRAIGHT AHEAD STEERING POSITION I VEHICLES ALL TYPES with power assisted steen'ng NOTE : Before adjusting, check that the tyre pressures are correct. I. ON THE ROAD 1. Determine the position of the steering wheel f[...]

2 OPERATION No D. 445 - 0 : Adjusting the strai g ht - ahead steering position for vehicles with power assisted steering. 10. Start the engine to put the circuits under pressure. 11. Put a chock ( a screw driver handle, for example) under the spring rod of the steering centralising cam roller, so that the roller is no longer in contact with the cam[...]

0 PERATION No D. 445 - 0 : Adjustin g the straight - ahead steering position for vehicles with power assisted steering Op. D, 445 - 0 b) If the distances (( ab )) are equal but both points (( b )) are on the left or the right of both points (( a )) : the vehicle deviated while moving forward. The steering must therefore be corrected by a certain an[...]

BRAKES OPERATION No D. 450 - 00 : Characteristics and particular features of the braking system Op. D. 450 - 00 1 I. CHARACTERISTICS VEHICLES ALL TYPES EXCEPT DV - DT and DP Brake accumulator : + 2 t 28 Inflation pressure : ................................................................ 40 , lo bars (569 - 142 psi) Sealing of valve : .............[...]

2 OPERATION N O D. 450 - 00 : I. CHARACTERISTICS : VEHICLES DV. DT. DP - Front brake pads : .............................................................. FERODO 623 - Parking brake pads : ............................................................. FERODO 583 - Rear brake shoes : .............................................................. FERO[...]

OPERATION N o D. 450-00 : Characteristics and particular features . Op. D. 450-00 3 of the braking system VEHICLES ALL TYPES I. PARTICULAR FEATURES . 1. Discs : - Maximum run out : ................................................................................................. 0,15 mm - Diameter : ..................................................[...]

4 OPERATION No D. 450-00 : Characteristics and particular features of the braking system . II. TIGHTENING TORQUES. 1. Front brake units : - Tighten bolts securing units on gearbox outlets to.: ........................ 130 to 140 m Λ N ( 13 to 14 mkg ) ( 94 to 101 ft.lbs ) - Tighten screws securing brake units on cross member to : .............. 40[...]

OPERATION No D. 451 - 0 : Checking and adjusting the braking system components Op. D. 451 -0 1 VEHICLES ALL TYPES I. ADJUSTING THE FRONT BRAKES ADJUSTING THE HYDRAULICALLY CONTROLLED BRAKE UNIT 1. Remove - The spare wheel - The headlamp control cross - bar - The spare wheel crossmember - The air intake 2. Loosen screw (1) 3. If the pads must be rep[...]

2 OPERATION N O D. 451 - 0 : Checking and adjusting the braking system components FITTING 11. Fit the gauge 3565 - T (see illustration) Turn the apparatus and note the point at which the diameter of the shoes is greatest by means of arm ((A)). Tighten the wing nut to secure the arm in this position. 12. Loosen the locknut (1) on the eccentric bushe[...]

OPERATION No. D. 453 - 0 : Checkin g and adjusting the brake control 0 p. D. 453 - 0 1 I VEHICLES ALL TYPES A. BLEEDING THE BRAKE SYSTEM s 1 BLEEDING THE FRONT BRAKES. D O not bleed the brake system under pressure. This prevents the formation of small bubbles in the fluid which could eventually produce air pockets in the system. 1. With the engine [...]

2 OPERATION No D. 453 - 0 : Checking and adjusting the brake control. II. BLEEDING THE REAR BRAKES 1. Place the vehicle over a pit or on an auto- lift, raise the front wheels of the vehicle. 2. Place the manual height control in the " low f ' position wait for the vehicle to settle down, then place the lever in the " high " posi[...]

OPERATION No D. 453 -0 : Checking and adjusting the brake control Op. D. 453 - 0 3 I VEHICLES ALL TYPES EXCEPT DV - DT B. BRAKE PEDAL CONTROL. 1. Adjusting the brake pressure distribution. NOTE : Use test bench 2290 - T ( for vehicles using s y nthetic LHS2 coloured red) or test bench 3654 - T ( [or veh~cles using LHM fluid coloured green). Connect[...]

4 OPERATION No D. 453 - 0 : Checking and adjusting the brake control Op. D. 453 - 0 10. Fit the mudshield protecting the suspension mechanism. 11. Start the engine and place the manual height control lever in (thigh n position. 12. Bleed the brakes (see same operation Chap. A ) fit the rear left wing. II. CHECKING THE PRESSURE SWITCH. Use test benc[...]

OPERATION No D. 453 - 0 : Checking and adjusting the brake control Op. D. 453 - 0 5 I VEHICLES DV - DT C. THE BRAKE CONTROL VALVE. NOTE : These vehicles use amineral L.H.M. a hydraulic fluid. The main reservoir is painted green and the components are painted or marked in green. I. CHECKING THE BRAKE CONTROL VALVE, IMPORTANT NOTE : Only use test ben[...]

6 OPERATION No D. 453 - 0 : Checking und adiu 3ting t/lc Orake control II. CHECKING THE BRAKE CONTROL VALVE FOR LEAKS. IMPORTANT NOTE : Only use test bench 3654 - T intended for mineral LHM fluid i this bench is painted green) and its accessories 3655 - T (the tubes and pressure gauges bear a green marking) 5. Connect bench pump opening eta )) to a[...]

OPERATION N O D. 453 - 0 : Checkin g and adjusting the brake control OP. 453 - 0 7 Ill. CHECKING THE FUNCTIONING OF THE SECURITY VALVE. IMPORTANT NOTE : Use exclusively test bench 3654 - T intended for mineral fluid LHM. ( This bench is [~uinted green ) and its accessories 3655 - T (pipes and pressure gauges bear a green rmzrking ) 10. Connect the [...]

8 OPERATION No D. 453 - 0 : Checking and adjusting the brake control. IV. CHECKING THE SECURITY VALVE PRESSURE SWITCH. 2388 bis IMPORTANT NOTE : Use exclusively test bench 3654 - T intensed for mineral fluid LHM. (this bench is painted green) and its accesso - ries 3655 - T (pipes and pressure gauges bear a green marking ) 15. Connect the security [...]

OPERATION No D. 454 - 0 : Checking and adjusting the parking brake Op. D. 454 - 0 1 I VEHICLES ALL TYPES 1. ADJUSTING THE CLEARANCE BETWEEN CALIPER AND DISC. NOTE : Access to the L.H. caliper can be gained from under the vehicle 1. Put the front of vehicle on stands 2. Loosen the screws (1) and insert a 4mm shim between caliper and disc 3. Tighten [...]

2 OPERATION N O D. 454 - 0 : Checking and adjusting the parking brake Ill. ADJUSTING THE SHEATH TENSION 9. On vehicles fitted with mechanical gear change Put the front of vehicle on stands 9a. On vehicle fitted with hydraulic gear change Remove the front left wing and the mudshield protecting the suspension mechanism. Put front of vehicle on stands[...]

ELECTRICITY OPERATION N o DX. 510 - 00 : Assembly of electrical equipment. Op.DX.510 - 00 1 DX - DJ Sept. 1965 4 Sept. 1966 I BULB TABLE Description Type of bulb Quantity Headlamp - Dip European P 45 t 4l(yellow selective) 12 V - 45/40 W Front direction indicators Rear direction indicators Stop lamp BA - 15s - single contact - 12 V - 15 W (large bu[...]

ELECTRICITY - WIRING DIAGRAM[...]

OPERATION No DX. 510-00 : Assembly of electrical equipment . Op. Dm. 510-00 3 MARKING OF PARTS 1. Front right direction indicator. 2. Front right headlamp. 3. Front right QI headlamp. 4. Town horn. 5. Country horns. 6. Front left QI headlamp. 7. Front left headlamp. 8. Front left direction indicator. 9. Front right brake unit. 10. Starter motor. 11[...]

OPERA T ION N o DX 510-00 : Assembly of electrical equipment . Op. DX. 510-00 5 Harness Wire No Colour of ends Wiring schedule Front 1 Red Starter motor relay (13) Red to starter motor relay switch (34) Front 2 Green Starter motor relay (13) Black to regulator terminal « BAT » (12) Green to fusebox (29) (Nº 1 and 2 fuses) Black to switch for lig[...]

OPERA T ION N o DX 510-00 : Assembly of electrical equipment . Op. DX. 510-00 7 Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front 15 16 17 18 19 20 21 22 Green Green Brown Brown Grey Grey Violet Violet Blue Blue Blue Blue White Yellow White White Direction indicator switch (49) to direction indicator [...]

OPERA T ION N o DX 510-00 : Assembly of electrical equipment . Op. DX. 510-00 9 Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Flying lead Flying lead Flying lead Flying lead Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. 34 35 36 37 38 3[...]

OPERA T ION N o DX 510-00 : Assembly of electrical equipment . Op. DX. 510-00 11 Harness Wire No Colour of ends Schedule of Wiring Front L.H. Front L.H. Flying lead Rear Rear Rear Rear Rear Rear Rear Rear Rear Rear Flying lead Flying lead Horn harness to compressor -do- -do - -do- 30 35 43 8 13 14 18 32 34 35 36 44 45 46 47 48 49 50 51 Green Green [...]

OPERATION No DY. 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 1 DY - DL - DE September 1965 September 1966 BULB TABLE Description Headlamp-main/dipped Front flashers Rear flashers Stop lamp Rear lamps Number plate lamp Spare bulbs Front parking lamps Front interior lamps on « PALLAS » Quantity 2 6 6 2 2 Type of bulb Europe[...]

ELECTRICITY Ley to colours Red R Black N Violet Vi Mauve Mv Green Ve Brown Mr Blue BI White Bc Yellow J Grey Gr WIRING DIAGRAM[...]

OPERATION N 0 DY. 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 b 3 SCHEDULE OF PARTS 1. Front RH direction indicator 2. Front RH headlamp 3. Front RH Q.I. headlamp 4. Town horn 5. Country horns 6. Front LH Q.I. headlamp 7. Front LH headlamp 8. Front LH direction indicator 9. Starter motor 10. Dynamo 11. Voltage regulator 12.[...]

OPERA T ION N o DY 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 5 Harness Wire No Colour of ends Wiring Schedule Front Front Dynamo Dynamo Dynamo Front Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 10 11 12 13 Red Red Green Black Green Black Black Black Black Yellow Yellow Brown Brown Red Red Red Red Yellow Gre[...]

OPERA T ION No DY 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 7 Harness Wire No Colour of ends Wiring Schedule Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front 14 15 16 18 19 20 22 23 24 25 26 27 28 29 30 31 32 White Violet White Green Green Brown Brown Violet Violet Blue[...]

OPERA T ION No DY 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 9 Harness Wire No Colour of ends Wiring Schedule Front Front Front Front Front Flying lead Flying lead Flying lead Flying lead Front RH Front RH Front RH Front RH Front RH Front RH Front LH 33 34 35 36 37 38 39 40 41 13 24 26 30 34 42 14 Red Red Red Red Red Red G[...]

OPERA T ION No DY 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 11 Harness Wire No Colour of ends Wiring Schedule Front LH Front LH Front LH Front LH Front LH Front LH Flying lead Rear Rear Rear Rear Rear Rear Rear Rear Rear Rear 20 22 24 27 30 35 43 8 13 14 18 32 34 35 36 44 45 Blue Blue White White Yellow Yellow Mauve Mauve[...]

OPERA T ION No DY 510-00 : Arrangement of the electrical installation . Op. DY. 510-00 13 Harness Wire No Colour of ends Wiring Schedule Flying lead Air horn Air horn Air horn Air horn 47 40 49 50 51 Violet Mauve Black Black Black Black Yellow White White White Mauve Brown Brown OPTIONAL FITTINGS. 1. On request a fresh air blower ( 59 ) is fitted. [...]

OPERATION N 0 DX. 510-00 a: Assembly of electrical equipment . Op. DX. 510-00 a 1 (battery on the R.H. side) DX, DJ, DY, DL September 1967 September 1967 DS 21 AND DS 21 M VEHICLES MARKING OF PARTS 1. Front right direction indicator 2. Front right headlamp 3. Front right Ql headlamp 4. Town horn 5. Country horns 6. Front left QI headlamp 7. Front l[...]

ELECTRICITY - WIRING DIAGRAM Colour code Red R Black N Violet V Green Ve Brown Mr Blue B1 White Bc Yellow J Grey Gr Mauve Mv[...]

OPERA T ION Nº DX 510-00 a : Assembly of electrical equipment . Op. DX. 510-00 a 3 (battery on the R.H. side) Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 10 Red Red Green Black Yellow White Red Black Black Black Black Yellow Yellow Brown Brown Red Red Red Yellow Bl[...]

OPERA T ION Nº DX 510-00 a : Assembly of electrical equipment . Op. DX. 510-00 a 5 (battery on the R.H. side) Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Red Red Blue Violet Blue White Violet White G[...]

OPERA T ION Nº DX 510-00 a : Assembly of electrical equipment . Op. DX. 510-00 a 7 (battery on the R.H. side) Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Flying lead Flying lead Flying lead Flying lead Flying lead. Front R.H. Front R.H 27 28 29 30 31 32 33 34 35 36 37 38 39 12 22 Mauve Yellow Y[...]

OPERA T ION Nº DX 510-00 a : Assembly of electrical equipment . Op. DX. 510-00 a 9 (battery on the R.H. side) Harness Wire No Colour of ends Schedule of Wiring Front R.H. Front R.H. Front R.H. Front R.H. Front L.H Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Flying lead Rear Rear 24 26 30 40 13 16 19 20 2[...]

OPERA T ION Nº DX 510-00 a : Assembly of electrical equipment . Op. DX. 510-00 a 11 (battery on the R.H. side) Harness Wire No Colour of ends Schedule of Wiring Rear Rear Rear Rear Rear Rear Rear Rear Flying lead Flying lead Horn Harness to compressor { 13 17 28 30 31 33 42 43 44 45 46 47 48 49 White Blue Violet Red Red Mauve Mauve Mauve Red Green[...]

OPERATION Nº DV. 510-00 a : Assembly of electrical equipment. Op. DV. 510-00 a 1 DV Sept. 1966 Sept. 1967 BULB TABLE Description Main beam / dip Front direction indicators Rear direction indicators Stop lamps Rear lamps Number plate lamp Spare bulb,: Front parking lamps Interior lamp Panel lighting Brake warning lamp Charge warning lamp Clock ligh[...]

ELECTRICITY WIRING DIAGRAM Violet Vi Green Ve Brown Mr Blue BI White Bc Yellow J Grey Gr Mauve Mv[...]

OPERATION No DV. 510-00 a: Assembly of electrical equipment . Op. DV. 510-00 a 3 MARKING OF PARTS 1. Front R.H. direction indicator 2. Front R.H. headlamp 3. Front R.H. QI headlamp (optional) 4. 2 nd country horn 5. 1 st country horn 6. Front L.H. QI headlamp (optional) 7. Front L.H. headlamp 8. Front L.H. direction indicator 9. Voltage regulator 1[...]

OPERA T ION Nº DV 510-00 a : Assembly of electrical equipment . Op. DV. 510-00 a 5 Harness Wire No Colour of ends Schedule of Wiring Front Front Dynamo Dynamo Dynamo Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 10 11 12 Red Red Green Black Yellow Black Black Black Red Yellow Yellow Brown Brown Red Red Yellow Green Black Black Green [...]

OPER A TION Nº DV 510-00 a : Assembly of electrical equipment . Op. DV. 510-00 a 7 Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front Flying lead Front Front Front 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 White Violet White Green Green Brown Brown Violet Violet Blue Blue Blue Blu[...]

OPERA T ION Nº DV 510-00 a : Assembly of electrical equipment . Op. DV. 510-00 a 9 Harness Wire No Colour of ends Schedule of Wiring Front Front Front Front Front Flying lead Flying lead Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front L.H. Front L.H. Front L.H. 28 29 30 31 32 33 34 12 20 22 25 29 35 13 18 19 Red Red Red Red[...]

OPERA T ION Nº DV 510-00 a : Assembly of electrical equipment . Op. DV. 510-00 a 11 Harness Wire No Colour of ends Schedule of Wiring Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Rear Rear Rear Rear Rear Rear Rear Rear Rear Rear Flying lead 20 23 25’ 30 36 7 12 13 16 27 29 30 31 37 38 39 Yellow Yellow Mauve Mauve Green Green Red Red Br[...]

OPERA T ION Nº DV 510-00 a : Assembly of electrical equipment . Op. DV. 510-00 a 13 Harness Wire Nº Colour of ends Schedule of Wiring Horn to compressor Horn to compressor Horn to compressor Horn to compressor Flying lead 40 41 42 43 44 Black Black White Yellow White White Brown Mauve Brown Violet Mauve Mauve Horn harness junction to « SANOR » [...]

OPERATION No DX. 510-00 b : Arrangement of the electrical installation . Op. DX. 510-00 b 1 DX - DJ - DY - DL Sept. 1967 Dec. 1967 BULB TABLE Description Main beam/ dip Q.I. headlamp Auxiliary headlamp Front direction indicators Rear direction indicators Quantity 2 2 2 2 Type of bulb. European P45t 41 (yellow selective ) 12V - 45/40 W. Q.1. bulb 12[...]

Colour code Red R Black N Violet V Green Ve Brown Mr Blue BI White Bc Yellow J Grey Gr Mauve Mv ELECTRICITY - WIRING DIAGRAM D . 51-24[...]

OPERATION No DX. 510-00 b: Arrangement of the electrical installation . Op.DX. 510-00 b 3 VEHICLES DS 21 AND DS 21 M MARKING OF PARTS. 1. Front R.H. direction indicator 2. Front R.H. headlamp 3. Auxiliary headlamp or Q.I. headlamp 4. R.H. country horn 5. L.H. country horn 6. Town horn 7. Auxiliary headlamp or Q.I. headlamp 8. Front L.H. headlamp 9.[...]

OPERA T ION No DX 510-00 b: Arrangement of the electrical installation . Op. DX. 510-00 b 5 Harness Wire No Colour of ends Wiring schedule Front 1 Red Starter relay ( 15 ) Red To switch for starter relay ( 41 ) Front 2 Black Starter relay ( 15 ) ( not disconnectible ) Black To voltage regulator + terminal ( 20 ) Yellow To fuse box R.H. ( 24 ) ( fus[...]

OPERATION No DX 510-00 b: Arrangement of the electrical installation . Op. DX. 510-00 b 7 Harness Wire Nº Colour of ends Wiring schedule Front 10 Blue Switch ( 42 ) for windscreen wiper Blue To windscreen wiper motor ( 23 ) Front 11 Red Switch ( 42 ) for windscreen wiper Red To windscreen wiper motor ( 23 ) Front 12 Blue Switch ( 57 ) for directio[...]

OPERATION No DX 510-00 b: Arrangement of the electrical installation . Op. DX. 510-00 b 9 Harness Wire Nº Colour of ends Wiring schedule Front 25 White R.H. auxiliary headlamp relay ( 27 ) ( terminal 2 ) Mauve To front R.H. wing junction Front 26 White L.H. auxiliary headlamp relay ( 27) ( terminal 2 ) Mauve To front L.H. wing junction Front 27 Gr[...]

OPERATION No DX 510-00 b: Arrangement of the electrical installation . Op. DX. 510-00 b 11 Harness Wire Nº Colour of ends Wiring schedule Flying lead 37 Mauve Earth Mauve To front R.H. auxiliary headlamp relay ( 27 ) ( terminal 4 ) Mauve To front L.H. auxiliary headlamp relay ( 26 ) ( terminal 4 ) Flying lead 38 Brown Earth Brown To switch ( 41 ) [...]

OPERATION No DX 510-00 b: Arrangement of the electrical installation . Op. DX. 510-00 b 13 Harness Wire Nº Colour of ends Wiring schedule Front L.H. 16 Grey Front L.H. junction Grey To harness for front brake pads ( 11 ) and ( 12 ) Front L.H. 20 Blue Front L.H. junction Blue To town horn ( 6 ) Front L.H. 21 White Front L.H. junction White To count[...]

OPE RATION No DX 510 - 00b : Arrangement of the electrical installation OP. DX 510-00b 15 Rear Rear Rear Rear Harness - Wire NO Colour of ends Green Green Brown Brown Yellow Yellow Grey Red Schedule of wiring Rear junction To rear L.H. parking lamp ( or sidelamp ) ( 67 ) Rear junction To R.H. ( 60 ) and L.H. ( 62 ) interior lamps Fuel gauge ( 55 To[...]

OPERATION N 0 DV. 510-00 b: Arrangement of the electrical installation . Op. DV. 510-00 b 1 DV September 1967 December 1967 SCHEDULE OF PARTS 1. Front R.H. direction indicator lamp 2. Front R.H. headlamp 3. Front R.H. auxiliary Q.I. headlamp 4. Second country horn 5. First country horn 6. Front L.H. auxiliary Q.I. headlamp 7. Front L.H. Headlamp 8.[...]

ELECTRICITY - WIRING DIAGRAM Colour code White BC Blue B 1 Grey G r Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi[...]

OPERATION No DV 510-00 b: Arrangement of the electrical installation . Op. DV. 510-00 b 3 Harness Wire Nº Colour of ends Wiring schedule. Front 1 Red Starter relay ( 10 ) Red To switch ( 31 ) for starter relay Front 2 Black Starter relay ( 10 ) ( not disconnectible ) Black To voltage regulator + terminal ( 13 ) Yellow To R.H. fuse box ( 17) ( fuse[...]

OPERA T ION Nº DV 510-00 b : Arrangement of the electrical installation . Op. DV. 510-00 b 5 Harness Wire Nº Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front Front Flying lead Front Front Front Front 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 White Violet White Green Green Brown Brown Vio[...]

OPERA T ION Nº DV 510-00 b : Arrangement of the electrical installation . Op. DV. 510-00 b 7 Harness Wire Nº Colour of ends Schedule of Wiring Front Front Front Front Flying lead Flying lead Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. Front L.H. 30 31 32 33 34[...]

OPERA T ION Nº DV 510-00 b : Arrangement of the electrical installation . Op. DV. 510-00 b 9 Harness Wire Nº Colour of ends Wiring Schedule Front L.H. Rear Rear Rear Rear Rear Rear Rear Rear Rear Rear Flying lead Compressor Horn Compressor Horn Compressor Horn Compressor Horn Flying lead 37 7 12 13 16 28 30 31 32 38 39 40 41 42 43 44 9 45 Brown B[...]

OPERATION No DX. 510 - 00c : Arran g ement of the electrical installation. Op. DX. 510-00c 1 DX - DJ - DY - DL - DV +December 1967 +October 1968 ARRANGEMENT OF THE ELECTRICAL INSTALLATION[...]

Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi ELECTRICITY WIRING DIAGRAM D. 51 - 26[...]

OPERA T ION Nº DX 510-00 c : Arrangement of the electrical installation . Op. DX. 510-00 c 3 The assembly of electrical equipment of the DX 510-00 c differs from that of the DX 510-00 b in that : 1 - The relay ( 27 ) for the RH ( 3 ) and LH ( 7 ) auxiliary headlamps replaces the two relays ( 27 ) and ( 28 ). The feeds leads Mv 25 for the RH ( 3 ) [...]

OPERATION N 0 DX. 510-00 d: Arrangement of the electrical installation . Op. DX. 510-00 d 1 DX - DJ October 1968 January 1969 SCHEDULE OF PARTS 1. Front RH direction indicator 2. Front RH headlamp 3. Auxiliary RH QI headlamp 4. RH country horn 5. LH country horn 6. First country horn 7. Auxiliary LH QI headlamp 8. Front LH headlamp 9. Front LH dire[...]

White Be Blue BI Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi ELECTRICITY WIRING DIAGRAM[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 3 Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 Red Red Black Black Green Red Blue Red Black Black Black Black Yellow Yellow White White Red Grey Brown Green Black Red Black Black Blac[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 5 Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Direction indicator switch Front Front Front Front Front Front Front Front Front 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 White White Red Red Blue Blue Violet Red Gr[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 7 Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Front Front Front Front Front Front Front 26 27 28 29 30 31 32 33 34 35 36 37 38 White Yellow Yellow Brown Blue Green Green Green Mauve Yellow Yellow Mauve Red Blue Red Red[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 9 Harness Wire Nº Colour of ends Wiring schedule Front Flying lead Flying lead Flying lead Air horn Air horn Air horn RH Front RH Front RH Front RH Front RH Front RH Front 38 39 40 41 42 43 44 14 26 27 31 34 45 Brown Brown Brown Brown Mauve Mauve Mauve Mauv[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 11 Harness Wire Nº Colour of ends Wiring schedule LH Front LH Front LH Front LH Front LH Front LH Front LH Front LH Front LH Front Flying lead Rear Rear Rear Rear Rear 15 19 23 24 26 27 32 34 46 19 7 14 15 22 29 Violet Blue Grey Grey Blue Blue White White Y[...]

OPERA T ION Nº DX 510-00 d : Arrangement of the electrical installation . Op. DX. 510-00 d 13 Harness Wire Nº Colour of ends Wiring schedule Rear Rear Rear Rear Rear 31 32 37 47 48 Red Green Green Green Brown Brown Yellow Yellow Grey Red Rear junction to rear RH parking lamp ( or tail lamp ) ( 59 ) Rear junction to rear LH parking lamp ( or tail [...]

OPERATION N 0 DY. 510-00 d: Arrangement of the electrical installation . Op. DY. 510-00 d 1 ( fixed auxiliary headlamps ) DY - DL - DV September 1968 January 1969 PART SCHEDULE 1. Front RH direction indicator 2. Front RH headlamp 3. Auxiliary RH Q.I. Headlamp 4. RH country horn 5. LH country horn 6. First country horn 7. Auxiliary LH Q.I. headlamp [...]

Key to colours White Bc Blue BI Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Violet Vi Green Ve ELECTRICITY - WIRING DIAGRAM[...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 3 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 Red Red Black Black Green Red Blue Red Black Black Black Yellow Yellow White White Red Grey Brown Green Blac[...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 5 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Direction indica- tor switch Front Front Front Front Front Front Front Front 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 White White Red Red Bl[...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 7 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule Front Front Front Front Front Front Front Front Front Front Front 25 26 27 28 29 30 31 32 33 34 35 Yellow Yellow Yellow Yellow White Brown Mauve Mauve Blue Green Green Green Mauve [...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 9 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule Front Flying- lead Flying lead Flying lead Air Horn Air Horn Air Home RH Front RH Front RH Front RH Front RH Front RH Front 36 37 38 39 40 41 42 14 25 26 27 31 43 Brown Brown Brown[...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 11 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule LH Front LH Front LH Front LH Front LH Front LH Front LH Front LH Front LH Front Flying lead Rear Rear Rear Rear Rear 15 19 23 24 25 26 27 32 44 19 7 14 15 22 29 Violet Blue Grey [...]

OPERA T ION No DY 510-00 d : Arrangement of the electrical installation . Op. DY. 510-00 d 13 ( fixed auxiliary headlamps) Harness Wire Nº Colour of ends Wiring schedule Rear Rear Rear Rear Rear 31 32 35 45 46 Red Green Green Green Brown Brown Yellow Yellow Grey Red Rear junction To rear RH parking ( or tail ) lamp ( 58 ) Rear junction To rear LH [...]

OPERATION No DX. 510 - 00 e : Arrangement of the electrical installation (Q.I. auxiliary headlamps) Op. DX. 510 - 00 e 1 I DX - DJ Jan I969 4 Sept I969 ARRANGEMENT OF THE ELECTRICAL INSTALLATION[...]

ELECTRICITY Yellow Brown Mauve Black Rad Green Ve Violet Vi WIRING DIAGRAM[...]

OPERATION No DX. 510 - 00 e : Arrangement of the electrical installation. Op. DX. 510 - 00 e 3 (0.1. auxiliary headlamps ). The assembly of electrical equipement of the DX. 510 - 00 e only differs from that of the DX. 510-00 d in that : There is a flying lead (N7) feeding the cigar lighter (32), connected to the terminal for accessories (20) (this [...]

OPERATION No DY. 510 - 00e : Arrangement of the electrical installation. Op. DY. 510 - 00e 1 ( Fixed auxiliary headlamps ). BASIC DIAGRAM of circuit for main andauxiliary fixed headlamps (not Q.I.) 1) Vehicles produced belween October 1968 and January 1969 ( see diagram DY. 510 - 00 d ). - Earth /////////////// ///-I // ////7/// // ////7/////7/////[...]

Key to colours White Bc Blue BI Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Violet Vi Green Ve ELECTRICITY - WIRING DIAGRAM[...]

OPERATION N o DY. 510-00e : Arrangement of the electrical installation. f Fixed auxiliary headlamps ) Op. DY. 510 - 00e 3 Since January 1969, vehicles equipped with fixed secondary headlamps have been fitted with the same cable system as those equipped with secondary Q.1 headlamps. The assembly of electrical equipment differs from previous models i[...]

OPERA T ION Nº DY 510-00 e : Arrangement of the electrical installation . Op. DY. 510-00 e 5 ( fixed auxiliary headlamps) The assembly series DY. 510-00e differs from the previous series DY. 510-00d in the following ways corresponding with page 7 of the latter. Harness Wire Nº Colour of ends Wiring schedule Front Front RH Front RH Front LH Front [...]

OPERATION No DX. 510-00.f : Arrangement of the electrical installation Op.DX.510-00f: 1 I BULB TABLE Description Quantity 2 Type of bulb European P45 t 41 (yellow selective) 12 V - 45 / 40W QI bulb 12 V - 55 W or European P 45 t 41 e ell ow selective) 12 V - 45 / 40W (main beam only) Main beam / dip Auxiliary headlamp Front direction indicators Rea[...]

FUSE TABLE - Cigar lighter , - Rear harness t interior lamps. - Ignition switch to : - switch for heated rear window -t heated rear window - Flasher unit -F switch for direction indicators - front and rear direction indicators - Tension regulator -t alternator (field winding circuit) I I I - Terminal for accessories -F lighting for glove compartmen[...]

OPERATION N o DX. 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 3 MARKING OF PARTS l - Front R.H. direction indicator. 2 - Front R.H. headlamp. 3 - Front R.H. auxiliary headlamp. 4 - R.H. country horn. 5 - L.H. country horn. 6 - First country horn. 7 - Front L.H. auxiliary headlamp. 8 - Front L.H. headlamp. 9 - Front L.H.[...]

Colour code White Bc Blue BI Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi ELECTRICITY WIRING DIAGRAM[...]

OPERA T ION No DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 5 Harness Wire Nº Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front 1 2 3 4 5 6 7 8 9 10 11 Red White Black Black Green Red Blue Red Black Black Black Brown Red Green Black Black Black Red Green Black Black R[...]

OPERA T ION No DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 7 Harness Wire Nº Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front Front Front 12 13 14 15 16 17 18 19 20 21 22 23 24 White White Mauve Yellow Mauve Yellow Blue Red Green Mauve Red Red Red Green Red Green Gr[...]

OPERA T ION Nº DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 9 Harness Wire Nº Colour of ends Schedule of Wiring Front Front Front Front Front Front Front Front Front Front Front Front Front Front Front 25 26 27 28 29 30 31 32 33 34 35 36 3 37 38 39 Yellow Yellow Violet White Mauve Red Red Red White White Blue Blue R[...]

OPERA T ION Nº DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 11 Harness Wire Nº Colour of ends Schedule of Wiring Front Flying lead Flying lead Flying lead Flying lead Flying lead Front Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front R.H. Front L.H. 40 10 37 39 5 43 41 15 17 19 20 24 42 16 Brown Yellow R[...]

OPERA T ION Nº DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 13 Harness Wire Nº Colour of ends Schedule of Wiring Front L.H. Front L.H. Front L.H. Front L;H. Front L.H. Front L.H. Front L.H. Flying lead Front L.H. Rear Rear Rear Rear Rear Rear Rear 17 19 20 22 23 25 38 38 42 4 14 15 16 24 25 32 Green Green Mauve Mauv[...]

OPERA T ION Nº DX 510-00 f : Arrangement of the electrical installation . Op. DX. 510-00 f 15 Harness Wire Nº Colour of ends Schedule of Wiring Rear Rear Rear Flying lead Flying lead 33 34 40 44 45 Violet Red Red Brown Brown Yellow Yellow Front harness junction to rear R.H. stop lamp (56) to rear L.H. stop lamp (57) Earth for interior lamps (48),[...]

OPERATION No Dm. 510-00 : Arrangement of the electrical installation . Op. Dm. 510-00 1 VEHICLES WITH MANUAL GEARCHANGE DJ, DJ.IE,- DV, DT April 1971 BULB TABLE Norm DESCRIPTION Headlamp-Dip Auxiliary headlamps Front indicators Rear indicators Stop lights Rear side-lights Number plate lamp Spare bulb Front side-lights Quantity 1 2 or 2 6 6 2 Base P[...]

Yellow Brown Mauve Mv Black Red Green Ve Violet Vi[...]

2 OPERATION No Dm 510 - 00 : Arrangement of the electrical installation FUSE TABLE - Cigar lighter - Rear harness + interior lamps. - Ignition switch to : - switch for heated rear window - heated rear window - Flasher unit -m switch for direction indicators front and rear direction indicators - Tension regulator - alternator (field winding circuit)[...]

OPERATION N o Dm. 510-00: Arrangement of the electrical installation . Op. Dm. 510-00 3 MARKING OF PARTS 1 - Front R.H. direction indicator. 2 - Front R.H. headlamp. 3 - Front R.H. auxiliary headlamp. 4 - R.H. country horn. (DJ) 5 - L.H. country horn. 6 - First country horn. 7 - Front L.H. auxiliary headlamp. 8 - Front L.H. headlamp. 9 - Front L.H.[...]

4 OPERATION No Dm 510-00: Arrangement of the electrical installation . Op. Dm 510-00 Harness Wire No Colour of ends Schedule of Wiring Front 1 White Starter motor switch (47) Red to starter motor lead Front 2 Black “+ve ” terminal of the battery (18) Black to « + » alternator terminal (12) Green to fuse box (27) (fuse No 1) Red to fuse box (2[...]

OPERATION N o Dm. 510-00: Arrangement of the electrical installation . Op. Dm. 510-00 5 Harness Wire No Colour of ends Schedule of Wiring Front 12 White Alternator (12) (terminal R) White to relay-voltage regulator unit (15) (terminal R) Front 13 Mauve Lighting switch (43) Yellow to fusebox (27) (fuse No 4) Mauve to lighting for heating controls (4[...]

6 OPERATION No Dm 510-00: Arrangement of the electrical installation . Op. Dm 510.00 Harness Wire No Colour of ends Schedule of Wiring Front 25 Yellow Switch (45) for direction indicators Yellow to warning lamp cluster (44) (white housing) (L.H. indicator warning lamp) Violet to front L.H; wing harness White to rear harness Front 26 Mauve Windscree[...]

OPERATION N o Dm. 510-00: Arrangement of the electrical installation . Op. Dm. 510-00 7 Harness Wire No Colour of ends Schedule of Wiring Front 40 Brown Warning lamp cluster (44) (yellow housing) (fuel gauge receiver) Yellow to rear harness Front L 41 Joint earth (securing of indicator light cluster 31) Yellow to warning lamp cluster (44) (yellow h[...]

8 OPERATION No Dm 510-00: Arrangement of the electrical installation . Harness Wire No Colour of ends Schedule of Wiring Front L.H. 17 Green Front harness Green to front L.H. headlamp (8) (dip) Front L.H. 19 Mauve Front harness Mauve to auxiliary L.H. headlamp (7) Front L.H. 20 Yellow Front harness Yellow to front L.H. headlamp (8) (main beam) Fron[...]

OPERATION N o Dm. 510-00: Arrangement of the electrical installation . Op.Dm. 510-00 9 Harness Wire No Colour of ends Schedule of Wiring Rear 33 Violet Front harness junction Red to rear R.H. stop light (56) Red to rear L.H. stop light (57) Rear 34 Brown Front harness junction Brown to each interior light (48), (Sl), and (53), (54) (DJ except PA) R[...]

OPERATION No. Dm 510-00 a : Arrangement o/ the electrical installation Ope Dm 510-00 a I MANUAL GEARCHANGE VEHICLES DV - DT-Dl -Dl.lE -September 1971 FITTING THE ELECTRICAL INSTALLATION New presentation of the " fittin g the electrical installation" Operations : Henceforth these o~erations will consist of two Darts : - a basic diagram and[...]

2 OPERATION No. Dm 510 - 00 a :Arrangement o/ the ele, tri,,cd irc.st,~llrt/ir,r, PRESENTATION OF THE DIAGRAMS 1. BASIC DIAGRAM a) Details : The different circuits are represented in a functional way. Certain parts used in several circuits are therefore " exploded " into several parts placed on different lines. b) References : Three kinds[...]

BASIC DIAGRAM (Vehicles DV - - DT - Dl Dl.lE since Se p tember 1971) IIIIIIIII IIIIIIIII IIIIIIIII IIIII 12345678911234567891123456789112345 10 20 30 IIII 111 11111 111111lIII I IIIIIIIII IIIIIII 67891123456789 1234567891123456789II2345678 40 50 60 70 LIST OF PARTS NOTE : Ref = reference number of parts on installation and basic diagrams. Position [...]

Manual 814 - 1 INSTALLATION DIAGRAM (1)V - DT - DJ IE vehicles since september 1971) COLOURCODE Ve = Green Vi = Violet Bc = White B1 = Blue Gr = Grey J =Yellow Mr = Brown Mv = Mauve N = Black R = Red[...]

OPERATION No. Dm 510 - 00 a : Arrangement o/ th~ elec/rrcal installation Qp. Dm 510 - 00 a 3 FUSE TABLE I - Cigar lighter + battery I - Rear harness interior lamps. Lighting switch side lamp terminal (marked Mauve) - Ignition switch to : - Reversing lamp switch reversing lamps (except DV) - Switch for heated rear window heated rear window (option D[...]

BULB TABLE Norm Power 45 40 W I Use Socket Vol taqe French Yellow I Headlamps - dip and main beam Headlamps t-- Yellow selective H 1 iodine Front indicators Rear indicators Stop lamps - - - Reversinp lamps /<,t, f3/d 1 I / Rear sidelamps No plate lighting Emergency lamp 1 Front sidelamps I Interior 1 D?DT Festoon I lighting Boot lighting Festoon[...]

OPERATION No Dh 510 - 00 a : Arrangement o/ the electrical installation Op. Dh 510 - 00 a 1 HYDRAULIC GEARCHANGE VEHICLES DX-DX.IE-DY I September 1971 FITTING THE ELECTRICAL INSTALLATION New presentation of the " Fitting the electrical installation " operations : Henceforth these operations will consist of two parts : - a basic diagram an[...]

PRESENTATION OF THE DIAGRAMS 1. BASIC DIAGRAM a) Details : The different circuits are represented in a functional way. Certain parts used in several circuits are therefore " explcded " into several parts placed on different lines. b) References : Three kinds of references are used : - the figures which refer to single parts (and not the w[...]

BASIC DIAGRAM (Vehicles DX - DX.IE - DY since september 1971) IIIIIIIII IIIIIIIII IIIIIIIII IIIIIllll 11 111111 111111lIIII IIIIIIIII IIIIIII 123456789112345678911234567891123456789I123456789 1234567891123456789II2345678 10 20 LIST OF PARTS NOTE : Ref = reference number of parts on installation and basic diagrams. Position = number of the vertical [...]

INSTALLATION DIAGRAM ('llehicfes DX - DX.IE - DY since september 1971) D. 51 - 71 a Bc = White Gr = Grey COLOURCODE B1 = Blue J = Yellow Mr = Brown N = Black Ve = Green Mv = Mauve R = Red Vi = Violet[...]

OPERATION No. Dh. 510 - 00 a : Arrangem~nt o/ the electrrcal installation Op. Dh. 510 - 00 a 3 FUSE TABLE - Cigarette lighter - Rear harness + interior lamps. + battery - Ignttion switch to : - Reversing lamp switch - reversing lamps - Switch for heated rear window - heated rear window - Flasher unit - switch for dlrectlon lndlcators - front and re[...]

4 OPERATION No. Dh. 510 - 00 a : Arrangemen/ o/ the elec~rical installation BULB TABLE Use Quantity Socket Voltage Power nterna French Headlamps - Dip and main beam Yellow Selective Yellow Selective auxiliary H 1 iodine P 25/1 Pear- shaped Rear indicators Stop lamps Reversinq lamps Rear sidelamps No plate lightlng Emergency lamp Front sidelamps Int[...]

OPERATION No. Dbw. 510 - 00 : Fittmg the elrc.trica1 sjstern (z~ehicles fitted rcith an nutonlatic Op. Dbw. 510 - 00 1 I I R Front hornerr DIAGRAM OF THE SYSTEM KEY Existing harness -- - - - - DBW. VEHICLES, ALL TYPES BASIC MACRAM NOTE . - Dbw veh~cles (i.e w~th BORG - WARNER gearboxes) are fitted with the basic harnesses 01 the hydraulic qearchanq[...]

OPERATION No D.IE - 51 1 - 00 : Arran g ement of the electrical installation electronic fuel iniection system. Op. D. IE - 51 1 - 00 VEHICLES D. IE- ALL TYPES 4 March1970 ARRANGEMENT OF THE ELECTRICAL INSTALLATION OF THE ELECTRONIC FUEL INJECTION SYSTEM (Vehicles produced up to March 1970) NOTE : For the arrangement of the general electrical instal[...]

WIRING DIAGRAM Electronic fuel iniection system Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 8 Starter mtr cntrl rela) 9 Cold start Injector 10 Throttle spi[...]

OPERA T ION Nº D.IE. 511-00 : Arrangement of the electrical installation Op. D.IE. 511-00 3 electronic fuel injection system. PART SCHEDULE 1. Ignition distributor and triggering contacts 2. Battery 3. General feeder relay 4. Pump relay 5. Impulse relay 6. Thermal sensor 7. Cold start time delay thermal switch 8. Starter motor control relay 9. Col[...]

OPERA T ION Nº D.IE. 511-00 : Arrangement of the electrical installation . Op. D.IE. 511-00 5 electronic fuel injection system. Harness Wire Nº Colour of ends Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Black Black Black Black Yellow Yellow -brown Brown [...]

OPERA T ION Nº D.IE. 511-00 : Arrangement of the electrical installation . Op. D.IE. 511-00 7 electronic fuel injection system. Harness Wire Nº Colour of ends Wiring diagram Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- Flying lead 15 16 17 18 19 20 21 22 23 24 25 26 27 Yellow-grey Grey White White Grey Grey Green[...]

OPERATION No D.IE 51 1 - 00a : Arran g ement of the electrical installation Op. D. lE 51 1 - 00a 1 electronic fuel inie tion system. (Since March 1970) VEHICLES D. IE- ALL TYPES b March 1970 4 April 1971 ARRANGEMENT OF THE ELECTRICAL INSTALLATION OF THE ELECTRONIC FUEL INJECTION SYSTEM (Vehicles ~roduced between March 1970 and April 19711 NOTE : Fo[...]

WIRING DIAGRAM Electronic fuel iniection system I Key to colours Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time dela) /thermal swltch 8 Starter mtr cntrl reli 9 Cold start Injector 10 Throttle[...]

OPERA T ION Nº D.IE. 511-00 a : Arrangement of the electrical installation Op. D.IE. 511-00 a 3 electronic fuel injection system. PART SCHEDULE 1. Ignition distributor and triggering contacts 2. Battery 3. General feeder relay 4. Pump relay 5. Impulse relay 6. Thermal sensor 7. Cold start time delay thermal switch 8. Starter motor control switch 9[...]

OPERA T ION Nº D.IE. 511-00 a : Arrangement of the electrical installation Op. D.IE. 511-00 a 5 electronic fuel injection system (since March 1970) Harness Wire Nº Colour of ends or self-adhesive number Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- 1 2 3 4 5 6 7 8 9 10 11 1[...]

OPERA T ION Nº D.IE. 511-00 a : Arrangement of the electrical installation Op. D.IE. 511-00 a 7 electronic fuel injection system (since March 1970) Harness Wire Nº Colour of ends or self-adhesive number Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- Flying lead Engine -do- -do- -do- 18 19 20 21 22 23 24 [...]

OPERA T ION Nº D.IE. 511-00 a : Arrangement of the electrical installation Op. D.IE. 511-00 a 9 electronic fuel injection system (since March 1970) Harness Wire Nº Colour of ends or self-adhesive number Wiring diagram Engine -do- -do- -do- -do- -do- -do- 6 11 12 13 21 22 23 6 6 11 12 12 13 Blue 21 21 22 22 23 23 12-way union (20) to injector (14)[...]

OPERATION No. DX.IE 511-00 : Arrangement of the electrical rnsrallation electron~c fuel injection system Op. DX.IE 511 - 00 1 ARRANGEMENT OF THE ELECTRICAL INSTALLATION OF THE ELECTRONIC FUEL INJECTION SYSTEM DX.IE VEHICLES April 1971 (Vehicles DX.IE produced since April 1971) NOTE : For the arrangement of the general electrical installation : see [...]

Manual 814 - 1 Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 5 Impulse Relay 6 Thermal sensor 7 Cold start time delay /thermal swltch 8 Starter mtr cntrl rela) 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 1[...]

2 OPERA T ION Nº D.IE. 511-00 : Arrangement of the electrical installation electronic fuel injection system (Since April 1971). PART SCHEDULE 1. Ignition distributor and triggering contacts 2. Battery . 3. General feed relay 4. Pump relay 5. Impulse relay 6. Thermal sensor 7. Cold start time delay thermal switch 8. Starter motor control switch 9. [...]

OPERA T ION Nº DX.IE. 511-00 : Arrangement of the electrical installation . Op. DX.IE. 511-00 3 electronic fuel injection system (since April 1971) Harness Wire Nº Colour of ends or self-adhesive number Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- 1 2 3 4 5 6 7 8 9 10 11 12 14 [...]

4 OPERA T ION Nº DX.IE. 511-00 : Arrangement of the electrical installation . electronic fuel injection system (since April 1971) Harness Wire Nº Colour of ends or self-adhesive number Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- Flying lead Engine -do- -do- -do- -do- 18 19 20 21 22 23 25 26 27 28 35 29 3 4[...]

OPERA T ION Nº DX.IE. 511-00 : Arrangement of the electrical installation . Op. DX.IE. 511-00 5 electronic fuel injection system (since April 1971) Harness Nº of Wire Colour of ends or self-adhesive number Schedule of wires Engine 11 12 18 21 22 23 35 11 12 12 13 Blue 21 21 22 22 23 23 Grey Grey 12-way union (20) to injector (11), cylinder 1 to i[...]

OPERATION No DJ. lE 51 1 - 00: Arran g ement of the electrical installation electronic fuel iniection system. (Since 1971) Op. DJ. I E 51 1 - 00 1 VEHICLES DJ. IE b April 1971 ARRANGEMENT OF THE ELECTRICAL INSTALLATION OF THE ELECTRONIC FUEL INJ ECTlON SYSTEM (DJ.I& uehicles produced since April 1971) NOTE : For the arrangement of the general e[...]

Colour Code Blue BI White Bc Grey Gr Yellow J Brown Mr Mauve Mv Black N Red R Green Ve Violet Vi COMPONENTS 1 Dlstrlbutor 2 Battery 3 General feed relay 4 Pump Relay 6 Thermal sensor 7 Cold start tlme delay /thermal swltch 9 Cold start Injector 10 Throttle spindle sw. 11 Cyllnder 1 Injector 12 Cyllnder 2 Injector 13 Cyllnder 3 Injector 14 Cyllnder [...]

2 OPERA T ION Nº DJ.IE. 511-00 : Arrangement of the electrical installation of the electronic system. PART SCHEDULE 1. Ignition distributor and triggering contacts 2. Battery 3. General feed relay 4. Pump relay 5. Impulse relay 6. Thermal sensor 7. Cold start time delay thermal switch 8. Starter motor control relay 9. Cold start injector 10. Throt[...]

OPERA T ION No. DJ.IE-511-00 : Arrangement of the electrical installation Op. DJ.IE-511-00 3 electronic fuel injection system (since April 1971) Harness Wire Nº Colour of ends or self-adhesive number Wiring schedule Electronic control unit -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- -do- 1 2 3 4 5 6 7 8 9 10 11 12 13[...]

OPERA T ION Nº DJ.IE 511-00 a : Arrangement of the electrical installation Op. DJ.IE 511-00 electronic fuel injection system. Harness Nº of Wire Colour of ends or self-adhesive number Schedule of wires Electronic control unit -do- -do- -do- -do- -do- -do- - do - - do - -do- Flying lead Engine -do- -do- -do- 18 19 20 21 22 23 25 26 27 35 23 3 4 5 [...]

OPERA T ION Nº DJ.IE-511-00 a : Arrangement of the electrical installation Op. DJ.IE-511-00 5 electronic fuel injection system (since April 1971) Harness Nº of Wire Colour of ends or self-adhesive number Schedule of wires Engine -do- -do- -do- -do- -do- -do- -do- 6 11 12 13 21 22 23 35 6 6 11 12 12 13 Blue 21 21 22 22 23 23 Grey 12-way union (20)[...]

OPERATION No D. 513-00 : Electrical installation lor coolins system. Op. 0. 513 - 00 1 D VEHICLES all types AIR CONDITIONING SYSTEM (COOLING SYSTEM) FITTING THE E L E C T R I C A L INSTALLATION P.T.O. I[...]

BASIC DIAGRAM D. 64 - 53 INSTALLATION DIAGRAM[...]

The electrical installation for the cooling system consists of three extra harnesses. The general electrical installation of the vehicle is identical to the standard installation of the corresponding type(rirwcuct1 Gc:urc.hc~rrgct (jr 11, tlrctrrlic Gectrc./~c~rc6c cx,hit~lca). REFERENCE NUMBERS FOR THE PARTS. The references for those parts common [...]

OPERATION No 8. 530 - 0 : Charncteri~tics and rhccis on electrical units Op. 0. 530 - 0 1 I.- CHARACTE RlSTlCS I VEHICLES ALL TYPES 1 - Batteries - Battery 200/40 A.H. : C ehicles all type., 4 Oct. 1966 I elricle., ull lypea ~cithou~ QI heudlamp.s und uiilholrl heuting - 200 C (680 F) + Oct. 1966 4 Sept. 1967 Vehicles all types + Sept. 1967 - - Bat[...]

2 OPERATION No D. 530 - 0 : Characteristics and checks on electricnl units II - RE - SKIMMING 1 - D y namos : - Vehicles all types (except DX-DJ-DXF-DIF) Brand name of dynamo I DUCELLIER I PARIS - RHONE I Period of use Brand name of starter motor Type of starter motor Type of dynamo Minimum diameter after skimmina of commutator 49/ 1968 Type of sta[...]

OPERATION No D. 530 - 0 : Characteristics and checks on electrical units. Op. D. 530 - 0 3 3. D' emarreurs : Brand name of starter motor DUCELLIER Types of starter motor Testing on the vehicle a) Battery charged, intensity absorbed pinion blocked. ........................ b) Starting current. ................... c) Starter motor removed, curre[...]

4 OPERATION N o D. 530 - 0 : Chnructeris~ics and checks on e!ectrical units. 1 IV - ADJUSTING THE VOLTAGE REGULATORS 1 - Regulator for dynamos : a) DUCELLIER regulator - 12 volts - 8243 F and PARIS - RHONE regulator - 12 volts - YT 2113. Cut in voltage - 12 to 13.5 volts (cold and hot). Cut out voltage = at least 1 volt less than the cut in voltage[...]

OPERATION No D. 530 - 0 : Characteristics and checks on electrical units. Op. D. 530 - 0 5 Checkin g the alternator output. The alternator output must be measured when the alternator is working at maximum speed. 1. Disconnect the negative battery lead. 2. Disconnect the excitation lead (yellow end) from the (( EXC )) terminal (1) and the charge lea[...]

6 OPERATION No D. 530-0 : Characteristics and checks on electrical units. 4. Connect a voltmeter with a jumper lead to the excitation circuit. - Connect the ccf)) voltmeter terminal to the cctn regulator terminal (2) (coloured violet). - Connect the N-)) voltmeter terminal to the earth 5. Connect the negative battery lead. Start the engine and allo[...]

OPERATION No. D. 530 - 0 : Cl~arac~cris~ics and checks on electrical units Op. D, 530 - 0 7 Vlll - ADJUSTING THE CONTROL PINION OF A PARIS - RHONE STARTER MOTOR (Starter motor removed) 1. Remove the rubber plug (2) of the solenoid. 2. Disconnect the feed wire (6) of the inductors from the solenoid terminal (5). 3. Remove the shunt connector between[...]

8 OPERATION No D. 530 - 0 : Characteristics and checks on electrical Vlll - ADJUSTING THE CONTROL PINION OF A DUCELLIER STARTER MOTOR (Starter motor removed) 1 Remove the plastic plug (2) of the solenoid (3). 2 Disconnect the feed wire (6) of the inductors from the solenoid terminal. 3. Remove the shunt connector between the positive terminal (4) o[...]

OPERATION No D. 540 - 0 : Checking and adiusting the headlcmpa unri c.ontrol., Op. D, 540 - 0 1 VEHICLES ALL TYPES September 1967 MAIN HEADLAMPS WITH SELF - LEVELLING DEVICE D. 54 - 6 1. Front torsion control rod. g. Clamp for torsion control rod (1). h. Lever with cable hook for torsion control rod (1). 4, Front anti - roll bar. 5. Rear anti - rol[...]

2 OPERATION No D. 540 - 0 : Checking and adjusting the heactlamps and controls PRE - ADJUSTING THE HEADLAMP CONTROL. IMPORTANT NOTE :Ensure that the car is in running order, heights correctly adjusted and tyres inflated to the right pressures. The manual height control lever should be in (( normal )) position. 1. Position the front control torsion [...]

OPERATION No D. 540-0 : Checking and adjustin g the headlamps and controls. Op. D. 540 - 0 3 c) Angular position : Make an angle of 90' f 5' between centre line of cable - hook lever (k) and cable (8). 3. Adjust control rods (9) and (10) screwed into R.H. (11) and L.H. (12) so that they protrude (a) by 23 2 1 mm. For items (10) and (12) s[...]

4 OPERATION No D. 540 - 0 : Checking and adjustin g the headlamps and controls. To obtain this measurement, proceed as follows . a) Disconnect control assembly. b) Position lever (( e )) so that main R.H. head- lamp is correctly adjusted for height. For this : Use apparatus of type (( Reglolux )) or (( Reglos- cope )). Ensure that the car and appar[...]

OPERATION No D. 540 - 0 : Checkin g and adjustin g the headlamps and controls. Op. D. 540 - 0 5 e) Position control rod (13). - Turn curved part (a) of the front rod (13) towards the front R.H. wing. - Turn curved part (b) of the front rod (13) towards the engine. - Tighten the adjuster until the upper end (c) is at the same level as the section (d[...]

6 OPERATION No D. 540 - 0 : Checking and adjusting the headlamps and controls. I 3 If this is not the case, loosen fixing screws (17) on control bar (16). '1 Move the bar sideways, (there are slots in the bar 4 for this purpose). Tighten screws (17) and readjust ? the play. ADJUSTING THE MAIN HEADLAMPS. 6. Ensure : - that the upper fixing scre[...]

OPERATION No D. 540 - 0 : Checking and adjusting the headlamps and controls. Op. D. 540 - 0 7 - that the wires of the wing harness do not hinder the movement of the main headlamp. - that the harness is held by the rubber collar on the lower part of the wing, - that the rivets (18) are tight, - that the rod (9) does not touch the sides of the slot ([...]

8 OPERATION N o D. 540 - 0 : Checkinn and adjusting the headlamps and controls. NOTE : 1) The torsion control of the main headlamps may also of controlled by rocking the car. to and fro by leaning on the bumpers. The dipped beam should remain between lines ii B )) and (i C )). 2) When driving at night, make sure that the limit of the dipped beam is[...]

OPERATION N o D. 540 - 0 : Checking und ndjusting the henrllurnps und ( ontrols. Op. D. 540-0 9 DIRECTIONAL CONTROL OF AUXILIARY HEADLAMPS D . 54.7 1; Control lever 2. Rear control :od 3. Sleeve 4. Front control rod 5. Return lever plate 6. Return lever 7. Spacing rod KEY 8. Return spring 9. R.H. adjusting sleeve 10. L.H. adjusting sleeve 11. R.H. [...]

10 OPERATION No D. 540 - 0 : Checking and adjustin g the headlamps and controls. ADJUSTING THE DIRECTIONAL CONTROL. (Auxiliary headlamps ) 11. Position the rear direction control rod (2) in the control lever (1) (the curved part of the rear rod (2) should point downwards). Pass the rear control rod (2) through the hole in the battery support. Attac[...]

OPERATION No D. 540 - 0 : Checking and adjusting the headlamps and controls. Op. D. 540 - 0 11 12. Position return lever (6). a) Set the wheels for straight ahead steering. (Roller in the hole of the cam). 13. Attach the directional control cables. a) Pass the cable and sheath assembly (14) and (18) into the guide (17), orienting it as in the diagr[...]

12 OPERATION No D. 540 - 0 : Checking and adjustin g the headlamps and controls. b) Attach the R.H. adjuster sleeve (11) to the under side of the return lever (6). c) Attach the L.H. adjuster sleeve (12) to the upper side of the return lever (6). Keep the sleeves (11) and (12) in place with circlips (16). d) Hook L.H. control cable (14) in the L.H.[...]

OPERATION No D. 540 - 0 : Checking and adjustin g the headlamps and controls. Op. D. 540 - 0 13 NOTE : Turn the steering wheel fully to the right and make sure that the end of return lever (6) does not touch the radiator ventilation conduit (19). If it does, move the conduit (19) to the left until the nearest point of return lever (6) and the condu[...]

14 OPERATION No D. 540 - 0 : Checking and adjusting the headlamps and controls. ADJUSTING THE AUXILIARY HEADLAMPS. 14. Make sure, - that the upper fixing screw (15) of the front panel closing plate is tight, - that the closing plate and panel are tightly fixed to the front unit, - that the front wing fixing screws are tight. Check that the headlamp[...]

OPERATION No D. 540-0 : Checking and adjustin g the headlamps and controls. Op. D. 540 - 0 15 15. Make sure that the car's engine is running, height adjusted, types correctly inflated. Put the manual height control lever in the (( normal N position. Put the circuit under pressure and run the engine at idling speed during the adjustment. Place [...]

16 OPERATION No D. 540 - 0 : Checking and adjusting the headlamps and controls 17. Adiustrnent of auxiliary headlarnps. Second method. Use tool 3901 - T. This gives precise adjustment and makes the operation easier. NOTE . The wheels must be set exactly in the straight ahead position. a) Check and adjust straight ahead position. (see 5 12 same oper[...]

OPERATION N o D. 540 - 0 : Checking and adjusting the headlamps and controls. Op. D. 540 - 0 17 e) Adiustment of headlamp height. Run the engine at idling speed, with the manual height control in the (( normal )) position, wait for the car to become stable. Rotate in turn the adjuster screw (16) for each headlamp, to bring the bubble to the centre [...]

18 OPERATION No D. 540 - 0 : Checkin g and adjustin g the headlamp and controls REPLACING A QUARTZ - IODINE BULB. PRECAUTIONS. This operation should only be carried out with the headlamp extinguished. After switching off, it is advisable to allow 5 minutes for cooling before handling. Do not touch the bulb with the fingers. If this is done inaverte[...]

1. Front torsion control rod. g. Clamp for control rod (1) h. Lever with cable hook for control rod (1) 4. Front anti - roll bar. 5, Rear anti - roll bar. 6. Rear torsion control rod. 7. Front torsion control cable 8. Rear torsion control cable 9. R.H. control rod OPERATION No DX, 540-0 : CXeckin,: and nrljusting the headlamps and controls. Op. DX.[...]

2 OPERATION N o DX. 540 - 0 : Checkin g and adjustin g the headlumps and controls. b) Angular positioning : obtain an angle of 90 + 5' between the centre line of the lever with the ca - ble hook cth )) and cable ( 7 ), adjusting clamp (( 9)) on the anti - roll bar if necessary. 2. Positioning the rear torsion control rod (6) on the rear anti -[...]

OPERATION N o DX. 540-0 : Checking and adjustin g the headlamps and controls. Op. DX. 540 - 0 3 Adjust the length of the return spring (15). This length m must equal = 70 f '8 mm, measured as shown in the photograph. To obtain this distance : a) Disconnect the control assembly. b) Position the lever (e) of the headlamp control cross - bar so a[...]

4 OPERATION No DX. 540 - 0 : Checkin g and adjustin g the headlamps and controls. 5. Checking the operation of the control bar (16). NOTE : So that this bar can rotate properly, it is necessary that : - the bearings (18) lie against the inside of the wings correctly, - the rubber joints (17) are correctly fitted to the bearings (18) on the engine s[...]

OPERATION N o DX. 540 - 0 : Checking and adjusting the headlamps and controls. Op. DX. 540-0 5 NOTE : If this is done too quickly, the timing device in the front R.H. wing will slow down the movement of the headlamp. In this way, it is possible to check the front and rear headlamp controls. If one or the other is faulty, the liquid does not remain [...]

6 OPERATION No DX. 540 - 0 : Checkin g and adjustin g the headlamps and controls. NOTE : - Do not press onthe adjusting screw with a screw - driver. After each adjustment tap the headlamp glass to stabilize its position. - Do not interfere with the adjustment of the screw (24) locked with a hexagonal nut. 10. Adiust the position of the delay device[...]

OPERATION No DY. 540 - 0 : Adjustin g the headlamps. Op. DY. 640 - 0 1 VEHICLES ALL TYPES EXCEPT DX - DJ -+September 1967 ADJUSTING THE MAIN HEADLAMPS. IMPORTANT NOTE. 1) Make sure that the engine is running, heights adjusted, tyres correctly inflated. 2) Put the manual height control in n normal )) position and run the engine at idling speed durin[...]

2 OPERATION N o DY. 540 - 0 : Adjustin g the headlamps. VEHICLES ALL TYPES September 1967 ADJUSTING THE MAIN HEADLAMPS AND FIXED AUXILIARY HEADLAMPS. 5. Make sure : - that the panel and the panel closing plate are tightly fitted, - that the wing is tightly fitted, - that the headlamp unit support is tightly fitted in the wing. 6. IMPORTANT NOTE : M[...]

OPERATION No D. 560 - 0 : Checkin g and adjustin g the windscreen wipers. Op. D. 560-0 1 VEHICLES ALL TYPES POSITION OF ARMS. 1. Loosen screws (1) 2. Position wiper arms on their axes as illustrated below. 3. Tighten screws (1) to 4 dN (0,4 m. kg) (2,9 FT LBS)[...]

OPERATION No. D. 640 - 00 : Characteristics and parrlcular points o/ air-cond~rio~~in~ system (coolin g s yslern) Op. D. 640 - 00 1 ALL TYPES OF VEHICLE except DV COOLING SYSTEM This allows the air entering the passenger compartment to be cooled whilst at the same time extracting part of its moisture. (this reduces misting up) 1. DIAGRAM SHOWING WO[...]

2 OPERATION No. D. 640 - 00 : Chclracteristics and particular poinls of ~lre air conditianing s)stern (cooLinK system) I I. COMPONENTS Compressor : .. ................................*..... YORKA.206 (MITCHELL 7 039) Lubricating oil : ................................. . . TOTAL " LUNARIA 25 " Electromagnetic cut - in : ...................[...]

OPERATION No. D. 640-0 : Checking and adjusting the air conditioning system (cooling system) Op. D. 640 - 0 I S.O.G.E.V. EQUIPMENT FOR FILLING THE COOLING CIRCUIT sold under ref. No. B 01.1 409/2 Replacement Parts : The parts listed below can be obtained directl y from the relevant suppliers or via the S.O.G.E.V. Marking Number of Name and address [...]

IMPORTANT MOTE The operating instructions (ref. 7 407 400) supplied with the S.O.G.E.V. vacuum pump must be consulted before starting up the latter, and for matters concerning its maintenance and repair. The incorrect connecting up of the eiectric motor, or starting the vacuum pump without " G " oil would bring about rapid deterioratlorl [...]

OPERATION No D. 640-0 : Checking and adjusting the air conditioning system (cooling system) Op. D. 640 - 0 3 1. FILLING THE COOLING CIRCUIT using S.O.G.E.V. equipment and a PRESTOGAZ R. 12 spray. NOTE : Equipment used in this operation : a) S.O. G. E. V. equipment - Reference : B. 01 1409/ 2 - Supplier : Etablissements S.O.G.E.V. 25 rue de Chony 26[...]

4 OPERATION No. D. 640 - 0 : Checking and adjusting the air - conditioning (cooling system) 2. Check the oil level in the compressor NOTE : This check can only be carried out after the circuit has been drained. If this is not done, dan g erous spurts of oil and coolant will result. a) Remove the oil filler plug at " a " and insert the dip[...]

OPERATION N D. 640 - 0 : Checking and adjustin g the air - conditioning Op. D. 640 - 0 5 b) Connect the spray to the circuit : Screw the spray A fitted with the " Prest - vanne " union, on to the tap (3) marked " FREON " ; do not tighten fully, but only until the end of the tap comes into contact with the valve; do not turn the [...]

Manual 814 - 1[...]

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Manual 814 - 1[...]

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Manual 814 - 1[...]

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Manual 814 - 1[...]

OPERATION No D. 800 - 02 : Adjusting the body panels OP. d. 800 - 02 1 ((a ,) The edges of the doors should be parallel and within 2 mm. ADJUSTING THE BONNET, FRONT WINGS AND DOORS. I( bn The top of the door should be at the same level as or slightly below ( by 1-2 mm ) the rear point of the bonnet. VEHICLES ALL TYPES b~e~ternber 1967 ,(c )) The (([...]

2 OPERATION No D. 800 - 02 : Adjustin g the body panels ADJUSTING THE BOOT LID, REAR WINGS AND DOORS 8127 ((a 11 Top of front door level with or slightly above (by 1 - 2 mm ) top of rear door. ((b~ Play of 2 - 6 mm between wing and bumper. ((c )) The wing must be parallel with boot lid pro - file. c(d )) Edge of the door parallel ( within 2 mm ) to[...]

OPERATION No D. 840 -0 : Adjusting the doors and locks Op. D. 840 - 0 1 I. ADJUSTING THE REAR DOORS. ADJUSTING THE DOORS AND LOCKS. NOTE : For this operation the rear wings should already have been adjusted. VEHICLES ALL TYPES +September 1967 1. The depth to which the latch is engaged in the the catch must be at least 4 mrn, with clea - rance betwe[...]

OPERATION No D. 852 - 0 : Adjusting the bonnet - (locking and unlocking). Op. D. 852 - 0 I ADJUSTING THE BONNET 365 VEHICLES ALL TYPES 1- 9/1967 VERY IMPORTANT NOTE : When the bonnet is closed, it cannot be opened if the cables are not connected to the unlockin g mechanism. The mechanism is not accessible from the outside. If, by mistake, the bonne[...]

2 OPERATION No D. 852-0 : Adjustin g the bonnet - (In /he even[ of the mechanism being disconnected) II - ADJUSTING THE BONNET (In the event of the mechanism being disconnected) NOTE : It is possible to open a bonnet of which the opening mechanism has become disconnected : - either because the cables are not connected to the bolts - or because the [...]

OPERATION No D. 961 - 0 : Checking and repairing of a heated rear window Op. D. 961 - 0 1 CHECKING AND REPAIRING OF A REAR WINDOW HEATING RESISTANCE. I. CHECKING Force of the heating resistance : a) Saloon : 4 6/ 1972 ........................... 73 to 84 Watts under 13,5 + 0.2 volts ........................... 6/ 1972 95 to 110 Watts under 13.5 + 0[...]

2 OPERATION No D. 961-0 : Checking and repairing a heated rear window. c) Preparing the rear windows: With the resistance no longer under voltage : Clean out the area treated with the powder, contained in the bottle marked " Bimspulver " . Sprinkle this powder on a small piece of rag and rub. Then wipe clean with a second piece of rag. Pl[...]

LIST OF SPECIAL TOOLS IN VOLUME No 1 OF MANUAL 583 DESCRIPTION ENGINE Engine - gearbox assembly support Gearbox support Engine support adjuster template Electric tachometer Graduated circuit for adjustment of automatic advance Fuel pump pressure control gauge Oil pressure adapter Pulley alignment measuring rod Belt tension hook Belt tension lever C[...]

LIST OF SPECIAL TOOLS IN VOLUME NV OF MANUAL 583. DESCRlPTlON STEERING Straight ahead position adjuster Steering adjuster Hydraulic test - bench ( LHS2 ) Hydraulic test - bench (LHM ) Test - bench accessories ( LHM ) Straight ahead position gauge BRAKES Stand Centring apparatus for rear brake shoes Hyfraulic test - bench (LHS2) Hydraulic test - ben[...]

SPECIFICATIONS OF TOOLS NOT ON SALE. 1 MR. 630 - 42,' 13 Split pin 0 = 3 Flat washer 0 = 20 Std ~imensions ex. MR. 3301 - 260 rom F1 to ground 162 8 ,5 465 / A ram F 1 to ground 1 18 8-4 pleces sheet metal thickness 5 mm j- Blunted onqles 10 mm 23 290 - 93 - - 35 I D - 2 angle - pieces 20 x20 x3 1 62 E - 2 angle - pleces 20 . 20 . 3 0= 20 278 [...]

2 SPECIFICATIONS OF TOOLS NOT SOLD. MR. 630 -43/20 ex. MR. 3301 - 240 Soldered nuts - Sheet metal 2 mm MR. 630 - 51/3 MR. 630 - 51/38 ex. MR. 1401 - 30 ex. MR. 3725 - 110 C 4 Shee+.metd 5 Th. 15/10[...]

SPECIFICATIONS OF TOOLS NOT SOLD 3 MR .630-51/49 ex. MR .3756-60 ex. MR. 4541[...]

4 SPECIFICATIONS OF TOOLS NOT SOLD MR. 630-56/ 1 1 Semi - hardened steel MR. 630 - 66/11 ex. MR. 4208 al surface 12 A/F MR. 630 -66/ 11 B ex. MR. 4208-20[...]

SPECIFICATIONS OF TOOLS NOT SOLD. 5 MR. 630 72/ 10 ex. MR. 4531 r viewed ur c - 12 1 1 I Spacer sheet metal 2 mm I No 1 3 1 Reinforcement Sh-et metal 2 mm. 4 11 I ~hrust Sheet metai 2 mm. Q~Y 1 Descri pt~on Tubeframe5. 1Odcvelopped length 12451 7 8 2 1 Collar screw 1:=6 5.1. length=35[...]

6 SPECIFICATIONS OF TOOLS NOT ON SALE MR. 630 - 66/ 15 ex MR. 4538 Extended length - 300 Semi - hardened steel 4 = 5[...]

SPECIFICATIONS OF TOOLS NOT ON SALE 7 Lever r,b ,7 5 20 t ~~ot iron 5x20 I c Pin to be riveted Tube 15 . 21 Steel C 35[...]

8 SPECIFICATIONS OF TOOLS NOT ON SALE Extended length Moteriol : Mild steel wire 0=3[...]