Pug 505 Manual Service

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294 Index
spec1f1ca11ons 85 M
lhrottle butterfly in111al setting - l 04
1hrottle switch ad1ustment - l 04 Main and big -end bearing shells
Fuel and exhaust systems ( Part D : Fault diagnosis) - 11 0 examination and renova11on - 51
Fuses and relays 234. 238 Main bearings and c rank shaft
refitting - 52. 69
Maintenance. routine
H body and fittings
bodywork and underframe - 210
Halfshaft ( Estate models) upholstery and carpets - 211
removal and refitting - l 69 braking system - 172
Handbrake clutch 125
ad1ustment cooling system - 76
all models 188 electrical system - 234
rear disc brake models ~ l 87 engine 32. 34
rear drum brake models - l 87 fuel and exhaust systems - 86
cables renew al - 188 ignition system - 11 2
lever removal and refitting - 189 manual gearbox and automatic transmission - 132
w arning light sw itch - 188 propeller shaft - 158
Headlamp rear axle 165
beam alignment 248 suspension and steering - 195
beam load ad1uster - 248 Manifolds, general - 98. 108
bulb renew al 244 Manual gearbox and automatic transmission - 131 et seq
unn removal and refitting - 248 Manual gearbox and automat ic t ransmission
Heater descripuon - 132
blower removal and refitting - 230 fault diagnosis - 156
malllx removal and refitting - 229 maintenance, routine - 132, 133
removal and re fitting - 230 specifications - 131 . 132
Horn unit torque wrench settings - 132
removal and ref1111ng - 248 M anual gearbox
HT leads. general 122 removal and refitting
Hydrauli c flexible hose Estate models - 137
removal and refitting - 1 30 Saloon models - 135
Hydraulic system (bleeding) Manual gearbox (BA7)
brakes 186 clutch housing dismantling and reassembly 146
clutch 130 dismantling into major assemblies - 137
gearchange ad1ustment - 151
input shaft dismantling and reassembly - l 40
inspection - 140
1ntermed1ate housing ( BA7/5) dismantling and reassembly - 146
Ignition module laygear bearing preload adjustment - 149
removal and refining - l 20 laygear dismantling and reassembly - 144
lgm tion syst em l 11 et seq mainshaft dismantling and reassembly 140
Ignition system rear housing dismantling and reassembly - 146
COii - 122 reassembly - 149
condense• 11 5 selector rods dismantling and reassembly 144
contact breaker points - l l 2. 11 3, 114 synchro units centralisation - 148
descri ption - 112 5th speed driven gear dismantling and reassembly - 144
distributor 11 5. 116 Manual gearbox (BA10)
me1ntanence. routine - 112 d1smanthng into major assemblies 152
module 120 gearchange adjustment - 153
spark plugs HT leads and distributor cap - 122 input shaft dismantling and reassembly - 152
spec1hcauons 111 intermediate housing ( BA70/ 5)
TDC sensor removal and refitting - 122 dismantling and reassembly 152
timing 121 mainshaft dismantling and reassembly 152
timing plate ( fuel in1ect1on engines) setting - 121 mainshaft bearing ( BAl 0/ 5) preload ad1ustment - 152
torque wrench settings - 111 overhaul, general - 152
Instrument Illuminat i on rheostat selector rods dismantling and reassembly 152
removal and 1efitting - 242 Master cylinder
Instrument panel removal. overhaul and refitting
dismantling and reassembly - 242 brakes - 182
removal and refitting 242 clu tch - 127
Intermediate shaft M i rror (exterior)
examinauon and renovation - 69 removal and refitting
refut1ng 70 electrically operated - 223
Introduct i on t o the Peugeot 505 - 5 manually operated - 223
M ount ings (engine)
removal and refitting - 42. 65
J
Jacking 8
0
L
Oil f ilter and filter housing
Lubricants and fluids. recommended 24 reassembly - 57
l ·l
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Models covered by this manual

All Peugeot 505 models w 11h four-cylinder petrol engines
Saloon Estate and Family Estate, including special/ limited editions OUCKHAMS
, 796 cc. 1971 cc. 1995 cc & 2165 cc
Ooc$ 1101 cnver Diesel or V6 engme models
What the
·'
- Ciet atolittle
know your car
better press say
'These are really
II The clear, step-by- step illustrated instructions cover the dismantling, worthwhile manuals which
IJ inspection, repair and refitting of the engine. cooling system, fuel and can save you a lot of
f, emission control systems. exhaust, ignition system, clutch, manual money
Autocar
I~ gearbox, propeller shaft or drive shafts, braking system, electri cal system.
I• suspension, steering, bodywork and fittings. Routine maintenance, 'Haynes manuals are
complete specifications and detailed fault diagnosis procedures are also outstanding for giving the
included. For rear axle differential units and automatic transmissions learner mechanic an easy
Ii (where applicable) the removal, refitting and fault diagnosis procedures to follow guide to doing
most any type of repair on
only are covered. maintenance work on his
O NLY HAYNES COMPLETELY STRIP AND REBUILD THE CAR FOR or her car
EACH MANUAL Rofld & Trflck
Saving you money from ·n1ese au1hen11c manuals

are actually written from
· start to finish
~· practical experience ..
Car Mechanics
Whether you just want to change your oil or replace your plugs, or change Excellent value for money,
beginners and experts
your clutch or rebuild your gearbox, the Haynes manual will show you should find ii equally
how, and can help you save pounds on servicing and repair bills. useful. overall a mine of
Info rmation.
I• Mocor
Ii' elping you make things go 'It is thus opportune tha1 a

simply splendid Owners
a little turther Workshop Manual has just

come ou l. Every
imaginable job is
A Haynes manual can help you stretch your motoring budget that little bit illus1rated ...
further in other ways too. Regular maintenance and servicing will mean Autosporr
your car is safer t o drive whilst giving you more of those precious mpg.
What's more, a car that is well looked after will ' For the home mechanic
Haynes DIY workshop
hold its price better and last a lot longer !
..._,,
manuals show clearly
slep-by st1:1p service
-·
o Hj
opera1ions m pictures
H 412874 ISBN 0 85696 762 9 Sunday Mlfror
0 0
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..
Peugeot
505
Owners
Workshop
Manual
A K Legg reno M1M1
Models covered
All Peugeot 505 models with four-cylinder petrol
engines. Saloon, Estate and Family Estate, including
special/ limited editions
, 796 cc, , 971 cc, 1995 cc & 2165 cc
Does not cover Diesel or V6 engine models
Hay nes Publishing Group

Sparkford Nr Yeovil
Somerset BA22 7JJ England
Haynes P~blications. Inc
861 Lawrence Drive
Newbury Park
California 91320 USA
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..
Acknowledgements
Thanks are due to the Champion Sparlong Plug Company limited,
who supplied the illustrations showing the spark plug condit ions. and
to Ouckhams Oils, who supplied lubrication data. Certain other
illustrations are the copyright of Peugeot Talbot M otor Company
limited, and are used wi th their permission. Thanks are also due to
Sykes -P1ckavant, who S\Jpplied some of the w orkshop tools. and all
the staff at Sparkford who assisted in the production of this manual.
© Haynes Publishing Group 1989
A book in the Haynes Owners Workshop Manual Serles
Printed by J . H. Haynes & Co. Ltd, Sparkford, Nr Yeovil,

Somerset BA22 7JJ, England
All r ight s reserved. No part o f this book may be reproduc ed or

transmitted in any form or by any means, electronic or
mechanical. inc luding photoc opying. recording or by any
Information storage o r retrieval system. without permission
in writing from the copyright holder.
ISBN 0 85696 762 9
British library Cataloguing In Publication Data

Legg, A K (Andrew K.) 1942 ·
Peugeot 505 (4 cyl, petrol) owners workshop manual
1 Cars. Maintenance & repair, Amateurs' manuals
I Thie II Series
629 28'72
ISBN 0 -85696-762-9
J .\
Whilst every care is taken to ensure that the information in
th is manual is co rrect , no liability can be accepted by the
authors or publishers for l oss. damage o r injury caused by any
errors in. or o m issions from, the information given.
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Contents
Pege
About this manual 5
Introduction to the Peugeo t 505 5

1
General dimensions. weights and capacities 7

\
Jacking, towing and wheel changing 8
Buying spare parts and vehicle identification numbers 9
General r'epair procedures 10
Tools and working facilities 11
Conversion factors 13
Safety first! 14
Routine maintenance 15
Recommended lubricants and fluids 24
Fault diagnosis 25
Chapter 1 Engine 28
Chapter 2 Cooling system 75
Chapter 3 Fuel and exhaust systems 83
Chapter 4 Ignition system 111
Chapter 5 Clutch 125
Chapter 6 Manual and automatic transmission 131
Cl;lapter 1 Propeller shaft 157
Chapter 8 Rear axle 113
Chapter 9 Braking system 171
Chapter 10 Suspension and steering 191
Chapter 11 Bodywork and fittings 210
Chapter 12 Electrical system .. 233
Index 291
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4 ----------------------------------------------------------------------------.........
Peugeot 505 SR Saloon (1981 model)
Peugeot 505 GR Estate (1981 model)

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Abo ut this manual

I ts aim There is an alphabetical index at the back of the manual as well as a
The aim of this manual is to help you get the best value from your contents list at the front. Each Chapter is also preceded by its own
vehicle. It can do so in several ways. It can help you decide what work individual contents list.
must be done (even should you choose to get it done by a garage). References to the 'left' or 'righf of the vehicle are in the sense of a
provide information on routine maintenance and servicing, and give a person in the driver's seat facing forwards.
logical course of action and diagnosis when random faults occur. Unless otherwise stated, nuts and bolts are removed by turning
However. it is hoped that you wi ll use the manual by tackling the w ork anti-clockwise. and tightened by turning clockwise.
yourself. On simpler jobs it may even be quicker than booking the car Vehicle manufacturers continually make changes to specifications
into a garage and going there twice. to leave and collect It. Perhaps and recommendations, and these, w hen notified, are incorporated into
most important. a lot of money can be saved by avoiding the costs a our manuals at the earliest opportunity.
garage must charge to cover its labour and overheads. Whilst ev ery care is taken to ensure that the information in
The manual has drawings and descriptions to show the function of this manual is correct, no liability can be accepted by the
the various components so that their layout can be understood. Then authors or publishers for l oss, damage or injury caused by any
the tasks are described and photographed in a step- by-step sequence erro rs in. o r omissions from. the information given.
so that even a novice can do the work.
Project vehicles
Its arrangement The vehicles used in the preparation of this manual, and appearing
The manual is divided into twelve Chapters, each covering a logical in many of the photographic sequences. were a 1985 model Peugeot
sub-division of the vehicle. The Chapters are each divided into 505 GR Saloon and a 1987 model Peugeot 505 GTI Family Estate.
Secttons. numbered w ith single figures. eg 5; and the Sections Into
paragraphs (or sub-sections). w ith decimal numbers following on Engine codes
from the Section they are in. eg 5.1. 5.2. 5.3 etc. For the sake of simplicity, the engine codes quoted in th is manual
It 1s freely illustrated, especially in those parts where there is a may appear in a slightly-abbreviated form. It is hoped that this will not
detailed sequence of operations to be carried out. There are two forms lead to confusion. but if so, refer t o the list below:
of illustration: figures and photographs. The figures are numbered in
sequence w ith decimal numbers. according to their position in the XM7 = XM7A (1796 cc, overhead valve. carburettor)
Chapter - eg Fig. 6.4 Is the fourth drawing/ illustration in Chapter 6. ~1 • XN1 r XN1A (1 971 cc.. o'Hrllud l/lllve. t:M/Jiri@r)
Photographs carry the same number (either individually or in related m = ZEJK ( 1995 CC, overhead camshafl', fuerm1ect1onr
groups) as the Section or sub- section to which they relate. ZDJ ,. ZDJL (2165 cc. overhead camshaft, fuel injection)
Introduction to the Peugeot 505

The Peugeot 505 is a sturdy well -designed car, using a proven Overhaul and repair operations are generally straightforward, with
mechanical layout w ith th e engine in the front and rear-wheel -drive. the excepti9~ of some areas of the fuel injection system and automatic
Saloon models have a fully-independent rear suspension. whereas transmissioli. which requ ire specialised equipment.
t
Estate models have a rigid rear axle and torque tube suspension.
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General dimensions, weights and capacities

Dimensions
Overall length:
Saloon .......................................•..........•................................................... 4579 mm (180.4 in)
Estate ....................................................................................................... 4901 mm (193.1 in)
Overall width ................................................................................................ 1737 mm (68.4 in)
Overall height:
Saloon •..........•....................•........•... :........................................................ 1446 mm ( 57.0 in)
Estate ....................................................................................................... 1544 mm (60.8 in)
Wheelbase:
Saloon ..................................................................................................... . 2743 mm (108.1 In)
Estate ....................................................................................................... 2900 mm (114.3 in)
Track (front):
Saloon ..................................................................................................... . 1481 mm (58.4 In)
Estate ....................................................................................................... 1496 mm (58.9 in)
Track (rear):
Saloon ...................................................................................................... 1445 mm (56.9 in)
Estate ....................................................................................................... 1450 mm (57.1 in)
Weights
f<"efb weight:
Saloon - carbul8ttor engine ............................................................... .. 1215 to 1235 kg (2679 to 2723 lb)
Saloon - fuel Injection engine .............................................................. 1265 to 1285 kg (2789 to 2833 lb)
Estate - except Family .......................................................................... . 1300 to 1365 kg (2867 to 3010 lb)
Estate - Family ....................................................................................... . 1340 to 1400 kg (2955 to 3087 lb)
Maximum tow ing weight (braked trailer):
Saloon ...................................................................................................... 1300 kg (2867 lb)
Estate ...................................................................................................... . 1500 kg (3308 lb)
Maximum roof rack load:
Saloon .............................................................•........................................ 75 kg (165 lb)
Estate •.............................................................................•........................ 100 kg ( 221 lb)
Capacities
Engine oil:
XM 7 and XN1 ......................................................................................... 4.0 litr91! (7.0 pints)
ZEJ and ZOJ ........................................................................................... 5.0 litres (8.8 pints)
Cooling system:
Carbure11or engines w ith manual gearbox .......................................... 18.4 litres (14.8 pints)
Carburettor engines. with automatic transmission ........................... .. 1 .3 litres (12.8 pints)
Fuel injection engines ............................................................................ 7.5 litres (13.2 pints)
Fuel tank.
Pre-1984 models .................................................................................... 62 liuea (11 .4 gallons)
1984-on models ..................................................................................... 70 litres (16.4 gallons)
Manual gearbox:
BA7/ 4 .......................•.....................•........................................................ 1.15 litres (2.0 pints)
BA7/6 ...................................................................................................... 1.45 litres (2.6 pints)
BA1 0/5 ........................•...................................•................•.....................• 1.60 litres (2.8 pints)
Automatic transmission (drain/ refill ): I
3 HP22 .........•...............•........•.............•................................................... 1.6 litres (2.8 pj ~ts)
4 HP22 ................................................................................................... . 2.6 litres ( 4.6 pldts)
Rear axle/final drive:
Saloon ...................................................................................................... 1.66 lltres (2.7 pi~ts) ~
Estate ....................................................................................................... 1.6 litres (2.8 pl~ /

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Jacking, towing and wheel changing

Jackmg
To avoid repetition. the procedure for raising the vehicle is not but care must be taken not to damage the fuel tank, spare wheel carrier.
included before each relevant operation described in this manual. and exhaust.
To raise 1he front of the veh icle, position the trolley jack under the
front crossmember. then support the vehicle w ith axle stands under the
body channel sections. Wheel changing
To raise the rear of the vehicle. pos111on the trolley jack under the The jack supplied wi th the vehicle is only suitable for wheel
rear suspension crossmember on Saloon models, or under the rear changing, and must not be used w ithout supplementary supports
racking points on Estate models If a cradle 1s made to clear the rear when working under the veh icle.
antHoll bar Estate models may be raised beneath the rear axle. To change a wheel. first chock the diagonally-opposite wheel. and
Pos111on the axle stands beneath the rear crossmember ( Saloon) or rear apply the handbrake. Remove the jack and handle from the leh-
axle (Estate) (Saloon) or right-hand ( Estate) side of the luggage area. Using the
handle in the slotted bolt head. turn the handle 15 turns anti -clockwise
Towmg to lower the spare wheel Unhook the carrier and remove the spare
The towing eyes may be used for towing or being towed in an wheel. Using the handle, prise off the w heel trim. loosen only the
emergency on normal road surfaces. wheel nuts with the handle. Hook the 1ack in the appropriate iacking
When being towed, remember to unlock the steering column by point. then raise the vehicle until the wheel is clear of the ground.
switching the ignition on. Unscrew the nuts and remove the wheel. Fit the spare wheel, and
The vehicle should not be towed for more than 30 miles (50 km) on tighten the nuts in diagonal sequence. lower the jack. and finally
normal roads The gear lever must be in neutral on manual gearbox tighten the wheel nuts. Refit the wheel trim. Fn the removed wheel in
models. and 'N' on automatic transmission models. the carrier. with its outside face uppermost. Raise the carrier. Refit the
The vehicle should be towed w ith the rear wheels off the ground, 1ack and handle.
Towing eye Remove the trim panel ••• for accesa to the jack and handle on
Saloon models
Jack end handle on Eatete models Lowering the apare wheel Jacking point
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Buyi ng spare parts and

vehic le ident ification numbers
Buying spare parts
Spare pans available from many sources, for e)(ample Peugeot possible. Quote the car model. year of manufacture. and tdentificauon
garage~. other garages and accessory shops, and motor factors. Our numbers as appropriate
advice regarding spare partS is as follows. The vehicle identification number Is given on a plate located either
Olf1c1a/ly-appo1nted Peugeot garages - This Is the best source of on the engine compartmen t front cross panel or on the side of the
pans wh ich are peculiar to your car, and are not generally available (eg right-hand front suspension tower. The serial number is also stamped
complete cyli nder heads. Internal gearbox components. badges. directly on the body. on the right- hand side of the engine
in terior trim etc), It is also the only place at which you should buy pans compartment.
ti your vehicle ts still under warranty - non-Peugeot components may The paint code is located on the outer edge of the left- hand front
invalidate the warranty. To be sure of obteining the correct parts, 11 will suspension tower.
always be necessary to give the storeperson your car's vehicle The engine number 1s stamped above the left-hand engine
1denuf1cauon number (VIN). and if possible, to take the 'old' pan along mounung on overhead valve engines. or on a plate, attached to the
for pos1uve 1dent1ftcauon. Many pans are available under a factory right- hand side of the cylinder block. on overhead camshaft engines.
&)(Change scheme - any parts returned should always be clean. It
obviously makes good sense to go straight to the specialists on your
car for this type of pan, for they are best equipped to supply you.
Other dealers and accessory shops These ere often very good I AUT_ . I . .~T I
places to buy materials and components needed for the maintenance
> I I
of your cor (eg 011 filters. spark plugs. bulbs, drivebelts. oils and grease,
I
touch-up paint, fil ler paste etc). They also sell general accessories. K:
usually have convenient opening hours. charge lower prices. and can
often be found not far from home
I
••
•• I
Motor factors - Good factors w ill stock all of the more important
components which wear out relatively quickly (eg clutch components.
pistons. valves. exhaust systems. brake pipes/seals and pads etc).
Motor factors w ill often provide new or recond111oned components on
a pan exchange basis - this can save a considerable amount of money. Veh i cle i dentif i c at ion plate
Vehicle identification number (VIN) II TyptJ apptoval numbar

Modif1cauons are a conunuing and unpublicised process in vehicle b Vehicle identification number (VIN)
manufacture. quite apart from ma1or model changes. Spare pans
J-;i
c M aximum gross vehicle weight (GVW)
manuals and hsts are compiled upon a numerical basis, the Individual d' M aximum gross 1tam weight (G TW)
vehicle numbers being essential to correct identification of the e M aximum load on ftont ox/a
component required. f M aximum load on tear axle
When ordering spare pans. always give es much information es g /dentif1catlon or type cods variant
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General repair procedures

Whenever servicing, repair or overhaul work 1s carried out on the grease, water or other fluid before installing the bolt or stud. Failure to
car or rts components. it is necessary to observe the following do this could cause the housing to crack due to the hydraulic action of
procedures and Instructions. This will assist in carrying out the the bolt or stud as it is screwed in.
operation efficiently and to a professional standard of workmanship. When tightening a castellated nut to accept a split pin. tighten the
nut to the specified torque. where applicable, and then tighten funher
Joint mating faces and gaskets to the next split pin hole. Never slacken the nut to ahgn a split pin hole
Where a gasket is used between the mating faces of two unless stated in the repair procedure.
components, ensure that it is renewed on reassembly. and fit it dry When checking or retightenlng a nut or bolt to a specified torque
unless otherwise stated in the repair procedure. Make sure that the setting. slacken the nut or bolt by a quaner of a turn, and then retlghten
mating feces ere clean and dry with all traces of old gasket removed. to the specified setting.
When cleaning a joint face. use a tool which is not likely to score or
damage the face. and remove any burrs or nicks w ith an oilstone or fine Locknuts, locktabs and washers
file. Any fastening which w ill rotate against a component or housing In
Make sure that tapped holes are cleaned with a pipe cleaner, and the course of tightening should always have a washer between 1t and
keep them free of jointing compound if this is being used unless the relevant component or housing.
specifically instructed otherwise. Spring or split washers should always be renewed when they are
Ensure that all orifices. channels or pipes are clear and blow used to lock a critical component such as a big. end bearing retaining
through them. preferably using compressed air. nut or bolt.
Locktabs which are folded over to retain a nut or bolt should always
Oil seals be renewed.
Whenever an oil seal is removed from its working location. either Self. locking nuts can be reused in non· criucal areas. providing
individually or as pan of an assembly, it should be renewed. resistance can be felt when the locking ponion passes over the bolt or
The very fine sealing lip of the seal is easily damaged and w ill not stud thread.
seal If the surface it contacts is not completely clean and free from Split pins must always be replaced with new ones of the correct
scratches. nicks or grooves. If the original sealing surface of the size for the hole.
component cannot be restored, the component should be renewed.
Protect the hps of the seal from any surface which may damage Special tools
them in the course of lining. Use tape or a conl~I sleeve where Some repair procedures In this manual entail the use of special tools
possible. Lubri~te the seal hps with oil before fitting and, on dual such as a press. two or three· legged pullers. spring compressors ate.
lipped seals. fill the space between the lips with grease. Wherever possible, suitable readily available alternatives to the
Unless otherwise stated, oil seals must be fitted w ith their sealing manufacturer's special tools are described, and are shown in use. In
lips toward the lubricant to be sealed. some instances, where no alternative is possible, It has been necessary
Use a tubular drih or block of wood of the appropriate size to install to reson to the use of a manufacturer's tool and this has been done for
the seal and. If the seal housing is shouldered, drive the seal down to reasons of safety as well as the efficient completion of the repair
the shoulder If the seal housing tS unshouldered. the seal should be operation. Unle$$ you are highly skilled and have a thorough
fitted with its face flush with the housing top face. understanding of the procedure descnbed, never attempt to bypass the
use of any special tool when the procedure described specifies Its use.
Screw threads and fastenings Not only Is there a very great risk of personal injury, but expensive
Always ensure that a blind tapped hole Is completely free from oil, damage could be ~used to the components Involved.
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Tools and working facilities

Introduction
A selection of good tools is a fundamental requirement for anyone Tyre pressure gauge
contemplaung the maintenance and repair of a motor vehicle. For the GreastJ gun
owner who does not possess any. their purchase will prove a Oil can
considerable expense. offsetting some of the savings made by Fine emery cloth (1 sheet)
Wire brush (small)
doing- it-yourself. However, provided that the tools purchased are of
Funnel (medium size)
good quality. they w ill last for many years and prove an extremely
worthwhile investment. Repair and overhaul tool kit
To help the average owner to decide which tools are needed to carry These tools are virtually essential for anyone undertaking any major
out the various tasks detailed in this manual. we have compiled three repairs to a motor vehicle, and are additional to those given in the
lists of tools under the following headings: Maintenance and minor Maintenance and minor repair hst. Included in this list is a
repalf. Repalf ttnd overhaul. and Special. The newcomer to practical comprehensive set of sockets. Although these are expensive they w ill
mechanics should start off w11h the Mamtenance and minor repair tool be found invaluable as they are so versatile • particularly if various
kit and confine himself to the simpler jobs around the vehicle. Then. as drives are included in the set. We recommend the ~ in square-drive
his confidence and experience grow, he can undertake more difficult type, as this can be used with most proprietary torque wrenches. If you
tasks. buying eKtra tools as, and when, they are needed. In this way, a cannot afford a socket set. even bought piecemeal, then inexpensive
Maintenance and minor rtJpalr tool kit can be built- up into a Repair and tubular box spanners are a useful alternative.
overhaul tool kit over a considerable period of time without any major The tools in this list will occasionally need to be supplemented by
cash outlays. The eKperienced do-it -yourselfer will have a tool kit good tools from the Special hst.
enough for most repai r and overhaul procedures and will add tools
Sockets (or box spanners) to cover range in previous list
from the Special category when he feels the eKpense is justified by the Reversible ratchet drive (for use with sockets)
amount of use to which these tools w ill be put.
Extension p iece. 10 inch (for ustJ with sockets)
It is obviously not possible to cover the sub1ect of tools fully here.
Universal joint (for use with sockets)
For those who wish to learn more about tools and their use there Is a
Torque wrench (for use with sockets)
book ent1tled How to Choose and Use Car Tools available from the
'Mole' wrench · 8 inch
publishers of this manual.
Ball pein hammer
Soh-faced hammer. plastic or rubber
Maintenance and minor repair tool kit Screwdriver - 6 111 long x 5/ 16 in dia (flat blade)
The tools given In this hst should be considered as a minimum
Screwdriver - 2 in long x 5/ 16 in square (flat blade)
requirement 1f rouune maintenance. servicing and minor repa ir
Screwrlriver - 1'12 in long x 1/ 4 m dia (cross blade)
operations are to be undertaken. We recommend the purchase of
Screwdriver - 3 m long x 11a m d1a (electrrcians)
combinauon spanners (ring one end, open-ended the other); although
Pliers • electrrcians side cutters
more eKpens1ve than open-ended ones, they do give the advantages of
Pliers - netJdle nosed
both types of spanner
PlitJrs • circlip (internal and external)
Combmarion spanners - 10. 11. 12. 13. 14 & 17 mm Cold chisel • 1/ 2 mch
Ad1ust11ble spanner - 9 mch Sct1ber
Engme sump/gearbox/rear axle dram plug lcey Scraper
Sperle plug spanner ( with rubber insert) Centre punch
Spark plug gap ad1ustment rool Pin punch
Ser of feeler gauges Hacksaw
Brake ad1ustor spanner Valve grinding tool
Brake bleed nipple spanner Steel rula/~traight-edgtJ
Screwdnver. 4 m long x 'I'
in d1a (flat blade) A llen keys ~inc. splined/Torx type If necessary)
Screwdnver • 4 In long x '14 In dia (cross blade) Salectlon ol hies
Combinarion pliers - 6 Inch Wire brush (large)
Hacksaw fiunlor) Axle-stands
Tyre pump Jack (strong trolley or hydraulic type)
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12 Tools and working facilities
Special tools essential for fitting accessories such as mirrors and reversing fights.
T he tools in this list are those which are not used regularly, are Last, but not least. always keep a supply of old newspapers and
expensive to buy, or which need to be used in accordance w ith their clean. lint- free rags available, and try to keep any working area as clean
manufacturers· i nstructions. Unless relatively difficult mechanical jobs as p0ssi ble.
are undertaken frequently, It will not be economic to buy many of these
tools. Where t his 1s the case, you could consider clubbing together
w ith friends (or 1oining a motorists' club) to make a jo int purchase, or
borrow ing the tools against a deposit from a local garage or tool hire Spanner jaw gap comparison table
specialist
T he following list contains only those tools and Jnstruments freely Jaw gap ( in) Spanner size
available to the pu blic, and not those spacial tools produced by the
0.250 1/ 4 in AF
vehicle manufac turer specifically for its dealer network. You will find
occasional references to these manufac turers· special tools in the text 0.276 7 mm
of this manual. Generally, an alternative method of doi ng th e job 0.313 S/ 1e in AF
w ithout the vehicle m anufacturers' special tool is g iven. However, 0.315 8mm
sometimes. there Is no alternative to using them. Where this is the case 0.344 11/32 in AF; 1/ e in Whitworth
and the relevant tool cannot be bought or borrowed. you will have to 0.354 9mm
entrust the work to a franchised garage. 0.375 3/e i n AF
0.394 10 mm
Valve spring compressor ( where applicable) 0.433 11 mm
Piston ring compressor 7/ 1e in AF
0.438
Bal/joint separator 3/16 in Whitworth; 1/ 4 in BSF
0.445
Universal hub/ bearing puller 12 mm
0.472
Impact screwdriver 0.500 1/ 2 i n AF
M icrometer and/ or vernier gauge 0.612 13 mm
Dial gauge 0.525 1/ 4 in Whitworth; 6116 in BSF
Stroboscopic timing light 0.551 14mm
D well angle meter/ tachometer 0.563 9/ 16 in AF
Universal electrical mufti -meter 0.591 15 mm
Cyflnder compression gauge 6/ 16 in W hitworth; 3/a i n BSF
0.600
Lifting tackle 0.626 6/e in AF
Trolley j ack 0.630 16 mm
Light with extension lead 0.669 17 mm
0.686 11/16 in AF
Buying to ols 0.709 18 mm
For practically all tools, a tool factor is the best source since he w ill 0.710 3/a in Whitworth; 7/1& i n BSF
have a very comprehensive range compared w ith the average garage or 0 .748 19 mm
accessory shop. Having said that. accessory shops often offer excellent 0.750 3/ 4 in AF
q uality tools at discount prices, so it pays to shop around. 0.813 13/ 16 in AF
Remember, you d on' t have to buy the most expensive items on the 0.820 7/ 1& in Whitworth; 1/ 2 in BSF
shelf, but It is always advisable to steer clear of the very cheap tools. 0.866 22 mm
There are plenty of good tools around at reasonable prices, so ask the 0.875 7/a in AF
proprietor or manager of the shop for advice before making a purchase. 0.920 1/ 2 in Whitworth; 9/ 16 in BSF
0.938 16f1 e in AF
Care and maintenance of tools 0.945 24 mm
Having purchased a reasonable tool kit, it is necessary to keep the 1.000 1 in A F
too ls in a clean serviceable condit ion. After use, always wipe off any 1.010 9/ 16 In Whitworth; 5/e in BSF
dirt, grease and metal particles using a clean, dry cloth, before puning 1.024 26 mm
the too ls aw ay. Never leave them lying around after they have been 1.063 l1l 16 in AF; 27 mm
used. A simple tool rack on the garage or workshop wall. for items such 1.100 6/ a in Whitworth; 11/ 16 in BSF
as screwdrivers and pliers is a good Idea. Store all normal wrenches 1.125 11/ a In A F
and sockets i n a metal box. Any measuring instruments. gauges. 1.181 30mm
meters, etc. must be carefully stored where they cannot be damaged or 1.200 11/ 16 in Whitworth; 3/ 4 fn BSF
become rusty. 1.250 11/ 4lnAF
Take a little care when tools are used. Hammer heads inevitably 1.260 32mm
become marked and screwdrivers lose the keen edge -on their blades 1.300 3/ 4 in Whitworth; 7/a in BSF
from time to time. A lrttle timely attention with emery cloth or a file w i ll 1.313 15/16 in AF
soon restore Items like t his to a good serviceable fin ish. 1.390 13/ 16 in Whitworth; 16/1e in BSF
1.417 36 mm
Working faciliti es 1.438 17/ 16 i n AF
Not to be forgonen when discussing tools, is the workshop itself. If 1.480 7/ e i n Whitworth; 1 in BSF
anything more than routine maintenance Is to be carried out, some 1.500 11/ 2 lnAF
form of suitable working area becomes essential. 1.575 40 mm; 15/ 18 In Whitworth
It 1s appreciated that many an ow ner mechanic is forced by 1.614 41 mm
circumstances to remove an engine or similar Item, without the benefit 1.625 1&/ a In AF
o f a garage or workshop . Having done this, any repairs should always 1.670 1 in Whitworth; 11/ a In BSF
be done under the cover of a roof. 1.688 111/18 i n AF
W herever possible. any d ismantling should be done on a clean, flat 1.811 46 mm
w orkbench or table at a su itable working height. 1.813 11 3/ 16 i n AF
A ny w orkbench n eeds a vi ce: one with a jaw openlng of 4 Jn ( 100 1.860 1 ' l a i n Whitworth; 11/ 4 in BSF
mm) is suitable for most jobs. As mentioned previously, some clean dry 1.875 17/a in A F
storage space is also requ ired for tools. as well as for lubricants. 1.969 l· 50mm
cleani ng fluids, touch - up pai nts and so on, which become necessary. 2.000 2 in AF
A not her uem which may be required, and which has a much more 2.050 1114 in Whitworth; 13/a in BSF
general usage. Is an eleciri c drill w ith a chu ck capacity of at least 6/18 2.165 66 mm
in (8 mm) This. together w ith a good range of twist drills. is virtually 2.362 60mm

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Conversion factors
Length (dlSlance)
Inches (in) x 25.4 M illimetres (mm) x 00394 • Inches (1n)
Feet (ft) x 0.305 Metres (m) x 3.281 • Feet (ft)
Miles x 1.609 • Kilometres (km) x 0.621 • M iles
Volume (capacity)
Cubic inches (cu in; in') x 16.387 Cubic centimetres (cc: cm') x 0061 • Cubic inches (cu in; in')
lmpenal pints (Imp pt) x 0.5,68 Litres (I) x 1.76 Imperial pints (Imp pt)
lmponal quarts ( Imp qt) x 1 137 • Litres (1) x 0.88 • Imperial quarts (Imp qt)
lmpenal quarts ( Imp qt) x 1 201 = US quarts (US qt) x 0.833 - Imperial quarts ( Imp qt)
US qual'\S (US qt) x 0.946 Litres (I) x 1.057 • US quarts (US qt)
lmpenal gallons (Imp gal) x 4.546 - Litres (I) x 0.22 • Imperial gallons (Imp gal)
Impanel gallons (Imp gal) x 1.201 US gallons (US gal) x 0.833 • Imperial gallons (Imp gal)
US gallons ( US gal) x 3.785 litres (I) x 0.264 .. US gallons (US gal)
Mass (weight)
Ounces (oz) x 28.35 • Grams (g) x 0.035 • Ounces (oz)
Pounds (lb) x 0.454 Kilograms (kg) x 2.205 Pounds (lb)
Force
Ounces force (ozf. oz) x 0 .278 - Newtons ( N) x 3.6 • Ounces- force (ozf: oz)
Pounds-force (lbl; lb) x 4 448 ~ Newtons ( N) x 0.225 - Pounds-force (lbf; lb)
Newtons ( N) x 0.1 Kilograms-force ( kgf; kg) x 9.81 - Newtons ( N)
Pressure
Pounds-force per square inch x 0.070 Kilograms-force per square x 14 223 Pounds-force per square inch
(psi, lbf/in'. lb/in 2 ) centimetre (kgf/ cm•; kg/cm2 ) (psi; lbf/ in'; lb/in2 )
Pounds-force per square inch x 0068 Atmospheres (atm) x 14.696 • Pounds-force per square inch
(psi: lbf/in2 lb/in') (psi; lbf/in2 ; lb/in 2 )
Pounds-force per square inch x 0.069 Bars x 14.5 - Pounds -force per square inch
(psi. lbf/in 2• lb/in1 ) (psi; lbf/ 1n2; lb/ in2 )
Pounds-force per square inch x 6.895 Kilopascals (kPa) x 0145 Pounds-force per square inch
(psi. lbf/in2. lb/in2 ) (psi; lbf/in•; lb/in')
Ktlopascals (kP3) x 0.01 Kilograms-force per squere x 98.1 - Kilopascals (kPa)
centimetre ( kgf/ cm•: kg/ cm')
M1lhbar (mbar) x 100 Pascals (Pa) x o.oi • Millibar (mbar)
M tlhbar (mbar) x 0.0145 Pounds-force per square inch x 68.947 .. Millibar (mbar)
(psi: lbf/ in2 ; lb/ in')
M 1lhba1 (mbar) x 0.75 = M illimetres of mercury (mmHg) x 1.333 = M illibar (mbar)
M tlhbar (mbar) x 0.401 Inches of water (inH,O) x 2.491 M illibar (mbar)
M tlhmetres of mercury (mmHg) x 0.535 Inches of water (inH,O) x 1.868 • M illimetres of mercury (mmHg)
Inches of water (lnH 20) x 0.035 Pounds-force per square Inch x 27.68 .. Inches of water (inH,O)
(psi; lbf/ in 2; lb/ in 2 )
Torque (moment of force)

Pounds-force inches x 1.152 = Kilograms-force cenumetre x 0.868 • Pounds- force inches
(lbl 1n. lb In) (kgf cm; kg cm) ( lbf In; lb in)
Pounds· force Inches x 0.113 = Newton metres ( Nm) x 8 85 • Pounds -force inches
(lbf 1n lb in) ( lbf in; lb in)
Pounds-force Inches x 0.083 s Pounds-force feet (lbf le lb ft) x 12 Pounds -force Inches
(lbf in. lb in) (lbf in, lb in)
Pounds- force feet (lbf ft: lb ft) x 0138 Kilograms-force metres x 7.233 • Pounds-force feet (lbf ft; lb ft)
(kgf m: kg m)
Pounds-force feet (lbf h; lb It) x 1.356 • Newton metres (N'Tl) x 0.738 - Pounds-force feet (lbf ft; lb ft)
Newton metres ( Nm) x 0102 • Kilograms-force metres x 9804 Newton metres ( Nm)
(kgf m; kg m)
Power
Horsepawer (hp) x 745 7 = Watts (W) x 0.0013 • Horsepower (hp)
Velocity (speed)
Miles per hour (miles/ hr, mph) x 1 609 • Kilometres per hour (km/hr, kph) x 0.621 • Miles per hour (miles/hr; mph)
Fuel consumption·
Miles per gallon lmpe11al ( mpg) x 0.354 K1lomerres per litre (km/ I) x 2.825 • Miies per gallon, Imperial (mpg)
M iles per gallon US (mpg) x 0.425 Kilometres per litre (km/ I) x 2 362 • M iles per gallon. US (mpg)
Temperawre
Degrees Fahrenheit - ('C x 1.8) T 32 Degrees Celsl~ (Degrees Centigrade; 'C) - ('F - 32) x 0.56
'It is common practico to convert from miles par gallon (mpg) to lltres/100 kilometres (l!T OOkm),
whore mpg (Imports/) x I/ 100 km • 282 and mpg (US) x I/ 100 km - 235
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Safety first!
Professional motor mechanics are trained 1n safe wori<ing proce· F1re
dures How ever enthusiastic you may be about getting on with the Job Remember at alt times that petrol (gasoline) ts highly flammable
in hand do take the time to ensure that your safety is not put at risk A Never smoke, or have any kind of naked flame around. when worki ng
moments lack of attention can result rn an accident, as can failure to on the vehicle. But the risk does not end there - a spark caused by an
observe curtain elementary precautrons. elect11c11I short -c11cu11, by two metal sur1aces contact ing each other, by
There will always be new ways of having accidents, and the careless use of tools. or even by static eloct11city built up in your body
following points do not pretend to be a comprehensive list of all under certain conditions. can ignite petrol vapour, which in a confined
dangers, t hey are intended rather to make you aware of the risks and to space rs highly explosive.
encourage a safety-conscious approach to all work you carry out on Always disconnect the battery earth (ground) terminal before
your vehicle working on any part of the fuel or efectrrcal system. and never rrsk
sprlhng fuel on to a hot engine or exhaust
It rs recommended that a fire ex11ngu1sher of a type surtable for fuel
and electrrcal fires rs kept handy in the garage or workplace at all times
Nover try to exunguish a fuel or electrical frre wrth water
N o te: Any reference to a 'torch' appearing in this manual should
Essential DOs and DON'Ts always be taken to mean a hand-held battery-operated electffc lamp or
DON ' T rely on a single 1ack when working underneath the vehicle. flashlight It does NOT mean a welding/gas torch or blow/amp
A lways USP reliable additional means of support, such as axle stands.
securely placed under a part of the vehicle that you know will not grve Fumes
way Certain fumes are highly toxic and can quickly cause unconscious·
DON 'T attempt to loosen or tighten high- torque nuts (e.g wheel hub ness and even death if rnhaled to any extent. Petrol (gasoline) vapour
nuts) while the vehicle rs on a 1ack. rt may be pulled off comes into thrs categ ory. as do the vapours from certarn solvents such
DON 'T start the engine without f irst ascertaining that the transmission as trichloroethylene. Any drainrng or pourrng of such volat1le fluids
is neutral (or Park' where applicable) and the parking brake applied should be done rn a welt venu lated area
DON 'T 5uddenly remove the filler cap from a hot cooling system W hen using cleaning fluids and solvents, read the rnstructrons
over with a cloth and release the pl'essure gradually first, or you may carefully Never use materials from unmarked containers - they may
get sc lded by escaping coolant. grve off poisonous vapours.
DON 'T attempt to drain o rl unul you are sure 11 has cooled sufficiently Never run the engine of a motor vehicle rn an enclosed space such
to avoid scaldi ng you . as a garage. Exhaust fumes contain carbon monoxide which IS
DON 'T grasp any part of the engine, exhaust or catalytic converter extremely poisonous; 1f you need to run the engine. always do so in the
without lrrst ascertaining that ti 1s suff1c1ently coot to avoid burning open air or at least have the rear of the vehrcle outside the workplace.
you If you are fortunate enough 10 have the use of an inspecuon pit,
DON 'T allow brake fluid or antifreeze to contact vehicle paintwork. never drain or pour petrol. and never run the engine, wh ile the vehicle
DON ' T syphon tox ic liquids such as fuel. brake fluid or antifreeze by is standing over it ; the fumes, being heavier than arr. will concentrate in
mouth. or allow them to remain on your skin. the p11 wrth possibly lethal results.
DON T inhale dust - n may be in1urrous to health (see Asbestos
b..low) The battery
DON T allow any spilt oi l or grease to remain on t he floor - wrpe 11 up Never cause a spark, or allow a naked hght. near the vehicle's
stra1gll! aw ay before someone shps on 11 banery It will normally be grving off a certa in amount of hydrogen gas.
DON T use 111-frttmg spanners or other tools wh ich may shp and cause which 1s highly explosive
1n1ury Always drsconnect the banery earth (ground) terminal before
DON 'T attempt to hft a heavy component which may be beyond your working on the fuel or electrical systems.
capab1hty g et assistance. If possible, loosen the filler plugs or cover when charging the
DON ' T rush to finish a 1ob, or take unverified short cuts battery from an external source Do not charge at an excessive ra te or
DON 'T allow children or animals in or around an unattended vehicle. the battery may burst.
00 wear eye protection when using power tools such as drill, sander, Take care when topping up and when carrying the banery, The acid
benc h grinder etc, and when working under the vehicle . electrolyte. even when diluted, rs very corrosive and shou ld not be
00 ui.e a bamer cream on your hands prror to undertaking drrty JObs allowed to contact the eyes or skin
11 will protect your skin from infection as well as maktng the dirt easier If you ever need to prepare electrolyte yourself, always add the acrd
10 remove afterwards; but make sure your hands aren't left slippery. slowly to the water. and never the other way round. Protect against
Note 1ha1 long- term contact with used engine 011 can be a health splashes by wearing rubber gloves and gaggles.
'1al3rd When 1ump starting a car using a booster battery, for negative earth
DO keep loose clothing (cuffs. ue etc) and long hair well out of the (ground) vehicles, connect the 1ump leads in the following sequence
w ay cJf moving mechanical parts Frrst connect one 1ump lead between the pos1uve ( +) terminals of the
DO remove rr ngs, wristwatch etc, before wo1krng on the vehrcle - two batteries. Then connect the other 1ump lead first to the negative
e r crally t he elec111cal system. ( ) terminal of the booster battery, and then to a good earthing
DO ensur tha t any lifting tackle used has a safe working load rating (ground ) point on the vehicle to be started. at least 18 1n ( 45 cm) from
ad1.<1ua1e for the 1ob the battery rf possrble. Ensure that hands and iump leads are clear of
DO keep your work area tidy - 11 is only 100 easy to fall over articles left any movrng parts, and that the two vehicles do not touch . Disconnect
lying around the leads in the reverse order.
DO get someone to check periodically that all is welt, when w orking
alone on the vehicle. Mains electricit y
00 corry out w o rk rn a logical sequence and check that everything Is When usrng an electno power tool, 1nspectron light etc, which
o r ct ly assembled and trghtened afterwords works from the mains, always ensure that the appliance is correctly
DO remember that your vehrcle's safety affects that of yourself and connected to its plug and that. where necessary, rt rs properly earthed
others If 1n doubt on any point, get specrahst advice. (grounded) Do not use such apphances 1n damp cond111ons and.
IF, 1n spite o f followi ng these precautions. you are unfortunate enough again beware of creaung a spark or applying excessrve heat rn the
to 1n1ure yourself seek medical attenuon as soon as possible v1c1n1ty of fuel or fuel vapour
Asbestos Ignition HT voltage

Certain l11cuon . 1nsula11ng. sealing, and other products such as A severe eJectrrc shock can result from touching certain parts of the
brake l1n1ngs. brake bands clutch linings. torque converters. gaskets. ignition system\ such as t he HT leads. when the engine rs running or
etc contarn asbestos Extreme care must be taken to avoid inhalation being cran ked , particularly 1f components are damp or the Insulation Is
of dust from such products smce 1t is hazardous to health If in doubt. defective. Where an electronrc Ignition system is frtted, the HT voltage
11i.sumu 111.11 thuy do contarn asbestos. is much higher and could provo fatOI

Routi ne ma intenance
Maintenance 1s essential for ensuring safety, and desirable for the Transmission (Chapter 6)
purpose of getting the best in terms of performance and economy from Check manual gearbox oil level, and top up if necessary
your car Over the years the need for periodic lubrication - oiling, Check automatic transmission fluid level. and top up if necessary
greasing and so on - has been drastically reduced, if not totally
eliminated This has unfonunately tended to lead some owners to think Rear axle/ final drive (Chapter 8)
that because no such action is required. components either no longer Check rear axle/final drive unit oil level, and top up if necessary
eiust. or will last fo1ever. This is a serious delusion. It follows the1efo1e
that the lorges1 initial element of maintenance is visual examination Steering (Chapter 10)
and a general sense of awareness. This may lead to 1epairs or renewals, Check power steering pump drivebelt condition and tension (if
but should help to avoid roadside breakdowns. applicable)
Models up to July 1984

Ev ery 16 000 miles (24 000 km ) or 18 months - whichever
comes f irat
Every 260 miles (400 k m) o r week ly - w h ichever comes f irst
Engine (Chapter 1)
Adjust the valve clearances
Engine (Chapter 1)
Check the engine oil level using the dipstick. The oil level must be Fuel system (Chapter 3)
maintained between the high end low markings at all times. Top up Check and adjust the accelerator cable
when necessary, but do not overfill Renew the fuel pre- filter (fuel injection engines)
Cooling system (Chapter 2) Ignition system (Chapter 4)

Check the coolant level. and top up if necessary Check and adjust ignition timing
Check for signs of leakage, and hose security Renew spark plugs
Fuel system (Chapter 3) Rear axle/ final drive (Chapter 8)
Check for signs of leakage, and hose security Check the driveshaft rubber bellows (Saloon)
Clutch and brake hydraulic system (Chapters 5 and 9) Braking system ( Chapter 9)
Check the hydraulic fluid level, and top up 1f necessary Check the operation of the handbrake
Transmission (Chapter 6)
Check for oil or fluid leaks Every 20 000 miles ( 32 000 km) o r 2 yea rs - whic hever
comes first
Suspension and steering (Chapter 10)
Check the tyre pressu1es and e>camlne tyre condition
Check the power steering flu id level (if applicable). and top up if Cooling system (Chapter 2)
necessary Renew the antifreeze mixture
Electitcal system (Chapter 12) Fuel system (Chapter 3)

Check the w indscreen (and if applicable, tailgate) washer reservoir Check the oil bath type air filter
fluid levels. and top up if necessary
Check thot all lights are clean, and functioning correctly Clutch and brake hydraulic system (Chapters 5 and 9)
Check the battery electrolyte level (except on low-maintenance or Renew the hydraulic fluid
ma1ntenanc.e-free batteries), and top up tf necessary
Propeller shaft (Chapter 7)
Grease the propeller shaft centre bearing
Grease the torque tube from bearing (Estate)
Every 6000 miles (8000 k m) or 6 months - w hichever comes
first
Every 30 000 miles (48 000 km ) or 3 years - w hichever
com es first
Engme (Chapter 1)
Renew engine oil and filter
Fuel system (Chapter 3)
Coo/mg system (Chapter 2) Renew the air filter element
Check the coolant hoses for damage Renew the main fuel filter (fuel injection engines)
Check dnvebelt condition and tension
Transmission {Chapter 6)
Ignition system (Chapter 4) Renew thebi\anual gearbox oil
Clean and adjust the contact breaker points (if applicable) Renew the awtomatic transmission fluid
Clutch and brake hydraulic system (Chapters 5 and 9) Rear axle/final drive (Chapter 8)
Check clutch and brake hydraulic circuits for leaks and condition Renew the rear axle/final drive unit oll

16 Routine m ai ntenance
Suspension and steering (Chapter 10) Steering (Chapter 10)

Check front hub bearing ad1ustment Check power steering pump drivebelt condition and tension (if
Check suspension rubber bushes applicable)
Check shock absorbers
Check suspension and steering balljoints
Every 12 000 miles (19 000 km) or 12 months - whichever
comes first
Every 40 000 m iles ( 64 000 km ) or 4 years - whichever
comes first Engine (Chapter 1)
,• Adjust the valve cleara nces
Engine (Chapter 1)
Renew the rocker shaft oil filter (overhead camshaft engines) Fuel system (Chapter 3)
Renew the timing belt (overhead camshaft engines) Check and adjust the accelerator cable
Renew the fuel pre -filter on fuel ln1ecuon engines
Models from July 1984 on
Ignition system (Chapter 4)
Check and adjust ignition timing
Renew spark plugs
Every 250 miles (400 km) or weekly - whichever comes first
Rear axle/ final drive (Chapter 8)
Check the driveshaft rubber bellows (Saloon)
Engme (Chap ter 1)
Check the engine oil level using the dipstick. The oil level must be Braking system (Chapter 9)
maintained between the high and low markings at all times. Top up Check the operation of the handbrake
when necessary, but do not overfill
Cooling system (Chapter 2) Every 18 000 miles (29 000 km ) or 18 months - whichever
Check the coolant level, and top up if necessary comes first
Check for signs of leakage, and hose security
Fuel system (Chapter 3) Fuel system (Chapter 3)

Check for signs of leakage, and hose security Ctean the oil bath type air filter
Clutch and brake hydraulic system (Chapters 5 and 9) Propeller shaft (Chapter 7)
Check the hydraulic fluid level, and top up if necessary Grease the propeller shaft centre bearing
Grease the torque tube front bearing ( Estate)
Check for oil or fluid leaks
Every 24 000 miles ( 38 000 km ) or 2 years - whichever
Suspension and steering (Chapter 10) comes first
Check the tyre pressures, and examine tyre condition
Check the power steering fluid level (if applicable). and top up if
necessary Cooling system (Chapter 2)
Renew the antifreeze mixture
Electrical system (Chapter 12)
Check the w indscreen (and if applicable, tailgate) washer reservoir Fuel system (Chapter 3)
fluid levels, and top up if necessary Renew the air filter element
Check that all lights are clean. and functioning correctly
Check the battery electrolyte level (except on low -maintenance or Clutch and brake hydraulic system (Chapters 5 and 9)
maintenance-tree batteries), and top up if necessary Renew the hydraulic fluid
Renew the manual gearbox oil
Every 6000 miles (9500 km) or 6 months - whichever comes Renew the automatic transmission fluid
first
Rear axle/ final drive (Chapter 8)
Engme (Chapter 1) Renew the rear axle/ final drive unit oil
Renew engine oil and filter
Suspension and steering (Chapter 10)
Cooling system (Chapter 2) Check front hub bearing adjustment
Check the coolant hoses for damage Check suspension rubber bushes
Check drlvebelt condition and tension Check shock absorbers
Check suspension and steering balljoints
Ignition system (Chapter 4)
Clean and adjust the contact breaker points (if applicable)
Every 36 000 miles (58 000 km ) or 3 years - whichever
Clutch and brake hydraulic system (Chapters 5 and 9) comes first
Check clutch and brake hydraulic circuits for leaks and condition
Transmission (Chapter 6) Engine (Chapter 1)

Check manual gearbox oil level. and top up if necessary Renew tl,I~ rocker shaft oil filter (overhead camshaft engines)
Check au tomatic transmission fluid level and top up if necessary Renew the.timing belt (overhead camshaft engines)
Rear axle/fine/ drive (Chapter 8) Fuel system (Chapter 3)

Check rear axle/final drive unit oil level, and top up if necessary Renew the main fuel filter (fuel injection engines)

Under- bo nnet view ( XN1 engine) - air cleaner removed for clari ty
I Br11ke fluid reservolf 10 Bonnet lock 1B Radiator

2 Brake vacuum servo unit 11 Battery 19 Fen temperature switch
3 Inlet manifold 12 Cooflng system expansion tank 20 Top flose
4 C11rbu1etto1 13 Altomator 21 Powo1-ass1stod sreermg fluid
5 St11rter motor 14 Coolant Jovel switch teservolf
6 Heater control vacuum reservolf 75 Dflvebelt 22 81ake mas111r cylinder
7 Engme 011 d1pst1ck and filler tube 76 Thermostat /lousing and water 23 Front susp0/ls1on top mountmg
8 Ignition coil and module covet pump 24 Fusebox
9 Washer fluid reservolf 77 Self-d1senqagmg fBn umt
J.\

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View of front underside o f Saloon (XN1 engine)
Power-assisted steering 5 Crossmember 11 Clutch slave cylinder

pump 6 Engme 011 dram plug 12 Gearch11nge rod
2 Towmg hook 7 Front 11nt1-roll bar 13 Gearbox drain plugs
3 Power-assisted steering 8 Front radius arm 14 Stetlfing gear
pump dflvebelt 9 Front brake caliper 15 Exhaust downpipe
4 Front jocking point 10 Steering track rod 16 Front coil spring
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,.----------------------------------------------------------------------------19
V iew of r ear underside of Saloon (XN1 engine)
1 Rear jacking point 6 Fuel tank 12 Rear brake ffexible hose

2 Rear anti-roll bar ltnk 7 Rear anu-roll bar 13 Final drive unit
mounttng 8 Spare wheel 14 Propeller shaft ltnk tube
3 Handbrake cable 9 Spare wheel carrier 15 Rear suspension
4 Rear shock absorber 70 Exhaust rear silencer crossmember
5 Rear suspension trailing arm 11 Driveshaft 16 Rear brake compensator

20--------------------------------------------------------------------------.. .
Under - bonnet view (ZOJ engine)
1 Brake fluid reservoir 70 Engine oil level dipstick 19 Power-assisted steering lluid
2 Brake vacuum servo unit 11 Battery reservoir
3 Engme oil !tiler cop 12 Cooling system expansion 20 Coolant level switch
4 Fuel injector tank 21 Air cleaner
5 Throttle housing 13 Top hose 22 Airflow sensor
6 Inlet manifold and air box 14 Thermostat housing 23 Mixture adjustment screw
7 D1stnbutor 15 Supplementarv a" device 24 Front suspension top
8 Ignition coil and module 16 Self-disengaging fan unit mounting
cover 17 Radiator 25 Fusebox
9 Wosher fluid resetvo/r 18 Idle air adjustment screw
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~----------------------------------------------------------------------21
View of front underside of Estate (ZDJ engine)
Power-assisted steering 5 Alternator 10 Gearchange rod

pump 6 Front radius arm 11 Gearbox drain plugs
2 Crossmember 7 front anti-roll bar 12 Steering gear
3 Front jacking point 8 Steering track rod 13 Elthaust downptpo
4 Engine oil drain plug 9 Clutch slave cylinder 14 Front brake caliper
J .\

22
View of middle underside of Estat e { ZDJ engine)
1 Hydrau!tc brake Imes 5 Rear brake compensator 8 Exhaust system mounting

2 Fuel feed and return lines 6 Torque tube 9 Intermediate exhaust pipe
3 Electric fuel pump 7 Torque tube stay bar and silencers
4 M ain fuel filter
J.

,-----------------------------------------------------------------------------23
View of rear underside of Estate (ZDJ engine)

1 Torque tube 6 Fuel tank 9 Spare wheel
2 Handbrake cable 7 Panhard rod 10 Spare wheel caffler
3 Rear antt· roll bar 8 Rear axle /Iller and drain 11 Rear exhaust pipe and
4 Rear shock absorber plugs silencer
5 Rear coll spring 12 Rear axle
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Reco mmended lubricants and fluids

Component or system Lubric ant type/spec ificati on Duc khams re<:ommendation
and general g reasing
Engine (1) Multigrade engine oil. viscosi ty SAE 10W/ 40 Duckhams QXR, Hypergrade, or 1 OW/ 40
Motor Oil
Cooling system (2 ) Ethylene glycol based antifreeze Duckhams Universal Antifreeze and
Summ~r Coolant
Manual gearbox (3) Mulugrade engine oil, viscosity SAE 10W/ 40 Duckhams QXR. Hypergrade, or 10W/ 40
Motor 0 11
Automatic transmissio n (4 ) Dexron II ATF Duckhams D- Mat1c
Power steering reservoir (5) Dexron II ATF Duckhams 0 - Matic
Rear axle/ tina l d r ive un it (6):

Exc~pt hm11ed-sllp differential Gear oil. viscosity SAE 80W/ 90 Duckhams Hypoid SOS
L1n111ed-sl1p differential Gear 011. viscosity SAE 90 Duckhams Hypoid 900 L
Brake/ clutch fluid reservoi r (7) Hydraulic fluid to SAE Jl 703 or DOT 3 Duckhams Universal 8rake and Clutch
Fluid
Hub bearings (8) and Mul11-purpose lithium- based grease Duckhams LB 10

general greasing
Steering rack (9) L1th1um -based molybdenum disulphide grease Duckhams LBM 10
Driveshatr CV Joints (10) Special lubricant supplied 1n repair ki t
J.1

Fault diagnosis
Introduction •
The vehicle owner who does his or her own maintenance according Veri ty t he fault . This is simply a matter of being sure that you
10 the recommended schedules should not have to use this section of know what the symptoms are before starting w ork. This is particularly
the manual very often. Modern component rellablllty is such that. important If you are Investigating a fault for someone else w ho may not
provided those items subject to wear or deterioration are Inspected or have described it very accurately.
renewed at lhe specified Intervals, sudden failure is comparatively rare.
Faults do not usually just happen as a result of sudden failure. but
develop over a period of time. Major mechanical failures in particular Do n' t overloo k the obvious. For example. if the vehicle won't
are usually preceded by characteristic symptoms over hundreds or start. Is there petrol in the tank? (Don•t take anyone else's word on this
even thousands of miles. Those components which do occasionally particular point. and don·t trust the fuel gauge either!) If an electrical
fail without warning are often small and easily carried In the vehicle. fault is indicated, look for loose or broken wires before digging ou t the
With any fault finding, the first step is to decide where to begin test gear.
invest1gat1ons. Sometimes this is obvious, but on other occasions a
little detective work will be necessary. The owner who makes half a Cure the d isease, not the symptom. Subst ituting a flat battery
dozen haphazard adjustments or replacements may be successful in with a fully charged one will get you off the hard shoulder, but if the
cunng a fault (Or Its symptoms). but he will be none the w iser if the underlying cause is not attended to. the new battery will go the same
fault recurs and he may well have spent more time and money than was way. Similarly, changing oil -fouled spark plugs for a new set will get
necessary. A calm and logical approach will be found to be more you moving again, but remember that the re.ason for the fouling (i f it
satisfactory in the long run. A lways take into account any warning wasn't simply an incorrect grade of plug) will have to be established
signs or abnormalities that may have been noticed in the period and corrected.
preceding the fault - power loss, high or low gauge readings. unusual
noises or smells, etc - and remember that failure of components such
as fuses or spark plugs may only be pointers 10 some underlying fault. Do n't take anything for granted. Particularly. don't forget that
The pages which follow here are intended to help in cases of failure a 'new' component may itsel f be defecuve (especially if ifs been
to start or breakdown on the road. There is also a Fault Diagnosis rattling round in the boot for months), and don't leave components out
Section at the end of each Chapter which should be consulted if the of a fault diagnosis sequence just because they are new or recently
preliminary checks prove unfruitful. Whatever the fault. certain basic i itted. When you do finally diagnose a difficult fault, you 'll probably
principles apply, These are as follows: realise that all the evidence was there from the start
l~
Carr ying a few spar es may save a long,w a lk l

26 Fault diagnosis
Electrtcal faults
Electrtcal faults can be more puzzling than straightforward
mechanical failures. but they are no less suscepuble to logical analysis
1f tho basic principles of operation ere understood. Vehicle electrical
wiring exists on ox1romely unfevouroblo conditions heat, vibration
and chemical attack - and the first things to look for are loose or
corroded connections and broken or chafed wires. especially where
the wires pass through holes 1n the bodywork or are subject to
v1bra11on
All metal -bodied vehicles on current producuon have one pole of
the battery earthed . 1e connected to the veh1cfe bodywork. and on
nearly 111 modern vehicles 1t is the negauve ( ) terminal The various
electrical components - motors, bulb holders etc - are also connected
to earth, either by means of a lead or directly by their mountings.
Elecmc current flows through the component and then back to the
battery vro the bodywork. If the component mounttng is loose or
corroded or 11 a good pa th back to the battery is not available, the A si mple test lamp is useful fo r tree i ng electr ical faults
circuit will be incomplete and malfunction w ill result. The engine
and/ or gearbox are also earthed by means of flexible metal straps to the
Do not use on f uel in1ection system circuits
body or subframe; if these stra ps are loose or missing, starter motor,
generator and ignition trouble may result
Assuming the earth return to be satisfactory. electrical faults will be
.:.
due either to component malfuncuon or to defects on the current
~ NEGATIVE
supply fnd1v1dual components are dealt with 1n Chapter 12 If supply
wores are broken or cracked internally this results on an open-circuit,
and the easiest way to check for this 1s to bypass the suspect wore
tempora11ly with a length of w11e having a crocodile clop or suttable
connector at each end. Alternat ively, a 12V test lamp can be used to
verify the presence of supply voltage at various points along the wore
and the break can be thus isolated.
18in.MIN
II o bare portion of a hve w ire touches the bodyw ork or other
earthed metal part. the elec1r1c1ty will take the low -resistance path thus
formed back to the battery: this is know n as a short -circuit. Hopefully a
short -c1rcu11 wi ll blo w a fuse, but otherwise It may cause burning ol
the msulo11on (and possibly further short circuits) or even a lire. This 1s
why it is inadvisable to bypass persistently blow ing fuses w ith silver
DISCHARGED
c
foll or wore 0 -
BATTERY
0
Spares and tool kit 0
Most vehicles are supplied only with suff1c1ent tools for wheel 0
chongong. the Maintenance and minor repatr tool kit detailed on Tools 0
and working facilities, with the addition of a hammer, is probably
suff1c1ent for those repairs that most motorists w ould consider POSITIVE
attempung at the roadside. In add1t1on a few Items w hich can be f111ed
wnhout too much trouble in the event of a breakdow n should be
carried E~penence and available space wi ll modify the list below. but Jump start lead con nect ions f or negative earth vehicles -
the followmg may save having to call on professional assistance: co nnect l eads in order s hown
Spark plugs. clean and correctly gapped
HT lead and plug cap - long enough to reach the plug furthest
from the d1stnbutor
D1str1butor rotor. condenser and contact breaker points (as
appltcable)
Dflvebelt(s) - emergency type may suffice
Spare fustJs
StJt of principal light bulbs
Tm of radiator sealer and hose bandage
EKhaust bandage
Roll of insulating tape
Longth of soft iron wire
Length of electrical flex
Torch or inspection lamp (con double as test lamp)
81ttery 1ump leads
Tow rope
lgnmon waterproofing aerosol
L1tte of engine otl
Sealed can of hydraulic !IU1d
Emergency windscreen
Worm dflve cltps
Tube of ft/fer paste
If spare fuel os carried. a can designed for the purpose should be
used to m1n1m1se risks of leakage and collision damage. A first aid kit
and a warning 1r1angle, whilst not at present compulsory in the UK. are
obviously sensible items to carry In addition to the above. Crank engine and check for spark. Note use of insul ated
When touring abroad It may be ad visable to carry addltional spares tool to hold plug lead

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Fault d iagnosis 27
which, uvon 1f you ca nnot fit them yourself, could save having to wait Engine cuts out other causes
while pons ore obtained. The items below may be worth considering: Serious overheating
Chokt1 and throttle cables (as app licable) Major mechanical failure (eg camshaft drive)
Cylinder head gosket
Alternotor brushes
Fuel pump repalf kit (1f applicable) Engine overheate
Tyro v11fve core
One of the motonng organisauons w ill be able to advise on Ignition (no -charge) warning light illuminated
ava1lab1hty of fuel etc in foreign countnes. Slack or broken drivebelt - retension or renew ( Chapter 2)
Engine will no~ start

Ignition warning light not illuminated
Coolant loss due to internal or external leakage (see Chapter 2)
Thermostat defective
Engme fails to turn when starter operated Low oil level
Flat battery (recharge, use 1ump leads. or push start) Brakes binding
Bauery terminals loose or corroded Radiator clogged externally or internally
Banery earth to body defective Self-disengaging cooling fen not operating correctly
Engine earth strap loose or broken Engine waterways clogged
Stoner motor (or solenoid) wlftng loose or broken Ignition timing incorrect or automatic advance malfuncuoning
Automatic transmission selector in wrong pos1t1on, or inhibitor M i xture too weak
switch faulty
lgn111on/starter switch faulty N ote: Do not add cold water to an overheated engine or damage may
Mo1or mechanical failure (seizure) result
Staner or solenoid internal fault (see Chapter 12)
Starter motor turns engine slowly low engine oil pressure

Pan1aily discharged battery ( recharge. use 1ump leads, or push
start)
Battery terminals loose or corroded Gauge reads low or warning light illuminated with engine
Bauery earth to body defective running
Engine earth strap loose Oil level low or incorrect grade
Staner motor (or solenoid) w inng loose Defective gauge or sender unit
Starter motor internal fault (see Chapter 12) Wife 10 sender unit eanhed
Engine overheating
Starter motor spins without turning engine Oil filter clogged or bypass valve defective
Flat battery Oil pressure relief valve defective
Starter motor pinion sticking on sleeve Oil pick-up strainer clogged
Flywheel gear teeth damaged or worn 0 11 pump worn or mountings loose
Starter motor mounting bolts loose Worn main or big -end bearings
Note: Low oil pressure in a high-m//eage engine et tickover is not
Engme turns normally but fails to start necesserlly o cause for concern Sudden pressure loss at speed is far
Damp or dirty HT leads and distributor cap (crank engine and more significant. In any event. check the gauge or warning light sender
check for spark) before condemning the engine
D1ny or incorrectly gapped distributor points (if applicable)
No fuel 1n tank (check for delivery at carburettor)
Excessive choke (hot engine) or insufficient choke (cold engine)
Fouled or incorrectly gapped spark plugs (remove, clean and Engine noises
regap)
Other 1gn111on system fault (see Chapter 4) Pre-ignition (pinking) on acceleration
Other fuel system fault (see Chapter 3) Incorrect grade of fuel
Poor compression (see Chapter 1) Ignition timing incorrect
Ma1or mechanical failure (eg camshaft drive) Distributor faulty or w orn
Worn or maladjusted carburettor or airflow sensor
Engine fires but will not run Excessive carbon build-up in engine
lnsuff1c1ent choke (cold engine)
Air leaks at carburettor or inlet manifold Whistling or wheezing noises
Fuel starvation (see Chapter 3) leaking vacuum hose
Ballast resistor defective, or other ignition fault (see Chapter 4) Leaking carburettor or manifold gasket
Blowing head gasket
Engine c uts out and will not restart Tapping or rattling
Incorrect valve clearances
Engine cuts out suddenly - ignition fault Worn valve gear
Loose or disconnected LT w ires Worn timing chain or belt
Wet HT leads or distributor cap (after traversing water splash) Broken piston ring (ticking noise)
Coil or condenser failure (check for spark)
Other 1gmt1on fault (see Chapter 4) Knocking or thumping
Unintentional mechanical contact (eg fan blades)
Engine misfires before cutting out - fuel fault Worn drivebelt
Fuel tank empty Peripherlil component fault (alternator. water pump etc)
Fuel pump defecuve or filter blocked (check for delivery) Worn ~q-end bearings (regular heavy knocking, perhaps less
Fuel tank filler vent blocked (suctton will be evident on releasing under loep)
cap) Worn main bearings ( rumbling and knocking, perhaps worsening
Carburettor jets blocked (fuel contaminated) under load)
Other fuel system fault (see Chapter 3) Piston slap (most noticeable when cold)
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Chapter 1 Engine
Contents
Part A General Part C: Overhead camshaft engines (ZEJ and ZDJ)

General descr1p11on ....................- ..................... -............................... 1 Camshaft - removal and refitting .............. ... ... ... ..... ... ..... ... 24
Rou tine mn1ntenance .......................................................................... 2 Crankcase ventilat ion system - description ....................................... 31
Cylinder head - dismantling. decarbon1sing and reassembly ......... 33
Cylinder head - removal and refitting .......... ... .................... 25
Part B Overhead valve engines (XMT and XNI) Engine complete dismantling ... .... . ..... .. .......................... 30
Crankcase venttlat1on system - descrrption .. .. ... .. ... 12 Engine complete reassembly ..................................................... 36
Cylinder head dismantling, decarbonisi ng and reassembly .. ..... 14 Engine - reassembly (general) ............................................................ 35
Cylinder head removal and ref1uing ............................................... 6 Engine - refitting ................. .. ................ ........................................ 38
Engine complete dismantling .. ....................................................... 11 Engine removal ............ .................... ....... ............. ............................. 27
Engine complete reassembly . ...................... ............................ ... 17 Engine ancillary components - refining ............................................. 37
Engine reassembly (general) ....................................................... 16 Engine ancillary components - removal ...... .. ......................... .. 29
Engine ref1111ng ............................................. - ......... -..................... 19 Engine components - examinatton and renovation
Engine - removal ........ ... .. ... .............................................. 8 (general) .............. .. ...................... .. 32
Engine ancillary components - refining ... ... .... .................... 18 Engine dismantling - general ............................................................ 28
Engine ancillary components - removal ........................................... 10 Engine mountings - removal and refining ... .... .. .......................... 26
Engine com ponents - examina tion and renovation (general) ........ 13 Examination and renovation of dismantled components ............... 34
Engine dismantling - general ..... .................. .................................... 9 Initial start -up after major overhaul ................... .. ........................... 39
Engine mounting s - removal and refitting ... ...... .................. ......... 7 Operations possible with engine in car .............................................. 21
Examination and renovation of dismantled components ................ 15 Timing belt removal and refining ........... ................................. ... 23
lnrttal start up aftec ma1or overhaul ................ ............................ 20 Valve clearances - adjustment ...............- ...................-............ 22
Operattons possible w i th engine 1n car ................. ....................... 3
Timing chain and sprockets - removal
and refitting ........................................................................................... 5 Part D : Fault diagnosis
Valve clea rances - ad1ust ment ............................................................ 4 Fault diagnosis - engi ne .................................................................. . 40
Specifications
Overhead valve engines (XM7 and XN1 )

Type ............................................................................................. Four-cylinder, overhead valve. wet liners. alloy cylinder head. cast
iron block
General
Code and displacement:
XM7A ...................................................................................... ,..... . 1796 cc
XN1 /A ................................................................................................. 1971 cc
Bore
1796 cc ................................................................................................... 84.0 mm
1971 cc ........................................................................................ 88.0 mm
Stroke ... ........................... .... ......................................... 81 .0 mm
Compression ratto ... .. ................................................................................ 8.8 : 1
F111ng order ................................................................................................. 1-3-4 -2 (No 1 at flywheel end)
Cylinder head
Nominal height ................................................................................ 92.5 :!: 015 mm
Maximum distortion .................................................................................... 0.10 mm
M 1n1mum height ........................................................................................... 92.1 mm
Valves
Valve seat combined angle:
Inlet ............................................................................ 120·
Exhaust ................~ ..................................................... 90•
Valve spri ng free length:
Inner 39.6 mm
Outer 44.0 mm
Valve clearances (cold):
Inlet .................................................................................................... 0.10 mm (0.004 1n)
Exhaust ................................................................................................ . 0.25 mm (0.010 1n)
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Chapter 1 Engine 2.9
Camshaft
Endfloa1 ......................................................................................................... 0.05 to 0 .14 mm
Ma>ttmum run - out ........................................................................ ............. . 0.02 mm
Cylinder li ners
Prottus1on (fitted) above block ................................................................. . 0 .07 to 0 .14 mm
Maximum height di fference between adjacent liners ............................. 0 .04 mm
Maximum ovality and taper ........................................................................ 0 .03 mm
Piston· to · llner matching:
, ..............................................................................................................
liner notches
2
Piston reference
A
B
3 ......................................................................................................... c
4 .............................................................................................................. . D
Pi stons and rin gs

Material ........................................................................................................ A luminium and silicon
Ring gaps:
Top compression .................................................................................... 0.20 to 0 .50 mm
0 11 scraper (midd le) ............................................................................... 0.40 to 0 .55 mm
Oil control (bottom) ..... ,........................................................................ 0.25 to 0 .4 0 mm
Crankshaft
Endfloat ........................................................................................................ 0 .08 to 0.20 mm
Lubrication sy stem
Oil pump type ............................................................................................... Two-gear type. driven from camshaft
011 pressure.
At 850 rpm ............................................................................................. . 2.7 :l: 0 .8 bar (39.2 :l: 11 .6 lbf/ in')
At 2000 rpm ........................................................................................... . 3.3 :l: 0.7 bar (4 7.9 ± 10 .2 lbf/ in')
At 4000 rpm ............................................................................................ 3 .8 ± 0.8 bar (5 5.1 :l: 11.6 lbf/l n')
Oil 1ype/specif ica tion .................................................................................. M ultig rade engine oil. viscosity SAE 10W/ 4 0 (Duckhams QXR.
Hypergrade. or 1 OW / 40 M otor Oil)
Sump capacity .............................................................................................. 4 litres (7 pints)
Torque wren c h settings Nm lbf ft

Cylinder head bolts:
Stage 1 .................................................................................................. . 50 37
Stage 2: Loosen in sequence, then ..................................................... 20 15
Further 11gh1en:
M12 boltS .................................................... ,.................................... . Angle -tighten 90'
Ml 1 bolts .......................................................................................... A ngle -tighten 180'
Stage 3 .................................................................................................... Warm up eng ine to normal operat ing temperature
Stage 4 (u p to VIN 1 845 001) ........................................................... Let engine cool for six hours. t hen repeat stage 2
Stage 4 (VIN 1 845 001 on) ................................................................ Angle- tighten 35'
Rocker arm assembly nuts .......................................................................... 15 11
Front engine p late ........................................................................................ 10 7
Camshaft thrust p late ................................................................................. . 17 13
Camshaft sprocket ..................................................................................... . n 11
Oil filter housing ......................................................................................... . 13 10
011 pressure sw itch ...................................................................................... 40 30
Crankshaft main bearing bolts ................................................................... 75 55
Big-end cap nuts ......................................................................................... 40 30
Flywheel/ drivepla te bolts ............................................................................ 68 50
Crankshaft pul ley nut .................................................................................. 170 125
Oil pump ....................................................................................................... 10 7
Sump ....................................................................................................•....... 10 7
Crankshaft balance weight ......................................................................... 68 50
Timing cover ................................................................................................. 10 7
Engine mounting to crossmember ............................................................. 35 26
Overhead camshaft engines (ZEJ and ZDJ)

Type ............................................................................................................. Four-cylinder overhead camshaft. wet liners, all oy cylinder head
and block
General
Code and displacement:
ZEJK ........................................................................................................ . 1995 cc
ZDJL ....................................................................................................... 2165 cc J\
BOfe ............................................................................................................. 88.0 mm
Stroke.
1995 cc ................................................................................................... . 82.0 mm
2165 cc .................................................................................................. . 89.0 mm

30 Chapter 1 Engine
Compre~s1on ratio
1995 cc 9.2 1
2165 cc 9 .8 1
Firing order 1- 3 -4 -2 (No 1 at flywheel end )
Cylinder head
Nominal he1gh1 111 .6 mm
Maximum distortion 005mm
Valves
Valve sea1 combined angle: •'
Inlet 120'
Exhaust 90'
Valve spring free length 46.0 mm
Valve clearances (cold)
Inlet 0 10 mm (0.004 in)
Exhaust 0 .25 mm (0 010 in)
Valve t1m1ng (0 35 mm clearance)
Inlet valve opens ................................................................................... 20' BTDC
Inlet vulve closes ................................................................................ 60' ABD C
Exhaust valve opens .. ........................................................................ 60' BBDC
Exhaust valve closes ............................................................................ 20' ATDC
Camshaft
Endfloa1 0 .05 to 0 .13 mm
Cylinder liners
Pro1rus1on (f itted) above 1he block .. .. ......................... 0 .08to015 mm
M mumum height difference between adjacent hners ................... .. 0.04 mm
M&J<1mum ovahty and taper .... .... ............... ..... .. ............................... .. 0 .03 mm
P1ston-to-llner matching
Liner notches Piston identi f ication
1 Green
2 ... Blue
3 Red
Pistons
Material Aluminium and silicon
Ring gaps
Top comp1ess1on ................................................................................... 0 .20 to 0 .36 mm
011 scraper (middle) ......................... ,_......................................... 0 .40 to 0 .55 mm
011 conuol (bottom) .............................................................................. 0 .25 to 0.40 mm
Crankshaft
End float
ZEJ engine ............................................................................................. 0.05 to 0 .26 mm
ZOJ engine ....................................................................................... 0.05 to 0 .30 mm
ThrustWasha1 1h1cknesses available ....................................................... 2.80. 2 85. 2.90 and 2 .95 mm
Lubrication system
011 pump type ................................................................................... Two-gear type, driven from intermediate shaft
011 pump clearances
Gear taa1h· 10 body ............................................................................. 0.05 to 0 .12 mm
Gaar endfloat ......................................................................................... 0.02 to 0 .10 mm
Oil pressure (minimum ).
z~ z~
At 900 rpm .............................- ........................................... 1.0 bar ( 14.5 Ibf/ in') 1.5 bar (21 8 lbf/ in')
At 3000 rpm ......................................................................................... 3.0 bar ( 43.5 lbf/ in1) 3 .5 bar (50.8 I bf/in')
011 type/spec1f1catlon .................................................................................. Multigrade engine oil, viscosity SAE 1 OW/ 40 (Duckhams OXR.
Hypergrade, or lOW/ 4 0 M otor Oil)
Sump capacity ......................................................................................... . 5 htres (8.8 pints)
Torque wrench setti ngs Nm lbf ft

Cvhnder head bolts
Stage 1 50 37
Stage 2 Loosen a quaner-turn in sequence. then ............................ 95 70
Stage 3 Warm up engine to normal operating temperature. then allow 10 cool
for two hours
Stage 4 Loosen a quaner- turn in sequence. then ............................ 95 70
T1m1ng gear sprockets ......... .. .. ............... ....... .. ............................ . 50 37
lntermecllate shalt housing ................................................................... 13 10
Timing belt tensioner .. ................................................................... 25 18
Crankshaft pulley bolt:
ZEJ .............................................................................................. . 80 59
ZDJ .................................................................................................. 130 96

Chapter 1 Engine 31
Torque wrench setti ngs (cont) Nm lbf ft

Flywheel /dnveplate .... .............................................................................. 65 48
Oil pump .................- ......- .................................... 45 33
Main bearing ca ps . ..............................................................................._ 95 70
Big-end caps
ZEJ ......................................................................................... .. 48 35
ZDJ .................................................................................................. 65 48
Rocker shaft filter bolt ................................................................................ . 20 15
The three-bearing camshaft Is located high in the left- hand side of

PART A : GENE RAL the cast iron cylinder block, and IS driven by a timing chain from the
.• front of the crankshaft. A hydraulic chai n tensioner is employed. The
crankshaft incorporates five main beari ngs.
The light alloy cylinder head 1s of crossflow design. with inlet
1 General description valves on the left· hand side, and exhaust valves on the nght. The
rocker arm assembly is secured to the top of the cylinder head by the
Overhead valve engines (XM7 and XN1) cylinder head bolts. and also by nuts on studs. The valves are opened
The XM 7 and XN1 engines are of the same basic design. but of and closed by pushrods located in tappets on the camshaft.
different capacities. the increased capacity of the XN1 being achieved The lubrication system consists of a two -gear type oil pump, driven
by 1 larger bore size. The angina ls mounted longitudinally at the front by the camshaft and located in the sump. and a canister· type oil filter,
of the vehicle, and 1s fitted w ith a carburettor. It Is canted to the right, to located on the left- hand side of the engine. An externally-mounted
lower the bonnet line, and because of th is, the sump has an irregular lubrication pipe supplies 011 to the rocker arm assembly from the oil
shape. gallery 1n the cylinder block.
Fig. 1 .1 Cross-section of the overhead val ve ehaine (Sec 1 )

32 Chapter 1 En gine
Fig. 1.2A Engine oil lubrication diagram (Sec 1)
Overhead valve engine
Overhead camshaft engines (ZEJ and ZDJ) endfloat is taken up by side thrustwashers The connecting rods also
The ZEJ and ZOJ engines are of the same basic design. but of have aluminium/Un shell bearing type big-ends.
different capac111es. the increased capacity of the ZOJ being achieved Aluminium pistons are employed, the gudgeon pins being a press
by a longer stroke. The engine is mounted longitudinally at the front of flt in the connecting rod small-ends. and a sliding f11 in the pistons. The
the vehicle It incorporates a crossflow design head. having the inlet No 1 piston is located at the flywheel end of the engine {at the rear).
valves and manifold on the left-hand side of the engine and the Removable wet cylinder liners are employed, each being sealed 1n the
exhaust on the right. The 1nchned valves are operated by a single rocker crankcase by a flange and O·ring. The liner protrusion above the top
shaft assembly. which 1s mounted directly obove the camshaft The surface of the crankcase 1s crucial. when the cylinder head end gasket
rocker arms have a stud-and-locknut type of ad1uster for the valve are tightened down, they compress the hners to provide the upper and
clearances prov1d1ng easy ad1ustment. No special tools are required to lower seal of the engine coolant c1rcu1t w ithin the engine. The cylinder
set the clearances The camshaft 1s driven via HS sprocket from the head and crankcase are manufactured in light alloy.
timing bolt, which In turn is driven by 1he crankshaft sprocket
This belt also drives en intermediate shaft, which drives the 011
pump by means of a shon driveshaft geared 10 11 2 Routine maintenance
The d1str1butor 1s driven from the rear end of the camshaft by means
of an offset dog Ca11y out the lollowmg procedures at the 1nt11rv11fs given m Rouune
A spring loaded 1ockey wheel assembly provides the timing belt maintenance at tho front of this manual
tension ad1us1ment A single. twin or triple pulley 1s mounted on the
front ol the crankshaft and this drives the alternator/water pump Check engine 01/ level
drivebelt. 1he power steering pump drivebelt, and the air conditioning 1 Remove the p\1 level d1ps11ck from the left-hand side of the engine
compressor drivebelt, as applicable. The crankshaft runs in the main (photo). Wipe ii Glean with a cloth, th en re-lnsen 11 and withdraw it
bearings which are shell-type aluminium/tin material. The crankshaft again.

------------------------------------------------------------------33
Fig . 1 .2 8 Engine oil lubricat ion diagram ( Sec 1)
Overhead cam engine
J.

34 Ch apter 1 Engine
2 It tha 011 is below the upper notch on the d1pst1ck (photo). top up drarn plug and allow the orf Lo dram (photo) On completton, refit and
w11h the correct grade of 011 On carburettor engines. unchp the tighten the dram plug.
crankc.1~e ventilation frher from the orl filter tube on the left- hand side 6 Fill the engine wuh the specified grade and quanrny of fresh 011
of the t.inyine and pour OJI into the tube. On fuel in1ec11on engines.
remove 1h1 cap from the valve cover (photo) Renew the oil filter
3 On comple11on. refit the filter or cap, and Insert the dipstick in us 7 Posrtron a suitable contalne1 beneath the 011 filte1 On carburettor
tub• engines, U is located on the front !eh - hand srde of the engine On fuel
1nject1on engines. It is on the right -hand srde of the engine.
Renew the engme 011 8 Unscrew and discard the orl filter, using a filter removal strap if
4 It tS bt•st to change the engine 011 w11h the engine ho1. after a run necessary (photos). If one Is no1 ilvarlable, drive o large screwdrrver
5 Position a sui tahle container beneath the sump, then unscrew the through the filter canister. and use rt as a lever to unscrew the filter.
9 Smear the rubber sea ling nng of the new filter with engine 011. and
tighten it by hand only
Adjust the valve clearances

10 Refer to Section 4 or 22, as applicable.
Renew the timing belt (ZEJ/ZDJ engines)

11 Refer to Secuon 23.
Renew the rocker arm oil filter (ZEJ/ ZDJ engines)

12 Refer to Sec11on 25 paragraph 22
PART B: OVERHEAD VALVE ENGINES (XM7
AND XN1)
3 Operations possible with engi ne i n car
The following operations can be earned out wuhout having to

remove 1he engrne from the vehicle
(a) Valve clearances adjuscment
(b) Timing chain and sprockets removal and refitcing
(c) Cylinder head - removal and refitting
2 1 Removing the oil level dipstick ( d) Engine mountings - removal and relictmg
2 2A Minimum (A) and maximum (B) level 2.28 Topping-up a fuel 1n1ect1on engine 2.5 Oil drain plug on a fuel 1n1ect1on engine
notcht1s on the 011 level d1pst1ck With 011
2 SA Rcniovmg the 011 fllter w11h a removal 2.88 Removing the orl !titer on a f11el ' 2 SC Removing the 011 filter on a
Strdp m1ect1on engine carburettor engine

Chapter 1 Engi n e 35
4 Valve clea rances - adjustment
1 The valve clearances must be ad1usted with the engine cold First
remove the air cleaner (Chapter 3).
2 Disconnect the HT leads and extensions from the spark plugs.
Unscrew ond remove the spark plugs.
3 Unscrew the va lve cover retaining bolts. noting the location of th e
diagnosuc socke t bracket and HT lead holder.
4 lJ ft off the valve cover.
6 Turn the engine with a spanner on the cranksha ft pulley nut. until
eKhaust valve No 1 (right-hand rear) is fully' open.
6 Using feeler blades. check that the cleara nce between the end of
the valve stem and the rocker arm 1s as given In the Specifica tions, for
inlet valve 3 ond exhaust valve 4. Note that the inlet and exhaust valve
clearances are dilferenl. IN
7 If ad1ustment is necessary, loosen the locknut on the rocker arm,
reposnion the ball stud, and retighten the locknut (photo). The feeler Fig. 1 .3 Cylinder head va lve positions (Sec 4)
7 Release the w iring harness from the clips on the timing cover.
8 The crankshaft must now be locked, in order to unscrew the
crankshaft pulley nut If the engine is in the vehicle, remove the
gearbox front cover, and use a w ide- bladed screwdriver to lock the
starter ring gear. If the engine is removed, the starter ring gear may be
locked using a bolt and bent piece of metal (photo). If the sump is
removed. use a block of wood to jam the crankshaft.
9 Unscrew the cra nkshaft pulley nut, and slide the pulley from the
nose of the crankshaft (photos).
10 Unscrew the nuts and bolts. and remove the timing cover and
gasllet (photos).
11 Remove the oil thrower from the crankshaft (photo).
12 Push the tlming chain tensioner plunger fu lly into the body, then
lock it by inserting a small screwdriver in the hole, and turning the pawl
anti -clocllwise (photo).
13 Unbolt and remove the timing chain tensioner, and extract the
tensioner oil filter from the block (photos).
14 Flatten the lockwasher and unscrew the bolts securing the
camshaft spwcket to the camshaft (photo) .
15 Remove the camshaft sprocket, and release the timing chain from
both sprockets ( photo).
16 Slide the cra nkshaft sprocllet off. and remove the Woodruff key
(photos).
17 Clean the components, and check them for wear and damage.
4.7 Ad1usting the valve clearances
Wear in the timing chain is indicated if It is deeply bowed when held
horizontally. Wear of the sprocket teeth is indicated if they are deeply
undercut.
blade should be a firm sliding fit after completing the ad1ustment. 18 Commence refitting by pressing the Woodruff key squarely into the
8 Turn the engine half a turn clockwise, so that No 3 exhaust valve is crankshaft nose (photo).
now fully open The cleara nces of inlet valve 4 and exhaust valve 2 may 19 Slide the sprocket fully onto the cranllshaft and over the key.
now be checked and ad1usted 20 Check that th e crankshaft and camshaft are aligned as shown in
9 Using the following table, check and adjust the remaining valve Fig. 1 .5. Both the cranllshaft sprocket marll and the camshaft bolt hole
clearances. indicated must be on the centre-line (photo). Reposition the camshaft
and crankshaft if necessary.
Exhaust valve Adjust inlet Adjust exhaust
open valve valve
1 3 4
3 4 2
4 2 1
2 1 3
10 On completion, refit the valve cover, spar!( plugs, HT leads, and air
cleaner
5 Timing chai n and sprockets - removal and r efitting
1 Remove the air cleaner (Chapter 3).

2 Disconnect the battery negative lead
3 Remove the radiator, drivebelt and fan (Chapter 2), and the spar!(
plugs (Chapter 4).
4 Remove the power steering and air conditioning compressor
drlvebelts (Chapters 10 and 11 ) as applicable.
5 Pivot the alternator away from the engine. Fig. 1 .4 Exploded view of t he timing c hain tensio ner (Sec 5)
6 Pos111on the crankshaft with No 1 piston (rearmost) at TDC on the
compression stroke. 1 Locking pawl - ( a) locked. (b) released

36 Chapter 1 Engine
21 Frt 1he timing chain to the camshaft sprocket. with the double 37 Reconnect the battery negative lead
white reference marks either side of the mark on the sprocket ( photo) 38 Relit the air cleaner (Chapter 3)
22 Engage tho ti ming chain wuh tho crankshaft sprocket, so that the
whne reference mark 1s aligned with the mark on 1he sprocket (photo)
23 Fn the ca msha ft sprocket to the camshaft. then fit the lockwasher
and bolts Tighten the bolts to the specified torque, and lock them by
bending th11 lockwasher onto the bolt flats (photos)
24 Insert 1he liming chain tensioner 011 filter 1n the block.
25 Refrt the t1m1ng chain tensioner. and tighten the bolts
26 Check that the reference marks are correctly ahgned. Release the
tensioner plunger by turning the pawl clockwise (photo)
27 Locate the 011 thrower, and the Woodruff key for the crankshaft
pulley on the crankshaft
28 Pos1t1on the gasket on the engine front plate. Refit the urning cover.
and hand tighten the nuts and bolts
29' :The timing cover must now be centrahsed before refitting the
crankshaft pulley. Peugeot garages use a special tool for this purpose,
but the pulley may be used by wrapping adhesive tape around it
(photo) II the cover is not centraltsed correctly, oil may leak past tho
pulley. or the pulley may emit noise.
30 Shde the pulley ( taped) onto the crankshaft (engaging the
Woodruff key) and into the ti ming cover, so that 11 holds the cover
firmly
31 Tighten the urning cover nuts and bolts to the specified torque
(photo)
32 Remove the pulley, peel off the tape, then refit it. taking care to
engage the Woodruff key in the pulley slot
33 Fit the crankshaft pulley nut, and ughten to the specified torque
with the crankshaft locked as described 1n paragraph 8 (photo).
34 Chp tho wmng harness to the 11m1ng cover.
35 Refit the power steering and air conditioning compressor Fig. 1.6 A lignment of the camshaft and c rankshaft sprocket
dr1vebelts (Chapters 10 and 11 ). prior to fitting the timing c hain ( Sec 5)
36 Refit the spark plugs (Chapter 4), and the dri11ebelt, Ian, and
radiator (Chapter 2}. a M ark on sprocket
5 8 One method of locking the stoner ring 5 9A Unscrew the crankshaft pulley nut 5 98 and w11hdraw the pulley note
gear Woodruff key (arrowed)
510A T1m1ng cover retaining nuts 5 1 OB Timing cover retaining nut and bolt 510C Removing the timing cover ..•
(arrowed)

...
5 100 and gasket 5.11 Removing the oil thrower 5 12 T1mtng chatn tensioner locked 1n the
compressed position
5 13A Removing the 11m1ng chain tensionei 5 13B T1mtng chatn tensioner 011 filter 5 14 Removing the camshaft sprocket bolts
(arrowed) and lockwasher
5 15 Removing the camshaft sprocket and 5 1 SA Wtthdraw the crankshaft sprocket 5 1 SB and Woodruff key (arrowed)
t mng chain
!i 18 Wood1ufl key httod to crankshaft nose 6.20 Aligning the crankshaft and camshoit 5.21 Timing chain and camshaft sprocket
for timing chain fitment alignment marks (arrowed)

38 Chapter 1 Eng i ne
5 22 T1m1ng chai n and crankshaft sprocket 5.23A Tighten the camshaft sprocket 5 238 ... and bend the lockwasher onto the
alignment marks (arrowed ) bolts ... bolr flats
5.26 R;ileasong the t1m1ng chain tensioner 5 29 Adhesive tape wrapped around tho 5.31 Ccntr:il1sed ummg cover
crankshah pulley for centralising the urning
cover
<;,,\a~ . aN.i <11!.W:.\\. \.M. 1!.l..\\al.l'!.\ c:\.o~\\~'~
l1om \t\1!. mat-.\lo\<1 at-.d \'Ho
front mounting brackets
3 Disconnect the battery negative lead.
4 Disconnect the w iring harness from the cylinder head, noting the
location of Individual wires.
5 Remove the air cleaner and carburettor (Chapter 3).
6 Remove th e drivebelt. fan . and radiator top hose. with reference to
Chapter 2.
7 Disconnect the HT leads and unchp the distributor cap. Remove
the spark plug exten51ons
8 Disconnect the heater and bypass hoses.
9 Disconnect the heater. econostat and brake servo vacuum hoses
from the inlet manifold
10 Unboll the power-assisted steering fluid reservoir from the cylinder
head
11 Disconnect the crankcase ventllauon hose from the inlet manifold,
and unchp the 011 separator from the orl filler tube (photos).
12 Unchp the d1agnos11c socket from ns bracket on the valve cover
(photo).
13 If the engine 1s out of the vehicle. remove the inlet and exhaust
manifolds at this stage
14 Unscrew the valve cover retaining bolts. noting the location of the
d1agnos11c socket bracket and HT lead holder (photos)
l 5 Lift off the valve cover. and remove the rubber seals from the bolts
5 33 Tightening the crankshaft pulley nut
(photos)
16 Remove the valve cover gasket (photo)
17 Remove the rubber seals and seaungs from the spark plug tubes
(photos)
6 Cylinder head - removal and refitting 18 Unscrew and remove the spark plugs.
19 Unscrew the union bolts, and remove the rocker arm lubrication
pipe from 1he rear of the cylinder head and block (photo). Recover the
~o\e·. Spec1ol 1ools moy be required lo release the cylinder head from C.O?~I 'Nat."lll'&
its gasket Refer to paragraph 23 20 Progressively unscrew the cylinder head bolts. using a reversal of
the 11ghtening seQuence shown In Fig. 1.8. Recover the washers 11
' t)1am \\\e c.oo\m<;) 'lt'f'lt\~l'I\ a'lt de~l\~d \t\ Ct\a?\~1 1 . \\\\~d.
2 Temporarily 1ack up tho lront of the vehicle. support ll on axle 21 Remove tho rocker arm assembly from 1he cylinder head, after

6 11 A 01sconnec11ng the crankcase 6 11 B Removing the o I separator from the 6 12 D1agnost1c socket and bracket
ven11la11on hose from the inlet manifold oil filler tube
6 14A Valve cover retaining bolt with 6.15A . and remove the valve cover
d1agnosuc socket bracket and earth cable
6 I 58 Removing the rubber seals from the 6 16 Valve cover gasket removal 617A Removing the spark plug tube rubber
valve cover bolts seals ...
6.19 Rocker a;m lubrication pipe removal

40 Chapter 1 Engine
removing the retaining nuts (photo)

22 M ake some holes in a piece of cardboard, corresponding 10 the
puahrod posi tions In tho cylinder head, then remove the pushrods and
piece them In the cardboard 10 ensure correct refitting. Note that the
exhaust pushrods are longer than the inlet pushrods (photos).
23 Rock the cylinder head 10 release 11 from the gasket. The Peugeot
tool for doing th is Is shown in Figs 1 6 end 1 7. and consists of the two
nght angled levers.
24 Remove the cyhnder head from the block by sliding it across the
gasket (photo) This is necessary to prevent the cylinder hners from
being disturbed and possibly breaking the l ower seals. Remove the
gasket from the block (photo) If further worl!-- 1s 10 be earned out on
the engine such as cleaning the pistons. the liners must be clamped in
pos1uon. using clamps made from metal plate and suitable bolts
{photos) Do not turn the engine w ithout having the clamps fitted.
25 Thoroughly clean the mating faces of the cylinder head and block,
and obtain a new head gasket
26 Commence reassembly by removing the liner clamps.
27 Locate the now cylinder head gasket on the block w ith the word
OESSUS uppermost. If available. obtain the spacial Peugeot head
centrahzing bolts. and insert them in the right-hand corner holes.
Alternauvely. use suitable long studs
28 Lower the cyhnder head onto the gasket
29 Aefu the pushrods and rocker arm assembly
30 Apply a httle grease to the cylinder head bolt threads and the
washers (1f luted ). then insert them and lightly tighten them (photos).
Remove the guide studs. and similarly fit the corner bolts.
31 Usmg the sequence shown in Fig. 1 8, 11ghten the cyl inder head Fig. 1.6 Using the special tools to free the cylinder head
bolts to the Stage 1 torque, given in the Specifications Section (Sec 6)
(photo)
32 Tighten the rocker arm nuts to the specified torque (photo).
33 Carry out Stage 2 on all cylinder head bolts in sequence.
34 Note that Stage 2 involves three operations on each bolt -
complete all three operations on each bolt before proceeding to the
next one Use an angle indicator to ensure correct tightening ( photo).
35 Rein the rocker arm lubrication pipe, together with new copper
350
washeri. and ughten the union bolts
36 Fii the seattngs and rubber seals to the spark plug tubes.
37 Ad1ust the valve clearances with reference to Section 4.
38 Aeht the valve cover together with a new gasket and rubber seals,
and tighten the bolts.
39 Refit the mlet and exhaust manifolds. 1f removed (Chapter 3) 0
40 Clip the diagnostic socket to tts bracket M
.-
41 Refit the separator to the 011 filler tube. and connect the crankcase
ven11let1on hose to the inlet manifold.
42 Refit the power -assisted steering fluid reservoir. end tighten the
bolt
43 Refit the vacuum and coolant hoses. "11_
44 Refit the spark plugs and their extensions. end the HT leads
45 Rehl the radiator top hose. fan. and dr1vebelt, with reference to
Chapter 2 Fi g . 1 .7 Dimensions (in mm) of the cylinder heed removal
46 Aeftt the carburettor and air cleaner ( Chapter 3). special tools ( Sec 6)
47 Aelu the wmng harness
48 Reconnect the exhaust downpipe
49 Reconnect the battery negative lead
50 Refill the cooling system (Chapter 2)
51 Aun the engine at 2000 rpm for approximately twelve minutes, or
unti l the self-disengaging fen cuts m, then run II at 1200 rpm for five
minutes
8 4 , 5 9
52 On vehicles up to VIN 1 845 001 , switch off the engine, and allow
11 to cool for six hours.
0 0 0 0 0
53 Oeprossurize the cooling system by temporarily removing the
ptessure cap from the expansion tank Where appropriate, take
precautions against scalding by placing a pad of cloth over the cap as it
tS unscrew ed
54 Remove the valve cover, and cerry out Stage 4 tightening on all
cylinder head bolts in sequence, using en angle indicator to ensure
0
@ @ 0 0
® ® 0 0
corre"t ughtening where necessary

55 Ad1us1 the valve clearances as described in Section 4. then reftt the
7 3 2 6 10
valve cover H.19230
56 On vehicles up 10 and mcludmg VIN 1 620 021 . the cylinder head
bolts should be ret1ghtened, end the valve clearances adjusted, after Fig. 1 .8 Cylinder head bol t tightening sequence (Sec 6)
1000 to 1500 miles (1600 tP 2400 km).
57 On vehicles w ith a VIN later then 1 620 021 , only the va lve J.I
clearances need be ad1usted after the mileage given above. The
cylinder head bolts do not require retlghtenlng.

..
6.21 Rocker ilrm assembly removal 6 22A Removing the pushrods 6.228 Inlet pushrods (leh) and exhaust
pushrod (right)
6 24A Removing the cylinder head 6.24B Removing the cylinder head gasket 6.24C Liner clamps fined to the block
6 240 Liner clamps 6.27 Cylinder head gasket top marking 6.30A Applying grease to the cylinder head
bolts ..•
6 308 and washers -

6.31 Tightening the cylinder head bolts ' 6 32 Tightening the rocker arm nuts

42 Chapter 1 Engine
5 Disconnect the radiator top and bottom hoses from the engine
(photos)
6 Disconnect the heater hoses from the water pump and cylinder
head Also disconnect the bypass hose (photos) ,
7 Disconnect the fuel feed and return hoses from the fuel pump and
carburettor
8 Disconnect the heate1 econostat ond brake servo vacuum hoses
from the inlet manifold (photos)
9 Disconnect the accelerator cable from the carburettor
10 The engine w iring harness may be leh on the engine 1f desued by
disconnecting the mulu -plugs beneath t he co1l loca11on If 11 is decided
10 remove 11 at this stage. disconnect 11 from the temperature sensor. 011
level switch. reversing lamp switch. alternator. 011 pressure sw itch and
starter motor (photos)
11 Disconnect the coil HT lead.
12 Remove the sta rter motor as descnbod m Chapter 12
13 Apply the handbrake, then iack up the front of the vehicle and
support on axle stands
14 Unbolt ond remove tho gearbox front cover and the TDC sensor
cover. without disturbing the sen mg o f the sensor (photos)
15 On au tomauc transmission models. mark the torque converter 1n
relatton to the dnveplate. then unscrew the four bolts The engine will
need to be turned to gain access to each bolt
6 34 Angle lightening the cylinder head bolts 16 Unscrew the nut and disconnect t he engme·to-body earth cable
Unbolt the battery negauve lead from the cylinder block (photos)
17 Position a container beneath the engine sump. then unscrew the
dram plug and dram the engine 011 (photo) On compleuon refit and
tighten the dram plug.
7 Engine mountings - removal and refitting
18 Unscrew the exhaust downpipe-to-manifold nuts, and ue the
downpipe 10 one side
1 Remove lhe air cleaner (Chapter 3) 19 On models htted with air cond111on1ng. remove the compressor
2 Unscrew and remove the bolls securing the mountings to the front from the engine. and support 11 on one side without disconnecung
crossmember the pipes. Similarly remove the condenser.
3 Support the weight o f the engine with a hoist 20 On models fined with power assisted stee11ng. remove the pump,
4 Unscrew and remove the nut(s) , and remove the mounting p1lla1 and support 11 on one side w11hout d1sconnecung the pipes
from the bracket Recover the shield (photos) 21 Unscrew and remove the bolts securing the engine mounung
5 Unbolt the bracket from the cylinder block (photo). brackets to the crossmember (photo)
6 Ref1111ng 1s a reversal of removal. but ughten the nuts and bolts to 22 Connect a hoist to the engine. and raise 11 un11t the gearbox
tho spcc1fled torque touc hes the body. Support the gearbox m this pos111on wnh a trolley
tack
23 Using a 10 mm Allen key. unscrew the gearbox-to-engine bolts
(photo)
8 Engine - removal 24 Pull the engine forwards and disconnect tt from the gearbox and
clutch On automauc transmission models. make sure that the torque
1 Remove the bonnet, as described 1n Chapter 11 converter remains fully engaged wuh the transm1ss1on (refer 10
2 Remove the battery, as described m Chapter 12 Chapter 6 if necessary)
3 Remove the air cleaner assembly, as described m Chapter 3. 25 Lift the engine from the engine com partment, taking care not to
4 Remove the radiator and fan, as described m Chapter 2. damage the su rrounding components (photo)
7 4A Loh h~nd engine mounti ng 7 48 Removing the righ t -hand engine mounting shield (arrowed)
J·I

7 5 Removing the nght-hand engrne 8 SA 01sconnectrng the top hose from the 8 58 D1sconnec11no the bottom hose from
mounting bracket engine the water pump
8 6A Drsconnectrng the heater hose from 8.68 01sconnecung the heater hose from 8 6C Disconnecting the bypass hose from
the water pump the cylinder head the water pump ..
8 60 and carbureuor 8 SA Disconnect the heater vacuum hose ... 8.88 .. and brake servo vacuum hose from
the inlet manifold
810A Engine wmng harness mulu plugs 8 1OB Coolant temperature senso1 arid 8 10C Ori level warning switch (arrowed)
wiring and wiring

8100 Reversing lamp sw itch and wiring 8 1OE Coolant temperature switch and wmng
81 4A Removing the gearbox front cover 8.14 B Removing the TDC sensor cover
8 16A En11m11 to body earth cable (arrowed ) 8 168 Battery negauve lead· tO· englne securing bolt (arrowed)

Chapter 1 Eng i ne 45
8 1 7 Unscrewing the engine 011 drain plug 8.21 Engine mounting bracke1- to· crossmembe1 bolt (arrowed)
8 23 Unscrewing a gearbox-to-engine bolt (arrowed) 8.24 Lifting the engine from the engine compartment
bench. When the stage 1s reached where the sump and pistons are to
9 Engine dismantling - general
be removed. turn the engll"le on its side. Turn the block upside- down to
remove the crankshaft
Stand the engine on a strong bench so as to be at a comfortable 7 Wtierever possible temporarily refit nulS. bolts and washers
working height Fa1hng this 1t can be stripped down on the f loor. but at finger- tight from wherever they were removed This helps avoid later
least Stan d ll on a sheet of hardboard loss and muddle. If they cannot be refitted, then lay them out 1n such a
2 During the dismantling process. the greatest care should be taken fashion 1ha t ts clear where they came from.
to keep the exp0sed parts free lrom din As the engine is stripped, clean
each pan in a bath of paraffin
3 Newr immerse parts with internal oil ways in paraffin - to clean. wipe
down carefully wuh a parafftn· dampened rag 01lways can be clea ned 10 Engine ancillary componen ts - removal
out w ith a piece of wire If an air line is avatlable, all parts can be blown
dry and the oilways blown through as an added precaution.
4 Re· use ol old gaskets Is false economy. and can give 11se to oil and Before complete engine dismantling begins. remove the following
wat..r luaks. 1f nothing worse. To avoid the poss1b1hty of trouble after Items·
the engine has been reai;sembled, always use new gaskets tliroughout. Inlet and exhausr manifolds (Chapter 3)
5 Do riot throw the old gaskets away, as 11 someumes happens that Alternator (Chapter 12)
an immediate replacement cannot be round. and the old gasket is theri Clutch (Chapter 5)
very u1111ful as a template. Heng up the gaskets on a suuable nail or Engine mourwng bracltecs (Secuon 7)
hook as they are removed Oil 11/teJ /Section 2)
6 To st11p the engine II ls best to work from the top downwards. The Distributor (Chapter 4 )
l!ngrne oil sump Is an irregular shape, and It will be necessary to use Water pump ( Chapter 2)
woorten blocks to support the engine in an upright pos1t1on on the Fuel pump (Chapter 3)

46 Chapter 1 Engine
paragraph 17.
11 Engine - compl et e dismantling
19 Lock the camshaft by placing a block of wood inside the
crankcase, then unscrew the flywheel /drlvepla te bolts and remove the
Remove che uming chai n and sprockets as described In Section 5 flywheet/dnvepfate.
2 Unbofl the oil filler housing from the block. Remove the gasket 20 Check that the main bearing caps are fde nuf1ed for position. The
(photo). No 1 cap (rear) is identified by its seal slots. No 2 cap should have a
3 Remove the oil level dips11ck. dab of red paint on 11. No 3 (centre) is marked witn green paint. No 4
4 Unbolt the oil filter housing from the block. and remove the gasket with white paint, and No 5 (front) with blue paint. If necessary, mark
(photo). the caps with a centre-punch.
5 Remove the cylinder head as described in Section 6. 21 Before removing che main bearing bolts, check che cranllshaft
6 Remove the tappets from the block, keeping them Identified for endfloat. using a feeler blade between the rear crankshaft web and the
pos111on (photos). • thrustwasher on the rear main bearing cap (photo) .
7 Unscrew the bolt and w ithdraw the distributor bracket (photo). 22 Unscrew the main bearing bolts. and remove the caps. Remove the
8 Using a hooked Instrument, remove the oll pump driveshaft seals and thrustwashers from the rear cap (photo).
(photo) 23 Lift the crankshaft from the crankcase. and recover the chrust-
9 Unscrew the bolts securing the sump to the block (photo) . Where washers (photo).
an alloy sump 1s fined. unbolt the steel plate for access to the four 24 Remove the main bearing shells. keeping them identified for
concealed bolls. position.
1O Remove the sump and gasket (photos). 25 Remove each liner from the cylinder block, using a wooden mallet
11 Unscrew the bolts and remove the oil pump (photos) . to tap them free 1f necessary (photo) Mark the liners for position.
12 Recover the 0 -ring seal from the oil pump base, and remove the using a spirit marker pen, or by scratching the liners on their outer
location dowels lrom the block (photos). surfaces.
13 Unscrew the bol ts and remove the front plate from the dowels on 26 Remove the base shims from the liners.
the cylinder block Remove the gasket ( photos) .
14 Unscrew the bolt and slide out the camshaft thrustplate (photo)
15 Remove the camshaft trom the block, being careful not to damage 12 Crankc ase ventilation system - d escription r
the bearing surfaces (photos).
16 Mark the big-end caps and connecting rods in relation to each 1 The crankcase ven ti lation system is designed to extract oil fumes
other, so that rhey may be refined m the correct positions. Number and blow-by gases from within the crankcase, and to feed them mto
them from the flywheel end. the combustion chambers, where they are burnt.
17 Turn the crankshaft so that No 1 piston is at the bottom of its 2 The system consists of a wire-mesh oil separator, located on the
stroke. Unscrew the big-end nuts and remove the cap (photo). Using top of the oil filler tube. and two hoses to the inlet manifold and air
the handle of a hammer, push the No 1 connecting rod and ptSton from cleaner.
its liner. If the bearing shells are to be used again, keep them taped to 3 On h1gh-m11eage engines, the hoses and separator may become
the cap or connecting rod blocked with sludge, and the system should therefore be periodically
18 Remove the remaining pistons using the procedure described in checked and cleaned
11 .2 Removmg the oil filler housing and 11 .4 Removing the oil filter housing and 11 .6 Removing a tappet
gasket (arrowed) gasket
11 7 Removing the distributor bracket 1 1 .8 Oil pump drive shaft removal 11 .9 Unscrewing the sump bolts

11 1OA Removing rhe sump 11.1 OB ... and gasket 11.11 A Unscrew the bolts ...
11 11 B and remove the 011 pump 11.12A Removing the 011 pump 0 -ring 11 12 8 and the location dow els
seal .
11 1 JA Unscrew the bolts 11 .138 ... and remove the front plate ..• 11 1 JC and gasket
11 .14 Removing rhe camshaft thrustplate 11.1 SA Removing the camshaft 11 . 1 58 Camshaft removed from the engine

48 Chapter 1 Eng i ne
11 17 RP.moving a brg -end cap 11 21 Checl<ing the cranksha ft endfloat 11 .22 Thrustwasher removal from the rear
with a feeler blade main bearing cap
11 23 Lifting the crankshaft from the 11 25 Removing a liner from the cylinder
crankcase block
5 Beaung m mind that the cylinder head 1s of light alloy construcuon

13 Engine components - examination and renovat ion and 1s easily damaged use a blunt scraper or rotary wrre brush to clean
(general) all traces of carbon deposrts from the combustion spaces and the ports
The valves and valve guides should also be freed from any carbon
1 W11t the tlng1ne dismantled, all componen ts must be thoroughly deposus Wash the combusuon spaces and ports down with paraffin.
cleaned and examined for wear as described rn the following Sections. and scrape the cylinder head surface free of any foreign matter w ith the
2 If a high mileage has been covered, en her from new or since the last side of a steel rule. or a s1m1lar article
engine rebuild and general wear is evident, consideration should be 6 If the engine 1s installed In the car, clean the pistons and the top of
given 10 replacing rhe engine with a reconditioned one. rhe cylinder bores. If the pistons are still in the block, th en 11 1s essen ti al
3 II a single component has malfuncuoned. and the rest of the engine that great care is taken to ensure that no carbon gets into the cylinder
is in good cond1 t1on. endeavour to ftnd out the cause of its failure 11 it1s bores. as this could scratch the cylinder walls or cause damage to the
not readily apparent. For example, rf a bearing has failed. check that the piston and rings. To ensure this does not happen. first turn the
ad101niny 01lw11ys are clear. the new bearing will not last long 1f u 1s not cra nkshaft so that two of the pistons are at the top of their bores Stuff
berng lubucaced rag into tho other two bores, or seal them off w11h paper and masking
4 If uncertain about the cond111on of any components. seek a second tape. The waterways should also be covered with small pieces of
opinion from , Peugeot garage masking tape, to prevent particles of carbon entering the cooling
5 Chock on the ava1lab1h1y of replacement parts before discarding the system and damaging the coolant pump
old one~ Check the new part against the old. to ensure that you have 7 Press a little grease into the gap between the cylrnder walls and the
the correct replacement two pistons which are to be worked on. Wrth a blun t scraper, carefully
6 Somo of the measurements necessary will require the use of feeler scrape away the carbon from rhe piston crown. taking great care not ro
blades. a micrometer or vernier gauge, and a diol test 1nd1cator scratch the aluminium. Also scrape away the carbon from the
However. in many instances wear will be visual ly evident, as the old surrounding lip of the cylinder wall When all carbon has been
component can be compared with a new one removed. scrape away the grease. which w ill be contaminated with
carbon particles, taking care not to press any into the bores. To assist
prevention of carbon build up, rho piston crown can be polished w ith a
meral polish Remove the rags or maskrng tape from the other two
14 Cylinder head - dismantling. decerbonlslng and cylinders. and turn the crankshaft so that the two pistons which were
reassembly at the bottom are now at the top. Place rag in the cylinders which have
been decarbonised. and proceed as 1ust descnbed
1 Using a valve spring compressor compress the first valve spring 8 Eicamrne the head of the valves for pitting and burning, especially
and remove the spht collets (photos) the heads of the eichaust valves The valve seats should be eicam1ned at
2 Gently release the coml)fessor and remove n the same ume If the putrng on the valve and seat tS very shght. the
3 Toke off the SPfing retainer. the springs and the spring seat marks can be removed by grinding the seats and valves together wuh
(photos) coarse, and then fine. valve grinding paste
4 Remove oil the other valves 1n a similar way. keeping them in their 9 Where bad Ptltjng has occurred to the valve seats, it w ill be
orig1nsl titted sequence, together wnh their associated components necessary to recut them and fir now valves. This lauer job should be
(photo) Remove one! discord rhe valve stem 011 seals entrusted ro the local agent or engineering w orks In practice, 11 1s very

Chapter 1 Engine 49
seldom that the seats are so badly worn. Normally, it Is the valve that is Springs suffer from fatigue, and it is a good idea to renew them even if
too badly worn for refitting, and the owner can easily purchase a new they look serviceable.
set of valves and match them to the seats by valve grinding. 12 The cylinder head can be checked for warping either by placing it
10 Valve grinding is carried out as follows. Smear a trace of coarse on a piece of plate glass, or using a straight- edge and feeler blades
carborundum paste on the seat face. and apply a suction grinder tool to (photo). If there is any doubt about Its condition or If its block face Is
the valve head. With a semi -rotary motion, grind the valve head to its co rroded, have It re-faced by your dealer or motor engineering works.
seat hftmg the valve occasionally to redistribute the grinding paste 13 Test the valves in their guides for side-to-side play. If this ls any
(photo) When a dull man even surface is produced on both the valve more than almost-imperceptible. new guides must be fitted, again a
seat and the valve, wipe off the paste and repeat the process with fine 1ob for your dealer.
carborundum paste, hfling and turning the valve to redistribute the 14 Commence reassembly by pressing the new valve stem oil seals
paste as before A light spring placed under the valve head w ill greatly into position, using a suuable size socket to press them on (photo)
ease this operatton. When a smooth unbroken ring of light grey matt 15 Oil the stem of the first valve. and push It into ns guide.
finish 1s produced, on both valve and valve seat faces. the grinding 16 Fit the spring seat, inner and outer springs, and spnng retainer
operauon 1s complete. Carefully clean awtiy every trace of grinding (photo).
compound. take great care to leave none in the valve guides. Clean the 17 Compress the valve spring, and using a httle grease. locate the split
valves and valve seats w ith a paraffin-soaked rag. then with a clean cotters in the valve stem cut-out.
rag. Finally, 1f an air line Is available, blow the valve, valve guides and 18 Gently release the compressor. checking to see that the collets are
valve pons clean. not displaced.
1l Check that all valve springs are intact. If any one is broken, all 19 Fit the remaining valves in the same way.
should be renewed. Check the free height of the springs against new 20 Tap the end of each valve stem w ith a plastic or copper-faced
ones If some springs are not within specifications, replace them all. hammer to settle the components.
14 l A Compress the valve spring with the 14.1 B ... and remove the spht collets 14.3A Remove the spring retainer ...
tool (arrowed)
14 38 outer spring ... l 4.3C ... inner spring .. 14.30 . and spring seat
~-~ --0~
~ zn=- Q •MI~ :
14 4 Valve components 14.10 Grinding-in the valves 14.12 Chocking for cylinder head diston1on

50 C hapter 1 Engine
14.14 F1tring ihe new valve stem oil seals 14. l 6 Valve spring refitted
15 Examination and renovation of dismantled com ponen ts
1 With the engine stripped down. and all parts thoroughly clean. it is
now time to examine everything for wear. The following items should
be checked. and where necessary renewed or renovated . as described
in the following sub-Sections.
Cy/mder block and crankcase

2 Clean away all old gasket material, and then examine the casting
for cracks, particularly around bolt holes. II they are found, specialist
welding or cold repair will be required .
3 Clean out the oilways and galleries with compressed air or wire.
4 If the cylinder bores are worn. this w ill be evident by the emission
of e11haus1 smoke and general deterioration in engine performan ce,
together wnh increased otl consumption. A good way to test the
condition of the engine when It is still in the car is to test the
compression. Have the e"gine at normal operating temperature wuh
tho spark plugs removed, Screw a compression tester (available from
most accessory stores) into the first plug hole. Hold the accelerator
pedal fu lly depressed, and crank the engine on the starter motor for
several revolutions. Record the reading . Zero the tester. and check the
remaining cylinders in the same way. All four compression figures
should be approximately equal, and a minimum of 10.3 bar ( 150 Fig . 1.9 Relationship of co nnecting rod oil spra y hole to the
lbf/ in') If they are all low, suspect piston ring or cylinder bore wear If arro w o n the piston crown (Sec 15)
only one reading is down, suspect a valve not seating, or a broken
piston nng
5 The cylinder bores must be checked for taper, ovality, scoring and
scratching. Start by examining the top of the cyl inder bores. If they are slide 11 up them. Remove the other rings in a suyular way.
at all worn, a ridge w ill be felt on the thrust side This ridge marks the 11 Clean carbon from the ring grooves: a segment of old piston ring is
limit of piston ring travel useful for this purpose.
6 An internal micrometer or dial gauge can be used to check bore 12 Clean out the 011 return holes in the piston ring grooves, and fit the
wear and taper, but this 1s a pointless operation 11 the engine is new piston rings.
obviously worn. as indicated by e11cessive oil consumption. 13 If proprietary rings are being fitted to old pistons, the top ring will
7 The engine is fined with renewable 'wet' cylinder liners. and these be supplied stepped. so that it does not impinge on the wear ridge.
are supplied complete with piston. rings and gudgeon pin. 14 Insert each piston ring in !Urn squarely into its bore, and check the
ring end gap. II 1t is not within the specified tolerance. carefully grind
Pistons and connecting rods the end face of the ring. This does not apply to new rings supplied as
8 The pistons may be separated from the connecting rods by part of Peugeot piston/ liner sets. which are pre-gapped, and must nqt
extracting a circlip and pushing out the gudgeon pin (photos) . Make be altered.
sure that' the components are identified for location, if they ere 10 be 16 Now c heck the flt of each compression ring in us groove with a
re -used feeler gauge. If it is tight, the ring may be ground on a sheet of
9 When reassembling the pistons. make sure that the arrow on the wet-and-dry paper, laid flat on a piece of plate glass.
piston crown points in the direction shown in Fig. 1.9. m relatton to the 16 Fit the rings 10 the piston. using the feeler blade method as
011 spray hole In the connecttng rod (photo). With new components. it described for removal. Work from the top of the piston, fitting the oil
may be necessary to immerse the piston 1n boiling water, 10 expand it control ring fim .
pflor to pressing in the gudgeon pin. 17 Lubricate the piston rings. and locate the compression ring gaps at
10 Remove the piston rings from the top of the piston (photo). To i 20• lntel"r.ls from the 1oln in the oil control ring expander. Posiuon the
1ivo1d breaking a ring, either during removal or refitting, slide two or 011 contr6f ring rail gaps approximately 20 to 50 mm (0.8 to 2.0 Jn)
three old feeler blades at equidistant points behind the top ring. and each side o't the e11pander join (photo)

Chapter 1 Engine 51
Crankshaft the stated underslze as running clearances have been allowed for
18 Examine 1he crankpln and main 1ournal surfaces for signs of dunng their manufacture.
scoring or scra1ches. and check the ovahty and taper of 1he crankp1ns 25 Main and big-end bearing shells can be 1den11hed as to size by the
and main iournals If the bearing surfaces are excessively scored or marking on the back of the shell (photos) Standard size shell bearings
worn oval the crankp1ns and/ or main iournals will have to be are marked STD or 00. unders1ze shells are marked with the unders1ze
reground such as 0.020 u/ s. This marking method applies only to replacemen t
19 Big and and crankp1n wear is accompanied by a dlstlnc1 metallic bearing shells. and not to those used during production.
knocking. particularly noticeable when the engine is pulling from low
revs. and some loss of 011 pressure. Flywheel/ drivebelt and starter ring gear
20 Mam bearing and main journal wear 1s accompanied by severe 26 If the starter ring gear teeth on the flywheel (manual transmission)
engine v1brat1on rumble getting progressively worse as engine revs or torque converter driveplate (automatic transm1ss1on) are excessively
increase and again by loss of oil pressure worn, 11 will be necessary to obtain complete new essernbl1es. It 1s not
21 If the cra nkshaft requires regrinding, take it to an engine possible to obtain separate ring gears
recond111onlng specialiSl, who will machine 11 for you and supply the 27 On manual transm1ss1on models, examine the clutch mating
correct unders1ze bearing shells The balance weights must be removed surface of the flywheel, and renew the flywheel 1f scoring or cracks are
before regrinding the crankshaft. but the reconditioning specialist will evident
do this and mark them so that they are refitted in their onginal 28 On automatic transmission models. the driveplate face should be
pos111ons checked for run-out. using a dial gauge. The maximum permissible
22 Check the spigot bearing in the rear of the crankshah, together run-out is 0.3 mm (0.012 in). Renew the plate 1f this figure 1s
w11h the 011 seal If necessary, pnse out the oil seal, and use an extractor exceeded.
to remove the bea11ng bush (photo). If an extractor is not available. hit 29 The flywheel/ d11veplate retaining bolts must be renewed on
the bush w11h grease. then dnve a close -fitting metal dowel through assembly.
the bush The hydraulic acuon should force out the bush Drive in the
new bush, followed by the oil seal. and lightly grease it (photo) . Camshaft
30 Inspect the camshaft journals and lobes - scoring or general wear
Big-end and main bearing shells will indicate the need for new parts.
23 Inspect the big-end and main bearing shells for signs of general 31 The camshaft sprocket teeth should not be chipped or badly worn.
wear scoring. pitting and scratches. The bearings should be matt grey 32 The camshaft thrustplate should not be badly scored, otherwise
m colour With lead-indium bearings, should a trace of copper colour camshaft endfloat will be excessive.
be no11ced. the bearings are badly worn, as the lead material has been 33 Also check the oil pump/distributor driveshafl gear for wear and
worn away to expose the indium underlay Renew the bearings if they damage
are in th is co ndition. or 1f there are any signs of scoring or pitting. You
are strongly advised t o r enew t he bearings - regardless o f Timing chain
their co ndition at t ime of major overhaul. Refi tting used 34 Refer to Section 5.
bearings is a fal se economy.
24 The undersizes available are designed to correspond with Cylinder head
crankshaft regrind sizes The bearings are. in fact, slightly more than 35 RP.fer to Section 14.
15.SA Extract one of the circhps . 15 SB and press out the gudgeon pin to 15.9 011 spray hole (arrowed) in the
remove the connecting rod connecting rod
15 10 Removing 1he piston rings 15.17 Correct posuiontng of the oll control 15.22A Using an extractor 10 remove the
11ng rails and expander spigot bearing bush from the crankshaft
T rial version of ABC Amber PDF Merger, http://vvww.processtext. com/abcpdfmg .htm l

52 Chapter 1 Engin~
36 If the c yltnder head 1s machined, us depth must not be reduced to

17 Engine - complete reassembly
less than 92.1 mm (3.63 In). On XN1A engines. 1t 1s also necessary to
fit a special 1 6 mm (0.063 l n) t hick head gasket.
Crankshaft and main bearings
Rocker arm assembly 1 Place the cylinder block upside-dow n on the bench.
37 If necessary. the assembly may be dismantled by unscrewing the 2 Press the new main bearing shells into their locattons In the
end bolts rrom the shafts (photos). Keep eac h component on the crankcase (photo). Note that 11 the crankshaft has sediment chambers
bench 1n the order of removal. to ensure correct reassembly ( Fig. 1 10), Nos 1, 3 . and 5 shells are grooved. and Nos 2 and 4 shells
38 Check the rocker arm bushes for excessive wear (photo). Also are plain . Where the crankshaft does not have sediment chambers, the
check the ball-studs. and rhe hardened surface on the ends or the arms. shells are grooved 1n the block, and p lain 1n the caps M ake sure that
39 Clean all the components. in particular internal oilways. then the shell tabs engage the cu1-ou1s.
reassemble in reverse order 3 Oil the bearing shells, then lower the crankshaft into the crankcase
(photos).
01/ pump 4 Insert the thrustwashers without location tabs each side ol No 1
40 The 011 pump may be d ismantled by unbolt ing the bottom filter and journal. with the lubrication grooves towards the crankshaft (le away
cover and removing the two gears. from the bearing) (photo).
15 22B Dnv1ng in the new oil seal 15.25A Main bearing shell marking 15.250 Big-end bearing shell marking
15 37 A Unscrew the end bolt ... 15.37B .•. and dismantle the rocker arm 15.38 Rocker arm showing bush (arrowed)
assembly
41 The gears can be removed as a set. and this is recommended 11 the

engine has covered a high mileage. even i f wear appears 10 be minimal.
42 After reassembling the oil pump, prime it with engine oil
16 Engine - reassembly (general)
1 To ensure maximum life with minimum trouble from a rebuilt

engine. not on ly must everything be correctly assembled. but must also
be spotlessly clean. all the ollways must be clear. locking washers and
spring washers must always be f itted where indica ted, and all bearing
end other working surfaces must be thoroughly lubricated during
assembly
2 Before assombly begins. renew any bolts or studs rf the threads are
in any wav damaged. and whenever possible use new spring washers.
3 Apart from your normal tools, a supply of clean rags. an oil ca11
ftlled with engine 01 1 (an empty plastic detergent bottle, thoroughly
cleaned and washed out. will do jus t as well). a new supply of assoned
spring washers, a set of new gaskets, and a torque wrench, should be Fig. 1 .10 Crankshaft with sediment c hambers - arrowed
collected together. (Sec 17)
J .\

Chapter 1 Engine 53
5 Press 1he new bearing shells lnto the main bearing caps. and 011 the
shells (photos)
6 Apply a lmle grease to the plain sides of the thrustwashers ( with
location tabs) then stick 1hem io 1he No 1 main bearing cap, whh the
lubric;a11on grooves l acing ou twards.
7 Fit Nos 2 to 5 main bearing caps. msert 1he bolts and tighten to the
specified torque. N ote: The casting marks must be on the flywheel
sidt. c;,ps 2 ond 3 hove two morks. and caps 4 ond 5 have one mark
(photo)
8 Fit the special rubber seals to the grooves in No 1 main bearing cap.
and hghlly grease their outer edges (photo).
9 Cui some thin strips of cellu loid to prevent the rubber seals
stretching when refitting the cap Grease the ships, then press them
against 1he seals and carefully lower lhe No 1 cap into position
(photo).
10 Insert and t1 gh1en the main beanng cap bolts 10 the specified
torque ( pho10)
11 Using a pair of pliers. pull out 1he str1ps of cellu loid (photo).
12 Trrm the ends of the rubber seals to 2.0 mm (0 .08 in) above the
lace of the block. usmg two feeler blades as a guide (photo) .
\ 3 Using a dial test mdica1or or feeler blades. check that the
crankshah endfloat rs as given 1n the Specif1cauons (photo).
Flywheel or drtveplate (automatic transmission)

14 Locate the tlywheel/ driveplate on 1he cranksha ft flange. Fil the Fig . 1.11 Four points for c hec king the cylinder liner
loclong plate and Insert the bolts. If there is no locking plate. apply protrusion (Sec 17)
lockmg llu•d to the threads ol 1he bolls (photo).
15 Lock the crankshaft usrng a block of wood in the cran kcase. and
ughten the bolts to the specified torque (photo}. Bend the locking
plate tabs to lock the bolls where applicable.
Early type
Cylinder liners/ pistons and connecting rods
16' upport the engine upright. then flt the liners without their seals in
tl\e prev1ously-no1ed positions. Make sure that the flats are ad1acent to
each other and evenly spaced (photo).
17 The liner protrusion above the lace of the cylinder block mus1 now
be measured in order 10 calculate the correct shims 10 fo on rhe base of
each hner Usrng a dial 1est Indicator and magneuc stand. zero the
md1aa101 on the lace of the cylinder block (photo).
18 Record the protrusion of each liner at the four points indicated in
Flg. 1 11 (photo) The maximum difference between the lour
measuremenrs on one liner must not exceed 0.07 mm (0.003 in). If all
the hners are new , they may be repos111oned and checked again 1n
order 10 obtain the correct measurements
19 Note the hrghest protrusion of each liner, and select a seal
ttuckness to give the specified protrusion, preferably as near to the
upper hmlt as possible. Only one seal is permitted to be fitted to each
liner On engines manufactured before April 1981 . the seals are of
svntheuc-fibre paper, but since this date, they are of aluminium-coated
Meel Select the correct thickness seals by referring to Fig. 1. 12 or 1.13
(ptioto)
Liner seal ~m ade from white synthetic fibre paper)
HIGHEST POI NT ON LINER SEAL TO BE FITTED

LINER, WITHOUT SEAL IOENTI FICATION THICKNESS
from + 0.039 to + 0.045 mm 0.070 to 0.105 mm
from+ O.Q19 to+ 0.038 mm 0.085 to 0.120 mm
from 0.006 to + 0.018 mm 0.105 to 0.140 mm
from 0.095 to - 0.007 mm 0.130 to 0.165 mm

J .\
Fig. 1.12 Cylinder liner seal selection c hart for pre -1981 models with fibre seals (Sec 17)

x A
+0 ,021
0,10
+0 ,010
- 0 ,009
0.12
+0 ,020
- 0080
0,15
- 0 ,010
Fig. 1 .13 Cylinder liner seal selection chart for 1981 -on 17 .2 Fitting a main bearing shell m the crankcase
models with aluminium seals - sizes in mm ( Sec 17)
A lmer prouus1on without seal Jt Seal to be fitted
17 3A 01hng the main bearing shells 17.38 Crankshaft located in the crankcase
17 4 F1u111g the crankshaft upper thrustwashers 17.SA Fitting a .:Oam bearing shell to the rear cap

17 58 01hng the main beanng shells 17 7 Cas11ng marks on the main bearing 17 8 F1t11ng the rubber seals to No 1 main
caps (arrowed) bearing cap
17 9 F111in9 No 1 main bearing cap 17 10 Tightening the main bearing cap 17 11 Removing the strips of celluloid from
bolts No 1 main bearing cap
17 12 Trimming 1he rubber seals on No 1 17 13 Checking the crankshaft endfloat 1 7 14 Applying locking fluid to the
m.11n 1Jea11n9 cap with a dial 1es1 1nd1cator flywheel bolts
17 15 T1ghten1n9 1he flywheel bolts 17 16 The liner flats must be ad1acen t to 17 17 Zero the dral test indicator on the
each o ther. and even ly spaced cylinder block

56 Chapter 1 Engine
20 Fit the seals 10 the base of each liner (photo) . On pre-April 1981
engines. fold the scalloped sections 1nio the grooves, and locate the
tabs at 11gh1-angles 10 the liner flats. as shown in Fig 1.14. On later
engines. pos111on the seal tongues at right -angles 10 the liner flats. as
shown 1n Fig. 1 12.
21 Rel11 the liners in the block. The liners must now be compressed,
and !heir protrusions rechecked A tool for doing this may be
constructed as shown In the photo, using blocks of wood and cylinder
head bolts Old valve springs may be used to compress the liner.
22 Record the m1Jx1mum protrusion of each liner {photo) . II the
difference between two adjacent liners exceeds the specifi ed allow·
able amount, reduce the thickness of the seal on the liner with the most
protrusion
23 Wuh the correct liner seals fined, clamp the liners, using the clamps
described 1n Section 6.
24 Press the big-end bearing shells into the big-end caps ano
connecting rod s. with the locating tabs engaged wilh the cut-outs
(photo). 011 the shells.
25 Check that the piston rings are correctly positioned as described 111
Secuon 15 then compress them with a piston ring clamp.
26 Turn the crankshaft so that No 1 big-end 1oumat is at its lowest
point Oil the bore of the liner. then inserl the piston so that the arrow
on its crown 1s pointing towards the front of the engine (photos) .
27 Using the handle of a hammer. tap the piston into the bore. white Fig. 1.14 Correct locations of the cylinder liner seal tabs (1)
gu1d1ng the connecung rod onto the big-end journal. ( Sec 17)
28 Fu the big-end cap and lighten the nuts to the specified torque
(photo). Check that the crankshaft rotates freely.
29 Refu the remaining pistons, using the procedure desctibed in
paragraphs 25 to 28.
Camshaft and timing chain

30 Oil the camshaft bearing journals. then insen the camshaft in the
block
31 Engage the thrustplate 1n the groove. lnsen and tighten the bolt to
the spec1f1ed torque ( photo).
32 Locate the gasket on the front of the cyl inder block. then fit the
front pla te and tighten the bolts to the specified torque.
33 Refit the urning chain and sprockets, with rele1ence to Section 5.
Oil pump and distributor driveshalt

34 Turn the engine so that No 4 piston (front) ls at the top of its stroke.
w nh the camshaft lobe high points pointing upwards (ie valves
rocking)
35 Using a dial test indicatot. set the piston 10 its TDC position
(photo)
36 Check that the timing mark on the crankshaft pullev is aligned w ith
the TDC notch on the timing plate. II not, loosen the nuts and
reposition the plate, then tighten the nuts. and apply a dab of paint on
them 10 seal them. Remove the dial test indicator on completion
37 lnsen the oil pump/ distributor driveshaft with the slot parallel 10
the crankshaft. As it engages the camshaft gear. It w ill turn Fig . 1.15 TDC position of the oil pump/ distributor
ant1-clockw1se to the position shown m Fig. 1. 15. Make sure that the driveshaft (Sec 17)
smaller segment on the drlveshaft is towards the block (photos)
38 Fit the distributor bracket. and tighten the bolt. a Larger segment
17 18 Checking the liner protrusion 17.19 The aluminium-coated seals are 17.20 Fitting a seal 10 a liner
available in three dflferent th1cknesses1 I,

Chapter 1 Engine 57
17 22 Measuring 1he maximum protrusion 17 .24 Fming a big-end bearing shell 10 us 17 .26A Inserting 1he piston (fitted with
of th liners cap clamp) Into the cylinder liner
1 I :lliS Arrow and markings on piston 17 28 Tightening the big-end cap nuts 17 31 Tightening the camshaft thrust plate
crown bolt
17 35 Oe1erm1ning the TDC position of No 17 37 A Initial f1ttmg posttton of 1he 011 17 378 Final hued pos111on of the 011
4 piston pump/ d1stnbutor driveshah pump/ distributor d11veshaft
39 Pr1!$S thei oil pump location dowels in 1he block 4 5 If removed , refit the oil level switch 10 t he sump and tighren h
40 Smeer a lit1le grease on the 0 -ri ng seal. and locate it m the oil (photos)
pump bodv recess.
41 Eng.lQG 1he 011 pump with the d11veshah. then insert and 11gh1en Tappets and cylmder head
1he bolls to the specified torque 46 Oil the tappets, and insert them 1n the11 original locauons
47 F1t the cvlinder head. with reference to Secuon 6
Sump OJ/ ltlter and hi/er housmgs and dipstick

42 Clean the mating faces of the sump and block 48 Locate a new 011 filter housing gasket on t he block If applicable.
43 Applv a bead of silicone 101n11ng compound 10 the 1om between trim off the corner of the gasket not requ11ed (photo) •
the t1m1ng cover and block (photo) 49 Refit the filter housing. Apply locking fluid to 1he boll threads, then
44 Locu111the gasket on the block. then rel111he sump and ughten the Insert them anp #•Ohlen 10 1he specified torque (photo)
bolts orooress1vely 10 1he specified 1orque Where an alloy sump is 60 Insert the oil.level dipstick in 11s tubo.
111100 apply locking fluid to the threads of the four concealed bolts 51 Relit t he oil filler housing. togerher with a new gasket, and ughten
bcloru 1ru1 rt1ng them Also lit the stool pla1e w 1h a new gasket. rhe bolts

58 Chapter 1 En gi n e
.·
17.43 Applying jointing compound to the 17.45A Inserting the oil level switch in the 17 .458 ... and tightening it
um1ng cover 1om sump •..
17 48 The right- hand lower corner of the 17.49 Applying locking fluid to the oil fi lter 19.0 Filling the engine with oil
011 filter housing gasket may be trimmed off housing bolts
engine as a new one, and restrict speed for the first 1000 km (600
18 Engine ancillary compo nents - refitting
miles).
6 It is recommended that the engine oil 1s renewed at the end of the
Refer to Section 10, and refit the components with reference to the first 1000 km (600 miles). Also the tension of the drivebelts should be
appropriate Chapter or Section. checked. and the idle speed and mixture adjusted If necessary.
1 Refer to Section 6, paragraphs 51 to 57 for details of retightening
the cylinder head bolts.
19 Engine - refitting
PART C : OVERHEAD CAMSHAFT ENGINES
Ref1t11ng 1s a reversal of the removal procedure given in Section 8. ( ZEJ AND ZDJ )
Pay particular attention to the following points:
(a) On automatic transmission models. apply grease to the spigot
hole in the dflveplate, and also apply locking fluid to the 21 Operations possible wit h engine in car
torque convercer-to -dnveplate bolt threads
(b) On manual gearbox models, apply a little higl) melting.point
The following operations can be carried out without having to
grease to the splines of the gearbox input shaft, and to the
front of the shaft which enters the spigot bearing remove the engine from the vehicle.
(c) Ad1ust the TDC sensor. with reference to Chapter 4 (a) Volve clearonces - odjustment
(d) Fill the engine with oil (photo) (b) Timing belt - removol and refitting
(e) Refilf ihe cooling system, with reference to Chapter 2 (c) Camshaft - removal and refitting
(d) Cyl/nder head - removal and refitting
(e) Engine mountings - removal and refitting
20 Initial start-up after maj or overhaul
22 Va lve c learanc es - adjustment

1 Before staning the engine. check that all hoses. controls and
electrical leads have been connected.
2 Make sure that tools and rags have been removed from the engine 1 The valve clearances must be adjusted with the engine cold. First
companment remove the inlet air ducting from over the rocker cover
3 Starting may take a little longer than usual. as the fuel pump and 2 Disconnect the crankcase ventilation hoses from the rocker cover.
carburettor must first fill with fuel. 3 Remove the d1agnosuc socket.
4 Have the throttle speed screw turned in an extra turn to increase the 4 On the ZEJ engine. remove the ln1ec1ors and cold start valve. and
engine idle speed This will help 10 offset the stiffness of the new position the fuelj IJipes on the right · hand inner wing.
engine components 5 Unscrew the nuts and remove the rocker cover.
5 If the ma1omy of internal components have been renewed, treat the 6 Remove the spark plugs.

Chapter 1 Engine 59
7 Turn the engine with o socket on the crankshaft pulley bolt, until
the exhaust valve of No 1 cylinder 1s fully open The clearances for No
3 cylinder inlet valve and No 4 cylinder exhaust valve can now be
checked and ad1usted using o feeler blade Remember No 1 cylinder 1s
11 the flywheel end of t he engine. and of course t he inlet and exhaust
valves are on the side adiacent 10 1he11 respecuve manifolds.
8 If the clearance requires ad1ustment. loosen the locknut, and with
the feeler 1n pos111on, turn the adjuster screw until the feeler blade Is
nipped and w ill not move. Now unscrew the adjuster until the feeler
blade 1s a stiff sliding fit Tighten the locknut and recheck the
clearance Refer to the Speciftcauons for the correct clearances
(photo) •
9 Repeat the ad1uS1men1 procedure using the following sequence
Exhaust valve Adjust inlet Adjust exhaust
open valve va lve
1 3 4
3 4 2
4 2 1
2 1 3
10 Reht the rocker cover. together with a new gasket and tighten the
nutJ
11 Ref•t the remaining components removed, using a reversal of the
removal procedure 22.8 Ad1ustrng the valve clearances
EXHAUST
Fig. 1 .16 Valve clearance adj ustment - cle arances in mm (Sec 22)
depress the brake pedel Unscrew and remove the crankshaft pulley
23 Timing belt - remova l and refitt ing bolt.
9 On automat ic transmission models, remove the TDC sensor plate
on the front of the transmission, and have on assistant lock the starter
1 Remove the radiator, drivebel t and fan. with reference 10 Chapter 2. ring gear with a w ide-bladed screwdriver. Unscrew and remove the
2 On models fitted with power steering, remove the pump drivebelt crankshaft pulley bolt
(Chapter 10) 10 Remove the pulley from the front of the crankshaft sprocket
J On models hned with arr conditioning, remove the compressor (photo).
dr111tbel1 (Chapter 11 ) 11 Remove the urning belt cover(s) (photo).
' Disconnect the battery negative lead 12 Refit the pulley bolt, t hen turn the engrne clockw ise until the
6 Remove the spark plugs (Chapter 4) timing mark on the camshaft sprocket is between the 10 and 11 o'clock
6 Remove the thermostat housing end tho additional air valve posulon (1e 45' frqrlt horizontal position) This 1s not in feet the No 1
(Chapu"s 2 and 3) TDC position, al1tio11gh No 1 piston is hell way up us compression
7 Remove the alternator (Chapter 12). st roke. Where the camshaft sprocket has a square hole In iti check Its
8 On manual gearbox models. have an essls1on1 engage top gear and posulon with reference 10 Fig. 1.17.

60 Chapter 1 Engine
Fig. 1 .17 Timing belt chart - ( A ) ZEJ engine, ( B ) ZOJ engine

( Sec 23)
1 Tensioner
2 Timing mark on sprocket (ZEJ)
3 Circular aperture (ZEJ)
4 Tuning mark on belt
5 Timing mark on sprocket (ZDJ)
6 Square aperture
7 Rotation direction arrows
13 Loosen the tensioner retaining nut and bolt.

14 Insert a screwdriver in the side of the tensioner support pla te, lever
tha plate against the spring tension, then tighten the nut to retain the
plate
15 Remove the urning belt. Note that the timing belt must not be
flattened to less than a 60 mm (2.4 1n) diameter arc, otherwise 11 may
be damaged
16 If necessary. the tensioner roller may be removed by unscrewing
th e nut and bolt, and the spring and plunger extracted from the water
pump housing (photos)
17 Commence reassembly by refitting the tensioner roller, together
with its spring and plunger. Lock the suppon plate in its retracted
pos1uon (photo)
18 Using a feeler blade. check that the clearance between the support
plate and the intermediate sprocket housing bolt is between 0.1 and
015 mm (0 004 and 0.006 m). If necessary, loosen the nut. remove the
bolt apply locking fluid to tis threads. then refi t and adjust. Tighten the
locking nut
19 Offer the urning belt to the sprockets. with the directional arrows
pointing clockwise. Besides the arrows, there should be three marks on
the urning belt, which should align with the urning marks on the
camshaft intermediate shaft, and crankshaft sprockets when the belt is
luted If the belt has no such marks, make some by referring to Fig.
1 20 Fig. 1.18 Retracting the tensioner support plate (Sec 23)
20 Centralise the belt on the sprockets. end recheck that the uming I)
marks are aligned 1 Nut
21 Loosen the tensioner nut and allow the spring to tension the 2 Screwdriver
urning belt. Tighten the tensioner retaining nut and bolt (photo). 3 Support plate

~-------------------------------------------------------------------------- 61
Fig. 1.19 Chec king the suppo rt plate c learance ( Sec 23)
1 Support plate
2 Ad/ustment screw and locknut
Fig. 1 .20 Tim ing belt mar ki ng diagram (Sec 23)
A ZEJ engine ( 116 teeth. white markings)

8 ZDJ engine (1 18 teeth. yellow markings)

62 Chapt er 1 Engi ne
23 10 Removing the crankshaft pulley 23 11 Removing the timing belt cover 23.16A Removing the timing belt tensioner
roller ...
23.168 ... followed bv the spring and 23 1 7 Tensioner roller loclcP.rf 1n 11!'< rP.tr>1c:1P.rl 23.21 T1ghten1ng the tensioner nut and bolt
plunger posiuon
24 Camshaft - removal and r efi t ting

22 Refn thi: 11ming bell cover(s)
23 Check that the locating pins are filled (photo). then fit the
crankshaft pulley against the sprocket Remove the ti ming belt as described 1n Sectton 23.
24 Clean the threads ol the crankshaft pulley bolt. then apply a httl e 2 Remove the rocker cover after disconnecting the inlet air ducting.
locking flu1d insert the bolt. and tighten 11 to the specified torque Recover the stud seals (photos)
(photo) Lock the crankshaft wnh reference to paragraphs 8 or 9. 3 Hold the camshaft sprocket stationary by inserting a lever through
25 Refit all the removed components with reference to the appropriate one of rts holes. Rest the lever on a piece of wood to prevent damage to
Chapte1s. and 1econnect the battery negauve lead. the cylinder head
23.23 Crankshaft pulley locating pins (arrowed) 23.24 T1ghtening the crankshaft pulley bolt

Chapter 1 Engine 63
4 Note the camshaft sprocket position in relation to the camshaft. as 17 Remove the special tool. 11 used
this varies according to engine type, and 1t 1s possible to fit the sprocket 18 Refit the tim ing belt w11h reference to Sectton 23
180' out 19 AdJUSt the valve clearances (Secuon 22).
6 Unscrew tho retaining bolt. and remove th·e sprocket (photo). Take 20 Refit the rocker cover
great care. as the sprocket is manufactured in sintered metal, and is
therefore rEl)atlvely fragile. Extract the Woodruff key.
6 Unbolt 1he timing belt rear cover (photo).
7 If desired. make up a special tool as shown in Fig 1.21 for
depressing the valves. In order to free the rocker arms from the
camshaft. Make the tool out of channel-secuon metal. and tighten
down on the rocker cover studs. Alterna11vely. t~e rocker arm ad1usters
should be fully loosened. •
8 Unbolt the camshaft thrustplate from the front rocker arm pedestal.
9 To remove the front 011 seal. refer to Fig. 1.22. Locate the sprocket
tho wrong way round on the camsha ft, against two strips of metal or
wood on the cylinder head. Insert and tighten the bolt. to pull out the
camshaft and force out the oil seal (photo) .
10 The camshaft can now be wi thdrawn carefully through the seal
aperture m 1he front of the cylinder head (photo) Take care during i ts
removal not to snag any of the lobe corners on the bearings as they are
passed through the cylinder head.
11 When rehtung, first check that the respective camshaft locauon
bearings m the cylinder head are perfectly clean, and lubricate with
some engine oil S1m1larly lubricate the camshaft 1ournals and lobes.
12 Insert the camshaft carefully into the cyli nder head. guiding the
cam sncuons through the bearing apertures so as not to score the
bearing surfaces
13 With the camsha ft in position. the front 011 seal can be carefully
drifted into pos1uon. Lubricate the seal lips with oil. and drive into its
locatton using o suuable tube drift Fig. 1 .21 Using the valve depressing tool (1 ) for camshaft
14 Locate the thrust plate in the camshaft groove, then insert and remova l w ithout removing cylinder head ( Sec 24)
tighten the bolts.
15 Refit the 1tm1ng belt rear cover and ughten the bolts.
16 Relit the camsha ft sprocket with Woodruff key. and tighten the
1eta1mng bolt to the specified torque (photos) Note that the offset 'a'
1n Fig 1 23 faces towards the cyllnd~r head. Make sure that the
sprocke1 1s fttted the correct way round. according to the engine type
(refer to Secuon 23 ti necessary)
Fig. 1.22 Method of removing ca m shaft front o il seal

( Sec 24)
1 Sprocket
2 Camshaft J.\
3 SU1ps of metal or wood Fi g . '1 .23 Camshaft sprocket (Sec 24)
4 01/ seal
5 Bolt a Offset towards cylinder head

64 Chapter 1 Engine
24.2A Removing a rocker cover stud seal 24.28 Rocker cover removal 24.6 Camshah sprocket and bolt
24 G Unbolung the um1ng belt rear cover 24.9 Camshaft front 011 seal removal 24 1 O Removing the camshaft
24 16A ComshaJr sprocket WoodrtJIJ key 24 168 Tightening the camsl'laft sprocket
(arrowed) bolt
7 On automatic tra nsmission models, disconnect the k1ckdown cable

26 Cylinder head - removal and refitting (Chapter 3)
8 Drsconnect the accelerator cable (Chapter 3).
Note Spec1al 1ools may oe required to release the cylinder head from 9 Disconnect the heater, econostat and brake servo vacuum hoses
its gas•1•1 Refer to paragraph 19 from the inlet manifold
10 Disconnect the w iring from the thermal urne swnch. supplernen·
1 Remove rhe 11m1ng belt as descrtbed in Sectron 23 tary air devrce. temperature switch and sender. and the 011 pressure
2 Remove the air cleaner (Chapter 3) switch
3 On the ZEJ engine. remove the mtiuure regulator. pipes and 11 Unchp the HT leads lrom thelf holders
tnJP.Ctort cold stan 1n1oc1or, and control pressure regulator. 12 Uncltp and remove the d1agnosuc socket. and unbolt the w111ng
4 On the Z.DJ engine. remove the 111111ow sensor and lllf ducttng retaining chp
5 Unscrew the exhaust downp1pe-10-manifold nuts. and 11e rhe 13 D1sconnec1 \he crankcase venttlat1on pipe
downpipe 10 one side. 14 Remove the lnlet and exhaust manifolds (Chapter 3).
6 D1• .:onncct the heater noses from the cyhnder head, and unbolt the 1 6 Unbolt the thermostat suppon casmg On cenain models, 11 is also
pipe loodrng to the warer pump (photo) nccessnry to remove the alternator end bracket

Chapter 1 Engine 66
16 Unbolt the rocker co11er. and remove the gasket 011. then screw them into positt0n Tighten them progress111ely in the
17 Progressively unscrew the cylinder head bolts, using a reversal of sequence shown In Fig. 1.24 Tighten all bolts to the Stage 1 torque
the tightening sequence shown In Fig 1 24 specified. then In sequence. loosen each bolt a quarter tum and
18 Remove the rocker shah assembly (photo) lighten to the specified Stage 2 torque ( photo)
19 Roel< the cylinder head to release 11 from the gasket The Peugeot 28 Refit the urning belt with reference to Section 23.
tool for domg this is shown 1n Figs 1 6 and 1 7 and is easily 29 Ad1ust the 11al11e clearances (Section 22)
fnbfl•.ated 30 Refit the rocker cover and gasket
20 Remove the cylinder head from the block by sliding 11 across the 31 Refit all the remo11ed componen1s with reference 10 the appro ·
gasket (photo). This is necessary to pre11ent the cyl inder liners from pnate Chapters where necessary.
bo1ng disturbed, and possibly breaking their lower seals If further work 32 Run the engine at 2000 rpm for approximately twel11e minutes. or
1 to be earned out on the engine. such as cleaning the pistons. tho unul the self-disengaging fan cuts 1n
liners must be clamped m position. using clamps made from metal 33 Switch off the 1gn111on. and allow the ongme to cool down for two
plJte and suitable bolts refer to Section 6 Do not tum the engine hours.
without having the clamps fitted 34 Depressunze 1he cooling system by temporarily remo111ng the
21 BefOfe refitung the cylinder head. check that all the mating surfaces pressure cap from the expansion tank Take precautions against
are perfectl y clean Loosen the rocker arm ad1uster screws fully back scalding
Also ensure that the cylinder head bolt holes 1n the crankcase are clean 35 Remove the rocker co11er. then m the correc t sequence. loosen each
and free of oil Synngo or soak up any 011 lefl 1n the bolt holes, and 1n bolt a quarter turn, and immediately reughten to 1he specified Stage 4
the 011 feed hole on tho rear left- hand comer of the block. This is most 1orqu·e.
1mponant, in order th at the correct bolt tightening torque can be 36 Check and 1f necessary adjust. the 11al11e clearances (Sec11on 22)
uppl1ud 37 Refit the rocker cover
22 Where fitted . unbolt and clean the 011 filter from the rear of the 38 Where the 11mmg co11er can be remo11ed without remo111ng the
cylinder head then refit and tighten it crankshaft pulley remo11e 11, and re-tension the timing belt by
23 II the crankshaft has been mo11ed. repos111on 11 with the urning ma1k loosenmg the tensioner nut and boll. then reughtemng them On
on the sprocket at 9 o clock. Check that the locauon dowel is 1n compleuon, refu the urning cover
pos111on at the front nght hand comer of the block
24 Remo11e the liner clamps
2& Fit the cylinder head gasket onto the cylinde1 block upper face. and
ensure thnt 11 Is exactly located (pho to) If possible. screw a couple of 26 Engine mountings - removal end refitting
guide studs into pos111on They must be long enough to pass through
the cylinder head so that they can be remo11ed when it is in position Apply the handbrake. then 1ack up the front of the vehicle and
26 Lower the cylinder head into posiuon. engaging wnh the dowel. support on axle stands.
and then locate the rocker assembly Make sure that all the locatmg 2 Using a hoist or a trolley 1ack. support the weight of the engine.
dowels are m pos1t1on, and as the assembly 1s lowered into pos111on, 3 Unbolt the engine mountmgs flom the crossmember and engine
locate the thrust plate m the camshaft groo11e brackets. If necessary. also unbolt the brackets
27 Lubricate the cylinder head bolt threads and washers with engme 4 Refitting is a reversal of remo11al
25 6 Water pump return pipe 25 18 Rocker shaft assembly removal 25.20 Cylinder head removal
25.25 Localing the cylinder head gaskel on 25 27 Tightening the cylinder head bolts
tho block

T rial ve rsion of ABC Ambe r PDF Merger v3.02, http://IMVw.processtext. com/abcpdfmg .html
66 Chapter 1 Engine
IN H.19230
Fig 1 .24 Cylinder head v alve positi ons and bolt tightening
sequence ( Sec 26)
Fig. 1 .25 left- hand engine mounting bolts (1 ) and nut (2)
( Sec 26)
27 Engine - remova l
gearbox in this pos111on w nh a trolley 1ack
l Remove the bonnet (Chapter 11) 28 Unbolt and remove the engine mounungs.
2 Remove the battery (Chapter 12) 29 Pull the engine forwa rds. and disconnect II from the gearbox and
3 Remove the air cleaner (Chapter 3). clutch. On automauc transmission models, make sure that the torque
4 Remove the radiator (Chapter 2). converter rema ins fully engaged with the transmission (refer to
5 On the ZEJ engine. remove the mixture regulator. together with the Chapt er 6 1f necessary)
PIP' s id n1ectors, with reference to Chapter 3 Also disconnect the 30 lift the engine from the engine compartment, taking care not to
told start pipe and the remaining atr ducting damage the surrounding components
6 On the ZDJ engine, remove the airflow sensor assembly and
remaining atr ducllng with refetence to Chapter 3.
7 Disconnect the accelerator cable (Chapter 3)
8 The engine wmng harness can remain on the engine 1f desired by
d1sconnecung the multi-plugs, or 11 may be removed by disconnecting
from the various electrical components, and 1dentllylng each wire for
1oca11on
9 On models fitted with power steering. remove the pow er steering
pump (Chapter 10)
10 On models f111ed with atr cond1uomng, remove the compressor
from thP engine and suppoo it on one side. w i tho ut disconnecting
the pipes Similarly remove the condenser
11 Remov11 the starter motor (Chapter 12) .
12 Apply the handbrake. then Jack up the front of the vehic le and
support on axle stands.
13 For additional working room It is recommended that the front
crossmember 1s lowered by 50 mm (2.0 In). To do this, disconnect the
steering column from the steering gear, replace two of the crossmem -
ber bolts with longer ones. remove the remaining two bolts, and lower
the crossmember
14 Unbolt and remove the gearbox front cover, and the TDC sensor
cover, without d1sturb1ng the setting of the sensor.
15 On automatic transmission models, mark the torque converter in
1elat1on to the drivepla te. then unscrew the four bolts. The engine will
neod to be turned to uain access to each bolt
16 Pos1t1on a container beneath the engine sump. then unscrew the Fig. 1 .26 Removing the engine ( Sec 27)
dram plug and dram the engine oil On completion, refit and tighten the
drain plug
17 Unscrew the exhaust downpope·to-mamfold nu ts, and ue the
downpipe 10 one side
18 Disconnect the radiator top and bottom hoses from the engine 28 Engine dismantling - general
19 Dosconnact the fuel feed and return hoses
20 On automatic 1ransm1ss1on models. disconnect the k1ckdown Refer to Section 9
cable
21 Disconnect the heater, econoS1at and brake servo vacuum hoses
lrorn the inlet manolold 29 Engine ancillary components - removal
22 Disconnect the coil HT lead
23 Disconnect the heater hoses from the cyltnder head. and the pope
lt111d1ng 10 the water pump Before complete engine d1smantltng begins, remove the follow ing
24 Unscr11w and remove the bolts secunng the engine mounttng ttems.
brackets to the crossmombor DistT1butor (Chapter 4)
25 Connect a hoist to the engine. and take ns weight Clutch (Chapter 5)
26 Unscrew the upper bolts securing the gearbox to the engine. Oil filter ($e~t1on 2)
27 R111se the eng1no unttl the gearbox touches tho body. Support the Water pump (Chaptor 2) and coolant retum pipe

Chapter 1 Engi n e 67
15 The big -end caps will not pass ou t through tho cylinder liners. so
30 Engine comp lete dism antling
each liner/ piston/ connect ing rod must be removed as an assembly out
of the top of the cylinder block Before doing this however.
1 Remove the cylinder head as descnbed in Sec11on 25 centre -punch each liner nm and ad1acent surface on the top of the
2 Unbolt the liming belt tensioner. and remove it cylinder block. so that they will be refined 1n their 011g1nal pos1t1on and
3 Hold the starter nng gear stationary using a wide-bladed orientation. 1f. of course. they are no1 being renewed completely.
screwdriver 16 Unbolt the big -end bearing caps, keeping the bearing shells taped
4 Unscrew the bolts and remove the flywheel (or driveplate - to thei r original cap or connecting rod 1f they are to be used again,
automauc transmission). The flywheel bolt holes are offset. so 1t can although this 1s no t to be recommended.
only be lilted one way. Renew the flywheel bolts when refining 17 Withdraw the cylinder liner/ piston/ rod assemblies
5 Unscrew the intermediate shaft sprocket. bolt ( photo). passing a 18 Unbolt and remove the main bearing caps, again keeping their
screwdriver shaft or rod through one of the holes in the sprocket. to bearing shells with their respective caps 1f they are to be refitted, again
lock against the front of the block. and retain the sprocket in position- not to be recommended.
whllst It ls being unscrewed 19 Note that the front and rear main bearing caps are located on
6 Withdra w the sprocket (photo). and remove tho Woodruff key from dowels. so 1f they are tight, tap them straight off. not 1n a sideways
the shaft directton.
7 Unbolt and remove the intermediate shaft housing cover, and the 20 Withdraw the crankshaft. noting the two semi -circular thrust
forked lockplate (photos) washers located In the crankcase. Remove the bearing shells. and
8 The 011seal can now be extracted . Prise it free with a screwdriver. identify them by marking with numbered tape if they are to be used
but take care not to damage the housing. again.
9 BefOfe th e intermediate shaft can be w i thdrawn. extract the 21 Using two screwdrivers inserted at opposite points, lever off the
d1str1butor d11ve pinion and 011 pump dnveshaft Withdraw the crankshaft sprocket. E1ctract the Woodruff key, and remove the belt
1ntermed1a1e shaft from the front of the block. guide.
10 Turn the engine on its side. then unscrew the securing screws and 22 Remove the crankshaft front and rear 011 seals, and discard them.
remove the sump pan If 11 is stuck tight, tap it gently with a mallet. 23 The flywheel mounting flange on the rear of the crankshaft
Remove the gasket. incorporates a sealed spigot bearing. This may be extracted i f worn by
l l Unbolt and remove the oil pump The pump flange is located on filling 1t full of grease, and then driving in a close-fi tting rod The
dowels so pull 11 straight off. hydraulic pressure created will force out the bearing.
12 Identify each big- end cap and rod to enable refitting in the correct
position
13 The main and big -end bearing caps are numbered from 1 to 4, from
the flywheel end of the block. The main bearing cap numbers are read
from the 011 filter side of the crankcase (photo). 31 Crankc ase ventilation sys'tem - descripti on
14 The big-end bearing caps and the11 connecung rods are not very
clearly marked, so it is best to centre -punch them at adjacent points. 1 Refer to Sect ion 12.
and on the 011 filter side, so that there 1s no doubt as to their position 2 The system consists of hose connections from the rocker cover to
ond 011enta t1on in the block the Inlet air ducting 11nd inlet manifold
. ' ~
J-_pl'_- .
, ;y:: ::: (.~../;,..
•
n
30 5 Unscrew the bolt . 30 6 ... and remove the intermediate shaft 30.7A Unscrew the bolts ...
sprocket
30.78 and remove the intermediate shaft 30.7C Unscrew the bolt (arrowed) ... 30.70 ... and remove the forked lockplate
housing cover

68 Chapter 1 Engine
32 Engine compo nents exo m m at1o n and renovati on

(general)
Rcfef ro St:CllOn 13
33 Cylinder head - d 1sm an tlm 9. dec arbo n ismg and

reassembly
1 Removu 1h11 cnmshah. w1rh reference 10' Section 24.

2 RtJfor 1<• St cuon 14 for valve removal and 1eht1m9. and decarbonis-
1ns1 proe-0dure~ Single valve spnngs are f111ed {photos)
3 Ei<am1nE rhe camshah for wear or scoring of the 1ournals or cam
lobus Any wear or scoring "' the camshaft bearongs will mean renewal
ot rhtl cvl1ndor hoad. .is 1hr. bearings are line-bored. and can not be
wplacud 111de1>ende11tly. It may be possible ro have worn cam lobes
reprohled by 11 specialist firm
4 Refit th~ camshaft. 109othor w1rh a new ool seal with reference to
Sf't:loOll 24
5 Nore 1h.11 11 1s not perm111ed to re face the cylinder head, so 11 the
warpaye u>.c.ceds the specrf1ed amount, the head will have to be
mnuwed
30.13 Main bearing cap number
.A
33 2A Compressing lhe valve spnng 10 33.28 Removing the retainer •.. 33 2C va lve spring ..
rnmove rht1 ~pill collars
33 20 spring ~at 33 2E and valve
Crankshaft
34 Examinatio n and renova tion o f dismantled components 3 The crankshaft 1• no1 r111ed woth removable balance we1gh1s
4 Renew al of the balf· bearong type spigot bearing 1s covered 111
Ri! fer 10 Secuon 15, norong the differences given in the follow ing Secuons 30 and 36
sub Soctron~
Camshaft
Pistons and connecting rods 5 Check th , bearings in the cylinder head If worn. a new head will be
2 rho udgeon pon 1s on interference ht in the connecting rod small required.
end cind remov.il or rclttt111g .Jnd changing a piston is a 1ob best left to 6 lnspnct 1h"a camshah 1ournals and lobes seorrng or general w ear
vour d11.1ltir or 11nyinu spoc1ahi.1 Thi:; 1s owing 10 the need for a press w ill 111d1ca1e the noed for new ports
and I'll and coreful he111rng of 1he connecting rod 7 Tho camsha ft sprocker 1001h should not be chipped or badly worn

Chapter 1 Engine 69
8 Tho C<lnll haft 1hru~1 plate should not be badly scored 01herw1se 25 To dismant le the pump. remove tho cover rt1tarn1ng bolts and
camshaft endfloa1 will be excessive detach the cover (photo)
26 Extract the gears and clean thP respecuve components (photo)
lnturmcd,;1te shaft 27 Inspect for any signs of damage or excessive wear Use a feeler
9 Cl' d< the 1ournafs and gear teeth for wear. chipping or sconng gauge 10 check the clearance between the rotor (gear) teeth and 111e
W> The sprocket 1ee1h should be free from wear and damage inner housing
11 The forked 1hrus1plo1e should be unwom. 01herw1se excessive 28 Also. check the geat endfloa1 using a s1ra1gh1-edge rule laid acrOl>S
shaft ondfloa1 will occur the body of the pump ond feeler gauge rnsened between the rule and
12 Wear 1n the shah bearings can only be rectified by the purchase of a gears
new crankcase 29 Compare the clearances with the allowable tolerances given 1n the
Spec1f1ca11ons at the start of 1h1s Chapter and. ti necessary renew any
Ttmmg belt and tensioner defecuvo parts or possibly the pump un11
13 ThP bell shou ld be without any sign of fraying, cuts or sphl s, and 30 Do not overlook the reltef valve assembly To e111ract it remove the
there shou ld be no deformauon of the teeth spit! prn and wit hdraw t he cup. sprrng, guide and piston Agam look
14 Evu11 1f the tlm1n11 bell appear:; to be m good cond1t1on, n 1s for signs of e><cess1ve wear or damage and renew as apphcable
rucommtinded that 1t rs ronowod at the spec ified intervals 31 Chock the pump drtveshaft for signs of wea1 or distortion, and
15 Check the bel11ens1oner pulley It should spin freely, without noise renew 1f necessary
If tt does not renew 11.
Rocker gear 35 Engine reassembly (g eneral}

16 Slight wear in the heels of the rocker arms can be removed using an
01lsto11e but ensure that the contour is maintained.
Refer to Secuon 16
17 Scoring or wear in the componen ts can only be recuf1ed by
d•smanthnn and renewing tho defective components
18 Unscrew the end plug from the shaft. and extract the plug and
filter This filter must be renewed at the specified intervals, or whenever
111s removed
19 Number the rocker arms and pedestals bearings. Note 1ha1 bearing
No 5 has two threaded holes 10 retain the 1hrus1pla1e which controls
the camshJlt endfloa1 and a hole for the roll pin. wh ich locates the
shah and pedestal Renew the roll pin rf rt 1s not the solid type
20 Keep the respecuve parts in order as they are removed from the
shalt and note their respective locat1ons. Note also that the machined
flat secuons on top of pudestals 1 to 4 all face towards the camshaft
sproc~et
21 Lubricate each component as rt is assembled w11h engine 011 Lay
the uedestJls. soJcers springs and rockers out rn order.
22 Support the rocker shah rn a soft 1awed vice. and rnsert the new
f1 ter into the end of 1. ftt the retaining bolt and tighten it 10 the
specified torque
23 Assemble the respective pedestals. rocker arms. spnngs and
!il>ilCers onto the shah When the shah assembly 1s complete. compress
the last pedestal to align the retaining pin hole rn the shaft and
pedestal Dnve a new prn rn10 pos111on 10 secure rt Early models fined
w11h a hollow type roll p in shou ld have the later solid type prn f111ed on
reas1>1•mbly
01/ pump 34.25 011 pump wtth cover removed

24 II is essenuat that all parts o f the pump are 111 good cond11ton for the
pump to work ettocuvely
36 Engine - c omplete reassembly
Crankshaft and main beaflngs

1 Invert the block. and locate the main beanng upper shells 11110-
pos111on. engaging the lock tabs rnto the cut -outs in the beanng
recesses Note 1ha1 all of the upper shells are grooved (photo)
2 Lubncate the shells w11h clean engine 011. fn the thrust washers to
No 2 main bearing so 1ha1 the 011 grooves are v1s1ble. and lower the
crankshaft 1n10 pos111on (photos)
3 Locate the shells rn the marn beanng caps 111 a similar manner to
that of the block. and lubr1ca1e. Note 1ha1 on the ZEJ engine the shells
are all grooved whereas on the ZDJ engrne they are all plam
4 Frt the bearing caps 11110 pos111on, then insert and 11gh1en the bolls
(photos) Do not f11 any side seals 10 caps 1 and 5 at this stage
5 Now check the crankshaft endfloa1. using a dial gauge or feeler
blade (photo) If necessary. select new thrust washers. and fu them 10
No 2 main bearing
6 Using tw1s1 drills measure the gap between the block and the
bonom of th.e groove 1n Nos 1 and 5 main bearing caps ( Fig. 1 27) If
less than 516 mm (0 197 1n) frt a 5.15 mm (0 203 in) 1hick side seal
(no referenc11 mark). If more than 5.0 mm (0 197 in), ftt a 5 4 mm
(0.213 in) thick side Seal (white reference mark). Note that seals must
34 26 Ex1ract1ng a gear from tho 011 pump also be f111ed where the caps were previously sealed by 1n1ec11ng
silicone sealant, bul first clean away all lraces of the silicone.

70 Chapter 1 Engine
7 Remove Nos 1 and 5 main bearing caps, and Iii the side seals so
that 1hey protrude 0.2 mm (0.008 1n) towards the block face. Smear
the seals with oil.
8 Refit tho caps. and 11ghten the bolts. To prevent the seals
stretching, 1t is recommended thal strips of celluloid are temporarily
placed against the seals as the caps are inserted. Pull out the strips after
11ghtening the bolts. Trim the visible ends of the seals so that they
protrude 0.7 mm (0.028 in)
9 Lubricate the new front and rear crankshaft oil seals. and carefully
locate them mto thei r apertures. tapping them fully Into position using
a tubular d11ft of a suitable diameter. Ensure that the seals face the
correcl way round. with lhe cavity/ spring side towards the engine.
Should 1he seal hp accidentally become damaged during fining ,
remove and discard 11. and fit another new seal (photos).
1 O If a new clutch spigot bearing is being fined, now is the time to do
11 D11ve 11 home using a suitable diameter tubular drift. N ote: When
fiuing this bearmg co the crankshaft, smear the outer bearing surface
with a suitable thread-locking compound. To the crankshaft front end,
lit the bell guide. the Woodruff key and sprocket (roll pins visible)
(photos)
Flywheel or driveplate (automatic transmission)

11 Locate the flywheel or d11veplate on the crankshaft mounting Fi g . 1 .27 Measuring the side seal grooves of Nos 1 and 6
flange. The bah holes are offset. so it will only go on one way ( photo). main bearing caps - for A . see text (Sec 36)
12 Use new fixing bolts. and having cleaned their threads. apply
thread-locking fluid 10 1hem. Insert and tighten the bolts (photos).
Cylinder liners/pistons/ connecting rods

Note: A piston ring compressor will be required for this operation
13 Before fitting the piston and connecung rod assemblies Into the
liners, the liners must be checked in the crankcase for depth of fitting.
This 1s carried ou t as follows.
14 Al1hough the cylinder liners fit directly onto the crankcase inner
fla nge. 0-ring seals are fitted between the chamfered flanges as shown
in Fig. 1.28 New 0-nngs must always be used once the cylinders have
been disturbed from the crankcase.
15 First insert a liner into the crankcase without its 0 -ring. and
measure how far it protrudes from the top face of the crankcase. Lay a
straight-edge ru le across its top face, and measure the gap to the top
face of the cylinder block with feeler gauges. It should be as given In
the Specifications.
16 Now check the height on the other cylinders in the same way, and
note each reading. Check that the variatton 1n protrusion on ad1oining
liners does not exceed the amount specified.
17 New liners can be Interchanged for position to achieve this if
necessary, and w hen in position. should be marked accordingly 1 to 4
from the flywheel end. The protrusion dimensions should become
progressively smaller from No 1 cylinder to No 4 cylinder.
18 Remove each liner in turn, and position an 0-ring seal on10 its
lower sectton so that 1t butts into the chamfered section, taking care
not to tw1s1 or distort 11.
19 Wipe the liners and pistons clean. and smear with clean engine oil.
prior to their respective fitting.
20 Refit 1he pistons to the liners, using a piston ring compressor
ughtened around well -oiled rings to install 1he piston in to the lowe1 Fig . 1 .28 Cylinder liner 0 -ring seal (1) and protrusion (A )
end of the cylinder liners. Fit the liners/pistons into the cylinder block (Sec 36)
Fn the big-end caps with shells (photos)
21 Observe the following important points:
into the cylinder, and insert a new spht pin to retain the valve assembly
(a) The aflows on top of the pistons must point towards the
in place. •
llvwheel (photo)
26 Fit the assembled pump into position on the locating dowels.
(b) The big end shells with otl holes must be fitted to the
Tighten the retaining bolts (photos) .
connectmg rods. and the shells without oil holes to the caps
(c) The connectmg 1od and cap bolts must be tightened to the
specifted to1que, with the numbered markings In alignment
Intermediate shaft and timing belt tensioner
27 Lubricate the shaft. and insert i t through the front of the crankcase
(plloro)
(photo).
(d) When assembled, rec/amp the liners and 1orate the crankshaft
28 Slide the lockplate fork into the protruding shaft location groove.
co ensu1e it rotates smoothly
and secure the plate with the bolt and washer. Check that the shaft is
free to rotate on completion.
Oil pump 29 Flt 1he new oil seal into the Intermediate shaft front cover. and
22 Lubricate the respective parts of the otl pump, and reassemble. lubricate its lips.
23 Insert the rotors and refit the cover. No gasket is fitted on this face. 30 Fit the front cover. together w ith a new gasket, and tighten the nut
24 Tighten the retainin g bolls to secure the cover. and bolts. l/
25 Insert the 011 ptessure relief \la lve assembly. fitting the piston into 31 Fit the Woodruf , key Into its groo\le In the shaft, and carefully
the spring, and the cup over the spring at the opposite end. Compress locate the intermediate shaft drive sprocket into position, with its large
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36 1 Fi11mg the main bearmg upper shells 36 2A Oihng mom bearing shells 36.28 Fitting thrust washers 10 No 'J main
bearing
36.2C Crankshaft located in crankcase 36.4A Fitting the mam bearing caps - note 36.48 Tightening the main bearlng cap
the locauon dowel (arrowed) bolts
36 5 Checking the crankshaft endfloat with 36.9A Fm1ng crankshaft front 011 seal 36.98 F1mng crankshaft rear 011 seal
feeler blades
36 1OA Clutch sp1go1 bearing in crankshaft 36.1 OB T1m1ng belt spacer/guide 36 1OC F111ing crankshaft sprocket
rear flange Woodruff key

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36 1OD Frtung crankshaft sprocket 36 11 Fitting tho flywheel 36.12A Apply locking llurd .•
36 1 28 then insert and tighten the 36.20A Fitting a piston and connecting rod 36.208 Fitting the liners/ pistons in the
flywheel bolts into the cylinder liner block
f(1 .,;;, I! -
~ .
:a!" 'a
.. ~· -'.~':-1'. .. '
. . . ..- .,
~: ~I
' t:.,. '""
• .! . ~
36 20C F1111ng a brg end cap 36 21A Arrow mark on tho top of the 36.21 B Tightening a big -end cap bolt
piston
36 26A Fu the 011 pump 36.268 ... and tighten the retaining bolts 36.27 Fitting the Intermediate shaft
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Chapter 1 Engine 73
offset inner face towards the crankcase. Use a su11able diameter dnr1 to 40 Engage the distributor drive pinion 1n1t1 ally w ith the 0 11 pump
tap the sprocket tnto position over the key. dnveshaft then turn the pinion so that its groove 1s parallel with the
32 Prevent the sprocket from rotating by inserung a screwdriver blade crankshaft. with the smaller segment facing outwards (photo)
or s1mllor through o sprocket hole, and tighten the retaining nul 41 Press the drive pinion fu lly into mesh with the 1ntermod1ate shalt
(complete with flat washer) to the specified torque gear. and check that its fina l posttton Is as shown 1n Fig. 1 29
33 Rein the water pump, with reference to Chapter 2
34 Rel it the timing bell tensioner, spring and plunger Lever the
support plate against the spring tension. and lighten the nut and bolt to 37 Engine ancillary components - refitting
hold the tensioner in its retracted position
35 Grease the end of the 011 pump driveshaft. then insert 11 through the
d1stnbutor aperture and into the 011 pum1{(photo) . Make sure tha t the Refer to Section 29. and relit the components whh reference to the
hm1ttng c11cl1p 1s tn position on the driveshaf1. and temporarily st1ck appropriate Chapter or Section Note that the water pump has already
some tape over the hole to prevent it fa lling out been refitted
Sump pan
36 Locate a new gasket on the sump or crankcase. 38 Engine refitting
37 Locate the sump pan. then tnsert and tighten the securing screws.
Ref1ttmg 1s a reversal of the remova l procedure given tn Section 27,
Cylinder head and timing belt with partlcular attention to the points given m Secuon 19.
38 Refer to Section 25
Distributor drive pinion

39 Set the engine at TDC on No 1 cylinder The mark on the camshaft 39 Initial start- up after major overhaul
sprocket should be ahgned wnh the tongue in the t1mtng bel t cover
aperture Refer 10 Section 20. 1gnormg the reference to Section 6
36.35 lnserung the oil pump dnveshaft 36 40 Fitting the distributor/oil pump dnve pinion
Fig. 1 .29 TDC position of the

distributor drive pi ni on
(Sec 36)

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74 Chapter 1 Engine
PART D : FAULT DIAGNOSIS
40 Fault diagnosis - engine
Symptom Reason(s)
Engine will not crank, or cranks very slowly Discharged battery

Poor battery connections
Starter motor fault
Engine cranks. but will not start No fuel reaching engine

Ignition circuit fault
Fuel system fault
Leak in crankcase vent system hoses
Leak in intake manifold
Engine stalls, or rough idle Leak in crankcase ven t syStem hoses

Leak 1n intake manifold
Very weak mixture
H8$tlatton or poor accelera11on Incorrectly ad1usted mixture

Clogged air cleaner
Excessive oil consumptton Worn piston nngs or cylinder bores

Worn oil seals or leaking gaskets
Excess111e mechanical noise from engine Incorrect valve clearances

General internal wear
Pinking on accelerauon l"uel octane too low

Overheating
Carbon build-up In engine
Excessive oil vapour being drawn into crankcase breather system
Upper cylinder lubricant being used
Weak mixture
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.·
Chapter 2 Cooling system

Contents
Antrfreeze mixture general . .•.. ·- .... .... 4 Radiator - removal. reparr and ref1tt1ng ..... ... ... 6
Cooling system - drarnrng flushrng and rehlhng ..... - .......... _.. . 3 Routine marntenance ........ ................ .. ..• ... .................... .. 2
011vebelt removal rehttrng and adiustment ...................... 7 Self-disengaging fan thermoswitch - removal and refitting .......... 9
Fault diagnosis coohng system .. .. .. ..... ......... .......... .... 10 Thermostat - removal. testi ng and ref1111ng ... ................. ............ 5
General descrrpt1on ... ... .. ... ................. .. ....... ..................... .... 1 Water pump - removal and refining ............................................ .... 8
Specrficat rons
Type Pressurised w 11h el(pans1on bottle. front -moun ted radiator w ith
belt -driven fan. w ater pump and thermostat
Coolant
Anufreeze 1ype/specif1ca11on Ethylene glycol based an tifreeze ( Duckhams Universal Antifreeze
and Summer Coolant)
Antifreeze mixture
Protectfon to 15 C (S'F) ................................................................... 27% antifreeze
Protection to 35·c ( 31 ' F) ..... .................................................. 50% anufreeze
SVlitem capacity·
Carburettor models (manual gearbox) .. ................................. .. 8 4 litres (1 4.8 pints)
Carburettor models (automauc transm1ss1on) .................................. 7.3 litres ( 12.8 pints)
Fuel 1n1ect1on models .... ......... .. .... . ................................. 7 5 lttres ( 13.2 plnts)
Pressure cap sett ing ........................................................................ 0.8 bar (11 .6 lbf/i n'), or 1.0 bar (14.5 lbf/in'), depending on model
Thermostat
Starts to open·
Carburettor models .............................._ ........................................... . 75 or 82' C ( 167 or 180' F)
ZEJ engrne models .. .... .................................................................. 83' C (181 'F)
ZDJ engine models .................................................................... 87'C (189'F)
Fully open (7 5 mm/ 0 3 rn) .
fl(cep1 GTI models ......... .................................................................... 95'C (203' F)
GTI models ............ ..... ..... .................................................................. 94' C (201 ' F)
Fan/ warni ng l amp operating temperatures

Radrator fan cut -m temperature ................................................................ 88' C ( 190'F)
Red..,tor fan cut-out temperature ......... .. ... . .................................... . 79'C (174' F)
Temperature warning lamp cuHn temperature
Early (blue) 105'C ( 221 'F)
Later (white) 11 o·c
(230' F)
/.)
Torque wrench settings Nm lbf ft
Water pump .. ....... ................................................................................. 15 11
Thermosta t housing cover ......................................................................... . 15 11

76 Chapter 2 Cooling system
General description
The cooling system 1s of pressurised type, incorporating an

expansion bo ttle. front mounted crossflow radiator with belt-driven
fan , water pump. and thermostat The cooling fan is temperature·
control led. and is only driven when It Is really needed. with a
cons&quent reduction 1n noise and power consumpuon. The viscous-
typa fan employs ii fl uid drive and temperature-controlled valve. The
self-disengaging fan employs an electromagnetic dnve, which is
energised by a thermosw itch in the radia tor.
The coohng sysiem functions In the following way After o cold
sta11 the thermostat valve is shut, and coolant circula tion is restricted
to the engine and heater matrix. When the coolant reaches the normal
engine operating temperature. the thermostat starts to open. allowing
the coolant to also circu late through the radiator. TM coolant is cooled
by the ac tion of the airflow through the radiator. enhanced when
necessary by the fan.
The radiator incorporates a low coolant level Indicator warntng
switch
2 Routine maintenance
Carry out the followmg procedures at the intervals given m Rouune

maintenance at the front of this manual
Check coolant level

1 Pos111on the vehicle on level ground
2 W11h the engine cold. check that the coolant level in the expansion
bottle is up to the ' MAXI' mark (photo)
3 If necessa1y unscrew the pressure e<1p and top up wrth the correct
antrfreeze mixture (photo) Refit the cap on completion.
Check coolant hoses

4 Examine all coola nt hoses for leaks. and tighten the securing clips
where necessary At the same time, check the radiator and water pump
for signs of leakage. Fig. 2.1 Cutaway view of the low coolant level indicator
warning switch ( Sec 1)
Check 1he drivebelt
5 Check the full length of the drivebelt for signs of fraying, glazing 1 Body
and cracktng 2 Terminals
6 If the dnvebelt needs tens1onrng or renewal, refer to Section 7. 3 Float
4 Magnet
Renew antifreeze mixture 5 Encapsulated reed contact
7 Drain the coohng system. and refill with new antifreeze mixture, a Switch in 'off' position
w11h reference to Secuon 3. b Switch m 'on' posw·on
2 2 Coohng system expansion bottle 2.3 Topprng-up the cooling system
j •\

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Chapter 2 Cooling syst em 77
3 Cooling system - d raining, fl ushing on d refilli ng
1 Pos111on the heater 111mperature control on full heat

2 Unchp the expansion bo1tle. and pour Its contents into a container
3 Suspend the expansion bottle from a convenient point on the
bonnl't as high ai; tho connecung hose will allow
4 Place a suitable container beneath the left hand side of the
rdd1ator. then unscrew the drain plug and drain the coolant (photo)
5 D1a1n the cylinder block by remoying the plug located on the
11qhl·hand rear (CIHUUrOllOr engines) Or left hand front (fuel in1ect1on
engines) of the block
6 Disconnect the wmng from the coolant level sender on the radiator
Unscrew the cap. and withdraw the sender from the radiator (photo5)
7 Provided that the coolant has beon renewed at the spec1f1ed
rntervals. flushing tho system should not be necessary If. how ever.
mamter ance has been neglected. and the coolant when drained Fig. 2.2 Cylinder block dr ain plug location on carburettor
coni.11ns excessive amounts ol sediment, the system should be flushed engines (Sec 3)
us follows Remove thfl thermo5ta1 as described in Section 5, then rof11
the housing cover and the hose Turn the heater control to the full heat
setting Disconnect the top hose at the radiator refit the radiator drain
plug .ind remove the cylinder block drain plug Flush the cyhnde·
block using water from a garden hose fed in through the top of the
radiator. un11I the water emerging from the block dram plug is clear
Now refit the block dram plug and the thermostat. remove the radiator
d1111n plug and flu~h the radiator through the top hose inlet
8 If mer a reasonable period the water still does not ru n clear. the
rm11ator should be removed and reverse flusherl. using a proprietary
chum1cal cleaner where necessary Reverse-flushing means that the
111111ttr 1s fed in throuoh the bottom hose port Note tha t later models
(VIN 1 926 390 onwards) may have an alumm1um·cored radiator. or
which chemical cleane1s should not be used
9 When flushing 1s complete ensure that all water has been drainec
horn the block and radiator then refit the hoses and plugs as necessary
10 To refill the system. f1rs1 loosen the bleed screw (if fitted) This will
Ile located either on the uppermost coolant hose on carburetto1
eng!n1;+~ (photo). or on the throttle housing on later fuel m1ect1on
Pn91nes On carbuie1101 engines w1thou1a blood ~crew. disconnect the
coolant hose from the carburenor automauc choke housing Fig. 2.3 Cylinder block drain p lug location on the f uel
11 Fill the radiator with fresh coolant (photo) and tighten the bleed injection engines (Sec 3)
scr.iw or refit the hose when the coolant emerges 1n a con11nuous
stream free of bubbles
12 Pour coolant into the eKpans1on bottle un11I the radiator overflows,
then 1mmed1ately refit the level sender and lighten the cap Reconnect
the wiring
13 Fill the expansion bottle to 25 mm {1 0 in) above the ·M A Xr level
.,
mark then fit and tighten the cap
14 Temporarily loosen the bleed screw or heater hose to release an y
llBPPtld air
15 Run the engine at a fast idle speed until 11 reaches its normal
operating temperature. 1nd1cated by the fan engaging then allow the
eng ne to tdle
16 Accelerate the engine briefly several 11mes 10 assist the bleeding
process then swnch 11 ott
17 Refit thu expansion bottle. beside the radiator
18 Allow the engine to cool completely
19 Check thot the coolnnt 1$ up to the 'MAXI level mark, and top up If
necessary
j.
Fig. 2.4 Coolan t bleed screw on the throttle housing o f Fig. 2.5 Refilling the coo ling system through the expansion
later fuel injec tion engines (Se c 3) b ottle (1 ) (Sec 3)
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78 Chapter 2 Cool i ng system
3 4 Removing the rndmtor drain plug 3.SA Disconnect the level sender wiring .. 3 68 ... unscrew the ca p ..
3 6C and withdraw tho sender 3.1 O Cooling system bleed screw (arrowed) 3 11 Filling the radiator with coolant
on carburettor engines
4 Antifreeze mix ture general engines, 1t 1s separate 10 the water pump. on the front left·hand side of
the cylinder head
2 Drain the cooling system as described in Secuon 3
1 Plain water should never be used in the cooling system. Apan from 3 Disconnect the radiator top hose from the thermostat housing
giving PfOtect1on against freezing, an antifreeze mixture protects the 4 Unscrew and remove the two thermostat housing cover bolts and
engine inremal surfaces and components against corrosion. remove the cover (photos) This may need to be tapped lightly with a
2 Ideally, a 50% mi xture of antifreeze and soh or dem1nerahsed water wooden or plastic - faced mallet to free 11
should be used 10 maintain maximum protecuon against freezing and 5 Remove the thermostat {photo). If 11 is stuck. use a sharp knife to
corrosion On no account use less than 25% antifreeze cut free the rubber seal from the housing
3 The coolant must be renewed at the specified intervals. as the 6 Ease the rubber seal from the edge of the thermostat.
corrosion inh1b11ors contained in the anulreeze gradually lose thou 7 If the thermostat 1s suspected of being faulty, suspend 11 in a
effectiveness 1f ma1nwnance 1s neglected container of water which 1s being heated Using a thermometer. check
that the temperatures at which the thermostat starts to open and at
which 11 1s fully open are as spec1f1ed
6 Thermostat remova l. test ing and ref itting 8 Remove the thermostat from the water. and allow 11 to cool Check
that the thermostat closes fully.
1 The thermostat housing on carburettor engines 1s integral with the 9 If the unit fails to operate as described. or is stuck open or shut.
water pump located on the front of the cylinder head. On fuel in1ec11on renew it w11h one of identical temperature rating (photo).
5 4A Unscrew tho bolts 6.46 ... and remove the thermostat housing 6 6 Removing the thermostat {carburettor
cover {carburettor engine) engine)

Chapter 2 Cool i ng system 79

10 Fit thu rubber seal on the thermostat fl ange, no11ng that the tab 3 Ref1111ng the drlvebelt 1s a reversa l of removal, bu t adjust the belt
locates •n the seal extension on carburettor engines (photo) . tension as follow s. Pivot the alternator so that the belt deflecuon,
11 Locate the thermostat 1n the housing under firm lhumb pressure at a point midway between the pulleys. Is
12 Clean the mating surfaces. then fit the cover and tighten the bolts. appro>omately 12.5 mm (0.5 1n) Do not over-tension, as this may
13 Reconnect the radiator top hose, and refill the system as described damage the alternator bearrngs. Tighten the alternator ad1ustment and
in Secuon 3 pivot bolts on completion. After a nomlmal mileage has been covered ,
check the tension of the drivebelt agarn
8 Radiotor removal. repair and refitting
8 Water p ump - remova l and refitting
1 Drain the cooling system as described 1(1 Section 3
2 Disconnect the top and bortom hoses from the radiator On Disconnect the battery negative lead
au toma11c transmission models, also disconnect the fluid cooler pipes 2 Orarn the cooling system as described rn Section 3, and remove the
3 Disconnect the expansion botlle hose from the left- hand side of radiator as described 1n Section 6
the md1a101 (photo) 3 Remove the drivebelt as desc11bed 1n Sec11on 7
4 Disconn ect the wiring from the 1hermosw11ch for the self - 4 Disconnect the heater, and where applicable, the automatic choke
d1~eng1.1g1 119 cooling fan. where fined (photo).
return hoses.
5 Unscrew and remove the upper mounting bolls, and Hit the radiator 5 Disconnect the radiator bottom hose. and on carburettor models,
from the bo ttom mounting brackets (photos) Take care not to damage th e top hose from the water pump.
the radiator matrix. 6 Disconnect the wire from the self-disengaging fan brush holder,
G If necessary. remove the rubber mounting pads and unscrew the where fitted (photo) .
thermosw1tch ( photos). 7 Disconnect the wire from the coolant temperature sender.
7 If the radiator is leaking, 11 must either be renewed or exchanged 8 Unscrew the nuts and remove the fan (photos)
fl)( a reconditioned unit. Repairs should be made by a specialist 9 Where a viscous coupling is fitted. unscrew the centre nut to
8 Clean any debris from the mat11x with water from a hose. remove 1t, then unbolt the pulley
9 R1lf1 111ng 1s a reversal of removal Refi ll the cooling system with 10 Unscrew the mounung nuts and bolts. noung the locauon of the
referent~ to Section 3.
different length bolts, then withdraw the water pump from the engine
(photos) On fuel in1ection engrnes, press the water pump towa1ds the
umrng belt when removrng 11, and after removing it, extract the
7 Drivebeft r emoval. refitting and adjustment
tensioner spnng and plunger from the water pump.
11 Remove the gaske t (photo) .
Loosen the alternator adjustment and pivot bolts, and swivel the 12 Clean the w ater pump and gasket surfaces (photo).
alterna tor towards the engine. 13 Where necessary. unscrew and remove the temperature sender
2 Slip the drivebelt from the alternator, water pump, and crankshaft (photo) . then release the spring chp and withdraw the self-
pullevi; md remove 11 over the fan (photo) d1sengog1ng fan brush holder
5 9 The temperature rating 1s stamped on 5 10 Fnung the rubber seal (carburettor 6 3 01sconnec11ng the expansion bottle
the thermostat engine) hose from the radiator
6 4 S1'1f d1i.engag1ng cooling fan 6 SA Unscrewing the radiator upper 6.58 A radiator bottom mounting bracket
thermosw1tch (arrowed) mounting bolts

6 6A Removing a radiator rubber mounting 6.66 Cooling fan thermoswitch (arrowed) 7.2 Removing the dnvebelt (fan removed
pad for clariwl
14 To remove the self-disengaging fan hub and pulley, unscrew the in Section 7. Refill the cooling system as described in Section 3.
centre nut. then slide the hub and pulley trom the impeller shaft
(photos)
15 II the water pump Is worn or leaking. It must be renewed If only the
9 Self- d isengaging fan thermoswitc h - removal and
bearing in the self-disengaging tan hub ls worn, it may be renewed
refitting
separately. Extrac t the c1 rcllp (photo) and use a soft-metal drift to drive
out the bearing. Press or drive the new bearing into the hub, using a
metal tube on the outer track Refit the circllp. Dram the cooling system as described In Section 3.
16 After reassemblfng the self-disengaging fan hub. check that the 2 Disconnect the two wires, then unscrew the thermosw itch from the
gap between the hub and pulley Is 0.3 mm (0.012 1n) using a feeler radiator side tank.
gauge. II necessary, ad1ust the three screws on the hub (photos). 3 Refitting 1s a reversal of removal . Refill the cooling system es
17 Refitting is a reversa l ot removal. Tension the drivebelt as described described in Section 3.
8 6 Disconnecting wire from 8.8A Unscrew the nuts (arrowed) ... 8.88 ..• and remove the fan
self -disengaging fan brush holder
8 10A Unscrew the mounung bolt ... 8.1 OC .. and remove the water pump
(carbureuor engine)

8100 Unscrew the mounting nuts and 8.1 OE ... and remove the water pump {fuel 8.11 Removing the water pump gasket
bolts injecti on engine) ( carbureltor engtne)
812 Rear view of water pump (fuel 8.13 Removing the temperature sender 8.14A Unscrew the nut ...
1n1ecuon engine) (carburettor engine)
8 148 and remove the self-disengaging 8.14C ... and pulley (carburettor engine) 8.140 Basic water pump (carburettor
fan hub engine)
8 lf> Removing the circlip from the 8.16A Reassembled self-disengaging Jan 8.1 6 B Ad1usung the gap on ihe
$ell disengaging fan hub unit self -disengaging fan unit

10 Fault diagnosis - cooling system
Symptom Reason (s)
Overheating Insufficient coolant in system

Loose drivebelt
Faulty self-disengaging fan or thermoswltch
Radiator blocked either internally or externally
Thermostat not opening
Overcoot1ng Faulty, incorrect or missing thermos1at
Loss of coolant
.· Damaged hoses or loose clips
Rad iator leaking
Expansion tank pressure cap defective
j ·I

.·
Cha pter 3 Fuel and exhaust systems

Contents
Part A General
General description and use of unleaded fuel 1 Fuel tank - removal, repair and ref1111ng .. 7
Rouune main tenance 2 Manifolds and exhaust system general ......................._........... 19
Part 8 Carburettor engines Part C : Fuel injection engines

Accelerator cable removal. refitting and ad1ustment ... ............•.. 17 Accelerator cable - removal and refrtung .. ..................................... 36
A11 cleaner element renewal .. .. ........................... 3 Air cleaner removal and refitting ..... ......... .................................... 22
Carbure11or general ... ... ... .................... .. 8 Air cleaner element - renewal . ... ... .. .... .... .... ................ ........... 21
Carburettor - idle speed and m1x-ture ad1ustment .......... ................. 9 Fuel filters - renewal ................... .......... ........... .... ............................. 26
Carburo11or - removal and ref ming ....... ............................................ 1O Fuel 1n1ection system - general descrrpuon and precautions ......... 20
Carbure11or (Solex 34 SISCA 3) - dismantling, Fuel level transmitter - removal and refmlng .................................... 34
reassembly and adiustment ......... .... ... .......... .... .......... ..... ...... .. 14 Fuel pump - removal and refitting ........... ......................................... 33
Carburettor (Solex 32-34 and 34-34 CISAC) - dismantling, Fuel tank - removal, repair and refining .. .......... ............................. 35
reassembly and adjustment .................... ......... .......................... .... 16 K-Jetronic system - idle speed and mucture adiustment ................. 23
Carburettor (Solex- 32· 35 MIMSA) d1smantltng, reassembly K-Jetronic system - throttle butterfly 1n111al setting ..................... 24
and adjustment ................. .... .. 13 K-Jetronic system components checking .. .. ..............•.....•. 25
Carburettor (Solex 32-35 TMIMA) dismantling, reassembly LE2-Jetronrc system - airflow sensor removal and refining .......... 31
and ad1ustment ...... ..................... .. ....... ...... ... .................... ..... 12 LE2-Jetronrc system - fuel miector removal and ref1tung .............. 32
Carburettor (Solex 34 . 34 Z1 ) - d1smantl1ng reassembly and LE2·Jetromc system - rdle speed and mu1ture adiustment ............ 27
adjustment . .. 15 LE2 ·Jetromc system - throttle butterfly initial setting 28
Carburett0t (Zen11h 35-40 INAT) - dismantling, reassembly and LE2 -Jetronrc system - throttle switch adiustment ......................... 29
ad1ustment ......... ................ ............... ... .. .... ........ ............. 11 LE2 -Jetronrc system components - checking .................................. 30
Ctloke coble removal, relining and adiustment .......................... 18 Manifolds and exhaust system - general ... ...... ............................. 37
fuel level transmitter - removal and refitting ... ............................... 6
Fuel pump cleaning .......................................................................... 4 Part D : Fault diaqnosis
Fuel pump remova l and refitting ..................................................... 5 Fault diagnosis - fuel and exhaust systems ... .................................. 38
Specifications
GeneriJI
Fuel tank capacity
Pre 1984 models ........ ················-··· .... .... ••.• •............................ 52 litres (11 4 gallons)
1984 -on models .................................................................................... 70 litres (15 4 gallons)
Carburettor engines
System type ........................................................................................ Rear-mounted fuel tank, mechanical fuel pump, single. fixed 1et.
downdraught carburettor
Carburettor cali brations and setti ngs

'Zenith 35 40 INAT Primary Secondary
Venturi diameter .............................. .. ........................................ _ .. , 22 mm 28mm
Mam iet ................................................................... _ .. x 112 5 X130
Progression 1et ............................................ _ .................................... . 50
Constant CO calibrator ........................................................................ 60
Air compensator .. .. ,._............................................................... 160 90
Emulsion tube ... ............................................................................... 9A 4N
Vent and idle iet .................................................................................... 120/ 45
Pump rn1ector tube . ............................................................................. 0.5 + 0.03 j' 0.6 t 0.03
Ennchener valve .... ............................................................................. 40
Fast idle speed ..................................................................................... 2800 rpm
Idle speed ................................................................................................ 900 rpm
CO% at idlo ............................................................................................ 2 ± 0.6
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84 Chapter 3 Fuel and exhaust systems
Car burettor calibrations and settings (cont)

Solex 32 35 TMIMA Pri mary Secondary
Ventu11 diameter 24 mm 27 mm
Main JCI
Code 211 / 1 120 160
Except code 211 ......................................................................... . 122.5 160
Air correcuon 1et
Code 211 1 155 180
Except code 211 / 1 .......................................................................... 165 130
Idle fuel 1et
Code 211 1 ................................................................................... 42 40
Except code 21 1/ 1 ........................................................................... 46 40
Idle a111e1 .................................................................................... 160 4.3 mm diameter
Constant CO 1et ................................................................................... 30
Accelerator pump iet ............................................................................. 40 50
Needle valve ................................................................................... 1.7 1.7
Econosta1 fuel jet .................................................................................... 80
Enr1chent1r fuel Jet ............................................................................... 60
Fast idle speed.
Code 21 1 / 1 ................................................................................... 3200 ± 50 rpm
Except code 211 /1 ........................................................................... 3800 ± 60 rp m
Idle speed . ........................................................................................ 900 rpm
CO% at idle ................................................................................... 2 ± 0.5
Solex 32·35 MIMSA: Primary Secondary

Veniu11 diameter 24 mm 27 mm
M ain 1et
Code 231 1 / 2 ............................................................................... . 122.5 140
Code 232 1/2 ............................................................................... . 120 140
Air correction 1et
Code 232, 2 ................................................................... . 160 140
Except code 232/2 ......................................................................... . 165 130
Idle fuel Jet
Code 231 1/2 ............................................................................... . 46 40
Code 232 1 '2 .............................................................................. 42 40
Idle air 1et .. . ................................................................................... 160 150
Constant CO 1et .. ..... .... ... •............................................................. . 30
Accelerator pump in1ector ................................................................... 40 50
Needle valve ..... .. ........................................................................... 17 1.7
Econostat fuel 1et.
Code 231 /232/1 ............................................................................. . 80
Code 231/ 232/ 2 ............................................................................. . 70
Idle speed ....................................................................................... 900 rpm
CO% at idle .... ...................................................................................... . 2 ± 0.5
Solex 34 BICSA 3·
Ventu ri d1amete1 .................................................................................... . 27 mm
Main 1et.
Code 299 .......................................................................................... . 140
Code 300 .......................................................................................... 137.5
Code 342 .......................................................................................... 137
Air correctton 1e1
Code 299 ......................................................................................... 220
Code 300 ..................................................................................... . 200
Code 342 ....................................................................................... 180
Idle 1et
Code 299 ...................................................................................... 47
Code 300 ...- ......._ ......... - ................................................... 45
Code 342 ....................._ ....................................... 43
Constant CO 1et .... ............................................................................... 35
Accelerator pump 1n1ec1or ..........., .. _ .................................................. 45
Needle valve ............................................................... 1.5
Econostat fuel 1et:
Codes 299 and 300 ......................................................................... 60
Code 342 . .. ........................................................................... 50
Idle speed .............................................................................................. 900 rpm
CO% at idle ............................................................................................ 2 ± 0.5
Solex 34 34 Z1 Primary Secondary

Venturi diameter ................................................................................ 25 mm 27 mm
M ain 1e1 ................................................................................. .. 117 130
Ai r correcuon i et .................................................................................... 140 130
Emulsion tube .................................................................................... 28 zc
Idling luol JOI .................. - ...................................................... .. 41 50
Idling air Jet ........................................................................................ 140 J·I 80
Ennchener fuel 1et .................................................................................. 50
Needle valve ..................................................................................... 1.8 1.8
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Carburettor calibrations and settings (cont) Primary Secondary

Solex 34-34 Z1 (cont)
Accelerator pump lnJector ................................................................ 40 55
Fast idle speed .. ... •.................................................. _ ....... .. 3400 :I: 50 rpm
Idle speed ..................................- ...............................- ........ 900 rpm
CO% at idle ......................................................................................... 1.5 ± 0.5
Solex 32· 34 CISAC Primary Secondary
Venturi diameter .................................................................................... 24 mm 26 mm
Main 1et ................................................................................................. 117 127
Air correction 1et:
Code 388 .............................................~:.......................................... . 180 150
Code 388 1 ..................................................................................... . 155 155
Emulsion tube .......................................... •....... ........................... 27 18
Idle fuel 1et .............................................................................................. 43 70
ldlo air JOI ........................................................................................... .. 180 150
Ennchener fuel 1et .. .. ........................................................................ 50
Needle valve ........................................................................................ 1.8 1.8
Accelerator pump in1ec tor ................................................................... .. 35 40
Fast idle speed ........................................................................................ 3400 :I: 50 rpm
Idle speed .......................................................................................... 900 rpm
CO% at idle ............. ............................................................................... 1.5 :I: 0.5
Solex 34 · 34 CISAC. Primary Sec ondary
Venturi diameter 25mm 27mm
Main 1et 117 130
A11 correction Jet
Code 394 .... ..................................................................................... 140 130
Code 396 ..................................................................................... 140 80
Emulsion tube ........................................................................................ 28 zc
Idling fuel jet ........................................................................................... 41 50
Idling air 1et ............................................................................................ . 140 80
Enrichener fuel JOI ... .. ............................................................... 50
Needle valve . .............................................................. . 18 1.8
Accelerator pump 1n1ector ..................................................................... 40 55
Fast idle speed .... ..................................................................... . 3400 ± 50 rpm
Idle speed .... ... ..................................................................................... 900 rpm
CO% at idle ........................................................................................... 1.5 ± 0.5
Torque wrenc h settings Nm lbf ft

Carburettor mounttng nuts ......................................................................... 18 13
Fuel injection engines

System type .......................................................................................... Rear-mounted fuel tank. Bosch K-Jetronic or LE2-Jetronic fuel
injection system, electric fuel pump
K-Jetronic fuel injection system

Idle speed
Manual gearbox models with ZDJ engine ....................................._ 750 t o 800 rpm
All other models .... ... ...... ........... . .................................- 900 to 950 rpm
CO'llt at idle . ...•...... ... , .............................................................................. 1.5 to 2.5
Fuel feed pressure
ZEJ engine ..........................•.....................•..........•.................................. 4.5 to 5.2 bar (65 to 75 lbf/i n')
ZDJ engine .......................... ..... .... .... ............................... ,............... .. 4.7 to 5.4 bar (68 to 78 lbf/ in')
Fuel pump delivery rate . ........ .... ............... ... ........................................... 760 cc/ 30 seconds (minimum)
Thl!fmal t1me switch cut-off temperature ................................................ . 30 10 4o•c (86 10 104. F)
Fuel control pressure (hot) .
ZEJ engine ............................................................... . 3.4 to 3.8 bar ( 49 to 65 lbf/ in')
ZOJ engine (no vacuum) ...................................................................., 2.5 to 2.9 bar (36 to 42 lbf/in')
LE2 -Jetronic fuel injection system

Idle speed
Manual gearbox models ..................................................................... 760 to 800 rpm
Automauc transmission models ............................................................ 900 to 950 rpm
CO DI idle ........ ... .... .. .. .... ........................................................... 0.5 to 1.5
Fuel pressure .... .... ............................................................................ 2.3 to 2 7 bar (33 to 39 lbf/ tn')
fuel pump delivery rate ........................................................................... 540 cc/ 15 Sef9nds (minimum)

M111n fuel filter union bolts ........................................................................ 35 26

PA RT A : GEN ERAL Clean oil bath type air cleaner

1 Some very early fuel injection models may be fined with an oil bath
1 General description and use of unleaded fu el type air cleaner. To clean it, remove the base and pour away the old oil.
Clean the element in paraffin, then add 0.26 litres (0.46 pints) of
engine oil and reassemble .
Description
The fuel system compnses a rear-moun ted fuel tank. single Check and adjust the accelerator cable
downdraught carburettor on overhead valve engines. and a Bosch 2 Check the accelerator cable tor smooth operation, and tor signs of
K-Je11on1c or L£2-Je1ron1c fuel mjecrion system on overhead camshaft fraying.
engines 3 Adjust the cable if necessary. w ith reference to Sectton 17 or 36, as
On carburettor engines. the fuel pump is mounted on the cylinder applicable.
block and driven by a plunger from an eccentric Oil the camshaft. On
fuel injection engines, the electric fuel pump is located by the fuel tank Renew the air cleaner element
beneath the rear of the vehicle. 4 Rater to Section 3 or 21 . as applicable.
Unleaded fuel Renew the fuel pre-filter (fuel injection engines)

Unleaded high-octane (95 RON ) fuel can be used successfully on 5 Refer to Section 26
certain models refer ro the list .below. Where an 1gmuon timing
ad1ustment 1s required, refer to the procedures given in Chapter 4. Note Renew the main fuel filter (fuel injection engines)
that, for example. retarding the ignition by 2· on a car normally timed at 6 Refer to Section 26.
o·
1 BTOC gives a new setting of a• BTDC. Although the details given
here are correct at the time of writtng. be sure to refer to a Peugeot
deafer tor the latest information PART B : CARBURETTOR ENGINES
XM7A XN1, and XN1A engine models. 1986 model yeer on 3 A ir c l eaner element - renewal
Unleaded fuel may be used without modification
Alf ZEJK and ZDJL engine models : Unleaded fuel may be used. The air cleaner element is removed from the rear of the assembly,
but 101a1d the 19nwon timing by 2 and therefore it Is necessary to remove the air cleaner completely .
Af/ other models Unleaded fuel must not be used 2 Loosen the clip and disconnect the hot air hose (photo).
3 loosen the clip and disconnect the air inlet ducting from the
carburettor (photos).
4 Unscrew the mounung nuts. withdraw the assembly, and dis-
2 Routine maintenance connec t the crankcase ventilation hose (photos).
5 Loosen the end cover screw(s), remove the cover and extract the
element (photos).
Ca1ry our the following procedures at the intervals given m Routine 6 Wipe clean rhe inside ot the main body and end cover.
ma1menance ar rhe from of lh/s manual 7 Fit the new element using a reversal of the removal procedure.
3 2 D1sconnecung the hot air hose 3.3A Loosen the clip .. 3.38 ... and disconnect the air inlet ducting
3 4A Unscrew the mounting nuts 3 46 . and withdraw the eu cleaner 3 .5A loosen the screw s ...
assembly

3 58 remove the cover 3 SC and extract the air cleaner element
4 Fuel pump - cleaning 5 Fuel pump - removal and refitting
Note The fuel pump may be one of several types, and may differ from Disconnect the inlet and outlet hoses (photos) Plug the inlet hoS&
the one described m this Section 2 Unscrew the pump mounting bolts, and hfl the pump away from
1 Disconnect the outlet hose. the block (phot os).
2 Remove the two screws and hit off the cover and gasket (photo) . 3 Remove the gasket. and 1f necessary extract the pushrod (photos)
3 Extract the gauze tilter from the pump body (photo). 4 Although it may be possible to dismantle the fuel pump. it is not
4 Using a small brush. clean the pump body and filter w ith fuel. If possible to obtain genuine Peugeot spare parts, so Jf the pump 1s
necessary mop out the fuel from the body and wipe away any defective. it is recommended that It is renewed.
sediment 5 Ref1111ng 1s a reversal of removal but f11 a new gaskeL If cnmp type
5 Ch1;11;k dllU 11 111;11;11s:;ary renew the gasket clips are fmed. It may be possible 10 re-use them and tighten them with
6 Relit the gau2e filter and cover. and tighten the screws. pincers (photo). but Jf they are broken or bent. replace them With
7 Reconnect the outlet hose sc1ew type chps
4 2 R&moving the fu&I pump cover 4.3 Gauze f1lte1 removal from the fuel pump 5 1A Disconnect the fuel pump inlet
5.1 B ... ond ou tlet hoses 5.2A Unscrew the fuel pump mounting bolts 5 28 Fuel pump removed

5.3A Removing rhe fuel pump gasket ... 5.38 ... and pushrod 5.5 Tight ening the fuel pump ou tlet hose
clip (arrowed)
6 Fuel level transmitter - removal and refitting

2 Remove the floor covering from the luggage compartment.
3 Prrse out the plastic cover to expose the fu el level transmitter
(photo)
4 Disconnect the wiring plug.
5 Using rwo screwdrivers. crossed tn a scissor-like arrangement,
unscrew the retaining ring
6 Withdraw the transmitter unit. taking care not to damage the float
as 11 passes through the hole in the tank. Remove the gasket.
7 Ref1thng is a reversal of removal, but fit a new gasket.
Fig. 3.1 Fuel tan k and fuel level

transmitter o n early models
( Sec 6)
1 Retaining ring
2 Spacer
3 Fuel level transmit/er
4 Nut
5 Washer
6 Fuel tank
7 Bolt
8 Bolt plate
9 Rubber buffer

6 3 Fuel level transmitter (1) and filter (2) 7.7 Fuel tank filler hose connection - cltp 7.8 Fuel tank mounting bolt (arrowed)
arrowed
7 Fuel tank - removal . repair and refitting 8 Carburettor - general
Chock the front wheels. then jack up the rear of the vehicle and A single carburettor rs fitted, of Zenuh or Sole)( manufacture and of
support on axle stands downdraught type Accordrng to model. the carburettor 1s either srngle
2 Remove the spare wheel or twin choke, and may have either a manual or automatic choke for
3 Disconnect the battery negative lead. cold starting.
4 Remove the rtoor covering from the luggage compartmen t.
5 Prise out the plasuc covers. Disconnect the wiring plug from the
level transmrtter and the hose(s) from the filter 9 Carburettor ..: idle speed and mixture adjustment
6 If the fuel tank has more than a small amount of fuel in 11. syphon
out the fuel The Mier neck may however be fitted w rth wire gauze to Note: The following ad1ustments must be made with the 1gn111on
prevent unscrupulous syphoning, in which case proceed to the ne)(t timing coffect/y 11d1usted. the air cleaner and filter element fitted. and
paragraph the engine at normal operating temperature On automatic llansmis·
7 Loosen the clip and disconnect the filler hose (photo). s1on models. select ·p·
8 Support the weight of the tank. then unscrew the mounting bolt(s)
and unhook the t:upport cogo lll the rear (photo), where fitted. 1 Turn 1lit1 idlt1 :;pt1t1c.I i;crew until the engine idles at the specified
9 Lower the fuel tank. and at the same time disconnect the vent and speed (photo).
fuel return hoses as applicable. 2 If available. use an exhaust gas analyser to check that the CO
10 If the tank 1s leakrng or is badly rusted, leave any repair to a content is as specified If necessary. turn the mixture screw as required
specialist On no account attempt to solder or weld a fuel tank, as 11 then re-ad1ust the idle speed screw to set the engrne speed to that
requires a great deal of purging before every trace of e)(plos1ve vapour spec1f1ed. Note that the mixture screw may be fitted with a tamperproof
1s removed cap (photo)
11 If the tank is suspected of containing sediment, pour in some fuel 3 To adjust the mixture without an analyser. remove the tamperproof
and shake the tank vigorously, repeating as necessary unul all traces of cap 1f fitted, and turn the mixture screw to obtain the highest engine
sediment are removed. speed. Screw 1n the idle speed screw to obtarn 950 rpm. then screw in
12 Refitting the tank 1s a reversal of removal. the mixture screw to obtain the specified speed.
Fig. 3.2 Idle speed (1) and mixture ( 2) screws on the Zenith Fig. 3. ~ .Idle speed screw (1) on the SolH 32- 35 TMIMA
35 40 I NAT cart>urettor (Sec 9) carburettor (Sec 9)

Fig. 3.4 Idle mixture screw (2) on the Solex 32 -35 TM IMA Fig. 3.5 Idle speed scr ew (1) on the Solex 32-35 MIMSA
carburettor (Sec 9) carburettor (Sec 9)
Fig. 3.7 Idle speed screw (1) on the Solex 34 BI CSA 3

carburettor (Sec 9)
Fig. 3 6 Idle mixture screw (2) on the Solex 32- 35 MIMSA

ca rburettor ( Sec 9)
Fig 3 8 Idle mixture screw (2) on the Solex 34 BICSA 3 Fig. 3.9 Idle speed screw (1) on the Solex CISAC
carburettor (Sec 9) carburettor ( Sec 9 )
I

9.1 Idle speed screw (arrowed) - Solex 32-35 TMIMA
Fig. 3.10 Idle mixture screw (2) on the Solex CISAC

carbu rettor (Sec 9)
10.2 Disconnecting the coolant hose for the automatic choke
9 2 Tamperproof cap fitted to 1he mixture ad1us1ment screw

(arrowed) - Solex 32-35 TMIMA
10 Carburettor - removal and refitting
Remove the air cleaner as described in Section 3

2 Where a coolant-operated automatic choke is fitted, drain the
cooling system (Chapter 2), then disconnect the coolant hoses from
1het carburet101 (photo) .
3 Disconnect the distributor vacuum hose.
4 Disconnect the fuel inlet hose. ,
5 Unhook the accelerator inner cable from the throttle lever. and
remove the outer cable from the bracket (photos).
6 As applicable. disconnect the choke cable or automatic choke
wmng
7 Unscrew the mounting nu!S and hit the carburenor from the inlet
manifold Remove the gaske!S (photos)
8 Ref111mg is a reversal of removal. but fit new gaskets. Ad1ust the
accelerator and choke cables with reference to Sections 17 and 18. 10.5A Unhooking the accelera tor Inner cable (arrowed)
and fill the cooling system with reference to Chapter 2.

10 58 Accelerator ou ter cable and bfacket 10 7A Unscrew the mounting nuts
10 78 and remove the carburettor ..
8 To ad1ust the automauc choke. hold the throttle lever open and turn
11 Carburettor ( Zenith 35-40 INAT) - dismantling. the automatic choke operaung lever ant1 -clockw1se Using a feeler
reassembly and adjustment blade. check that there 1s a gap of 0.15 mm (0.006 1n) between the
operating lever and the modulated spool withou t compressing the
Dismantle the carburettor with reference to Figs. 3.11 to 3 13. spring. II necessary, adjust the connecti on at the top of the choke
keeping eJch part 1dentif1ed for location operating rod.
2 Clean all the comp0nents in fuel. and obtain a repair kit of gaskets 9 Open the throttle lever, close the choke valve. then release the
and washers throttle lever Refer to Fig. 3.15 and check that the stop screw 1s
3 Reassembly 1s a reversal of dismantling, but carry out the p0si11oned as shown II not, bend the intermediate lever
ptOcedures given in the following paragraphs 10 The operation of the electric choke flap can be checked as follows
4 Apply locking fluid to the diffusion noule screws before inserting Open the throttle lever, close the choke flap then release the lever
and tightening them Apply battery voltage to the automauc choke At an amb1en1
6 Wh11n refnung the second barrel operaung capsule. press It against temperature of 18 to 20'C (64 to 68' F) tho choke flap should open In
the internal spnng before tightening the moun ting screws. four minutes.
6 Ad1u s1 the accelerator pump 1ets with reference to Fig. 3.14 11 To ad1ust the idle speed and mixture screws to 1he1r 1n111al settings,
7 The secondary thronle idling p0s111on is set at the factory. and first screw them right in Unscrew the le.le speed screw three turns, and
should not normally be tampered with If a new throttle valve has been the mixture screw four 1urns
lotted proceed as follows Open the throttle. open the choke, then 12 Wnh the carburettor refitted to 1he engine. the fast idle ad1ustment
release the thronle Ad1ust the secondary throttle stop screw so that 11 can be checked as follows Run the engine to normal operaung
1s 1ust p0ss1ble to see light between the valve and carburettor barrel temperature, then switch ott Open the throttle lever. close the choke
This should represent a gap of appro1uma1ely 0 05 mm (0.002 in) at valve, then release the lever Start the engine. and check that 11 is idling
the extremity of the valve Do not use feeler blades to check th e gap, as at the spec1f1ed l<!ft idle speed. If necessary, insert a screwdnver
the width of the blade will mean that the gap at the extremity of the through the bottoni of the automatic choke housing, and turn the
valve 1s excessive adjusting screw as required.

,------------------------------------------------------------------------93
Fig 31 1 Exploded view o f the Zen~h 35"'40 INAT

carbur ettor (Sec 11 )
1 Choko flap 9 lnsulatmg pad
2 Vacuum capsule and 10 Throttle valves
enochener VB/ve 11 Automatic choke
3 Gasket 12 Constant CO ClfCU1t
4 Venturts/ drffus1on nozzles adjusting screw
5 Secondary throttle operating 13 Mixture screw
capsule 14 Idle speed screw
6 Control quadrant shalt 15 Distributor vacuum take -off Fig . 3.13 Cover components o f the Zeni th 35~ INAT
7 Control spring 16 Accelerator cable bracket c arburettor ( Sec 11 )
8 Gasket
1 Pr1m11ry ek compensator 12 Primary main 1et
2 Secondary air compensator 13 Secondery main iet
3 Idle /et 14 Progressive transfer 1et
4 Primary accelerator pump 15 Accelerato1 pump suction
5 Secondary accelerator pump valves
6 Enflchemng valve 16 Pressu1e valves
7 Fuel tnlet union 17 N eedle valve
8 Pump piston conuol levers 18 Float
9 Jet 11rms 19 Constant CO calib1ator
10 Additional air jet 20 Full-load enrichener
11 Accelerator pump m1ectors calibrator
Fig , 3 12 Aut o m at ic c hoke components of the Zeni th 35- 40

INAT c arburetto r (Sec 11)
111 Anti flooding intermediate 2b Choke opentng 'modulated'
lever spool 1st Barrel 21\d Barrel
1b Anti.flooding lever 2c Choke opening control d
21 Choke openmg intermediate capsule Fig . 3 .14 Accelerator pump jet adjuatment In the Zenith
lever 35-40 INAT carburettor - dimensiona In mm (Sec 11)

12 Carburettor (Sol ex 32 -35 TMIMA) - dismantling.

reassemb ly and adjustment
1 Unscrew the studs from the base of the cerbureuor ( photo)

2 Remove the automatic choke cover (two screws) (photos)
3 Unscrew the fuel supply tube (photo).
4 Unscrew the cover screw s (photo)
5 Extract 1he circhp from the choke operating orm (photo).
6 Lift off the cover. and at the same ume. disconnect the choke
operating arm (photos).
7 Remove 1he cover gasket and the 0-nng seal (photos)
8 Unscrew and remove 1he various jets, keeping them idenufied for
locauon. Access to the main jets Is gained by removing the side plugs
(photos) .
9 Push out the pivot pin and remove the float ( photo).
10 Unscrew the needle valve (photo)
11 Clean all the components in fuel, and obtain a repair k11 of gaskets
and washers.
12 Reassembly Is a reversal of dismantling, but carry out the
procedures given m the following paragraphs
13 To check the float level ad1ustmen1. make a cardboard template to
the d1mens1ons shown m Fig. 3. 16. Lightly press on the float arm so
that the needle valve ball 1s compressed, then use the template to
check the float height w ithout the gasket fitted (photo)
14 Adjustment of the float level is by progressively tightening the
needle valve onto the special washer. Do not exceed a torque of 25 Nm
(18 lbf h). If the float is below the required level, ht a new washer
15 With the carburettor refitted to the engine, the fast idle ad1ustment
can be checked as follow s. Run the engine to normal operating
temperature. Remove the automauc choke cover. and remove the
spring. Push down the lever '2' ( Fig. 3.17) without forcing It, and
Fig 3 15 Automatic choke adjustment on the Zenith 35-40 check that the fast idle speed 1s now as specified If necessary adjust
INAT carburettor (Sec 11 ) the screw. Rein the spnng and cover on compleuon.
1 Operatmg lever 3 Cam

2 Fast idlo screw
TM IMA
MIMSA
lO H.12319
20
48 H.12927
Fig . 3.16 Floet l evel template dimensions (in mm) for t he

Solex 32- 35 TMIMA (and MIMSA) (Sec 12) Fig. 3.17 Fast Idle adjustment on the Solex 32-35 TMIMA
carburettor (Sec 12)
1 SpflnIJ 3 Stop screw

2 Lever
Trial version of ABC Amber PDF Merger, http://www.processtext.com/abcpdfmg.htm l

12 1 Removing the carburettor base studs 12.2A Removing the au1omatic choke cover 12.28 View of automa1ic choke with cover
removed
12.3 Fuel supply tube removal 12.4 Removing carbureuor cover screws 12.5 Ctrchp (arrowed) on the choke
operaung arm
12 6A L1h ofl the carburettor cover 12.68 and d1sconnec1 1he choke 12 7A Removing 1he cover gasket
operaung arm (arrowed)
12.78 0 ring seal (arrowed) in the cover 12.88 Accelera1or pump jet removal

12.SC Remove the side plugs ... 12 80 for access 10 the primary main ret 12 SE . and secondary main ret (arrowed)
(arrowed) ..
12.9 Removing the float pivot pin 12.10 Removing the needle valve 12 13 Checking the float level dimension
(arrowed) w ith a cardboard template
needle valve ball compressed, use the template to check the float
13 Carburettor ( Solex 32-35 MIMSA) - dismant ling,
height If necessary bend the float arm 10 ad1ust.
reassembly and adjustment
7 To adrust the accelerator pump stroke, allow the throttle valve 10
close onto a 4.0 mm (0.16 1n) twist drill. Back off the ad1ustment nut
1 The dismantling procedure Is very similar to that described for the until clear of the pump lever, then screw It in until it 1ust touches the
TMIMA carburettor in Section 12 lever.
2 After cleaning the components. obtain a repair kit of gaskets and
washers
3 ReBSSemble using a reversal of the dismantling procedure. but carry
out the procedures given 1n the following paragraphs 15 Carburettor (Sol ex 34 -34 Z1) - dismantling. re.assemb ly
4 Ch'1<:k the no.11 level ad1ustmen1 as described in Secuon 12. and adjustment
paragraphs 13 and 14
S To check the choke opening after starting (COAS ) semng. press 1 The procedures are similar 10 those described in Section 14. It is not
down the choke operating link. and check that the gap between the possible 10 adjust the choke opening alter starting (COAS) system,
choke valve and barrel Is 2.0 mm (0.08 In) using a tw ist drill If due 10 the need for special equipment
adjustment 1s necessary, loosen the locknut. turn the screw as required,
then tighten the locknut
16 Carburettor (Solex 32- 34 and 34- 34 CISAC) -

14 Carburettor ( So lex 34 BICSA 3) - dismantling, dismantling. reassembly and adjustment
reassembly and ad1ustment
1 The d1smantl1ng and reassembly procedures are similar 10 those
1 Disconnect the fast idle rod from the choke lever. described for the TMIMA carburettor in Section 12, but carry out the
2 Remove the screws and separate tho cover from the main body. procedures given In the following paragraphs.
Remove the gaske1 2 To check the float level adrustment. make a cardboard template 10
3 Unscrew and remove the various 1ets. keeping them 1den11f1ed for the dimensions shown in Fig. 3 21 W ith the gaske1 fitted and the
locauon needle valve ball compressed use tha template to check the height of
4 Clean all 1he components and obtain a repair kll of gaskets and the floats If necessary, bend 1he float tongue or arms
washers 3 To check the choke opening after starting (COAS) sening, close
5 Reassembly 1s a reversal of d1smanthng, bur carry out the the choke flap, 1tipn push the COAS rod againSt i ts stop. Check that 1he
procedures given in the lollow1ng paragraphs gap between the c;hoke flap and barrel 11 2 3 mm (0.09 1n) using a twiat
6 To check the llont level adjustment. make o cardboard 1empla1e 10 drill. If necessary, ad1ust the posiuon of 1he stop screw.
the d1mens1ons shown in Fig. 3.20. Wnh th e gasket fined, and the 4 To check the last idle ad1ustment. refer 10 Section 12. paragraph 15.

------------------------------------------------------------------------------97
H 1233 0
H.1292Co
Fig. 3.18 So lex 32-35 MIMSA carburettor components Fig. 3.19 Solex 34 BICSA 3 c arburettor comp onents (Sec 14 ) -
(Sec 13)
1 Choke lever 7 Pump adjusting nut
T Pflmary idle 1et 10 Constant CO screw 2 Throttle stop screw 8 M ain jet plug
2 Plugs 1 T Secondary throttle stop 3 Constant CO screw 9 Mixture screw
3 Acceleretor pump screw 4 Fuel filter plug 10 Idling 1et
4 Pneumatic chok11 opener 12 Fast idle screw 5 Accelerator pump 11 Fast idle link
5 M ixture screw 13 Lever 6 Pump valve end filter
6 Choice control 14 Return spring
7 Pflmilry throttle stop screw 15 Quadrant
8 Secondary idle /Of 16 Econostat
9 Full load enflchener
BICSA
...
~
ff l"Jll
-
I.. 4S
I I- 70
to
Fig. 3.20 Float level template dimensions (In mm) for the Fig . 3.21 :f loat level temp late dimensions for the Solex
Solex 34 BICSA 3 c arburettor (Sec 14) CI SAC carbu rettor (Sec 16)

17 Accelerator cable - removal. ref itting an d adjustment
Unhook the accelerator inner cable from the thronle lever, and
remove the outer cable from the bracket.
2 Working inside the vehicle. disconnect the cable end fitting from
the top of the accelerator pedal arm (remove the lower facia panel if
necessary)
3 Withdraw the accelerator cable through the bulkhead grommet.
4 Refining is a reversal of removal. but adjust the cable as follows
Pos111on a 5 Omm (0.20 in) thick spacer on the accelerator pedal stop,
and hold the pedal on 11. Fully open the thronle lever at the carburettor.
then apply slight tension to the outer cable and locatet he spring clip in
the ferrule slot nearest the bracket. Remove the spacer on completion.
18 Choke c able - remov al, refitti ng and adjustment
1 Remove the carburettor air inlet ducting.

2 Unscrew the pinch-bolts and disconnect the inner and outer cables
from the lever and bracket.
3 Release the cable from the clips in the engine compartment.
A Working Inside the vehicle, disconnect the warning lamp w iring 19.1A Removing the inlet manifold ...
and detach the cable from the support bracket.
5 Refilling is ll reversal of removal, but adjust the cable at the
carburenor end, so that when the control knob is pushed fu lly in, the
choke flap 1s fully open.
19 Manifolds and exhaust system - g eneral
1 The inlet manifold 1s located on the left-hand side of the cylinder

head To remove lt, first remove the carburettor (Section 10). Drain the
cooling system (Chapter 2) and disconnect the coolant hoses.
Disconnect the vacuum hose(s). then unscrew the mounting nu1s and
bolts and remove the inlet manifold and gasket (photos) Refitting 1J< a
reversal of removal. but fit a new gasket.
2 The exhaust manifold is located on the right-hand side of the
cylinder head. To remove 11. unscrew the downpipe-to-manifold nuts.
Remove the air cleaner, then unbolt the hot air shroud, noting that the
rear manifold nut must also be removed . Unscrew the mounting nuts
and remove the exhaust manifold and gaskets (photos). Refining is a
reversal of removal, but fit new gaskets. Check that the gaskets are
fitted the correct way round on the head.
3 The exhaust system is in four sections: the downpipe. front silencer,
intermediate pipe, and rear pipe and silencers (photos). It is suspended
on flexible rubber mountings. To remove the complete system, the
intermediate pipe must be separated From the tailpipe. When fitting the 19.1 B ... and gasket
exhaust system. locate it loosely in position. then connect the
downpipe to the exhaust manifold. together with a new gasket, and
lighten the nuts. Tighten the joint clamps and mountings to complete.
PART C FU EL INJECTION ENGINES
20 Fuel injection syst em - general desc ription and

precautions
The fuel 1n1ection system ls of either Bosch K-J etronic or

LE2-Jetronic type .
The Bosch K-Jetronic system contains no specialised electronic
components for normal running. although for cold start and warm-up.
some simple electrical components ore provided. The system functions
as follows An airflow sensor plate measures the volume of air entering
the engine, and varies the amount of fuel passing from the metering
unit to the ln1ectors The system Is supplied with a regulated fuel
pressure. The cold start in1ector provides additional fuel for starting the
engine. and the mixture is automatically adjusted during the warm-up
period by the pressure regulator.
The Bosch LE2-Jetronic system Incorporates an electronic control 19.2A Unscrew the bolts ...
unit ( ECU). located behind the glovebox (photo), which is continually

19 28 and nut 19 2C and remove 1he hot air shroud 19 20 Unscrew the nuts ...
19 2E and remove 1he exhaus1 19.2F .. and gaskets 19 3A Exhaust system front mounung .
manifold
19 38 downpipe 10 fron1 silencer 19.JC 1ntermed1a1e P•Pe·IO· rear pipe 1 9 30 .. 1n1ermed1a1e mounung ..
connecuon connection
19.3E and rear silencer bridging pipes 20.1 Bosch LE2-Je1ronlc etec1ronic con trol 20 2 Bosch LE2· Jetron1c fuel cu1-0H relay
unit

ioo~--------------------------------------------------------------------"""'
Fig. 3.22 Bosch LE2- Jetronic fuel Injection system co mponents - LHO shown, RHO similar (Sec 20)
1 Fuel pump 4 Injectors 8 Supplementary air device 12 Electronic control unit

2 Fuel filter 5 Fuel pressure regulator 9 Temperature sensor (ECU)
3 Distribution and 6 rhrottle switch 10 Tachymetric relay 13 Wiring connector
occumulotor pipe 7 Air/low sensor 11 Fuel cut-off relay 14 System fuse

supp/red wrth tnforma11on from the airflow sensor. throttle swrtch,

engine temperature sensor. and 19n111on coil. From this intormarton, the
ECU determines the 1n1ec11on penod of the m1ectors. and activates
them accordingly The system does not include a cold start intecto1 or
thermal 11me switch for cold starting. as is the case on the K-Jetronic
system w1ce thrs 1unct1on Is incorporated in the ECU. The throttle
sw itch incorporates an idle contact switch and a full-load contacr
sw 11ch The rdle switch cuts the fuel supply on overiun 1f \he engine
speed rs above l 300 rpm. and works in con1unct1on with the fuel
cut oll relay l PhOIO). The full -load comacr swrtch enrichens the
m1)(ture for lull powe1.
The follow1f\g Secuons describe procedu1es which can be carried
out by the home mechanic. Work involving the"use of pressure gauges
1t. not included
In 01tje1 lo prevem damage to rhe elecrncal componenis of the
u:2 Jevonic system, the following precautions should be noted:
(a) The battery must not be disconnected with the engi11e
running
(IJJ The cCU must not be d1sco11nected w1ch the 1gnt(JOl'I on
(C) A lest lamp should not be used for cfleck.ing che ctrc11i1s or
compommrs in situ
21 Ai r cleaner element - renewal 21 .2A Unscrew the nuts ...
1 D1sconnec1 the an duct from the front of the arr cleaner.

2 Unscrew the nuts and remove the end cover (photos).
3 Extract 1he element ( photo)
4 Discard the element, and wipe the casing interror and cover clean.
5 Insert the new element, then refit the end cover and air ducL
22 Air cleaner - removal and refitting
Reier to Sectton 21 and remove the air cleaner element. Therea~er,

the procedure 1s the same as 1ha1 described for the airflow sensor rn
Section 3 1 paragraph 2 onwards
23 K -Jetronic system - idle speed and mixture adjust ment
1 Run the engine to normal operaClng temperature.

2 Connect a tachometer to the engine, and checl< 1ha1 the idle speed
ts as given in the Specifications Section.
3 If cJdrustment 1s necessary, turn the air adjustment screw on the
left-hand srde of the by -pass casing.
4 If available. use an exhaust gas analyser to check thal !he CO
2l .2B ... and remove rhe end cover
Fig . 3.23 K-Jetronic idle air adustment screw (l) and

21 .3 Aff cleaner element removal
mixture screw {2) (Sec 23)

con1ent 1s as specified If necessary remove the tamperproof plug on gauge reads less then 65 mm Hg (2 2 1n Hg) If more, proceed as
the metenng/d1stnbuuon unit. and use an Allen key to adiust the follows.
mixture screw Ad1ustment Is very sensitive. and 11 is only necessary 10 12 Remove the bunerfly stop screw by screwing it right 1hrough th e
turn 1ho mixture screw a few degrees either way. Turn the screw in 10 housing When removed. clean the tocking fluid from its threads.
richen the mi>Uure and out to weaken the mixture 13 Apply fresh locking fl uid to the threads, 1hen refit the stop screw
5 After making an ad1ustment, remove the Allen key, then increase and turn It untlt it jusl contacts the lever Screw ti In a further 11/•
the engine speed several umes and reset the idle speed. turn&
6 To ad1ust the mixture without using an exhaust gas analyser, turn 14 With 1he engine idling, check that the vacuum gauge reads less
the air ad1ustment screw to obtain an Idle speed 50 rpm above the than 55 mm Hg (2.2 in Hg)
spec1f1ed speed Turn the mixture setew to obtain the maximum engine 15 Remove the vacuum gauge and connect 1he advance hose
speed then re ad1ust 1he air screw to obtain the 011ginal speed. Now l 6 Ad1ust the idle speed and mixture as described in Sectton 23
unscrew thA mixture screw to obtain the specified idle speed
7 Remove the 1achometer, and If applicable, the exflaust gas analyser
26 K -Jetronic system componen t s - c hecking
24 K· Jetronic system - throttl e butterfly initial setting 1 Air leaks 1n 1he inlet ducting after the metering/distributor unit will
weaken the mixture entenng the combustion chambers. Before
checking the sys1em components, check 1he areas arrow ed on Fig.
Note: A vacuum gauge 1s necessary for this procedure 3 24 for possible air leaks.
ZEJ engines Sensor plate

1 Run 1he engine to normal operaung 1emperature The following 2 Using a 0 10 mm (0.004 In) feeler blade, check lhat the sensor
procedure must be camed out with the cooling fan disengaged (1e after plate is centralised If necessary, loosen the bolt, repos1t1on the plate.
cutung out1 then tighten the bolt. Note that the plate has five punch marks. or the
2 Loo~en the locknu t on the throttle housing, and unscrew the stop word 'TOP' on its upper face
screw until clear of lhe stop 3 Check that with the sensor plate a1 rest. its upper edge 1s aligned as
3 Turn the stop screw unt1f 1t 1ust contacts the stop, then screw it m a shown m Fig. 3.26. Bend 1he spnng 1f necessary
further quarteHum.
4 Connect a vacuum gauge to tho distributor advance 1ake·off point Mixture regulator
on the throttle housing. 4 Run the fuel pump for 1en seconds by sw11ching on 1he 1gn111on.
5 With the engine Idling. screw in the air adjustment screw (on the 1hen switch off.
left-hand side of 1he bypass c11sing) as far as it wil l go. 5 Gently lift 1he sensor plate. ond check thal tts resistance 1s even.
6 Ad1us1 1he idle speed to between 700 and 750 rpm by turning the Release the plate, and check that it returns to its original position
stop screw on the lhrottle housing.
7 Check tha1 1he vacuum gauge reads less 1han 65 mm Hg (2.2 In Cold start injector
Hg) then tighten the locknut and apply a dab of paint to iL 6 Disconnect 1he w iring from the control pressure regulator and
8 Remove the vacuum gauge and connect thu advi111t;e hose. add1uonal air device.
9 Ad1ust the idle speed and mixture as desc11bed in Section 23. 7 Remove the cold start iniector. then operate the fuel pump by
sw1tch1ng on the 1gnit1on. and check tha1 the in1ector 1s fuel-tight. A
ZDJ engmes maximum of one drop per minute is allowable, otherwise renew the
1O Run the engine to normal operaung 1emperature. The following in1ector
procedure must be earned out with the cooling fan disengaged. 8 Pomt the 1n1ector int o a suitable container then operate the starter
11 Connect a vacuum gauge to the d1st11butor advance take·off poln1 (engine cold). The fuel spray angle should be approxima1ely so•, and
on the 1hrottle housing. With the engine idling, check that the vacuum 1he spraying 1ime betw een six and ten seconds
I
Fi g . 3.24 K· Jetronic air leak c hec king poin ts ( Sec 26)

Ch apter 3 Fuel and exhaust systems 103
Thermal ttme switch connected Operate the fuel pump by swuchmg on the 1gn111on. then
9 Remov11 1he 1hermal sw11ch immerse the probe end 1n water. and hit 1he sensor plate. and check that the fuel spray angle from each
connert 11 to a banery and test lamp os shown m Fig 3 28 1n1ector is approximately 36'
10 W11h th e water temperature below 30' C {86' F) the test lamp
should light
l 1 Slowly heat 1ho water. and check that tho tes1 lamp is extinguished
belween 30 ond 40' C (86 and 104 F) 26 Fuel f ilters - renewal
A dd1t1onal atr device
Chock the front wheels, then 1ack up the rear of the car and suppon
12 D1&eonnect the wmng from the conirol pressure regulator. and on axle stands.
d•sconnect the ou1le1 hose from the add1119nal air device 2 Fit hose clamps to the outlet hoses from the fuel tank and main fuel
13 Ai an ambient temperature of 20 C (68 F) the hole should be hit er
v1s1ble in the device valve 3 Loosen the chps and disconnect the hoses from the pre-filter Fu
14 Opera te th e fuel pump by sw11ch1ng on the 19n111on. and check that the new pre-filter w ith the flow arrow pomung away from the fuel tank
tht' valve closes after approximately five minutes Tighten the clips.
4 Unscrew the union bolts and disconnect the inlet and outlet hose~
Fuel m1ectors from the matn filter. Recover the copper washers.
15 For accurate checking of 1he fuel 1n1ector opening pressures, they 5 Unscrew the clamp bolt and remove lhe main filter. Refitting 1s a
~hould be removed and taken to a Peugeot dealer reversal of removal, but In new copper washers, and make sure that !he
16 The operation of the in1ectors may be checked by removing them flow arrow points away from the fuel tank.
and poinung them into a suitable container with the fuel pipes 6 Remove the hose clamps and low er the vehicle to the ground.
Fi g . 3. 26 K -Jetro nic sensor plate alignment {Sec 25)
1 Lip of cone 2 Spring
Fig. 3 27 Checking the cold start Injector on th e K-Jet r o nic Fig~ ~. 28 Chec king the thermal time switch on the
system (Sec 25) K- Jetronlc system ( Sec 25)

104 Ch apter 3 Fuel and exhaust systems
27 LE2-Jetronic sys tem - Idle speed and mixture adjustment
1 Run lh!> engine lo normal operating len1perature. then run 11 al

3000 rpm and wau unul the cooling fan has cut in and out twice.
2 Connect a tachometer 10 the engine, and check that the engine Idle
speed 1s os given 1n the Speclfica11ons Section.
3 If ad1ustment is necessary, turn the air adJustmem screw on the
bypass hose near the airflow sensor (photo)
4 Adiustment of lhe Idle mh<ture is only possible using an exhaust
gas analyser The m1 x1ure ad1us1ment screw is located In the airflow
sensor and may be covered wnh a tamperproof plug, which must be
drilled and prised out
5 Check thal the CO content is as specified. If necessary, insert an
Allen key and turn the mixture screw clockwise to nchen. and
an ti clockwise to weaken (photo)
6 Atte1 making an adjustment, remove the Allen key. then increase
tht1 engine speed several times and final ly reset the idle speed.
7 Remove the tachometer and exhaust gas analyser.
Fig . 3.29 LE2· Jetronic idle speed and mixture adjustment
screws ( Sec 27)
28 LE2-Jetron ic system - throttle butterfly initial setting Air adjustment screw (idle 3 Airflow sensor
speed) 4 Tamperproof plug
2 M ixiure adjustment screw
Note: A vacuum gauge is necessary for this procedure
Run the engine to normal operating temperature. The fol lowing
procedure must be earned ou t w ith the cooli ng fan disengaged ( ie alter
culling out)
2 Connect the vacuum gauge to the distributor advance take- off
point on the thrott le housing. With lhe engine idling, check that lhe
vacuum gauge reads less than 75 mm Hg (3.0 m Hg). If it is more,
proceed as follows.
3 Remove the bu tterfly stop screw by screwing It right through the
housing When removed. clean the locking fluid from its threads.
4 Apply fresh locking fluid to the threads, then refit the stop screw,
and turn •I untol it 1ust starts to open the throttle.
5 Turn the air ad1ustment screw ful ly 1n.
6 Using an Allen key. turn the mixture screw in from its normal
position by six full turns.
7 Start the engine. and ad1ust the mixture screw unt1I the idle speed is
600 rpm With an exhaust gas analyser. check that the CO reading 1s as
specified Ad1us1 the screw if necessary.
8 Check that vacu um reading is less than 75 mm Hg (3.0 in Hg), If
not, ad1ust the butterfly stop screw as necessary.
9 Remove the vacuum gauge and connect the advance hose.
Remove the exhaust gas analyser and tachomete<.
10 Ad1ust the throttle switch (Secuon 29)
11 Ad1ust the idle speed and mixture (Secnon 27).
27.3 Ad1us11ng the idle speed with the air adjustment screw
(arrowed)
29 LE2 -Jetronic system - throttle switch adjustment
Pull the connector from the throttle switch (photo)

2 Connect a voltmeter between the middle terminal on the connector
and earth
3 Pull the connector from the Ignition control module, then operate
the starter motor, and check that there 1s a reading of al least 9 volts.
4 Position a O 20 mm (0.008 in) feeler blade between the butterfly
stop screw and lever (photo).
5 Loosen lhe two thrott le sw itch screw s.
6 Connect an ohmmeter between terminals 18 and 2 on the throule
switch (photo) then rotate the sw itch until the internal contacts close.
and the readmg 1s zero ohms. Tig hten the screws with the switch in
this pos11101
7 Remove the feeler blade, and Insert in its place a 0.40 mm (0.016
1n) feeler blade The in ternal contacts should now be separated. and
the reading on the ohmmeter infinity. If not, repeat the procedure In
paragraphs 6 and 6
8 Check the full· throttle operation by connec11ng an ohmmeter
between terminals 18 and 3. The reading should change from infinity
to zero when the thro11le lever Is 4.0 mm (0. 16 1n) from the fully- open
stop (photo)
9 If the switch does not operate correctly, It should be renewed. 27 .5 Adjusting the mixture screw

29 l Pulling the connector from the throttle sw itch 29 4 Feeler blade pos111on for ad1usung throttle switch
..n..
29 6 Using an ohmmeter to ad1us1 the throttle switch
Fig. 3.30 Checking the full - throttl e o peration of the throttle

switch on the LE2-Jetronlc 1yst em (Sec 29)
1 Throttle lever X • 4.0 mm

2 Fully-open stop (0 16 in)
30 LE2-Jetronic system c omponents - c hec king
l Air leaks In the inlet ducting and hoses w ill weaken the mixture
entering the combustion chambers Before checking the system
components, examine the air ducting and hoses for cond1t1on and
security, with reference to Fig. 3.31 .
A irflow sensor
2 Pull the connector from the airtlow sensor (photo). and connect a
voltmeter bet~en wire 3SA and eanh.
19 8 Throulo lever (A) and fully-open stop ( B) 3 Disconnect the 1gnl11on control unit, 1hen operate 1he starter motor.
and check that a minimum of 9 volts 1s obtained

Fig. 3.31 LE2-Jetronic air leak check ing points - LHD

shown, RHO similar (Sec 30)
1 Airflow sensor 7 Brake servo

2 Cylinder heod 8 F11el press11re regulator
3 S11pplementary air device 9 Crankcase ventilation hose
4 Throttle ho11sing 10 Distriblltor
5 Idle speed adj11stment 11 Econoscope vac11um
ho11sing pick -11p
6 Vac1111m reservoir for heater 12 Air intake pipe
controls

5 Connect an ohmmeter between wire Ml 8 and earth. and check
that the read ing 1s less than 1 ohm.
6 Remove the air cleaner element \Section 21 ).
7 Using a screwdriver, open and close the sensor flap to check its
action, which should be smooth and easy. Clean the Interior of the
sensor if necessary.
8 Connect an ohmmeter between terminals 6 and 8 on the airflow
sensor. and check that a reading of 340 to 450 ohms is obtained.
9 Connect the ohmmeter between terminals 9 and 8. and check that
the reading Is now between 160 and 300 ohms.
10 Connect the ohmmeter between terminals 5 and 7, then move the
flap with a screwdriver. The resistance should vary between 60 and
1000 ohms.
Engine temperature sensor

11 Disconnect the wiring plug from the engine temperature sensor
(photo). and conn,ect the ohmmeter between w ire M49 and earth. The
reading should be' rAss than 1 ohm.
12 Connect the ohmmeter across the two terminals of the sensor. If
the reading is infinity, renew the sensor.

. Chapter 3 Fuel and exhaust systems 107
Supplementary air devtce

31 LE2-Jetronic system - airfl ow sensor removal and
13 Connect a vollmeter between wire 48 on the supplementary air
refitti ng
device w111ng plug and earth (photo)
14 Disconnect the 1gn111on con trol unit, then operate the starter motor,
and check that the reading is at least 9 volts
15 With the battery disconnected, connect an ohmmeter between 1 Remove the air cleaner element (Section 21 ) .
woe M34 on the connector and earth The r1:ad1ng shou ld be less than 2 Drsconnect the lnlet air ducting
I ohm 3 Disconnect the w ir1ng plug.
16 Disconnect both hoses from the device. and check that, at an 4 Unbolt the power-assisted steenng reservoir. and support to one
ambient temperature of 20'C (68' F). the opening m the diaphragm is side (photo).
visible through the end of the unit (photo) 5 Unscrew the mounting nut and lif1 the assembly from the rubber
17 Connec1 an ohmmeter across the terminals of the unit, and check mounting(s) (photos )
that a reading of 35 to 45 ohms 1s obtained at an ambient temperature 6 Flatten the locktabs and unbolt the air cleaner from the airflow
of 20 C (68'F) sensor (photo) .
18 Connect a 12 volt supply to the termina ls of the unit After hve 7 Refitting is a reversal of removal . After tightening the air cleaner
minutes. the diaphragm must be completely shuc bolts. lock them by bending the locktabs onto the bolt heads.
30 2 Pulling the connector from the airflow 30 11 Engine temperature sensor location 30.13 Supplementary air device w iring plug
ser soi (arrowed) (arrow ed)
30 16 Diaphragm opening (arrowed) visible 31 4 Unbolt ing the power-assisted steering 31.SA Air cleaner moun11ng nut ..
through the supplementary air device reservoir from the airflow sensor
31 .58 and rubber mounting 31 .6 Atr cleaner-to-airflow sensor bolts

(arrowed)

32 LE2 Jetronic system f uel injector removal and ref itt ing 35 Fuel tank - removal, repair and refitting
Disconnect !he air inlet ducting from the lhrottle housing. If Refer io Secti on 7
necessary also disconnect the ducung above the engine rocker cover
iJnd from th cr,lnkcase ven11lat1on pon (photos)
2 Unscre"" the union nut holding the fuel supply hose to the
d1s1nbu11on pipe (photo) 36 Accelerator c able - removal and refitt ing
3 Disconnect the hoses from the fuel pressure regu lator (photos).
4 Disconnect tho w1rtng plugs from the m1ectors (photo) The procedure 1s similar to that described In Section 17, but the
5 Unoolt the d1stnbut1on pipe from the inlet manifold {photo). adjustment ferrule 1s located on the inlet air box ( photos).
6 The rJ1str1bution pipe may now be removed together with the
in1ectors or the ch ps can be removed and the pipe and 1n1ectors
removtid s&µarately (photos).
7 Remove t11f 1n1ector seals and flt new ones. 37 Manifolds and exhaust system - general
8 Rel1ttmg 1s a reversa l of removal, but smear a little petroleum Jelly
on tho s1:1als to assist reassembly. 1 The mlet manifold Is located on the left-hand side of the cylinder
head (photo). To remove 11, disconnect the air inlet ducung and
accelerator cable. then remove the injectors and fuel distnbuuon pipe
33 Fuel pump - remova l and refi tting (Sections 32 and 36). Oram the cooling system {Chapter 2).
Disconnect all hoses and wiring, and unbolt the manifold from the
Choci.. the front wheels, then iack up the rear of the car and support cylinder head. Remove !he gaskets. Refitting is a reversa l of removal,
on axle stands but fit new gaskets.
2 Fit hose clamps to the pump inlet and outlet hoses (photo). 2 The exhaust manifold is located on the right -hand side of ihe
3 Where necessary. remove the mam fuel filter, wnh reference to cylinder head (photo). To remove it, remove the air cleaner and airflow
Section 26 sensor. Unscrew the downpipe-to· manifold nuts. Unbolt the hot air
4 Disconnect the wiring. shroud, then unbolt the exhaust manifold from the cylind1tt head.
5 Disconnect the inlet and outlet hoses. Remove the gasket. Refitting is a reversa l of removal, but fit new
6 Unscrew rhe mounting nuts and remove the fuel pump. manifold and downpipe gaskets.
7 Reflt11ng 1s a reversal of removal 3 The exhaust system ls in four sections. the downpipe, front silencer.
intermediate pipe, and rear pipe and silencers (photos). It is suspended
on flexible straps. To remove the complete system, all four secuons
should first be separated. Connect the sections loosely together
34 Fuel level transmitter - removal and refitting
initially when fitting, and fit a new gasket between the downpipe and
exhaust manifold. Tighten all connections and mountings securely to
Refer 10 Section 6. complete
32 1 A D1sconnecttng the air mlet ducting 32.1 B Crankcase ventilation hose 32.1 C Air ducting con nection above rocker
from tho 1hro1tle housing (arrowed) cover
32 2 Fuel !>Upply hose union nut (arrowed) 32.3A D1sconnecung lhe fuel return hose 32.38 Disconnecting the vacuum hose from
from the fuel pressure regulator the fuel pressure regulator

32 4 ln1ector w1nng plug removal 32.5 Unbolting the d1stribu11on pipe 32.6A ln1ector connecuon to distribution
pipe (arrowed)
32 68 Remove the clips 32.6C ... and pull off lhe distribution pipe 32.60 Injector removed separai ely
o~
0
32 6E D1stnbu11on pipe removal together 32.6F Distribution pipe, injectors. and seals 33.2 Fuel pump ( 1) and main filter (2)
with in1ectors
36 1 A Accelerator cable adjustment ferrule 36 1 8 Disconnecting the accelerator inner 37.1 Inlet manifold and air box
(arrowed) cable (arrowed)

110 Chapter 3 Fu el and exh au st system s
37 2 Exhaust manrfold and hot air shroud 37.3A Exhaust system front mounung ... 37.38 .. downp1pe- to · front silencer
connection ..
37 3C ftont mtermed1ate silencer 37.30 ... rear intermediate silencer 37.3E ... and intermediate pipe-to-rear pipe
mounung . mountmg and connection ... connection
PART 0 : FAULT DIAGNOSIS
38 Fault diagnosis - fuel and exhaust systems
Symptom Reaso n(s)
D1fflcult starung from cold Choke faulty (carburettor)

Fuel pump fault
Blocked fuel line or filter
Supplementary air device faulty (fuel in1ect1on)
Cold start injector faulty (fuel Injection)
Temperature.sensor faulty (fuel mjection)
D1ff1cult :.tarting w hen hot Choked air cleaner element

Fuel pump fault
Choke sucking on {carburettor)
Excessive fuel consumption Mixture too rich

Excessive fuel pressure (fuel in1ection)
Temperature sensor faulty {fuel injection)
M etering unrt or airflow sensor faulty (fuel injection)
Uneven 1dhng M ixture settmg Incorrect

Air leak m intake system
Throttle sw itch out of ad1us1ment (fuel ln1ecuon)
Loose electronic control unit connector (fuel injection)

.•
Cha pter 4 Ignition system

Contents
Condenser removal. tesling and refitting .. . .. ............. 7 Fa uh diagnosis - ignition system ..... ... ........... ................................... 16
Contact breaker points (cassette type) - ad1ustment ...................... 5 General description ............................... .... ....................................... 1
Contact breaker points (cassette type) - removal and lgn1t1on coil - removal. testing and refitting ..................................... 13
refitting .. .. ......... ....................... ..... .......... .................. ............. 6 Ignition module - removal and refilling ............................................. 10
Contact breaker points (standard type) - adiustment ..................... 3 Ignition timing - checking and adjustment ....................................... 11
Contact breaker points (standard type) - remova l and Routine maintenance ............................................................................ 2
1ef1111ng . ................................................................................................ 4 Spark plugs, HT leads and distributor cap - general ....................... 15
Distributor dismantling and reassembly .......................................... 9 TDC sensor - removal and refilling .................................................... 14
Distrtbutor - removal and refin ing ...... ........ ...................................... 8 Timing plate (fuel injection engines) - seuing ................................ 12
Specifications
Type Convenuonal (contact breaker). or transistorised
Distributor
Rotor rotation .... ................ .... .... ... .... .•• .. ........................................ Clockwise
Firing order .. ............... ................. ......... ................................................ 1·3·4· 2 ( No 1 at flywheel end)
Contact breaker points gap (conventional) ............................................. 0.40 mm (0.016 in)
Dwell angle (conventional) ....................................................................... 57 :l 2·
Dwell percentage (conventional) ............................................................. 63 :I: 2%
Pick-up coi l resistance (transistorised) :
Magneu-Marelli ...................................................................................... 815 :I: 55 ohms
Bosch (pre -January 1986) .............................................................. 1100 :1: 11 O ohms
Bosch (January 1986 on) ................................................................... 320 ± 30 ohms
Ducellter (pre ·January 1986) ............................................................... 1100 :I: 110 ohms
Ducellter (January 1986 on) .............................................................. 190 ± 30 ohms
Ignition timing (vacuum hose disconnec ted)

XM 7A engine .............................................................................................. 10• BTOC at idle
XN1 engine.
Single choke carburettor ....................................................................... 1 o• BTDC at idle
Twin choke carburettor ......................................................................... s• BTDC at idle
XNlA engine .............................................................................................. . 1 o• BTDC at idle
ZEJ engine ................................................................................................. . a• BTDC at idle
ZOJ engine .. ............................................................................................. . 1 o• BTDC at idle
Spark plugs
Type
XM7A an XN1 /A engines .................................................................. Champion N9YC. Bosch W7DC, Eyquem 750LS. or equivalent
ZEJ and ZOJ engines ............................................................................ thampion S7YC, Bosch H60C, Eyquem 803US. or equivalent
Electrode gap .. ......................................................................................... . 0.6 mm (0.024 in)
Ignition coil Conventional Transistorised

Pnmarv resistance ........................................................................................ 3.1 ohms 0.7 ohms
Secondary resistance .........•......................................................................... 6000 ohms 3850 ohms
J.
Torque wren ch settings Nm lbf ft
Spark plug - with sealing washer ............................................................. 22 16
Spork plug taper-seat ............................................................................... 16 to 20 11 to 15

,, 2 Chapter 4 Ignition syst em
1 General descript ion 2 Routine maintenance
The ignition syS"tem Is of either conventiona l (contact breaker) type Carry out the following procedures et tho mt(Jrvals given in Routine
or 1rans1stonsed type. employing an Ignition coll and distributor. maintenance at the front of this mBnual.
In order 1ha1 the engine may run correctly, 11 is necessary for an
electrical spark 10 1gn11e the fuel/ air mixture in the combustion Renew the spark plugs
chamber at exactly the right moment in relation to engine speed and 1 Remove the old spark plugs and fu new ones with reference to
toad Secuon 15
Basically, the 1gmtton system funcuons as follows. low tension
voltage from the banery 1s fed to the 1gn111on coil. where it is converted Check the ignition timing
into high tension voltage The high tension voltage.is powerful enough 2 Check and sf necessary adiust the 1gn111on urning. as descnbed in
to iump the spark plug gap in the cylinder many times a second under Section 11 .
high compression pressure, prov1d1ng that the ignition system is 1n
good working order Clean and adjust the contact breaker points
Tho 1gn11ton system consists of two individual circuits, known as 3 Remove. clean and refit th e contact breaker points as described In
the low tension ( LT) circuit and high tension (HT) ci rcu it. Sections 3 to 6, as appropriate.
The tow tension circuit (sometimes known as the primary circuit) 4 Always check the ignition timing alter cleaning the contac t breaker
compnses the 1gn111on sw itch, primary ignition coil windings. and the points.
contact breaker or control module. The high tension circuit (sometimes
known as the secondary ci rcuit) compnses the secondary igniuon coil
windings. d1s111butor cap, rotor arm, spark plugs and HT leads
The pnmary c1rcu11 is initiall y switched on by the contact breaker or
3 Contac t breaker points (standard ) - adjustment
control module and a magnetic field 1s formed wuhin the ignition coil.
At the precise point of ignition. the primary c11cu11 is switched off. and Release the two clips and lift away the d1st11butor cap Clean the
high tension voltage is then induced in the secondary circuit and fed to inside and outside of the cap wuh a dry cloth and. if the four segments
the spark plug via the distributor cap and rotor arm are slightly burned. scrape the deposit away w ith a screwdriver. Should
The 1gn111on 1s advanced and retarded automaucally by centrifugal the segments be badly burned, the cap must be renewed.
weights and a vacuum capsule, to ensure that the spark occurs at the 2 Check that the carbon brush is free to move in the cap, and that 11
correct instant 1n relauon to engine speed and load protrudes by at least 6 mm (0 25 in).
3 Prise the contact breaker points apart and examine the two faces. If
Note: When working on the trans/$1orlsed 1gnit1on system. remember they are rough, pitted. or dirty ihey must be removed for resurfacing or
thot the high tension voltage can be considerably higher than on the renewal as described in Section 4. Note th at the contour of the fixed
conventional system. and in certain circumstances could prove fatal contact must be retained for the system to operate successfully.
--1
-
Fig. 4. 1 Wiring diagram of the t r ansist orised ignition system (Sec 1 )
1
2
Battery
Ignition coll
3
4
Control module
Tachometer
5
6 S1Jark plua .
Distributor cap \ 7 Impulse generator and
pick· up coil

Fig. 4.2 Contact breaker points assembly - standard type

(S ec 3)
Ad1uster for vacuum control 2 Fixed contact locking screw
4 To adjust the contact breaker points accurately, a dwell meter w ill

be required but to obtain an 1n111al setting, first rotate the engine unttl
the heel of the contact breaker arm 1s on the peak of one of the four
cam lobes
5 Loosen the fixed contact locking screw and PoS1t1on the fixed Fig . 4.3 Contact breaker points assembly - cassette type
contact so that a feeler gauge of the spec1f1ed size 1us1 fits between the ( Sec 5)
two points Tighten the locking screw and recheck the ad1ustment
6 Connect a dwell meter and tachometer to the engine, then run the 7 Allen key 6 Heel or cam follower
engine at 2000 rpm (vacuum pipe disconnected) The dwell angle 2 Adjusting screw 7 Arm and support pivot pin
must be as specified If this 1s not the case. stop the engine and reduce 3 Contact pomts 8 Metal quadrant
the points gap to increase the dwell angle. and vice-versa. Note that a 4 Fixed contact 9 Contact breaker plate
hole 1s provided In the baseplate for fitting an eccentric con tact point 5 Contact breake1 arm
ad1uster but this tool 1s not an essential requirement.
7 The operation o f the vacuum advance uni t alters the ignition timing 2 There are two methods of checking end adjusting the gap between
by repositioning 1he moving contact point This action produces a the contact breaker points. The most accurate method is by using a
variation of the dwell angle. which will cause uneven timing unless set dwellmeter to determine the dwell angle. which is the angle through
correctly If the serrated cam or eccentric adiuster on the distributor which the distributor cam turns between the instance of closure and
beseplate heve been disturbed, they must be readjustttd by a opening of the contact breaker points during one ignition cycle. A
su1tably -equ1pped garage. To make a quick check on the adiustment. reductton of the points gap will increase the dwell angle, and
move the vacuum control rod through its entire stroke. and make sure wce · versa
that the moving contact operates over the central portion of the fixed 3 With the dwellmeter attached to the 1gni1ton system m accordance
contact with the equipment manufacturer"s instructions, measure the dwell
8 After ad1us11ng the contact breaker points, ref11 the distributor cap angle. This angle must be as specified If the correct type of meter ts
available. then measure the dwell percentage. which must also be as
specified. If necessary, use a 3 mm Allen key on the special adiustlng
4 Con tact breaker points (standard type) - removal and screw with the engine idling. Turn the key clockwise to i ncrease dwell,
refitting or anti-clockwise to decrease dwell.
4 The second method of adjustment requires the manufacture of a
special tool, tha t is a length of metal bar with a diameter of 17.0 mm
1 If the con tact breaker points are burned. pilled or badly worn. they
(0.67 m). Insert th is tool into the centre of the cassette in place of the
'hould be removed and either replaced or their faces must be hied
dnve spindle, and then ad1ust the points gap to 0.40 mm (0.016 in) by
smooth
using a feeler gauge
2 To remove the points. first detach the distributor cap and rotor arm
3 Unscrew and hft away the fixed plate locking screw and washer.
taking care not to drop them into the body of the distributor.
4 Unchp and hft away the hairpin shaped clip
5 Slacken the l T cables securing nuts, but do not completely remove
them Slide the contact breaker points cable terminal connector up
from the terminal. Note 11 1s located between the terminal bolt head and
the insulator
6 Lilt off the moving point pivot washer, and then very carefully
rainove the points assembly. Make o note of the location of 1he
insulation washers
7 Refnting the contact breaker points 1s the reverse sequence to
removal Reset the points gap as described In Section 3.
5 Contact breaker points (cassette type) - adjustment
1 The cond11ton of the contact breaker points w ithin the cassette can
be determined by measunng the voltage drop across them w ith the gap
clo~lld If the voltage reading obtained exceeds 0 2 volts. then suspect
a fault Apart from points 1n bad condition. faults may include the low
tension wire between the HT coil and distributor being defective, a Fig. 4.4 Access to cassette points adjustment (Sec 6)
defective earth between the distributor body and the engine, or an 1\
internal fault In the distributor. q Adjustment aperture 2 Sliding cover

114 Chapter 4 Ignition system
6 Contact breaker points (cassette type ) - removal and

refitting
1 The con tact breaker points form an integral part of the cassette.
Figs. 4.5 and 4.6 show removal of the cassette from the distributor, and
disconnection of the cassette from the vacuum capsule.
2 New cassettes are preset by the manufacturer, and require no
further ad1ustment. Take care when fitting the cassette over the cam, to
make sure that the contact heel is not damaged by coming into contact
with the apex of a cam. When refitting the rot or arm. ensure that it is
fully home in the drive spindle. and that the complete cassette/
condenser assembly is fully home in the distributor body Recheck all
t .· elecmcal connections after assembly. Reset the 1n11tal ignruon ti ming.
Fig. 4.5 Withdrawing the cassette from the distributor body

(Sec 6)
Fig. 4 .6 D isconnecting the cassette wiring ( Sec 6)
Fig. 4.7 Refitting the cassette on the $EV-Marcha l dist~ibutor ( Sec 6)

Chapter 4 Ignition system ,, 5
7 Condenser - removal. t est ing and r efitting
The purpose of the condenser (somettmes know n as a capacit or) is

10 ensure that when the contact breaker poin ts open there is no
sparking across them. which would waste voltage and cause w ear.
2 The condenser Is hued in parallel with the con tact breaker poin ts If
11 develops a shon c1rcu11. 11w ill cause ignition failure. as the points w ill
be prevented from interrupting the low tension circuit
3 II the engine becomes very d1H1cult 10 s1an. or begins to misfire
attar several miles running, and the breaker po1n1s show signs of
ucess1ve burning. then the condition of the condenser must be
suspect A funher test can be made by separating the points manually
(using an insulated screwdriver) w ith the ignition sw uched on. If this
is accompanied by a flash. 11 is 1nd1ca11ve tha t the condenser has failed.
4 W11hou1 special test equipment, the only sure w ay to diagnose
condenser 1rouble is to replace a suspected unit with a new one. and
nottng 1f there Is any 1mprovemem.
5 To remove tho condenser from the distribu tor. first detach the
condenser lead from the LT termina l post on the side of the distributor
body
6 Undo and remove the one securing screw. spring and shakeproof
washer noting the loca11ons of the washers Lill aw ay the condenser
7 Refilling of the condenser 1s simply a reversal of the removal 8.3 D1stnbutor wmng clamp (arrowed)
procedure
8 D istributor - rem o val and refitt ing
On fuel in1ec11on models. remove the battery to provide addn1onal

woiking room.
2 Disconnect the HT leads from the plugs and coil
3 0 1sconnec1 the w iring from the distributor On some models. the
wmng plug 1s secured by a metal clamp retained by a screw ( photo).
4 Disconnect the vacuum advance pope (photo)
5 Mark the distributor body and mounting in relauo n to each other to
ensure 1he correct igni11011 ti111i11y un rttlitmem
6 Unscrew the pinch-bolt (carburettor engine) or mounung nuts
(fuel in1ect1on engine). and withdraw the distributor from the cylinder
block ( photos)
7 Check the condotton of the 0 - ring seal on the base of the
d1st11but01. and renew 11 1f necessary
8 Ref1t11ng is a reversal of removal, but remove the distributor cap and
turn the rotor arm as required to align the dnv1ng dog with the offset
slot 1n the dnvegear If the old distributor 1s being refitted, align the
previously-made marks before tightening the pinch-bolt or mounting
nuts If a new distributor Is being llt1ed. transl er the mark from the old
unit for an approxima te setting.
9 Finally adiust the 1gni11on umong as described on Section 11 8.4 Disconnecting the vacuum advance pope
Fi g. 4.8 0 -ri ng seel (1 ) on the base of the dist ri butor f i tted 8.6A Unscrew the pinch-bolt (arrow ed) ..
to f uel injectio n engines (Sec 8 )

8.6B .. and withdraw the distributor 8.6C The complete distributor ( Ducellier type)
4 Mark the upper and lower housings 1n relation to each other.

9 Distributor - dismantl ing and reassembl y
Unscrew the cross-head screws and separate the housings (photos).
5 Invert the upper housing and mark the plastic ring in relation to the
Note: This Section describes lhe dismantling and reassembly housing. Prise out the ring (photo).
procedures for a distributor f itted to a 1971 cc carburettor engine. 6 Remove the pick-up coil ( photo) .
Exploded views of other distributors are shown m Figs. 4.1 O and 4. 11 , 7 Using circlip pliers, extract the circltp (photo).
and tha procedures for these are similar 8 Remove the w asher. Note where the vacuum advance capsule arm
is fitted, then remove the st ator. The stator should be marked on its
1 Release the clips and remove the distributor cap. underside at the hole where the arm fits (photos).
2 Remove the carbon brush from inside the cap (photo). 9 Remove the screws and w ithdraw the vacuum advance capsule
3 Pull off the rotor arm and remove the plastic cover (photos). from the upper housing (photos).
Fig. 4.9 Exploded view of the conventional Ducellier

d istributor (Sec 9)
1 Distributor cap
2 Cover
3 Carbon brush
4 Rotorarm
5 Contact breaker points
6 Baseplate
7 Cam and driveshalt
8 Vacuum advance capsule
9 Condenser
10 Drive dog

I
,_.-------------------------------------------------------------------117
~
0 H.20564
Fig. 4.10 Exploded v i ew o f con vent i onal Par is- RhOne d i stribut or ( Sec 9)
1 D1stflbutor cap 4 Cover 6 Baseplate and cpntact 7 Vacuum advance capsule

2 Carbon blush 5 Condenser points 8 Body
3 Rotor arm 9 Dflve dog

,•
H. 20565
Fig . 4.11 Exploded vi ew o f transist orised Bosch distributor ( Sec 9)
1 01s(ffbutor cap 5 B earing support 8 Pick- up coil 11 Oriveshafl

2 Wmng harness 6 Stop ring 9 Stator 12 Vacuum advance capsule
3 Rotor arm 7 Reluctor 10 Basepla1e 13 Body
4 Cover
10 Working on the lower housing, mark the reluctor In relauon to the housing (photo). Lightly oil the pivots. and apply two or three drops or
cenmfugal weight base oil beneath them to lubricate rhe shaft bearing.
11 Extract the c1rcl1p, disconnect the centrifugal weight springs. and 13 Reassembly is a reversal of dismantling. When refining the carbon
remove the reluctor from the shaft (photos). brush in the distrit:lulor cap, check that 11 moves freely and protrudes by
12 The centrifugal weights cannot be removed from the lower at least 6 mm (0. 25~n) .

9 2 Removing the carbo n brush from the • 9.3A Removing the rotor arm ...
d1str1bu tor cap 9.38 ..• and plastic cover
9 4A Remove the screws ... 9.48 ... and separate the housings 9.5 Removing the plasuc ring
( Ducelfier type)
9 6 P1ck·up coil removal 9. 7 Extract the circhp . 9.8A ... remove the washer ...
9.88 .. and lift oH the stator 9.SC Mark (arrowed) indicates vacuum 9.9A Vacuum advance capsule removal
capsule arm location ·\

9 98 The dismantled upper housing 9 11 A Extract tho c1rch p 9.11 B ... disconnect the springs
(arrowed) . (arrowed ) ...
9.11 C ... and r1:1111vv1:1 the 1eluctor 9.12 Centrifugal weights in the lower
housing
3 Disconnect the winng plug from the module (photo) .

10 Ignition module - removal and refitting 4 Unbolt the module from the alloy plate.
5 Refitting is a reversal or removal, but to ensure adequate cooling.
1 Slide the plosuc cover off the 1gnit1on coil and module (photo) clean the alloy plate and apply a little heat -conductive grease to the
2 Disconnect the battery negative lead base of the module.
10 1 Sliding the plasuc cover from the 1gn111on coil and module 10.3 Wiring plug cA,rrowed) on the 1gn1t1on module

11 Igni tion timing - checking and adjus t men t
Note Thn •qml/on t1mmg may be checked and od1usted usmg the
tt1• ~m f1aqnost1c socket but the special Pr.ugeot mstrument necess
,,,,. will not normally be available to the home mechanic
/nlllal setting (for starring engine alter reassembly)

1 Remove the spark plug from No 1 cylinder (flywheel end of
ting me)
3 Turn the engine 1n i ts normal direction of rotation using a spanner
on the crankshafl pulley bolt. and stop when air 1s forced ou t of No 1
cylinder th1ough the spartt plug hole
4 Slowly turn the engine 1n the same d1rec 11on unul the 1gn111on
ummg mark on the crankshah pulley 1s aligned w ith the urning mark on
thn t1mmg pla te (photo). Note that there are two t1mtng marks on the
pullev at 1 so· from each other. but only the mark identified by white
paint must be used for tim ing No 1 cyllnde1. The other mark is used by
the factory when setting tho timing plate.
5 Remove the distributor cap, and check that the rotor arm 1s potnting
to the No 1 HT lead segment position. If not, reposition the distnbuto1
body
6 On convenuonal 1gm1ton models, check that the contact breaker 11 4 lgn111on t1m1ng marks
points are 1ust separaung To do this . connect a 12 volt test lamp
between the co1l -10-d1stributor w ire and earth Temporarily reconnect
the battery and switch on the ignition, then move the distributor body
unul the test lamp 1us1 lights. indicating that the contact points have
s••parat ed. Tighten the mounting bolt or nuts.
7 On transistorised 1gnl11on models, check that the reluctor and stator
,11ms are in line with each other. Where the reluctor is completely
enclosed thlS w ill not be possible. but the rotor arm should be pointing
tow ards the mark etched on the nm of the distributor body.
8 Refit the d1strtbutor cap and No 1 spark plug. then reconnect the
battery negative lead.
Fmal settmg
9 Run the engine to normal operating temperature and allow 11 to
idle
10 Disconnect the vacuum pipe from the vacuum capsule on the
d1st11butor and plug It
11 With the engine stopped, connect a stroboscopic 11ming hght to
No 1 HT lead (flywheel end of the engine) i n accordance w ith the
equipment maker's tnstructions
12 Check that all leads are clear of moving parts, then start the engine
13 With the engine idling, point the timing light at the urning marks on
the front of the engine and crankshaft pulley The marks will appear
stauonarv and 1f the urning is correct, in alignment. The correc1
1gn111on urning is usually indicated on one of the HT leads (photo) 11 .13 lgn11ion timing indicated on one of the HT leads
14 II the marks are not aligned. loosen the distributor pinch -bolt or
mounung nuts. and move the distributor body slightly to bri ng them in
hne Tighten the bolt or nuts and recheck .
15 The cenuifugal weight advance mechanism may be checked by
1ncrnasing the engine speed, and noting that the timing mark on the
crankshaft pulley moves 1n an anti-clockwise direction. On the ZDJ
engine fined with LE2 -Jetronic in1ect1on, en additional mark is
provided on the t1m1ng plate showing the correct ttming at 4000 rpm
(24 BTDC)
16 WhPn ad1ustmen1 1s complete, swttch off the engine, remove the
uming light and reconnect the vacuum pipe
12 Timing plate (fuel inject ion engines) - setting
1 The nmrng plate is located on the front of the timing cover and is
set during producuon. If the plate has been moved or the timing cover
renew ed carry out the following procedure.
2 R~move the crankcase plug next to the distributor.
3 Sw itch off the 1gn1t1on
4 Using a spanner on the crankshaft pulley bolt. tum the engine 1n its
normal direction of rotauon unul the ttmrng mark on the camshaft geat
JUSI enters the aperture in the t1m1ng cover Flg.' 4.12 Setting the timing plate ( Sec 12)
5 If available. insert the special Peugeot tool 80133 in the crankcase
plug hole, then slowly turn the crankshaft unt1I the tool is fel t to drop Crankcase plug 2 TDC timing mark on
IPto rhe cut ou t In the counterbalance weight of the crankshaft If the camshaft near

122 Chapter 4 Igniti on system
special tool is not available, use an 8.0 mm (0.31 1n) diameter. 100 mm
(3 9 1n) long, rod instead.
6 Loosen the 11m1ng plate nuts. and align the O' (TDC) mark with the
mark on th e pulley.
7 Tighten the nuts. and apply a dab of paint on them to sa feguard the
setting
8 Remove the special tool. and refit the crankcase plug.
13 Ignition coil - rem oval. test ing and refitting
1 Slide the plasuc cover off the 1gnit1on coil and module.
2 Di sconnect the low tension wiring. noting its loca11on.
3 Disconnect the high tension (HT) lead from the coil tower (photo). Fig. 4.13 M ethod of using the special timing too l (Sec 12)
4 Unbolt the coil from the mounting plate.
5 Using an ohmmeter, check the resistance of the primary and
secondary windings. Connect the ohmmet er between the low tension
terminals to check the primary wind ings. and between the 15( +)
terminal and the HT terminal to check the secondary windings. Refer 10
th e Speci ficauons Secuon for the values
6 Ref11ting 1s a reversal of removal.
14 T DC sensor - r em ov al and refitting
1 The TDC sensor 1s for use with the diagnostic socket. and is located
on the fron t cover of the gearbox or automatic transmission. As a
special instrument and adaptor are requ11ed to make use of it. 11 will
normally be used only by a Peugeot garage
2 To remove the sensor. unscrew the mounting screw.
3 The sensor fom1s part of the diagnostic socket assembly so. if it 1s to
be completely removed. the socket must be unclipped from Its bracket.
and the remaining wiring and earth leads disconnected.
4 Refitting is a reversal of removal, but the ad1ustment procedure for
new and used sensors differs New sensors have three extensions on
the Inner face, and the unit should be inserted through the mounting
until the extensions 1ust touch tho flywheel Tho clomp screw is thon
tightened and clea rance is provided as the flywheel rotates and wears
1he ends of 1he extensions. Th is method should not be used when
refit ting a used sensor. In this case. cu1 oft the extensions completely. 13.3 Igni tion coil and HT lead
then insert the sensor until it touches the flywheel. move it out 1.7 mm
(0.07 in). and clamp 1t in this position.
11 Before clea ning a spark plug. w ash it in petrol to remove oily
deposns.
16 Spark plugs. HT leads and distributor c ap - gener al
12 Although a wire brush can be used to clean the elec trode end of
the spark plug. this method can cause metal conductance paths across
1 The correct funcuoning of the spark plugs is vital for the correct the nose of the insulator, and it is therefore to be preferred that an
running and efficiency of the engine, and it is therefore important to abrasive powder cleaning machine 1s used. Such machines are
keep them clean and correctly gapped in accordance w ith the intervals available quite cheaply from motor accessory stores, or you may prefer
given '" Routine maintenance. to take the plugs to your dealer who will not only be able to clean them
2 To remove the plugs. first open the bonnet and disconnect the HT but also to check the sparking efficiency of each plug under
leads, noung their positions (photos) compression.
3 On carburettor engines. remove the rubber tubes from the valve 13 The spark plug gap is of considerable importance. as. H 11 Is 100
cover (photo). and from the air cleaner. large or too small. the size of the spark and its eff1clency will be
4 Unscrew and remove the spark plugs from the cylinder head. On seriously impaired. For the best resu lts. the spark plug gap should be
carburettor engines. the plugs are deeply recessed, and a long plug set 1n accordance w11h the Specifications Section at the beginning of
spanner will be necessary to remove them (photos) this Chapter.
5 Unscrew the plug extension rods on carburettor engines (photo). 14 To set it, measure the gap w ith a feeler gauge and then bend the
6 Examinauon of the spark plugs will give a good indication of the outer electrode until the correct gap is achieved. The centre electrode
cond111on of th e engine. should never be bent, as this may crack the insulation and cause plug
7 If the insulator nose of the spark plug is clean and whi te, w ith no failure. if nothing worse.
depos11s. this is indicative of a weak mixture. or too hot a plug (a hot 15 Special spark plug electrode gap adjusting tools are available from
plug transfers heat away from the electrode slowly, a cold plug most motor accessory stores.
transfers heat away quickly). 16 Before refitting the spark plugs. wash each one thoroughly again
8 If the up and insulator nose are covered with herd black-looking using clean fuel in order to remove all traces of abrasive pow der, and
deposits. then this is indicative that the mixture 1s too rich. Should the then apply a smear or grease to the plug threads.
plug be black and oily, then it 1s likely that the engine is fairly worn. as 17 Screw each plug in by hand. This will ensure that there is no
well as the mixture being too rich chance of cross-threading.
9 If the insulator nose ls covered with light tan to greyish-brow n 18 Tighten to the specified torque. If a torque wrench 1s not availabl e.
deposits. then the mixture is correct. and 1t is likely that the engine is in 1ust lightly tighten each plug. It is beuer to undertlghten than strip the
good condition. threads from the11i'ght alloy cylinder head. Also w here the taper-seat
10 If there are any traces of long brown tapering stains on the outside type plugs are used (no sealing washers) overtightenlng can make
of tho white portion of the plug. then the plug wi ll have to be renewed, them very difficult to unscrew.
as this shows that there 1s a faulty 1olnt between the plug body and the 19 When connecting the spark plug leads. make sure that they are
insulator. and compression is being allowed to leak away. connected in their correct order

Measuring plug gap. A feeler gauge of the correct size (see Adjusting plug gap. The plug gap is adjust ed by bending the
ign1t1or1 .ystem specil1cattons) should have 11 slight ·drag when earth electrode lnworda. or outwards. as necessary until the
shd between the electrodes Adjust gap if necessary correct clearance ia obtained. Note the use ol the correct tool
N orm1I . Grev·brown deposits, lightly coated core nose. Gap Carbon fouling . Ory. black. sooty deposits. Will cause weak
ncreos1ng bv around O.OOl in 10 025 mm) per 1000 miles spark and eventually misfire Fault over-rich fuel mixture
1600 km) Plugs ideally suited to engine. and engine in good Check· carburettor mixture settings. float level and jet sizes
condition choke operation and cleanliness of air filter. Plugs can be re-
used alter cleaning
0 11 loullng. Wet, ollv deposits Wiii ceuse weak spark and Overheating. Electrodes have glazed appearanca. core nose
elll!ntually misfire. Fault · worn bores/piston rings or valve very white - few deposit&. Fault plug overheating Check: plug
gu des: sometimes occurs (temporarily) during running-In value 1gnit1on urning fuel octane rating (too low) and fuel
p rod Plugs can be re ·used after thorough cleaning mixture (too weak) Discard plugs and cure fault immediately
Eloctrode dam1ge. Electrodes burned away core nose has Split core noae (may appear inltlally ea a crack). Damage 1s
bumt.Jd glazed 1ppearanc11 Fault: pre 1gni11on. Check as for self evident but crack• will only show after cleaning. Fault. pre-
Overheating but may be more severe. Discard plugs and 1gni11on or wrdng gap-setting technique. Check: ignition timing,
r medy fault before piston or valve damage occurs cooling system. fuel octane rating (too low) and fuel mixture
(too week) Discord plugs rectify fault immedia tely

15 2A HT le.id~ on the carburenor engine 15 26 Disconnecung an HT lead 1 5 3 Removing a rubber tube on the
carburettor engine
15 4A Using o long plug spanner on the 15 46 Removi ng a spark plug l5 5 Spark plug and HT lead components
carburnnor engine (carburettor engine)
20 The i.park plug leads require no routine anentton other than being with well -insulated pliers While an assistant spins the engine on the
kept clean by wiping them regularly starter motor, check that a regular blue spark occurs. If so. the spatt
21 In order to min1m1se corrosion in the d1smbutor cap lead sockets plugs are probably the cause of non-starting, and they should therefore
smear the HT cable end fittings with a hght coaung of petroleum 1elly be removed. cleaned. and regapped.
22 Check the dtstnbutor cop whenever 11 1s removed If there are any 4 If no spark occurs, disconnect the main feed HT lead from the
very thtn black lines running between the electrodes. this indicates distributor cap, and check for a spark as in paragraph 3 If sparks now
tracking and a new cap should be fmed. Check the rotor arm in a occur. check the distributor cap, rotor arm. and HT leads as described
s1m1lar way Check that the spring-tensioned carbon brush In the in Secuon 15. and renew them as necessary
centre of th cap is free to move. and IS not worn excessively 5 Check the security of the wtrtng to the 1gniuon coil. distnbutor and
where applicable. the electronic module
6 On convenuonal 1gniuon models, check the contact breaker points
with reference to Secttons 3 to 6, as applicable. If necessary. also check
the condenser with reference to Sectton 7.
16 Fault diagnosis - i gniti on system 7 On transistortsed ign1t1on models. using an ohmmeter, check the
resistance of the distributor pick -up coil and the 1gn11ion coil windings
If the engine fails to start and yet was running normally when last Renew them 11 the readings are not as given in the Spec1f1cattons
ui>ed. first check tha t there is fuel 1n the fuel tank If the engine turns Secuon If necessary dismantle the d1st11but0<. and check that the gaps
over normally on the starter motor. and the battery 1s evidently between the reluctor arms and the stator ports are all equal
well-charged. first check the HT (high tension) c1rcu1 t 8 Using a voltmeter, check that there is battery voltage at the 1gn111on
2 A common reason for bad starting 1s we t or damp spark plug lends coil low tension 15 ( t ) terminal w ith the 1gnl11on swttched on
and d1s1rtbutor cap. Check both hems and wipe dry. ff· necessary 9 On transistorised 1gn1tion models. connect the voltmeter across the
3 ti the engine sull fails to start. first disconnect an HT lead from any coil LT te11111nals. and check that the reading ts zero wtth the 1gn11ton
spark plug. Using a natl inserted into the end f1tttng 11 necessary, hold swttched on. If 1t 1s not zero. the module may be defecuve. or the
the lead approximately 5 0 mm (0 2 1n) away fom the cylinder head coil- to module wrre may be earthed

Cha pter 5 Clutch

Contents
·'
Clutch 1nspecuon and renovation . ................................................ 4 Hydraulic flexible hose - removal and ref1111ng .......................... 10
Clutch reflmng .... ............ ....... .. .................................................... 5 Master cylinder - removal. overhaul and ref1111ng ............................ 6
Clutch removal ........................... .. .. ............................ .................... 3 Release bearing and fork assembly removal and ref1111ng ....... 8
Clutch hydraulic system - bleeding .. ...... .......................................... 9 Rouune maintenance . ...... ...... ... ... ... . .... .............. ........ ......... 2
Fault diagnosis - clutch ...................................................................... 11 Slave cylinder - removal. overhaul and refitting ............................... 7
General dascnpuon ......................... ............... ..... ............................. 1
Speci f i ca t i ons
Type Diaphragm spring. single dry plate. hydrauhc operation
Genera l
Friction plate diameter . .. .................................- ...... 215 0 mm (8.47 m )
Maximum machining of flywheel from new ............................................ 0 5 mm (0.02 in)
Clutch pedal free movement .................. ........ ......................................... 5 to 10 mm (0.2 to 0.4 1n)
Clutch fluid type/ specification Hydraulic fluid to SAE Jl 703 or DOT 3 ( Ou ckhams Universal Brake
and Clutch Fluid)

Clutch cover ................................. 15 11
General description
The clu tch 1s of diaphragm spring. single dry plate cype. with
hydraulic operation
The clutch pedal pivots in a bracket mounted under the facia, and
operates a pushrod on the master cylinder. The slave cylinder, mounted
on the left -hand side of the gearbox. pushes the clutch release fork
which pivots on a ball stud, and moves the release bearing against th e ©- --
centre of the diaphragm spring within the clutch cover. As the centre of
the diaphragm spring 1s pushed in. us outer edge pivots out and moves
the piessure plate away from the friction disc.
When th e clutch pedal is released. the diaphragm spring forces the
p<essure plate into contact with the fnction disc, which moves along
thfl input shalt splines and contacts the flywheel. The friction disc 1s
now firmly sandwiched between the pressure plate and flywheel, so
the d11ve is taken up.
No ad1us1ment 1s necessary to compensate for wear of the friction
d•SC linings, as hydraulic flu id 1s allowed to bleed back to the reservoir
when the clutch pedal is at rest As wear occurs. the slave cylinder
piston simply assumes a rest position which is further in the cylinder.
Carry out the following procedures at the intervals given in Routine

1n11ntenance at the front of this manual 0
Check the hydraulic circuit for leaks and condition

1 Apply the handbrake. Jack up the front of the vehicle and support
on axle stands
Fig. 5.1 Cross -section of the c lutch components ( Sec 1)
2 Check the hydraulic circuit flexible hoses and rigid line for leaks.
damage and detenorauon. 1 Clutch housing 5 Clutch cover and pressure
3 Check the slave cylinder for leakage of fl uid from the rubber boot. 2 Srtlner ring gear plata
indicating that the Internal seal 1s worn. 3 Flywheel 6 Release bearing
4 Check the master cylinder for leaks. both 1n the engine compart· 4 fflction disc 7 Releasa fork
men1 ilnd from inside the vehicle. 8 Stove cyllnder

126 Chapter 5 Clutch
3 Clut ch - r emoval
Access to the clu tcll is by either removing the gearbox or engine.

Unless work 1s also necessary on the gearbox. 1t 1s recommended that
the engine Is removed. as this Involves less work. Because the propeller
shaft Is enclosed, removal of the gearbox i nvolves moving the final
drive or rear axle rearwards. Removal of the engine is described in
Chapter 1. and removal of the gearbox 1n Chapter 6.
2 Mark the clutch cover in relation to the flywheel in case It 1s to be
reused
3 Using an Allen key, progressively unscrew the cover retaini ng
bolts. If the cover binds on the dowels. use a screw driver to release it
before removing the bolts.
4 Lifl the clu tch cover and friction disc from the flywheel.
4 Clutch - inspect ion and renovat ion
The clutch fr1c11on disc shou ld be inspec ted for wear and for
contamination by 011, Wear 1s gauged by the depth of the rivet heads
below the surface of the friction material. If this 1s less than 0.6 mm
(0.024 in), the linings are worn enough to Justify renewal.
5.1 Locating the friction disc on the flyw heel
2 Examine the fricti on surfaces of the flywheel and clutch cover.
These should be bright and smooth. If the linings have w orn too much.
11 1s possible that the metal surfaces may have been scored by the rivet
heads. Dust and grit can also have the same effect. If the scoring is very
severe. 11 could mean that even with a new friction disc. slip and
1uddenng and other malfunctions may recur.
3 If the flywheel face 1s deeply scored. either renew the flywheel, or
have 1t machined by a specialist. Note that if It is machined, the area on
which the cover locates must be machined by the same amount (Fig.
5.2) m order to maintain the same diaphragm pressure.
4 Renew the cover if the pressure plate 1s scored excessively, or 1f It
has a blue discolouration. Indicating that 11 has been overheated by
excessive shppmg at some time.
5 If the lru;hon disc is contaminated w ith oil, renew it and also rectify
the source of the 011 leak.
6 With the clutch removed. the release bearing should be checked for
excessive wear and noise. and renewed i f necessary - refer to Section
8. Also check the spigot bush in the crankshaft rear flange for wear
and, 1f necessary, renew it as described in Chapter 1.
r -
5.2 Using an alignment tool to centre the friction disc
Fig . 6.2 When machini ng the f lywheel. fa ces a and b m u st

be machined by equal amounts (Sec 4 )
5 Clutch - refitt ing
1 Locate the fric11on disc on the flywheel with the cushioning spring
hub facing outwards (photo). then place the cover assembly over It,
w ith the dowels and holes correctly aligned. and fit the bolts
finger- light.
2 It 1s now necessary to align the centre of the friction disc with that
of the flywheel To do this, use a special alignment tool located In the 5.3 Tightening th • •plutch cover bolts
crankshaft spigot bush (photo), or alternatively, a suitable diameter bar

or wooden dow el ca n be used. If the gearbox has been dismantled, use pushrod from the clutch pedal (photo). Withdraw the pushrod from
the input shah. or even an old shaft from another gearbox. the master cylinder.
3 With the friction disc centralized, the cover bolts should be 8 Unscrew the two mounting nuts and withdraw the master cylinder
tightened diagonally and evenly to the specified torque (photo) from the bulkhead (photo). Recover the gasket.
4 Remove the alignment tool 9 Clean the external surfaces of the•master cylinder. Disconnect the
5 Reftt the engine ( Chapter 1) or gearbox (Chapter 6) as applicable. supply hose.
10 Extract the spring chp from the mouth of the cylinder, and remove
the piston, seals and return spring. Prise out the inlet pipe and
grommet.
11 Clean the components in methylated spirit or fresh hydraulic fluid,
6 Master cylinder - removal. overhaul and refitting then examine them for wear and damage. The seals should be renewed
as a matter of course. If a genuine Peugeot repair kit is obtained, it will
Unscrew the filler cap from the brake fluid reservoir, and remove the include a new piston and return spring in addition t o the new seals.
level w arning lamp switch. Check the cylinder bore for signs of corrosion or excessive wear, and if
2 Using a pipette or syringe. draw fluid from the reservoir until the evident, renew the complete master cylinder.
level Is below the clutch master cylinder supply hose port. 12 Commence reassembly by inserting the return spring in the
3 Position a container or rags beneath the master cylinder to catch cyltnder. large diameter end first.
any spilled fluid. 13 Dip the piston and seals in fresh hydraulic flu id, and insert them.
4 Loosen the ch p and disconnect the supply hose from the reservoir. making sure that the seal lips face inwards.
5 Unscrew the union nut and disconnect the outlet pipe. Plug the 14 Depress the piston with a screwdriver. then refit the spring clip in
pipe end to prevent ingress of dirt. its groove.
6 Working inside the vehicle. remove the lower facia panel. 15 Refitting the master cylinder is a reversal of removal, but bleed the
7 Extract the split pin, remove the washer, and disconnect the system as described in Section 9.
Fig. 5.3 Clutch master cylinder components (Sec 6)
1 Chips 4 Grommet 7 Return spring 9 Piston

2 Supply hose from reservoir 5 Master cylinder body 8 Seal 10 Spring clip
3 Inlet pipe 6 Gasket

128
Fig 5.4 Clu t c h pedal components (Sec 6)
1 Nut 8 Pivot bolt

2 Washer 9 Split pm
3 Bush 10 Washer
4 Spacer 11 Washer
5 Rl'turn Spflng 12 Pusf,,od
6 Clutch pedal 13 Pad
7 Bush
6 7 Clutch master cylinder pushrod (arrowed) 6.8 Clutch master cylinder (A) and mounting nuts ( B)
.1

13 Dip the seal in fresh hydraulic fluid, and flt it to the piston.
7 Slave cylin der - re m oval. overhaul and refitting 14 Insert the piston and seal in the slave cylinder. Fit the pushrod
where applicable. followed by the rubber boot.
Apply the handbrake Jack up the front of the vehicle and support 15 Refitting the slave cylinder is a revttrsal of removal, but bleed the
on axl e stands system as described in Section 9.
2 Fit a hose clamp to the slave cylinder supply hose.
3 Loosen the hydraulic hose union at the slave cylinder.
8 Release bearing and fo r k assembly - removal and
Early carburettor models
refitting
4 The slave cylinder is retained by a c1rcllp located in a groove near to
the rubber boot end of the cylinder This must be released using a
screwdriver Detach the front circl1p from the gearbox. 1 Remove the engine or the gearbox (refer to Section 3, paragraph
5 Temporarily detach the steering rack and pinion from the front 1) .
crossmember and column, leaving the tr!lck rods attached to the 2 Remove the release bearing by turning It ant1-clockw 1se to
steering arms. disengage the ¢lip (photo).
6 Draw the slave cylinder towards the front of the clutch bellhousing. 3 To remove the fork. initially pull it outw ards to disconnect the
noting that the pushrod will remain connected to the clutch release spring clip from the pivot ball, then withdraw it from inside the
lork bellhousing (photo).
7 Unscrew the slave oyhnder from the hose. 4 Check the release bearing for wear by rotating it by hand. Any
undue slackness, noise, or binding means the bearing should be
Except early carburettor models renewed.
8 Unbolt the slave cylinder from the gearbox. then unscrew 11 from 5 Check the fork. pivot ball, and rubber damper for wear, and If
the hose (photos) necessary renew them. The rubber damper may be prised from the
groove in the pivot ball, and the pivot ball may be extracted from the
All models gearbox housing, preferably after removing the housing.
9 Pnse off the rubber boot and remove the pushrod where fitted. 6 Apply a little locking fluid to the shank of the pivot ball before
lO Extract the piston and seal. 1f necessary tapping the cylinder on a pressing it into the gearbox housing. Fit the rubber damper in the
block of wood. On early carburettor models, also extract the return groove.
sprl!lg. 7 Smear a little grease on the underside of the fork where it contacts
11 Clean the component!! 1n methylated spirit or fresh hydraulic flu id. the pivot ball.
then examine them for wear and damage Renew the seal and rubber 8 Refit the fork by inserting it through the betlhousing hole from
boot as a matter of course. The genuine Peugeot repair kit for early inside, then lifting the spring clip over the rubber damper and pushing
carburettor models includes a p1Ston and return spring in addition 10 the fork towards the guide sleeve. Note that the damper must be
the seal and boot. Check the cylinder bore for signs of corrosion or between the spring clip and fork (photo).
excessive wear, and 11 evident, renew the complete slave cylinder. 9 Smear a little grease on the guide sleeve. then refit the release
12 Commence reassembly by inserting the return spring where fitted. bearing and turn it clockwise (photo).
large diameter end first 10 Refit the engine or gearbox as applicable.
7 SA Clutch slave cylinder mounting bolts 7.88 Clutch slave cylinder removed 8.2 Removing the clutch release bearing
(arrowed)
8 3 Removing the release fork 8.8 View of fork spring clip (A) and 1 r~bber 8.9 Fitted release bearing and fork
damper ( 8 ) from outside the gearbdX,

, 30 C h apt e r 5 Clutch
operation of 1he clutch and brakes If air has been drawn into the
9 Clutch hydraulic syst em - bleeding
braking system, it will be necessary to bleed 1he system as described in
Chapter 9. Remove the bleed tube from 1he nipples.
1 Bleeding 1he clutch hydraulic system using the method described 7 Lower the car to the ground.
for th e braking system in Chapter 9 may not prove successful. because
air bubbles will tend to be trapped in the verucal hydraulic lines.
Reverse bleeding 1s recommended, whereby fluid 1s forced through
10 Hydrau lic flexi ble hose - removal and r efitti ng
the slave cylinder bleed screw and air is forced back through the
system Apply the handbrake Jack up the from of 1he vehicle and support
2 Peugeot garages use a special hand pump, but If this cannot be on axle stands
obtained the fol lowing method may be used. 2 Pos111on a coma1ner benea1h the clu1ch slave cylinder 10 catch any
3 Apply the handbrake Jack up the front of the vehicle and support spilled fluid.
on axle stands 3 To remove 1he upper (supply) flexible hose. use a pipette or syringe
4 Obtain a length of rubber or pfasuc tubing long enough to reach to draw fluid from the reservoir until the level is below the outlet port.
the left hand brake caliper from the clutch slave cylinder. Fill the Loosen the clips and remove the hose from the reservoir and mas1er
tubing with fresh hydraulic fluid, and connect rt up to both bleed cylinder.
nipples 4 To remove the lower (pressure) flexible hose. first fit a hose clamp
5 Loosen both nipples by a quarter of a turn each, and have an to the upper hose. Unscrew the ng1d pipe union nut from 1he end
ass1s1ant slowly depress the footbrake pedal. Remove the brake/clutch fitting. then pull out the clip and disconnect the hose from the bracket
fluid reservoir cap. and continue to force fluid into the system unul (photos}. Unscrew the hose from the slave cylinder
bubbles cease to surface. then tighten the nipples. 5 Refitting is a reversaf of removal, bu1 bleed the hydraulic sys1em as
6 Top up the lluld in the reservoir if necessary. then check the descubed 1n Secuon 9.
10.4A Inner view of cl utch flexible hose bracket 10.46 Outer view of clutch flexible hose bracket
11 Fault diagnosis - cl ut c h
Symptom Reason( s)
Clutch pedal spongy Air in hydraulic system

Deteriorated master cylinder or slave cylinder seals
Judder when 1ak1ng up drive Loose engine/gearbox mountings

Friction linings badly worn or contaminated with oif
Worn spigot bush in crankshaf1
Clutch slip Worn fnctlon linings

Cover diaphragm spring weak or broken
Friction linings contaminated with oil
Noise when depressing pedal Dry. worn or damaged release bearing

Cha pter 6 Manual gearbox

and automatic transmission
Contents
Automa tic transmission k1ckdown cable adju ment .........•.......... 29 Manual gearbox intermediate housing ( BA7/ 5) - dismantlmg and
Automa tic transmission removal and rofttttng . ... ... .... ......•..... .. 28 reassembly .............................................................................................. 13
Automatic transmission fluid draining and refilling .................... 27 Manual gearbox intermediate housing ( BA10/ 5) - dismantling
Automatic transm1ss1on gear selector lever adjustment ................ 30 end reassembly ...................................................................................... 24
Fault d1agnos1s manual gearbox and automauc transmission ..... 31 Manual gearbox laygear ( BA7) - dismantling and reassembly ...... 9
General description ........ ... .. .... ... ... ... .... ............ ............. 1 Manual gearbox laygear bearing (BA 7) - preload adjustment ...... 16
Manual gearbox ( BA7) - dismantling into major assemblies ......... 5 M anual gearbox mainshaft ( BA7) - dismantling and
Manual gearbox ( BA 10) - dismantling into major assemblies ...... 20 reassembly .............................................................................................. 8
Monuol gearbox ( BA7) - gearchange adjustment ........................... 18 M anual gearbox mainshaft ( BA 10) - dismantling and
Manual gearbox ( BA 10) gearchango adjustment ........................ 26 reassembly .............................................................................................. 22
Manual gearbox ( BA7) - inspection . ... .... .............................. 6 Manual gearbox mainshaft bearing ( BA10/ 5) - Pfeload
Manual gearbox ( BA10) - overhaul (oeneral) ............................... 19 adjustment .............................................................................................. 25
Manual gearbox ( BA7) - reassembly ... ................... 17 Manual gearbox rear housing (BA7) - dismantling and
Manual gearbox clutch housing ( BA7) dismantling and reassembly ... .................... ........... ......... .... ................................. 14
reassembly .. .. . .. ........ . 12 Manual gearbox (Saloon models) - removal and refining ............. 3
Manual gearbox ( Estate models) removal and refitting ............... 4 Manual gearbox selector rods (BA7) - dismantling and
Manual gearbox 5th speed driven gear (8A7) dismantling and reassembly ................................... ... ... ... .. ................................. 11
reassembly ..... ......... • 10 Manual gearbox selector rods (BA10) dismantling and
Manual gearbox input shaft ( BA7) - dismantling and reassembly .... ....................... ....... ...... ...... .... ..... ...................... .......... ..... 23
reas:.embly .... .......... ................ .... ... ..... .. .. ................................. 7 Manual gearbox synchro untts ( BA7) - centralisation .................... 15
Manual gearbox input shaft (BA 10) d1smantl1ng and Routine maintenance ......................................... .................................. 2
reassembly ... . ................... . ....... ... ... ....... ..... ..... ...... ...... ........... ...... 21
Specifications
Manual gearbox
Type ....................................................................................... . Four or five forward speeds. all with synchromesh. and one reverse
XM7 engine
t .......................................................................................................... . 0.2700
2nd .................................................................................................... . 0.4608
3rd .... .... ................................. .. .......................................... , 0.7098
4th ...................................................................................... 1.0000
Reverse .................................................................................................... 0.2669
BA7 '5 XN1 and ZDJ engines
1st ........ • .. .. ................................................................................ 0.2784
2nd .................................................................................................... 0.4789
3rd ...............................................- ...••.....•................................................ 0.7313
4th 1.0000
6th 1.2153
Reverse ........- ..........- .............- ........................................................... 0.2752
BA10/5 ZEJ engine XN1 engine
ht ......................... "........................................................................ 0.2893 0.2589
2nd ...........- .... ~ ..- ...................................................................... . 0.4851 0.4580
3rd .................................................................................................... 0.7109 0.6922
41h .................................................................................................... 1.0000 1.0000
5th ...................................... .............................................................. 1.2174 1.1854
Reverse ................................................................................................... 0.2863 0.2788

132 Ch apte r 6 Manual gearbo x and automatic transmission
Lubrication
Oil Lype/specihcat1on .................................................................................. Multigrade engine oil, viscositv. SAE 1 OW/ 40 (Duckhams QXR.
Hypergrade. or 10W/ 40 M otor Oil)
C pacu rain/ refill)
BA? ........ ........................................................................................ l .16 ( 2.0 pints)
BA7/ 5 .................................................................................................. i.45 tires (2.6 pints)
BA10/ 5 ............................................................................................... 1.60 litres (2.8 pints)
Torque wrench setti ngs Nm lbf ft

Mainshah nut ...... ....................................................................................... 55 41
Bearing retaining plate ................................................................................ 10 7
De tent plug .. . .......................................•.................................................... 12 9
~::~ ~:::~~ ~~::: =~ ~~ ::::::::::::::::::::::::::::::::::::::::::~:::::::::::::::::::::::::::::::
10 7
15 11
Clutch housing (to main casing) ............................................................... 28 21
Rear housing .............................................................................................. 15 11
Reverse lock-out plunger (4 -speed) ......................................................... 15 11
Dram and filler plugs ................................................................................... 28 21
Reversing light switch ............................................................................... .. 28 21
Intermediate housing (5-speed) ................................................................ 18 13
Reverse dnvmg gear ( BA10/ 4) .................................................................. 25 19
Clutch housing to engine ........................................................................... 55 41
Ratios
3 HP22.
1st ... ........................................................................................................ . 0.4033
2nd ............................................................................•............................. 0.6759
3rd ............................................................................................................ 1.0000
Reverse .................................................................................................... 0.4794
4 HP22.
1st ...............•............................................................................................• 0.4033
2nd ........................................................................................................... 0.6759
3rd ............ .............................................................................................. 1.0000
4th .. ..... .............................................................................................. 1.3734
Reverse .................................................................................................... 0.4795
Lubrication
Fluid type/specification ............................................................................... Dexron II ATF (Duckhams 0-Matic)
Capacity (from dry).
3 HP22 .................................................................................................... 5.2 litres (9.2 pints)
4 HP22 .................................................................................................. .. 5.0 litres (8.8 pints)
Capacity (drain/refill):
3 HP22 ................................................................................................. .. 1.6 litres (2.8 pints)
4 H P22 ............................................. ,...................................................... 2.6 litres (4.6 pints)

Torque converter housing to engine ....................................................... .. 55 41
Torque converter to driveplate .................................................................. . 30 22
Dipstick tube union ..................................................................................... 28 21
".
1 General description
The manual gearbox is of four- or five -speed type, with

Carry out the following procedures at the intervals given in Routine

'
synchromesh on all forward speeds. and one reverse. It incorporates an maintenance er the front of this manual
input shaft. mamshaft, and laygear. On 5-speed versions, the laygear
extension incorporates the 5th speed driving gear. which is in constant Renew manual gearbox oil
mesh with the driven gear on the mainshaft. The main casing is split 1 Apply the handbrake. Jack up the front of the vehicle and support
Into two halves. the left half being fitted with the selector rods and on axle stands.
forks. 2 Position a suitable container beneath the gearbox, then unscrew
The automatic transmission is of either three· or four-speed type. and remove the drain and filler plugs. and drain the oil.
incorporating hydraulic conirol of the epicyclic geartrain. The 3 Refit and tighten the drain plug.
four-speed version rs fitted with a torque converter with an integral 4 Jack up the rear of the veh icle until It is level. then fill the gearbox
lock-up device. which eliminates all slip in 4th gear when the vehicle is with oil until level with the bottom of the filler plug aperture.
travelling above 53 mph, and the transmission fluid temperature is 5 Refit and tighten the filler plug. Lower the vehicle to the ground.
above 2o·c.
Under these conditions, a valve in the valve block reverses
the flow of fluid within the iorque converter, and an Internal clutch Is Renew automatib ~ransmission fluid
brought into play. 6 Refer Lo Section 27.

Chapter 6 Manual gearbox and automatic transmissio n 133
Check manual gearbox oil level temperature. after driving for at least 3 miles.
7 Jack up the front and rear of the vehicle. and support on axle 11 Pos111on the vehicle on a level surface. and apply the handbrake
stands firmly
8 Unscrew the filler plug and check that the 011 level is up to the 12 With the engine idling. move the selector lever slowly through all
bonom ol 1he filler plug aperture Top up if necessary. the posittons, then select ' P'.
9 Rell! and 11gh1en the filler plug, 1hen lower 1he vehicle to the 1 3 Remove 1he dipstick and wipe It clean. 1hen re -1nsen and remove
ground again. The level should be within the 'Hot' ( 'Chaud') section.
14 If necessary. top up the level through the d1ps1tck tube. using a
Check automatic transmission flwd level funnel Do not top up over the maximum level mark The drfference
10 The engine and transmission must be at normal operattng between the level marks represents 0 5 pints (0.3 litres)
Fig. 6.1 Cross -sect ion of the BA7/ 4-speed gearbox ( Sec 1)
1 Input shaft 6 2nd speed gear 11 Speedometer driving gear 15 Input shaft lipped sul
2 Mamsh11ft 7 3rd speed gear 12 Gear selector control 16 Self-lubncating bush
3 Layge11r 8 3rd/ 4th synchro unit 13 Gear engagement control 17 Needle roller beaflng
4 1st speed gear 9 Reverse driving gear 14 Input shalt plf thrower 18 Ad1ustment shims
5 1st/ 2nd synchro unit 10 Reverse driven gear

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Fig. 6.2 Cross-section of the BA7/ 5-speed gearbox (Sec 1) co
~
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1 Input shaft 5 1st speed gear 9 3rd/ 4th synchro unit 12 5 th speed driven gear 3
2 Mainshalt 6 1st/2nd synchro unit 10 5th/ reverse synchro umt (no 13 Reverse driven gear
3 laygear 7 2nd speed gear synchro on reverse) 14 Speedometer driving gear
4 5th/reverse intermediate 8 3rd spead gear 11 5th speed driving gear 15 Ad1ustment shims
shaft
Ch apter 6 Manual gearbox and autom at ic transm ission 135
23 Unscrew the radiator top mounting bolts, and release the radiator
3 Manual gearbox (Sal oon model s) - rem oval and refitting
from lhe lower suppons. Position a piece of plywood or cardboard
between the radiator matrix and ran blades.
Note There are two methods of removing the gearbox. Method 1 24 Disconnect the exhaust downpipes from the manifold Also
involves removing the engine first and Method 2 involves moving the disconnect all the exhaust system mountings except the rearmost
Imo/ dflve unit rearwards one(s). and lower lhe exhaust to the ground.
25 Unbolt the exhaust heat shield an!;! front seat stiffener.
Method 7 26 Unbolt the link tube vibration damper and limiter, and remove the
1 Remove 1he engine as described in Chapter 1 damper stud.
2 Apply the handbrake. Jack up the front of the vehicle and support 27 Disconnect the fina l drive unit mounting(s) (refer to Chapter 8).
on axle stands. Lower the final drive unit so that the link tube rests on the rear
3 Working inside the vehicle, remove the centre console with crossmember.
reference 10 Chapter 11. 28 Disconnect the steering column intermediate shaft lower coupling
4 Unscrew the gearsuck knob from the steering gear.
6 P11se the rubber boot from the gearbox cover, and remove it from 29 On manual steering models. unbolt the steering gear from the
1he gears11ck (photo). crossmember, and lower it w ithou t disconnecting the track rods.
6 Remove the screws and lift off 1he gearbox cover (photos) . 30 On power steering models. remove the two front bolts from the
7 Disconnect 1he two gearchange rods from the gearbox levers crossmember. and m their place fit two long bolts which will allow the
(photos) crossmember to be lowered by 50.0 mm (2 0 in). Remove the rear bolts
8 From inside the vehicle, disconnect the gearchange rod from the and lower the crossmember.
control lever (photo). 31 Support the gearbox with a trolley iack.
9 Unscrew the nut and slide the control lever from the gearbox stud 32 Using an Allen key or socket, unscrew the bolts retaining the
(photos) propeller shaft hnk tube to the gearbox.
10 Remove the control lever from the rear mounting, and withdraw 33 Move the link tube rearwards by 20.0 mm (0.8 in). Refer to Chapter
the lever from the vehicle (photo). 7 and fit the propeller shaft support plate as described. Move the link
11 Using an Allen key or socket, unscrew the bolts securing the tube rearwards until the propeller shaf t is disengaged
propeller shaft link tube to the gearbox (photo). 34 Unbolt the staner motor from the clutch housing.
12 Unscrew the filler and dram plugs, and drain the gearbox oil into a 35 Unbolt the TDC sensor and clutch housing cover.
suitable container (photos) Refit the plugs on completion. 36 Unscrew the nut and disconnect the gearchange control rod front
13 Unscrew the nuts and detach the exhaust pipe bracket from the mounting. If difficulty is experienced, remove the centre console and
gearbox. Tie the exhaust pipe to one side. gearbox cover from inside the vehicle.
14 Loosen the retaining bolt and withdraw the speedometer cable 37 Disconnect the gearchange !i!ngagement and selection links.
(photos) 38 Disconnect the reversing lamp switch wirlng.
15 Disconnect the reversing lamp sw11ch wiring. 39 Unscrew the retaining bolt and withdraw the speedometer cable.
16 Remove the clutch slave cylinder (Chapter 5). 40 Remove the clutch slave cylinder (Chapter 5)
17 Support the front of the hnk tube with a trolley 1ack, then hit the 41 Lower the gearbox on the trolley 1ack to provide sutf1c1ent room to
gearbox forwards over the steering gear and crossmember. The remove the gearbox. Slightly raise the front of the engine also. using a
steering gear may be temporarily unbolted from the crossmember ii hoist or further trolley jack.
necessary. to provide additional clearance. 42 Unscrew the gearbox-to -engine bolts. then withdraw the gearbox
18 Refitting ts a reversal of removal. with reference t o Chapters 11 and direct from the engine and remove from under the vehicle.
1 Fill the gearbox wi th oil. up to the bonom edge of the filler plug, then 43 Refitting is a reversal or removal, but note the following additional
rein and ughten the plug. points:
Method 2 (a) Apply a little high melting-point grease to the splines of the
19 Jack up the front and rear of the vehicle, and support on axle gearbox input shaft, and to the fronc of the shalt which enters
stands. Disconnect the battery negative lead. the spigot bearing
20 Unscrew the filler and drain plugs, and drain the gearbox oil into a (b) Check that the clutch release bearing and fork are correctly
sunable container. Refit the plugs on compleuon. fitted
21 On carburettor engines. remove the air cleaner and air inlet duct, (c) Refit the final d!lve unit with reference ro Chapter 8
22 On fuel injection engines, remove the air inlet duct. and unbolt the (d) Fill the gearbox with oil. up to the bottom edge of the filler
pressure regulator. plug, then refit and tighten the plug
3.6 Removing the rubber boot from the gearbox co11er 3.6A Remove the screws ...

3.68 and lttt otf the gearbox cover 3 7A Gate gearchange rod (arrowed) 3 78 Speed gearchange rod (arrowed)
3 8 Gate gearchange rod (arrowed) on 1he 3.9A Unscrew the nut . 3 98 and remove the control lever
conuol t~er
310 Removing 1he control lever from the 3.11 Unscrewing 1he link 1ube-to-gearbox 3 12A Removing the filler plug
rear mounnng bolts
3 128 Aemovmq the drain plug 3. 14A Loosen 1he retaining bolt ·I 3.148 ..• and withdraw the speedometer
(arrowed) ... cable

Chapter 6 Manual gear box and automatic transmission 137
ber, and in their place fit two long bolts which will allow the
4 Manual gearbox (Estate models) - r emoval an d refitting crossmember to be lowered by 50.0 mm (2.0 in), Remove the rear bolts
and lower the crossmember, but do not allow the power steering pump
Jack up the front and rear of the vehicle. and support on axle pulley to contact the anti-roll bar.
stands 34 Slightly raise the front of the engine. using a hoist or funher trolley
2 Remove the centre console with reference to Chapter 11. Jack.
3 Unscrew the gearstick kn ob 35 Unscrew the gearbox-to -engine bolts. then wrthdraw the gearbo><
4 P11se the rubber boot from the gearbox cover and remove it from direct from the engine and remove it from under the vehicle.
the gears11ck 36 Refitting is a reversa l of removal. but note the following additional
5 Remove the screws and hft off the gearbox cover. points:
6 Puse out th e plug in front of the gearstick. and unscrew the top bolt (a) Appl y a lmle high meltmg-poini grease to the splines of the
from the rear engine mounting frame . gearbox input shaft. and to the front of the shaft which emers
7 Release the handbrake. then disconnect the inner cables from the the spigot bearing
equaliser (b) Check that the clutch release bearing and fork are correctly
8 Remove the bonnet (Chapter 11) fitted
9 Disconnect the battery negative lead (c) Make sure that the rear coll springs are correctly located in
10 Unscrew the radiator top mounting bolts. and release the radiator their seats
from the lower supports. Pos1t1on a piece of plywood or cardboard (d) Fill the gearbox with oil. up to the bollom edge of the filler
between the radiator matrix and fan blades. plug. then refit and tighten the plug
11 Remove the starter motor (Chapter 12) (e) Grease the torque tube balljomt
12 On carburettor engines. remove the air cleaner and air inlet duct.
13 On fuel rnJec11on engines. remove the air inlet duct. and unbolt the
pressure regulator.
5 Manual gearbo x ( BA7) - d ismantling into major
14 Disconnect the exhaust downpipes from the manifold and
assemblies
gearbox
15 Unbolt the TDC sensor and clutch housing cover.
16 Remove the clutch slave cylinder (Chapter 5). Clean the extenor of the gearbox.
17 Disconnect the reversing lamp switch wiring. 2 Unscrew and remove the locking bolt and extract the speedometer
18 Unscrew the retaining bolt and withdraw the speedometer cable. pinion adaptor {photos).
19 Disconnect the steering col umn intermediate shaft lower coupling
from the steenng gear. 4 -speed gearbox
20 Unchp the hydraulic brake pipe from the torque tube 3 Move the selector lever to neutral.
21 Refer to Chapter 9 and remove the rear brake compensator. without 4 Unscrew the bolts and withdraw the rear housing. using a wooden
disconnecting the pipes. mallet if necessary to tap the housing carefully and release it (photo).
22 Unbolt the rear brake three -way unron from the underbody
23 Suppon the gearbox with a trolley 1ack. 5-speed gearbox
24 Unbolt the engrne rear mounting from the underbody and gearbox. 5 Move the selector lever to neutral
25 Unboh the front seat reinforcement bar 6 Using a square drive. unscrew the plastic plug from the rear
26 Unbolt the rear an11-roll bar from the underbody. housing (photo).
27 Support the rear axle on a trolley 1ack. then disconnect the shock 7 Unscrew the bolts securing the rear housing to the intermediate
absorber lower mountings. housing.
28 Lower the rear axle suffrciently to allow the rear wheels to pass 8 Remove the rear housing by carefully tapping it free with a wooden
under the wing. mallet, while at the same time using a block of wood through the plug
29 Lower the gearbox until the engine is almost touching the steering hole to free the 5th/ reverse intermediate shaft from its bearing
gear (photos).
30 Unbolt the torque tube ball cover from the gearbox. 9 Extract the circlip from its groove In the mainshaft (photo).
31 Move the rear axle rearwards. and disconnect it from the gearbox. 10 Using a two-legged puller located under the 5th speed driven gear.
Take care not to damage the hydraulic brake pipes. Suppon the torque draw the speedometer dnvegear and 5th speed driven gear from the
tube on an axle stand mafnshaft (photos). Take care not to damage the gear teeth.
32 Recover the engine rear mounting frame. 11 Using circlip 'pliers. extract the location circlip from the mainshaft
33 Remove the two front bolts from the front suspension crossmem - (photos).
5 2A Remove lhe locking bolt ...

.
5.28 ... and extract the speedometer pinion adaptor

138 Chapter 6 Manual gearbox and automatic transmission
5 4 Removing the rear housing (4 -speed 5.6 Removing the plastic plug 5.8A Tapping the 5th/ reverse intermediate
gearbox) shaft from 11s bearing
5 88 Removing the rear housing 5.9 Extract the circlip ... 5.1OA ... pull off the speedometer dnvegear
and 5th speed driven goar from tho
mainshaft ...
5.108 and remove the gear 5.11 A Gear location circlip (arrowed) on 5.118 Removing the gear location circlip
mainshaft
12 Remove the shim and spacer from the end of the 5th/reverse the main casing halves, noting the location of the exhaust mounting
mtermed•a te shaft (photos). bracket, then withdraw the housing (photos) .
13 Remove the 5th speed driving gear and needle rol ler bearing
(photos) 4- and 5 -speed gearboxes
14 Mark the 5th synchro unit hub and sleeve in relation to each other. 21 Remove the clutch release bearing and fork as in Chapter 5.
15 Select 5th gear pos111on by raising the sele<:tor shalt and fork . 22 Unbolt and remove the clutch bellhousing.
16 A tool must now be made to support the selector shaft while the 23 Using an Allen key or socket. unscrew the boltS securing the
fork retaining roll pm 1s driven out. This may be made out of 6 mm bearing retaining plate 10 the main casing halves.
(0.25 1n) thick steel plate. and should be bolted to the intermediate 24 With the left-hand half of the main casing on the bench. unscrew
housing together w tth packing washers, to obtain the necessary height the bolts and litt off the right-hand casing half (pho1os)
(photo) refer also to Section 17, photos 17.20A and 17.208. 25 Lift the input shaft, mainshaft and lays haft together from 1he casing
Remove the tool after driving out the roll pin. half (photo). Keep the laygear bearing outer 11acks with their correet
17 M ove the selector shaft to neutral. then withdraw the 5th synchro bearings. to ensure correct refi tting.
sleeve and fork, followed by the 5th synchro hub {photos). 26 Release 1he laygear from the bearing retainer.
18 Wi thdraw the 5th/reverse intermediate shaft (photos) 27 Slide 1he 3rd/ 4th synchro sleeve to the 3rd gear position. then
19 Disengage the selector finger from the sele<:tor dogs. separate the input shaft from the mainshaft (photo) .
20 Unscrew the nuts and bolts securing the intermediate housing to 28 Remove the neE¥J\e roller bearing from the input shaft (photo).

5 128 ... and spacer 5.13A Removing the 5th speed driving
gear ...
5.138 and needle roller bearing 5.16 Using the special 1001 to support the 5.17 A Removing the 5th synchro sleeve
selector shaft while removing the roll pm and lorlc ...
5 178 and 5th synchro hub 5.1 SA 5th/ reverse intermediate shah 5.1 8 B ... and removal
location (arrowed) ...
5.20A Unscrew the Intermediate housing 5.206 Removing the exhaust mounun'g 5.20C Removing Lhe mtermedJate housing
bolts bracket I·\

140 Chapter 6 Man ua l gearbox and automatic transmission
6.24A Unscrew the bolts 5.248 .. and l1h off the right -hand casing 5 25 Gear shafts m the left-hand casing
half
5.27 Separating tne tn put shaft from the 5 28 Removrng the needle roller l>e11ru11J
mainshaft from the input shaft
6 Manual gear box ( BA7) - Inspection 4 Shde off the 3rd speed gear. and remove the needle roller bearing
(photos).
5 Invert the ma1nshaft rn the vice, so that the rear end 1s uppermost.
Clean all the components and examine them for general weer. 6 On the 4-speed version. use a puller to remove the speedometer
d1s1onion. and damage. pinion drivegear (photo)
2 Examine the gears for excessive wear and chipping of the teeth. 7 Unscrew the rear nut and remove 11 from the mainshaft (photo) .
3 Check all bearings for noisy operation and pitting of the balls or 8 Using a puller located under the 2nd speed gear, draw the gear
rollers assembly from the marnshah unul the rear bearing is free. Alternauvely.
4 E)(amine the selector forks. shafts and dogs for excessive wear rest the 2nd speed gear on the 1aws of the vice, and press or drive the
5 Check the synchromesh units for excessive wear of the cone faces mainshaft downwards
9 Remove from the marnshaft the reverse gear. the bearing rata1nrng
plate. the bearing, the shim and the 1st speed gear ( photos)
7 Manual gearbox input shaft ( BA7) - dismantling and 10 Remove the needle roller bearing and sleeve (photos).
reassembly 11 Mark the 1st/2nd synchro hub and sleeve in relation to each other.
then remove the unit complete (photos) .
Extract the circl1p from the input shaft. followed by the special 12 Remove the 2nd speed gear and the needle roller bearing. The
washer (photo) mainshaft is now completely dismantled (photos).
2 Using a puller or press. remove the bearing. 13 Commence reassembly by refitting the needle roller bearing to the
3 Remove the 011 thrower (1f fitted) and the shims malnshaft rear secuon. followed by the 2nd speed gear (photo).
4 Reassemble m the reverse order to drsmantl1ng (photo). If the input 14 Refit the 1st/ 2nd synchro unit with the bar marks (photo) away
shaft 3rd/ 4th synchro unit. 3rd/ 4th selector fork and shaft. or the from 1he 2nd speed gear
half·casrngs are renewed. flt the following shims· 15 Refn 1he sleeve and 1st speed gear needle roller bearing.
16 Refit the 1st speed gear and shim. Note that 1f the mainshaft.
035 mm (0014 in) shim ro input shafr w1rh oil rhrower
mainshaft gears and synchro unit. selector fork and shaft. or main
0.50 mm (0.020 m) shim to input shaft with oil seal
casing halves are renewed, a 3.3 mm (0.130 In) thick shim should be
fitted.
17 Posi tion the bearing on the ma1nsheh. w11h the outer circhp facing
8 Manual gearbox mainshaft ( BA7) - dismantling and
rearwards.
reassembly 18 Using a puller. draw 1he bearing fully onto the mamshaft Note that
the pressure should be applied 10 the bearing rnner track only (photo)
1 Mount the marnshaft rn a vice, with the front end uppermost Alternauvely. use a metal tube to drrve on the bearing inner track.
2 Mark the 3rd/4th synchro hub and sleeve 1n relauon to each other. 19 If a new shim has bean fitted do not refit the bearing retaining
then remove the sleeve photo). plate and revelSeigear at 1h1s stage. but refer to Sections 15 and 16.
3 Extract the clrcllp and specral washer. then slide off the 3rd/ 4th 20 If the original shim has been refuted, and the components
synchro hub (photos) II 1t Is tight. use a puller mentioned 1n paragraph 16 have not been renewed, refit the bearing

7 1 Circl1p (1) and special washer (2) on 7.4 Reassembled Input shaft 8.2 3rd/ 4ih synchro hub removal
the input shaft
8.3A Remove the circlip ... 8.36 ... special washer ... 8.3C ... and 3rd/ 4th synchro hub
8.4A Removing the 3rd speed gear ... 8.46 ... and needle roller bearing 8.6 Removlng the speedometer pinion
drlvegear (4 ·Speed gearbox)
8 7 Mamshaft rear nut removal 8.9A From the mainshaft. remove

reverse gear ...
1il. 8.96 ..• the bearlng retaining plate ..•

8.9C the rear bearing ... 8.90 ... the shim .. 8.9E ... and the 1st speed gear
8 1OA Removing 1he needle roller 8.1OB ... and sleeve 8 11 A Mark the 1st/ 2nd synchro hub and
bearing sleeve in relation to each other (arrowed)
s .11 B Removmg the 1st/ 2nd synchro unit 8.12A Removing the 2nd speed gear ... 8.128 ..• and needle rol ler bearing
8.1 2C The dismantled mainshaft ·I 8.14 Bar marking (arrowed) on the 1st/ 2nd
synchro unit

Ch ap ter 6 Manual gea rb o x and automatic transmission 143
retaining plate. w11h the machined face against the bearing.

21 Refit the reverse gear. with the tooth chamfer facing rearwards.
22 Fn 1he mainshaft nu1, and tighten it to the specified torque Lock 1t
bv peening the shoulder into the mainshalt cut·out (photos)
23 On the 4 -speed gearbox. use a metal tube to drive the speedometer
pinion dnvegear onto the ma1nshaft If 1he gear has a spigot. as shown
in Fig 6 3. this must face rearwards
24 Invert the ma1nshalt In the vice, so that the front end is uppermost.
25 Relit the needle roller bearing and 3rd speed gear.
26 Shde the 3rd/ 4th synchro hub on the ma1nshaft splines. Refit the
special washer and circlip. and use a metal tube to tap the circlip fully
1n 11s groove ( photo) . •
27 Relit the 3rd/ 4th synchro sleeve on the hub. making sure that the
previously-made marks are ahgned ®
8 .0310 D,
Fi g 6.3 Correct loc ation of speedometer pinion drivegear
(5) on the 4-speed gearbox (Sec 8) t 8 .0310 NY
a Indicates spigot
8 18 Ustng a puller to lit the mainshah bearing 8.22A Tighten the malnshalt nut •..
8 228 then peen the shoulder into the cut- out (arrowed) 8.26 Refitting the clrcllp

9 Manual g earbox laygear (BA7) - d ismantling and

reassembl y
4-speed gearbox
1 Extract the circflp and washer from the rear of the laygear.
2 Remove the reverse gear and beari ng outer track.
4 - and 5-speed gearboxes

3 Using a puller. draw off the rear beari ng.
4 S1m1larly remove the front bearing and washer.
5 Reassembly 1s a reversal of d1smanthng. but use a metal tube or
socket to drive the beari ng inner tracks into position.
10 Manual gearbox 6th speed driven gear (BA7) -

dismantling and reassembly
1 Using a puller located beneath the roller bearing, draw the bearing
and speedometer drivegear from the 5th speed driven gear (photo).
2 II the gear 1s being renewed. note that it must be matched to the
mamshah by having the same colour mark - either green or yellow.
3 Using a puller or metal tubing on the inner track, drive the bearing
onto the gear. then similarly drive the speedometer drivegear onto the
gear, making sure that the spigot end is away from the bearing (photo).
11 Manual gearbox selecto r rods (BA7) - dismantling and

reauembly
1 Move the 1st/2nd selector fork into 2nd gear position ( photo).
2 Drrve the roll pm from the 1st / 2nd forlt. then return the selector rod
to neutral
3 Move the 3rd/ 4th selector fork into 4th gear position. Fig. 6 .4 5th speed driven gear components (Sec 10)
4 Drrve the roll pm from the 3rd/ 4th forlt. then return the selector rod
to neutral Bf!Btmg 2 Spf!edomettr dnving gear
5 Remove the plug cove11ng the 1st/ 2nd detent, then extract the
spnng and detent ball 14 Insert the reverse/ 5th detent ball and spnng. Apply sealant to the
6 Slrde out the 1st / 2nd and 3rd/ 4th selector rods. and recover the plug threads, and ughten the plug into position.
forks 15 Move the reverse selector rod 10 neutral.
7 Recover the interlock ball and plunger, and the 3rd/ 4th detent ball 16 Grease 1he rnterlock pin, and insert it in the 3rd/ 4th selector rod .
and spring 17 Insert the interlock plunger so that h contacts the reverse selector
8 Remove the interlock pin from the 3rd/ 4th selector rod . rod .
9 Remove the plug covering the reverse (and 5th on the 5 -speed 18 Locate the 1st/ 2nd and 3rd/ 4th selector forks In the casing.
gearbox) deten t. then extract the spring and detent ball. 19 Insert the 3rd/ 4th selector rod through the casing and fork, until h
10 Slide out the reverse selector rod and fork, together w ith the reaches the detent hole. Insert 1he spring and detent ball. depress the
reverse Idler gear. ball with a screwdriver. then push the selector rod into neutral posilion
11 Drive the roll pm from the reverse idler shaft, then pull the shalt w hile removing the screwdriver.
from the casing Note that this roll pm is longer than the selector fork 20 Insert the interlock ball so that ii contacts the 3rd/ 4th selector rod
roll pins 21 Insert the 1st/ 2nd selector rod through the casing and forks.
12 Commence reassembly by rnsertmg the reverse idler shaft, alrgning 22 Insert the 1st/ 2nd detent ball and spring. Apply sealant to the plug
the holes. and driving 1n the roll pin. th1eads, end tighten the plug into position
13 Locate the reverse idler gear in the selector rod forlt. then insert the 23 M ove the 1st/ 2nd selector rod to neutral.
rod and locate the gear on the shaft. Note that the groove in the gear 24 Align the holes and dr1ve the roll pins into the 1st/ 2nd and 3rd/ 4th
must be away from the casing selec1or forks.
10.1 Using a puller to d ismantle the 5th 10.3 Reassembling the 5th speed driven 11 .1 Selector rods inside the !eh-hand
speed driven gear • gear using a puller casing

----------------------------------------------------------------------------- 145
Fig. 6 .5 Select or r od components { Sec 11 )
7 Detent balls 6 Plugs 10 Reverse selector fork 13 5th/ reverse selector rod
2 Interlock balls 7 1st/ 2nd selector fork (5-speed gearbox) (5-speed gearbox)
3 Interlock pin 8 3rd/ 4th selector fork 11 5th selector fork 14 Reverse selector fork and
4 Interlock plunger 9 1st/2nd selectorrod 12 3rd/4th selector rod rod (4 -speed gearbox)
5 Derent springs (5-speed gearbox)
Jl

146 Ch ap ter 6 Manual gearbo x and automatic tran sm issi o n
6 Compress the selecl or spring, and refit the plasuc half-shells

12 Manuel gearbox c lutch housing ( 8A7) - dismantling and 7 Align the holes. then drive in the outer and inner roll pins to secure
reassembly the selector finger (photo)
1 Using a dial te:;t indicator. check that the gearbox contact face 1s
not distorted by more than 0 10 mm (0 004 in) ( photo) If 1t is. renew 14 M anual gearbox rear housing ( B A7 ) - d ismantling and
1he housing r eassembl y
2 Prise 1he 011 seal from 1he release bearing guide tube in the housing
{photo)
4-speed gearbox
3 Extract the cucllp 1hen drive out the release bearing guide tube
1 Unhook the return spring.
with a block of wood (photos).
2 Unbolt the reverse lamp switch. after marking Its pos111on
4 Rein the release bearing guide tube. using a mallet and block of
3 Prise out the 011 seal
wood If the tube has a venulatton hole. this must be aligned with the
4 Note the fitted pos111on of the needle roller bearing, then drive 11 out
corresponding hole in the housing {photos)
using a metal tube
5 Reftt the corchp 5 It is not possible to remove the selector mechanism. and 1f this 1s
6 Refit the 011 seal (photo). and drive 111nto the tube squarely using a faulty, the complete housing must be renewed
block of wood 6 Reassembly 1s a reversal of dismantling, but note that the lettering
on the bearing should be facing outwards. To set the reverse lamp
switch posrtion, place a spacer 8.2 mm (0.323 in) thick between the
13 Manual gearbox intermediate housing ( B A7/ 5) -
gear lever pivot and the housing. then ad1ust the switch position so
dismantling and reassembly
that the plunger 1s 1ust touching the rubber stop on the selector lever
Using a suitable punch, drive out the inner then outer roll pins from 5 -speed gearbox
the selector finger 7 The ball - bearing (photo) may be driven from the housing using a
2 Compress the selector spring, then extracl the plastic half-shells drift entered through the rear of the housing
(photos) 8 Prise out the 011 seal ( photo).
3 Withdraw the selector shaft. and recover the selector finger. spring, 9 Extract the circlip. then drive out lhe bearing outer track, using a
and 0-ring seal (photos) drift through the cut -outs provided {photo).
4 Oil the 0-nng and shah. Fit the 0 - ring and locate the end of the 10 Reassembly Is a reversal of removal, but make sure that the oil seal
shaft in the housing {photo) 1s fitted the correct way round, with the ltps facing into the housing
5 Insert the shaft engaging the selector finger and spnng (photo) (photo)
12 1 Checking the clutch housing face for 1 2.2 Prising out the 011 seal 12.3A Extract the c1rchp ..
d1stortron
12 38 1hen drive out the release bearing 12 4A Entering the release bearing guide 12.4 B Final fitung of the release bearing
guide tube tube. Note the ven tilation hole position guide tube
(arrowed)

12 6 Ref1rnng the oil seal 13.2A Frtted selector spring and hall-shells 13.28 Piastre half-shells for selector spring
l3.3A Withdrawing the selector shaft 13.38 Removing the 0 - rmg seal 13.4 Refitung the selector shaft
t 3 5 lnsenmg the selector shaft through the 13.7 Fittmg the selector finger roll pins 14.7 Rear housing, showing the ball
salec1or finger and spring bearing (arrowed)
t 4 8 Removing the 011 seal 14 9 Circhp ( 1 ) and bearing track removal 14.10 Fitted 011 seal
CUl•OU I (2)

148 Ch apter 6 Manual gearbox and autom atic tran smissio n
dimensions 0 1 / 02 and 03/04 in Fig. 6.6 using vernier calipers.

15 Manual gearbox synchro units (BA7) - centralisat ion
4 If adjustment is required for the 1st, 2nd and 3rd synchronisers,
select a different shim for fitting under the rear bearing.
1 Assemble the input shaft and mamshah together with the spigot 5 If adjustment is required for the 4th synchroniser. select different
bearing, and locate the assembly 1n the left-hand casing. shims for fitting under the front bearing.
2 Fit the clutch housing and rea1 beari ng retainer to the casing. as 6 After makin9 the adjustment. dismantle the cl utch housing and rear
shown 1n Fig 6 6, and check that the selector forks are in neutral. bearing retainer. and separate the shafts. Proceed to check the laygear
3 Check that the synchro sleeves ere centralised by checking the bearing preload as described In Section 16.
'
Fig. 6.6 Centralisation o f the synch ro u nit s (Sec 16 )
1 Sliding sleeves 3 Bearing retaining plate 01 - 02

2 Synchro cones 03 - 04

Chapter 6 Manual gearbo x and automati c transmission 149
10 Insert the remaining casing bolts, and tighten them to the specified
16 Manual gearbox laygear bearing ( BA7) - pr el oad
torque (photo).
adjustment
4-speed gearbox
Lower the iavgear in the left- hand casing, and fit the rear bearfng 11 Smear RTV sealant on the casing rear face.
retainer 12 Refit the rear housing. at the same time engaging the selector
2 Fit the rig ht-hand casing, and tigh ten the four comer bolts and finger with the selector dogs. Insert and tighten the bolts, noting that
bearing retainer bolts hand-11ght. the studs for the exhaust bracket are located at the bottom.
3 Press on the front bearing outer track. while turning the laygear to 13 Refit the speedometer pinion adaptor and 0 -ring. Insert and
seat the bearings. tighten the locking bolt/ nut.
4 On casing halves located by two rol l pins, tighten the four casing
bolts to 10 Nm (7 lbl ft) . then tighten the bearing retainer bolts. 5-speed gearbox
5 On casing halves located by one dow el, tit the clutch housing, 14 Smear RTV sealant on the casing rear face ( phoio).
using lour bol ts tightened to 10 Nm (7 lbf ft) . Tighten the casing bolts. 15 Refit the intermediate housing, at the same time engaging the
followed by the bearing retainer bolts. to the same torque, then remove selector finger with the selector dogs. Tighten the nuts and bolts.
the clutch housing Check that the casing halves are not misaligned by 16 Refit the 5th/ reverse intermediate shaft.
more than 0.02 mm (0.0008 in). If they are. repeat the procedure 17 Refit the 5th/ reverse synchro hub (photo) . If a new hub is being
again fined, the grooved end must be towards the reverse gear.
6 Usmg a dial test indica tor, check that the run-out between the 18 Lift the 5th/reverse selector shaft to the 5th position.
casing face and the outer track is no more than 0.02 mm (0.0008 in) . If 19 Engage the 5th selector fork w ith the synchro sleeve, then lower
1t 1s lightly tap the outer track to correct. but do not allow the laygear to them onto the selector shaft and synchro hub. Make sure that the
bind. previously-made marks on the synchro hub and sleeve are ahgned
7 Measure the difference between the outer track and casing face, (photo).
then add 0.10 mm (0.004 in) to this for the thickness of the shim to be 20 Fit the selector shaft support tool previously described in Secuon 5.
fined under the laygear bearing. Align the holes In the shaft and selector fork. then drive in the roll pin
8 After making the adjustment. dismantle th e casing halves and (photos). Remove the tool.
remove the laygear. Reassemble the mainshaft as given in Section 8. 21 Select neutral, then refit the 5th speed needle roller bearing and
driving gear.
22 Locate the spacer on the 5th speed driving gear.
23 If new components have been fitted. it is now necessary to
calculate the thickness of the shim to fit on the 5th speed driving gear,
17 Manual gearbox ( BA7) - reassem b ly
in order to provide an endfloat of 0.06 mm (0.002 in). Temporarily refit
the rear housing without the bearing, and measure the distance from
1 F11 the needle roller bearing to the input shalt. then assemble the the access hole to the spacer on the 5th speed driving gear. Now
mainshaft to the input shaft. Check that the synchro unit sleeves are in remove the housing, fit the bearing. and measure the distance from the
neutral access hole to the bottom face of the bearing inner track, using a flat
2 Insert the laygear through the bearing retainer. and mesh it with the metal disc under the bearing for a base point. From the difference.
ma1nshaft and inpu t shaft (photo). M ake sure that the bearing outer deduct the endfloa t required, then obtain a shim of th is thickness, and
tracks are located on the bearings. locate h on top of the 5th driving gear spacer.
3 Lower the gear shafts into the left-hand main casing. and engage 24 Locate the circf ip in the mainshaft groove.
the selector forks with the synchro sleeves. 25 Oil the machined portion of the mainshaft. Engage the 5th speed
4 Apply RTV sealant to the mating faces, then refit the right-hand driven gear and speedometer drivegear splines w ith the malnshaft
casing (photo) . Insert and tighten the tour corner bolts to 5 Nm (3.5 lbf splines. then draw it fully onto the mainshaft using a long bolt, a nut.
ft) washer and metal tubing (photo) . Do not allow the gear teeth to fou l
5 Smear RTV sealan t on the mating face of the clu tch housing. Fit the each other.
main casing to the clutch housing. and tighten 1he bolts progressi vely 26 Fit the ci rclip to secure the speedometer drive gear (photo).
to 27 5 Nm ( 20 lbf ft) (photos) 27 Check that the dowels are fitted to the rear housing. Smear RTV
6 Turn the input shaft to seat the laygear bearings. sealant on the mating faces. then locate the rear housing on the
7 Insert the bearing retaining plate bolts, and tighten them to 10 Nm intermediate housing while engaging the selector hngers (photos).
(7 lbf ft ) (photo). 28 Insert the bolts and progressively tighten them. occasionally
8 Loosen the main casing corner bolts. then tap the casing halves striking the housing to assist seating of the bearing. Tighten the bolts
with a wooden mallet while turning the input shaft. Retighten the bolts to the specified torque (photo) .
to 15 Nm ( 11 lbf ft) (photo) 29 Fit the 0 -rlng to the plastic plug, then tighten 11 into the rear
9 On casing halves located by one dow el, check that the halves are housing.
not m1sahgned by more than 0.02 mm (0.0008 in) . If they are. loosen 30 Refit the speedometer pinion adaptor. Apply locking fluid to the
the bolts and repeat the tighten ing procedure. locking bol t, align the holes, and tighten the bolt.
17.2 Meshing the laygear wtth the 17.4 Applying RTV sealant to the left -hand 17.6A Apply RTV sealant to the mating
ma1nshalt and Input shaft casing mating faces faces ...

17 56 then lower the main casing on the } 7 5C and tighten the bolts 17.7 Tightening the bearing retaining plate
clutch housing bolts
17.8 Tightening the main casing corner 17 .1 0 Tightening the remaining main 17.14 Applying RTV sealant to the main
bolts casing bolts casing rear face
17 l 7 5th/ reverse synchro hub (arrowed} 17.1 9 5th synchro unit alignment marks 17 .20A Flt the special tool ...
(arrowed)
17 208 and d11ve 1n the roll pin 17 25 Refming the 5th speed dfiven gear 17.26 Fitted clrclip
and speedometer dnvegear

Chapter 6 M anual gearbo x and automatic tran smission , 51
1 7 27 A Rear housing locatton dowel 17.278 Refitting the rear housing 17.28 Tighten the rear housing bolts
progressively
locknut and adjust the dimension between the socket centres to the
18 Manual gearbox ( BA7) - gearchange adjustment following:
Saloon - BA7 /4 ·speed: 111 mm (4.4 in)
1 Ad1uStment is only possible on the gate gearchange rod. The Saloon - BA7/5 -speed: 703.5 mm (4.1 in)
dimensions of the remaining gearchange components vary according Estate - BA7/4- speed. 128 mm (5.0 in)
to model. so 11 1s important to obtain the correct part (s) . Estate - BA7/5 speed: 120 mm (4.7 in)
2 To adjust the gat e gearchange rod, remove the rod then loosen the 3 Tighten the locknut. then refit the rod.
Fig. 6. 7 Gearchange c omponent s (Sec 18 )
1 Cover
2 Rubber gaiter
3 Stud
4 Rubber mounting
5 Control rod
6 Gate gearchange rod
7 Speed gearchtmge rod

1 3
19 Manual gearbox (B A1 0) - overhaul (general )
l Although components of tha BA1O gearbox ara not Interchange· ~

2 4 A
abla with those of the BA 7 gearbox, the basic design is the same, and
the ma1onty of overhaul procedures are similar.
2 Secuons 20 to 26 inclusive describe the procedures which are
different The main areas of di fference between the two gearbox types
are as follows
(a) Intermediate housing on the BA 10/ 5 gearbox
(b) Mamshalt rear taper roller bearings on early BA 10/ 5
gearboxes
(c) Speedometer drive taken from the 5th speed driving gear
mscead of the 5th speed driven gear on the BA 10/ 5 gearbox
20 Manual gearbox ( BA10) - dismantling into major

assemblies
The procedure 1s as described in Section 5. except for the following

differences
2 Instead of a plastic plug on the rear housing, a metal plate is fitted, Fig. 6.8 Loosening the reverse d riving gear r etaining nut
with three securing bolts. ( Sec 20)
3 On the BAl0/ 4-speed gearbox. it 1s not possible to w ithdraw the
laygear through the rear bearing retaining plate. because the reverse 1 Nut 2 Adaptor
driving gear is larger than the hole in the plate. Before separating the
main casing halves. ti is therefore necessary to unscrew the nut and
remove the gear firsL To do this, engage 4th gear. then lock the
~
malnshaft while the nut is being undone.
21 Manual gearbox input shaft (BA10) - dismantling and 2 ' A

reassembly
1 The procedure is as described In Section 7, except for the following

differences
2 If the parts mentioned in Section 7. paragraph 4 are renewed, use a
0 20 mm (0.008 in) shim on the input shaft w ith an oil seal. and just fit
the oil thrower alone on the other type.
22 Manual gearbox mainshaft ( BA10) - d ismantling and

reassembly
The procedure 1s as described in Section 8. except for the following

differences
2 On early BA10/ 5 gearboxes, an additional spacer 1s fitted on the
inner side of the rear bearing.
3 If the pans mentioned in Section 8. paragraph 16 are renewed, use Fig. 6.9 Intermediate housing components on the
a 2.95 mm (0 116 in) shim next to the bearing. BA10/ 5-speed gearbox (Sec 24)
1 Cup 4 Selector linger

23 Manual gearbox selector rods ( BA1 0) - dismantling and 2 Spring 5 0 -ring seals
reassembly 3 Bush 6 Seal seating In housing
1 The procedure is as described in Section 11 . except for the finger on the splines. so that It is aligned with the shaft arm.
following differences. 7 Refit the bush. spring and cup.
2 The 3rd/ 4th detent ball and spring is located at the rear of the 8 Refit the washer and ctrclip.
half-casing, and is retained by the rear bearing outer track.
3 On the BA 10/ 4 -speed gearbox. the reverse idler gear dog is
retained by a detent ball and spring w ith a cover plug. 26 Manual gearbox mainshaft bearing (BA10/ 5) - prel oad
adjustment
24 Manuel gearbox intermediate housing ( BA10/ 6) - 1 Remove the rear bearing outer track from the rear housing.
dismantling and reassemb ly
2 Remove any shims. then fi t shims of 4.0 mm (0.158 m) thickness
and refit the bearing outer track.
1 Extract the circlip and washer from the end of the selector shaft. 3 Refit the rear housing and hand-tighten the three bolts. Turn the
2 Pull out the selector shah. and disengage It from the splined mainshaft several times. then hand-tighten the bolts again.
selector finger 4 Using feeler blades, check that the mating feces are parallel. If not.
3 Recover the spring cup, spring. bush and selector finger. loosen or tighten the bolts as necessary.
4 Extract the 0 -ring seals from the housing. 5 Note the gap between the housings. then deduct this from the 4.0
5 Dip the 0 rtngs in oil. then locate them in the housing. mm (0.1 in), and add the preload of 0.10 mm (0.004 in) . The resulting
6 lnsen the selector shaft, and at the same time locate the selector thickness 1s the shim 'th1ck.ness to fit instead of the 4.0 mm shim.

Chapter 6 Manual gearbox and automatic transmission 153
Fig. 6.10 Determining the mainshaft taper bearing p rel oad Fig. 6.11 Automatic transm ission flu id drain plug (1)
on the BA10/5 -speed gearbox (Sec 25) (Sec 27)
26 Manual gearbox ( BA10) - gearchange adjustment 4 Unscrew the drain plug, and allow the fluid to drain. As the fluid
will be very hot. take precautions to prevent scalding.
5 Refit and tighten the drain plug.
Refer 10 Section 18. but note the following dimension for the gate 6 Remove the dipstick, and refill the transmission w ith the correct
gearchange rod. grade and quantity of fresh fluid, using a funnel In the dipstick tube.
Saloon - BA 10/5 -speed: 111 mm (4.4 in) 7 Run the engine for 4 or 5 minutes. then check that the level is
w ithin the 'Cold' ("Froid') section on the dipstick.
27 Automatic transmissio n fluid - draining and refilling

28 Automatic transmission - removal and refitting
1 The engine and transmission must be at normal operating
temperature. after driving for at least 3 miles. 1 On Saloon models. follow the procedure given in Section 3.
2 Apply the handbrake. Jack up the from of the vehicle and support paragraphs 19, and 21 to 33 inclusive.
on axle stands. 2 On Estate models. follow the procedure given in Section 4,
3 Posiuon a suitable container beneath the transmission. paragraph 1, then paragraphs 7 to 14 and 19 10 34.
Fig. 6.12 Automatic transmission components (Sec 28)
1 Torque converter housing

2 Intermediate plate
3 Main housing
4 Rear housing
5 Sump
6 Identification plate
7 Selector lever
B Kickdown cable
9 Inhibitor switch and cable
10 Outlet union to fluid cooler
11 Dipstick tube
12 Torque converter

3 Dram the transmission fl~id as described 1n Section 27.

4 Unscrew 1he union bolts and d1sconnec1 the oil cooler pipes.
5 D1sconnec1 1he k1ckdown cable al tho carburettor or throttle
housing
6 Remove the starter motor 1f not already done
7 Unbolt and remove the dipstick tube.
8 On carbureuor engines. unbolt and remove the left. hand cover
from the torque converter housing.
9 Unbolt the transmission front cover. together with the TDC sensor.
10 Hold the drivepla ta stauonary wnh a screwdriver in the staner 11ng
gear teeth. then unscrew the torque converter-to-driveplate bolts,
turning the driveplate as necessary to gain access.
11 Maka sure that the transmission 1s firmly mounted on the trolley
1aek
12 Disconnect the gear selector lever
13 Disconnect the w111ng from the 1nh1b1tor swnch
14 Loosen the bolt and withdraw the speedometer drive cable.
15 Lower the transmiss ion on the trolley jack to provide sufficient
room to remove it Slightly raise the front of the engine also. using a
hoist or further trolley 1ack
16 Unscrew the transmission-to-engine bolts, then carefully
withdraw the transmission, making sure that the torque convener
remains fully engaged with the oil pump dnve. As a precaution. a Fig. 6 .13 Using a metal plate (1 ) to retain the t o rq ue
length of metal plate may be anached to the torque convener housing converter (Sec 28)
to keep the converter in place
17 Refitting is a reversal of removal, but note the following additional
points·
(a) Apply a little grease to the centre of the driveplate to assist
location of the torque converter
(b) Apply loclang fluid to the threads of tho torque converter-to
driveplete bolts before msening end tightening them
{ c) Refill the transmission w ith fluid, with reference to Section 27
{ d) Adjust the k1ckdown cable as descnbed in Section 29
(e) Ad1ust the gear selector lever as described m Section 30
29 Automatic transmission - k ickdown c able adjustment
Run 1he engine to normal operattng temperature. then switch 1t off

2 With the throttle in ns idling position, check that the clearance
between the stop on the k1ckdown cable and the end of the cable end
f1111ng 1s not more than 0.5 mm (0.02 in).
3 If ad1ustment 1s necessary. loosen 1he inner cable clamp screw on
the throttle lever, tension the cable as required, then tighten the screw
4 When fining a new cable. pull out the inner cable until kickdown
occurs. then crrmp the stop in the position shown in Fig. 6. 16.
Fi g . 6 .14 Rem oving the automatic t ransmission ( Sac 28)

30 Automatic transmission gear selector lever - adjustment
1 Apply 1he handbrake. Jack up the front of the vehicle and suppon
on axle stands
2 Disconnect the front of the gear selec1or rod from the lever on the
1ransm1ss1on
3 Place the transmission lever in nau1ral ('N')
4 Inside the vehicle, move the selector lever to ' N'
5 Offer the front of the gear selector rod to the pin on the lever, and
check that the centres of the pin and housing are ahgned. If not, ad1ust
!he selec101 rod length as raqu11ed
6 Apply a httle grease 10 the pin and housing. 1han assemble them.
noung that the vibration damper (where fitted) should be positioned
as shown 1n Fig. 6.1 7.
7 Lower 1ha vehicle to the ground.
Fig. 6 .15 Automatic transmission k ickdown cabl e

adjustment - dimension In mm (Sec 29)
1 Inner cable 3 Outer cable end fitting

2 Stop

-----------------------------------------------------------------------------155
Fig. 6.16 Correct position of crimped stop ( 1) when kickdown occurs (Sec 29)
X = 39.0 mm (1 .54 in)
Fig. 6.17 Automatic transmission selector lever component s (Sec 30)
1 Vibrauon damper 4 Identification mark 6 Locking ltnger

2 Lower lever 5 Transmission lever 7 Stop
3 Selector lever

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31 Fault d i agnosis - manual gearbox and automatic transmission
Symptom Reason(s)
M anual gearbox
Weak or ineflecuve synchromesh Synchromesh units worn or damaged
Jumps out of gear Gearchange mechanism worn

Synchromesh units badly worn
Selector fork badly worn
Excessrve norse Incorrect grade of orl. or orl level too low

Gear teeth excessively worn or damaged
Worn bearings
D1fliculty m engaging gears Worn selector components

Worn synchromesh units
A utomatic transmission
Automatic transmi ssion fau lts are almost always the resu lt of low fl uid level. or incorrect adjustment of the kickdown cable or selector lever.
Apan from this. any fault 1s probably internal and should be diagnosed by a Peugeot dealer. who w i ll have the special equipment necessary to
pinpoint the problem
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....
Cha pter 7 Propeller shaft

Contents
Fault d1agnos1s - propeller shah ..........•.............................................. 6 Propeller shaft (Saloon models) - removal. inspection and
General descnption ..........................................................•.................... 1 refitting .......... -······· .. ...................... .......... ......... ........................... 3
Propeller shaft cemre bearing - removal and refut ing ..................... 5 Rour ine maintenance ............................................................................ 2
Propeller shaft (Estate models) removal, Inspection and
refining ... .............................................................................................. 4
Specification s
Type
Saloon .......................................................................................................... . Propeller shaft enclosed in link tube. attached to rear of gearbox
and front of unsprung final drive unit
Estate ........................................................................................................... . Propeller shaft enclosed in torque tube. a11ached to rear axle and
pivoting on rear of gearbox

Saloon models
Link tube mounung nuts/bolts ····-············................................................ 60 44
Vibration damper .......................................................................................... 35 26
Front seat reinforcement bar ....................................................................... 18 13
Rear crossmember mounting nuts ............................................................. 35 26
Estate models
Torque tube front ball cover halves ........................................................... 18 13
Torque tube 10 rear axle ............................................................................. . 55 41
Front ball cover to gearbox ........................................................................ 43 32
On Estate models. the propeller shaft is enclosed 1n a torque rube.

General description
which Is bolted to the rear axle The front end of the torque tube
incorporates a spherical bearing, which allows the rear axle to move
On Saloon models. the propeller shaft is enclosed In a link tube. freely, so a universal J01nt is fitted between the gearbox output shaft
which 1s bolted to the rear of the gearbox and the front of the final drive and the propeller shaft. The rear of the propeller shalt has lnrernal
unit The sha ft incorporates internal splines at each end, which engage splines for Jl!tlgagement w ith the pinion shaft. whereas the front has
with the gearbox output shaft and final drive pinion shaft. A centre external splines to engage the universal joint. As on Saloon models. a
bearing supports the shaft withi n the link tube. cent re bearing supports the shaft within the torque tube.

158 Chapter 7 Propeller shaft
A I
Fig 7.1 C ross -section o f the propeller shaft fitted to Saloon models ( A ) and Es tate models ( 8 ) ( Sec 1 )
1 Link tube 3 Propeller shaft 5 Grease nipple

2 Torque tube 4 Centre beaflng
2 Routine maintenance 3 Propeller shaft ( Sal oon m odels) - removal . inspection

and refitt ing
CoJrry out tho following procedures at the intervals given in Routine
maintenance :11 the front of this manual Before commencing work, it Is recommended that the special tools
shown in Fig. 7.2 are obtained. or alternatively. fabricated. The guide
pins (Peugeot tool 0906 ZZ) are necessary to support the rea1
Grease propeller shaft centre bearing
crossmember. but long bolts and washers may be used instead The
l Chock 1he front wheels, then 1ack up the rear of the vehicle and
plate is necessary to support the propeller shaft within the link tube.
support on axh stands Locate the grease nipple 1n the middle of the
and may be made from plywood about 20 mm (0.8 in) thick.
hnk tube or 1orquo tube
2 Chock the front wheels. then 1ack up the rear of the car and support
2 Using a grease gun. force grease into the centre bearing.
on axle stands.
3 Refer to Chapter 3, and disconnect the exhaust system from 1he
Grease torque tube front beaflng (Estate models only) exhaust manifold and mounting rubbers. Tie the front end to the
3 With th~ 11eh1cle supported on axle stands. use a grease gun 10 underbody. and rest the rear end on the rear crossmember.
force greasu into the torque tube front ball, 1hrough the grease nipple 4 As applicable, unbolt the exhaust heal shield and front sea t
on 1he ball cover halves. reinforcement bar from 1he underbody.
A B
Fig. 7.2 Special tools required when removing the propeller shaft on Saloon models (Sec 3)
I
A Rear crossmembor support guide pins 8 .Propeller shaft holding plate

C h apte r 7 Propeller shaft 159
5 Sunpor1 the final drive unit. then euher unbolt the side mountings ( e) Lock the rear crossmembor mounting nuts by bending the tab
or upper bracke1 (according to 1ype), and tower the final drive unit so washers
that the link tube rests on the rear crossmember (f) Check. and If necessary top up, the gearbox oil level or
6 Suppon tho renr crossmembor with a trolley 1ack automatic transmission fluid level
7 Working ms1de the car, remove the rear sea l to grve access to the (g) Lubricate the propeller shaft centre bearing w ith grease
rear crossmember mountrng nuts. Do not confuse these nuts with the through the nipple on the link tube
rear sus'pensron crossmember moun11ng nuts which are not locked (h) Where a bump stop is fitted. the bracket must be centralised
w11h tah washers before tightening the bolts With the circular bump stop rubber
8 Unscrew the front nut on each side. the lift the tab washers and this is straightforward but with the elliptical rubber. refer to
remove the centre plug Screw the gurde prns or long bolts into the rear Figs. 7 6 and 7. 7. A 5.0 mm (0.2 rn) diameter twist drill should
crossmember threaded holes Leave the tommy bars rn the guide pins. be used to set the clearance between the rear of the rubber and
to suppon the rear crossmember the bracket
9 Unscrew the rear nuts and remove the tab washers.
10 Low er the rear crossmember unul the tommy bars or washers
con1ac1 the floor.
11 Suppon the frnat drive unit with the trolley jack.
12 Unscrew the four nuts secunng the final drive unu 10 the link tube.
then w ithdraw the fi nal dnve unrt rearwards. while gu1drng the
propeller shaft from the splines on the p1n1on shatt. Exuac1 the spring
from rns1de the rear of the propeller sh ah. and put it rn a safe place
13 Where applicable. unbolt the bump stop and bracket from the
bottom of the ltnk tube and crossmember
14 Unscrew the four bolts securrng the front of the link tube to the
gearbox (pho to), withdraw the hnk tube about 20 mm (0.81 i n) and
locate the suppon plate in the groove in the propeller shaft Use two
bolts to secure the plate to the bottom holes of the link tube.
15 M ove the exhaust system to one side
16 Release the propeller shaft from the g earbox output shaft splines.
then lower the front of the link tube and withdraw the assembly
forwards
17 Clean the outer surface o f the ltnk tube.
18 Wrthdraw the propeller shaft from the ltnk tube. Where fitted.
unbolt the vibration damper from the ltnk tube.
19 Examine the propeller shah for wear and damage, especially at the
splines and at the centre. where it 1s supported in the needle bearrng.
Mount t he shaft between centres and use a dial test indicator to check
tne 1un ou t on the centre bearing shoulder 11 should not exceed 0.2
mm (0 008 in)
20 S1mrlarly examine the hnk tube for wear and damage. With the tube
mounted between centres. the run-ou t at the centre should not exceed
2.0 mm (0.079 1n). and the run-out et each end should not exceed
0 05 mm (0 002 in).
21 Aefmmg 1s a reversal of removal. but note the following additional Fig . 7.3 Rea r crossmember support guide pin and tommy
points bar in position (Sec 3)
(a) Lub11cate the propeller shalt splmes with a little grease
(b) Tighten all nuts and bolts to the specified torque
(c) Ref er to Chapter 8 when refitting tho final drive unit
(d) Ref er to Chapter 3 when refiwng the exhaust system
3 14 Unscrewing the link tu be- to -gearbox bolls Fig. 7.4j ~ross -section of the vibration damper ( Sec 3)
1 Stud 2 N ut

Q Q
H.12937
W./2'33C:,
Fi g . 7.6 Adjustment of bump stop with elliptical rubber

Fig. 7.6 Bump stop with ci r cu lar rubbe r (Sec 3) ( Sec 3)
1 Rubber 3 Nut 1 Bracket 3 Nut

2 Bracket 4 Bolts 2 Rubber 4 Bolts
4 Unscrew and remove the bol ts securing the anti- roll bar links to the
underbody. and w ithdraw the links from the brackets.
5 Pull out the spring plate securing the flexible brake hose to the
torque tube. Do not disconnect the rigid brake line from the flexible
hose.
6 Release the rigid brake line support, and also unclip the rear brake
compensator supply line from the underbody.
7 Unbolt the compensator spring from the torque tube, and remove
the compensator from the underbody, but do not disconnect the
hydraulic lines
8 Unbolt the hydraulic line three-way union from the top of the rear
axle casl ng, but do not disconnect the hydraulic lines.
9 Unscrew and remove one of the nuts securing the front sear
reinforcement bar to the underbody. Loosen the remaining nut. and
swivel the bar to one side of the torque tube.
10 At the front of the torque tube, unscrew the bolts securing the ball
FRONT
Fig. 7 .7 Diagrammat ic t op view of elliptical rubb er bump
stop adjustment - dimension in mm ( Sec 3 )
4 Propeller shaft ( Estate models} - removal , i nspection

and refitting
1 Chock the front wheels, then iack up the rear of the vehicle and
support on axle stands positioned on the underbody.
2 Unscrew fully the handbrake cable adiustment nuts (see Chapter 9
1f necessary) ·l
3 Move the front seats fully forwards, and remove the centre console. Fig . 7.8 Unbol t ing the th r ee- way union (1) from the rear
Unhook 1he handbrake inner cables from the equaHser axl e ( Sec 4 )

Chapter 7 Propeller sh aft 161
covm halves to the rear of the gearbox. The bolts are socket· headed, so 36 Refit the anti-roll bar hnks to the underbody. and tighten the bolts.
an Allan key will be required to remove them 37 Reconnect the handbrake cables. and adjust as described in
11 Usm~J a trolley 1ack, ra ise tho rear axle slightly, then unscrew and Chapter 9.
remove both rear shock absorber low er mounting bolts 38 Refit the centre console.
12 Unscrew the nu ts securing the rear of the torque tube to the rear 39 Grease the propeller shaft centre bearing and torque tube ball
•uclu through the nipples provided.
13 Unscrew tha nu1 from the torque tube stay bar front mounting bolt 40 Check, and if necessary top up, the rear axle oil level
(photo) 41 Lower the vehicle to the ground
14 Lowe1 the rear axle sufficiently to allow the rear wheels to clear the
re.u wheel arches
15 Suppon the torque tube stay bars on axle stands.
16 Move the rear axle rearwards untrl the fro nt of the propeller shaft
slips horn the universal 1oint splines.
17 Remove 1he stay bar front moun11ng bolt. and w ithdraw the torque
tube forwards from the rear axle
18 Extract the spring trom 1ns1de the rea1 of the propeller shafi. and put
1t 111 a sale place. Also rem ove the rubber ganer.
19 Withdraw the propeller shaft rearwards from the torque tu be
20 Unbolt the torque tube ball cover halves, and remove the O· ring
(photo)
21 Clean the propeller shaft and examine 11 for wea r and damage,
r>SPf!c1ally at the splines, and at the cen tre where It 1s supported in the
needle bearing Mount the shaft between centres. and use a dial test
indicator to check the run-out on the centre bearing shoulde1 - 11
should not exceed 0 2 mm (0.008 in)
22 S1m1larly examine the torque tube (or wear and damage. Whh the
tube mounted betw een centres the run-out at the centre should not
exceed 2.0 mm (0079 1n).
23 Commence relming by applying grease to the torq ue ball Loc ate
the 0 ong. reassemble the cover halves then insert and tighten the
bolts to the specified torque
24 G1ease the propeller shaft splines and cent1e bearing shoulder Fit
thu 1ea1 ~p11ny CJnd 1ubber gaiter. making sure that the gaiter locates in Fig. 7.9 Disconnecting the torque tube and propeller shaft
the shah groove. from the rear of the gearbox ( Sec 4 )
25 Slide the rear of the propeller shaft onto the rear axle pinion shaft,
then locate the torque tube over the propeller shaft Tigh ten the nuts to Torque ball cover halves
the spec1f1ed toroue
26 Fil the stay bar front mounung boll aml 119hlt.m the nut.
27 Raise the lront of the torque tube Move the rear axle forwards, so
thilt the propeller shah engages the universal 101nt splines
28 Insert and ughten the bolts securing the ball cover halves 10 the
rear of the gearbox.
29 F11 and 11ghten the nuts securing the rear of the torque tube to rhe ®
reilr axle
30 Check that the rear coil springs are correctl y located in their cups.
Raise the rear axle on the trolley 1ack
31 Relit and ughten the rear shock absorber low er mounung bolts.
together with the spacer w ashers (refer to Chapter 10 1f necessary)
32 Refit the front seat reinforcement bar. and tighten the nuts
33 Refit the hydraulic line three-way union, and tighten rhe bolt.
34 Ref11 the compensa tor and spnng. and tighten the bolts.
3ti Reht the brake lines and llexible hose
®
Fig. 7 .10 Propeller shaft components (Sec 4)
3 Propeller shaft {rear end) 5 Rubber gaiter

4 Sprmg 6 Groove for gaiter
~ i -i:b::
I -=''
'
-=---e"!S---- -
C)
- ---lJlU.i
Fig 7.11 Torque tube ball cover halves (Sec 4 )
H
1 0 -rmg 2 Bolts Fig. 7.1 i Checking the torque tube for r un -out ( Sec 4)

4.13 Torque tube stay bar front mounting bolt (arrowed) 4.20 Torque tube ball cover halves and 0-ring
5 Propeller shaft centre bearing - removal and refitting
1 Before commencing work. It is necessary to obtain a tool for

removing and refitting 1he bearing. Peugeot tool 8.0403 is shown In
Fig 7.13, and consists basically of a shde hammer fitted w ith a rocker
which engages the bearing after inserting the tool. The tool also Fig . 7.13 Peugeot tool for removing and refitting the centre
incorporates a guide plate and depth setting ring. although this tool bearing (Sec 5)
ensures quick and accurate removal and refitting of the bearing, the
use of a wooden or soft metal dowel rod w ill also achieve the same 1 Slide hammer 4 Support
objective. 2 Depth setting ring 5 Removal rocker
2 Remove the propeller shaft as described 1n Sectlon 3 or 4, as 3 Guide plate 6 Guide bush
applicable.
J Unscrew the grease nipple from the centre of the tube.
4 Using a tape measure, determine the fitted position of the centre
bearing in relauon to 1he rear flange face of the tube. Since the bearing
has a centra l lubrication groove, this dimension will be the distance to
the grease nipple, less half the w idth of the bearing.
5 Dnve the bearing out of the rear of the tube. using one of the tools
described 1n paragraph 1. If using the special Peugeot tool, it 1s
recommended that the bearing is first driven forwards slightly, in order
to free n off. If this precaution is not taken, there is a risk of the tool
rocker damaging the bearing track.
6 Wash the bearing in a suitable solvent, and check it for wear and
damage If 1ha needle rollers are pined. Iha bearing should be renewed.
Temporarily fit the bearing on the propeller shaft, and check for
excessive play
7 To refit the bearing, first lubricate the inside of the tuba with engine
011.
8 Dip the centre bearing 1n oil, then insert it in the tube and drive it to
its correct position with the tool.
9 Refit and ughten the grease nipple.
10 Refit the propeller shaft with reference to Section 3 or 4, as
applicable Fig. 7.14 Centre bearing removal ( Sec 5)
6 Fault diagnosis - propeller shaft
Symptom Reason(s)
Noise from final drive unit/ rear axle lack of lubricant

Worn bearings. crownwheel and pinion
Worn centre beari 7~
Knock when taking up drive (Estate models only) Worn universal 1oint•bearings
Lack of grease on torque ball

Cha pter 8 Rear axle

Contents
Oriveshaft {Saloon models) - overhaul ............................................. 6 Halfshaft (Estate models) - removal and refining ............................ 7
Dnveshaft ( Saloon models) - removal and refitting ........................ 5 Rear axle and differential untt (Estate models) - removal and
Fault d1agnos1s - rear axle ................................................................... 8 refitting ................................................................................................... 4
Final dnve unu {Saloon models) - removal and refitting ............... 3 Rou1ino maintenance ............................................................................ 2
General descnpuon . ... ........... .............................. 1
Specifications
Type
Saloon ........................................................................................................... Unsprung final drive unit mounted on undarbody. separate driveshafts
wit h triple- pin spider constant velocity joints at each end
Es1ate ............................................................................................................. Conventional ri gid rear axle, and torque tube propeller shaft
Final drive ratio .................................................................................. 3.58 : 1, 3 .89 : 1, or 4 22 : 1
Lubrication
Final drive lubricant 1ype/spec1f1cat1on
Except hm1ted-slip d ifferential ....................................................... Gear oil, viscosity SAE SOW/ 90 (Ouckhams Hypoid SOS)
Ltm1ted·sl1p d ifferential ............ . .......................................................... Gear oil. viscosity SAE 90 (Ouckhams Hypoid 90DL)
Capacity:
Saloon ... .......................... ... .................................................... 1 5 5 litres (2.7 pints)
Estate ............................................................................................ 1.6 litres (2.8 pints)
Or1veshaft CV JOtnt lubricant type/ spec1f1cauon ..................................... . Special lubricant supplied In repair kit
Torque w r ench settings Nm lbf ft

Final dnve unit mounting:
Two side mountings ............................................................................. . 38 28
One top mounting .................... ........................................................... . 95 70
Rear hub earner (Saloon models) .......................................................... 50 37
Drweshaft/ hub nut (Saloon models) ........................................................ 280 207
Brake shoe backplate (Estate models) ...................................................... 50 37
type, incorporating a torque tube wtth enclosed propeller shaft

General description
A hmited·sli p differential umt 1s fitted to certain models It
incorporates a slip cone and four pressure springs. which lock the
On Saloon models, the final drive unit is mounted on the rear d1fferen1tal gears when one roadwheel loses traction and attempts 10
suspension upper crossmember, w11h separate driveshafts transmitting spin.
the dnve to hubs on the independent rear suspension arms. The Due to the need for specialised tooling, overhaul of the differential
dnveshafts incorporate inner and outer constant velocity joints of the unit Is not covered in this Chapter. Work of this nature should be
trlple·p1n spider type. On Estate models, the rear axle is of the rigid entrus14 t~ a Peugeot dealer or suitably-equipped engineering works.

Fig. 8.1 Cr oss- sectio n o f a dri vesha f t f itted to Sal oon models ( Sec 1 )
1 Stub BKlo and voke (tulip) 6 Cover 10 Dflveshaft 14 Stop ring

2 Spnng 7 Spacer 11 Cover 15 Stop
J Cup 8 Rubber bellows 12 Spider 16 Spring washer
4 Sp1dor 9 Retammg rmg 13 0 -nng 17 Yoke (tulip)
5 0 rmg
...
Fig . 8 2 Cutaway view of the limited - slip different i al unit ( Sec 1)
7 Slip cone 5 DifferentJal sun gear - 7 Differential sun gear - slip

2 Crownwheel cemer crownwheel side cone side
J Driveshaft 6 Crownwheel 8 Pressure spring cages
4 Pressure spflngs

Cmry 0111 /lie following procedures at the mtervafs given m Routine

mamt1mance at the front of this manual
Check the Oii ievei m the rear axle/ final drive umt
l With the vehicle over an 1nspecuon pit. or 1acked up level and
support11d on axle Slands unscrew the filler plug from the rear
axle final drive unu (photos) •
2 Using a shor t length of wire. check that the 011 level 1s up to the
bo1tom of the filler plug hole If not top up using the correct grade of
011 If constant topping-up 1s necessary investigate the cause. and
carry out repairs as required Areas to check are driveshaft oil seals In
Saloon models, and side tube gaskets on Estate models
Check drtveshaft rubber bellows (Saloon models)

3 Chock 1he lron t wheels. then 1ack up the rear of the car and suppon
on a>de stands Clean the dnveshaft rubber bellows and check them for
detenorauon and cuts
4 If necessary, renew the rubber bellows_
Renew rear axle/final drive unit oil

5 With the vehicle ove1 an 1nspec11on p11. or 1acked up level and 2 1A Final drive unit filler plug (A ) and drain (B) - Saloon models
supported on axle stands. unscrew the fi ll er and drain plugs, and allow
1he oil to dram into a suitable container
6 Refit and tighten 1he dram plug
7 Fill the rear axle/ final drive unit with the correct grade and quanllty
of 011
8 Refil and tighten the hller plug
3 Final drive unit ( Saloon models) - remova l and refi tting
Chock the front wheels. Jack up the rear of the car, and support on
axle stands pos1t1oned beneath the rear suspension arms.
2 Remove the Jett-hand rear wheel
3 Unscrew the filler and drain p lugs, and drain the oil from the final
dr1vt unu Into a suitable container Refit and tighten 1he drain plug.
4 Unchp the brake hydraulic line and hose from the left· hand rea1
suspension arm
5 On models with rear disc brakes. uncllp the left-hand handbrake
cable
6 On models with rear drum brakes, remove the left -hand rear drum
and disconnect the handbrake cable from the lever (refer to Chapter 9
,r necessary).
7 Unscrew the socket-headed bolts securing th e left·hand hub
carrier to the rear suspension arm
8 Lever lhe left -hand drlveshaft. together with the hub and brake 2.1 B Rear axle filler plug (A) and dram plug (B) - Esta1e models
assembly, from the final drive unit. and rest n on an axle stand_
9 Where applicable, unbolt the brake compensator lever, and unhook
lhe spring located to the left of the final drive unu.
10 Unbolt the exhaust mounting(s) from the final drive unit
l 1 Unscrew the nuts securing the propeller shah link tube to the final
dove unit
17 Suppon the final drive unit on a trolley Jack
13 Unscrew either the side mounting bolts (photo) or the lower link
mounung bolt (according to type). then free the final drive unit lrom
the link tube. making sure that the propeller shaft remains engaged
with the gearbox ou1put shaft.
14 Move the final drive unit to 1he left, and release it from the
11ght hand driveshah Support the dnveshaft on an axle stand
15 Lower the final drive unit, and withdraw 11 from under the car
16 Examine the dnveshaft oil seals in each side of the final drive unit
for detenorauon and signs of leakage, and 1f necessary, renew them . To
do this prise out the old seals. clean the seatings. then drive the new
seal into posmon using a block of wood Smear a little grease on the
011 seal lips. final drive pinion splines and dnveshaft splines M ake sure
thal th~ spring IS pos11ioned In the rear of the propeller shaft. Renew
the p1mon 011 seal 1f necessary.
t 7 Refnttng is a reversal of removal. but tighten all nuts and bolts to
the speci fied torque. Where applicable, make sure that the lower link
mounung bolt washers are correctly assembled, as shown in Fig. 8 .3 .
Where a bump stop is fitted to the bonom ol the hnk tube. ad1ust 1t as
described In Chapter 7 Refill the final drive unit with the correct grade
T rial ve rsion of ABC Ambe r PDF Merger, http:/Nllww.processtext. com/abcpdfmg_html

166 Chapter 8 Rear axle
and quantity of oil, and refit the filler plug. On completion, depress the
brake pedal several times, in order to set the brake shoes or pads in the 4 Rear axle and d i fferential unit ( Est at e m odels) - remov al
normal working position. and refitting
1 Chock the front wheels. Jack up the rear of the car, and support on
axle stands positioned under the rear jacking points. Remove both rear
wheels.
2 Unscrew the rear axle filler and drain plugs. and drain the oil into a
suitable container. Refit and tighten the drain plug.
3 With the handbrake released, remove the screws and withdraw the
brake drums.
4 Disconnect the handbrake cables from the shoe operating levers.
Remove the shoe steady springs. lever out the leading shoes. and use a
small dntt to dnve the handbrake outer cables from the backplates.
Unclip the cables from the axle tie-rods.
5 Disconnect the tension spring from the brake compensator and the
bracket on the torque tube.
6 Flt a brake hose clamp to the flexible hose for the rear brakes.
7 Unscrew the union nut and disconnect the rigid brake pipe from
the flexible hose, then detach the hose from the bracket on the torque
tube.
8 Unscrew the nuts securing the anti-roll bar links to the rear
underbody, then prise the links free.
1 Shafr
9 Unbolt the Panhard rod from the rear axle casing.
1O Support the rear axle with a trolley 1ack.
2 Thin flat washer
11 Unscrew the shock absorber lower mounting nuts, and detach the
3 Thick flat washer
4
shock absorbers from the rear axle.
Link
12 Lower the rear axle until all tension is released from the coil springs,
5 Stop plate
then hft the springs from their locations. Support the rear axle.
6 Self-locJ<ing nut
13 Unscrew and remove the bolt securing the front of the tie-rods to
the torque tube.
14 Unscrew the nuts securing the torque tube 10 the front of the
differential housing.
Fig. 8.3 Cross- section of link mounting for final d rive unit 15 Lower the rear axle, then support the torque tube and withdraw the
( Sec 3) rear axle rearwards. making sure that the propeller shaft remains in
Fig. 8.4 Rear axle components for Estate models (Sec 4)
I Side tube 4 Differential unit

2 Gasket 5 Filler plug
3 Thrust plate 6 Drain plug

engayemeni w11h the universal 1oin1 on the rear of the gearbox. Check Disc brake models
al50 that t he preload spring remains inside 1he rear of the psopeller l 0 Carefully lever the inner end of the driveshaft from the final dnve
sh11t1 untt. and withdraw 11. complete with t he disc and backplate. outw ards
16 To remove 1he d1fferen11al un11. disconnect the 11g1d brake pipes and from t he rear suspension arm
unscrew 1he nuts secuung the side tubes Recover the gaskets and side 11 Remove the backplate from t he inner end o f the the dnveshaft
plates 12 Using a puller or press, separate t he dnveshaft from the hub
17 Ret111ing 1s o reversal of removal . but note the following add111onat splines
points
(a) Renew the s1dt1 tube gaskets where removed All models
(b) T1gluen all nuts and bolts to the specrfied torque l 3 Ref11Ung Is a reversal of the removal procedure, but note the
(c} On complot1on. refill the rear axle with the correct grade and following add11tonal points
quan(l(y of ol/ and refit the f!ller plug (a) Clean the dflveshalt splines. than apply grease t o tha inner
(dJ Bleed tho rear brake hydraulic circuit (Chapter 9) splines, and spray the outer splines with M o/yko te 3 21. or a
similar molybdenum d1sulph1de-based liquid
(b) Apply grease to the lips of the seals In the hub and final dflve
6 Orivesha f t ( Saloon mod el s) remo val and refitting unit
(c) Renew spnng w ashers and the hub nut
(d) Tighten all nuts and bolts co the specified t orque
Chock the front whoels. then iack up the rear of the car and support
(e) A f ter tightening the flub nut, lock it by punching the shoulder
on axle smnds. Remove the rear wheel on the side being w orked on.
st opposite p oints int o tha grooves In the driveshaft stub
2 Using a trolley iack, raise the rear suspension arm wi1hout liftin g
(photo}
1ho roar o f the ccir off the axle stands.
(f) On compleuon. check and ii necessary t op up the final dflve
3 Uncl1p the flexible brake hose from the rear suspension arm
oil level
bracket and also release the rigid brake line where applicable.
4 On models with rear disc brakes. unbolt the caliper and support 11 to
one ~•de
5 On models w11h rear drum brakes. remove the drum. disconnect the
handbrake cable from the shoe operaung lever. and unclip ihe cable
from the rear suspension arm
6 The hub must now be held stauonary while the hub nut is
loosened To do this. f11 a length of metal bar to two wheel studs with
its end r~ting on the floor Unscrew and remove t he hub nut and
washer then remove the metal bar
7 Using an Allen key through the hole in the d11ve flange. unscrew
the socke1 headed bolts secunng the hub earner to 1he rear suspension
arm
Drum brake models

8 Support the hub and brake shoe backplate assembly, then carefully
lever the •nner end of the drtveshah from the final dnve unit. low er 11.
and support 1t on an axle 5tand Be prepared for slight 011 leakage from
the final d11ve unn Take care not 10 damage the rigid brake pipe
leading 10 the rear wheel cylinder A n alternative met hod to remove the
drivesh aft is to screw two long bolts into the rear suspension arm from
the inner side. to act as extractors by pressing against the inner race o f
Fi g . 8.5 Using two long b o lts ( 81 and 82) when removing
the hub If this method is used. a lever will not be required, and rhe
the d r lveshaft on Saloo n models (Sec 5)
bolts will also keep the hub suspended
9 Using o suitable pulle1. press the drlveshaft from rhe hub spli nes,
1 Driveshaft inner splines
ond w ithdraw 11 inwards from the rear suspension arm.
Fig. 8 .6 Driveshaft and d isc assembly (Sec 5)
6 Drivesh a ft ( Sal oon m o dels) - overhaul
M ount the drlveshalt vertically in a vice

2 Bind some adhesive tape around the oil seal bearing face of the
tu hp to protect 11 from damage.
3 Using a pair of end cu11ers. carefully bend back t he cover (Fig. 8.7).
4 Disengage the cover by lightly tapping w lth a soft- faced hammer
(Fig. 8.8)
5 13 Lock the hub nut at opposite points (arrow ed) 5 Remo'1'1 the tulip by raising 11 vertically. On the w heel side Joint.
recover the sp ring and th rust cup.

168 Chapter 8 Rea r axle
Frg 8 7 Bendrng back the end o f t he driveshatt cover Fig. 8.8 Releasin g the cover from the tulip (Sec 6 )
(Sec 6)
6 Slide tho gn11er down on the shaft as far as possible

7 Bind somfl adhesive tape around the bearing pack This is a paired
component and mus\ not be separated (Fag 8 .9)
8 Carefully remove as much grease as possible. Do no t use any
~olvents
9 Using a large vice or press. extract the bearing pack (Fig 8 10}.
Don't forgtit to hold the dnveshafl or 11 will drop onto the floor There Is
no need to remove the three punch marks on the shaft, as they will
disappear during removal.
10 Remove the protector and rubber nng.
11 D1smantl nu thti d1fferen11al end side 101nt is s1m1lar to that for the
wheel side
12 Should both protectors need renewal , there 1s no need to remove
both bearing packs The protector for the second 101nt can be removed
ov11r the end of the hrst 1oant
13 Remove the 0 rang from the tuhp and then remove as much grease
as possible from ns1de the tulip Do not use any solvents.
14 If the drffere11taal side tuhp needs attenuon because of wear or
damage to the nylon stop carefully cu t this away using a sharp chisel
15 Using" screwdriver remove the retaining washer through the cut
an the nylon stop
16 Remo11e the punch marks from the washer using a small rotary file
or ston,
17 Finally clc1111 out the tuhp really thoroughly so that no traces of
abras111e or metal are fett behind
18 Obtain the new protector assemblies and the correct amount of Fig. 8.9 Wrap tape around the bearing p ack ( Sec 6)
grease (130 un1s per side 101n1)
19 To reassemble first fit tho gaiter and spacer together Grease 11 and
Fig. 8 .10 Pressing the drlveshaft from the bearing pack

(Sec 6} Fig . 8 .11 Removi~g the O · ring (2) from the tulip (1 ) (Sec 6)

insert into the cover. Push rhe spacer 1n until it abuts.

20 Hold the shaft vertically In a vice. and slide on the reta ining ring
and previously-assembled protector.
21 Ref11 the bearing pack to the shaft. and using a tubular drih. drive It
down the shah until 11 abuts.
22 Check rhat the lower part of the bearing pack is flush w ith the
bottom of the shaft groove.
23 M ake three equidistant punch marks, spreading the splines on the
shah towards the hub of the bearing pack using a sharp centre-pu nch.
24 If the nylon stop has been removed. refit it to the interior of the
tuhp
25 Insert the washer, and then make three equidistant punch marks to Fig. 8.12 Final assembly of wheel side joint (Sec 6)
secure 11 inside the tulip. •
26 Insert 180 gms of grease into each side JOlnt. Spread the grease A = 88 mm (3.5 In)
inside the tulip and gaiter.
27 Remove the adhesive tape from the bearing pack.
28 Place the cup and spring on the wheel end of the shaft.
29 Fi t a new 0 -ring to the tu hp, and then refit the tulip.
30 The tuhp cover must now be crimped. For this, the use of a press
will make life far easier. With the spacer held in position. bend over the
hp using a hammer.
31 Fit the retaining nng to the gaiter. Slide a piece of welding wire or
small electrician's screwdriver between the gaiter and shaft to release
the air trapped. Do not puncture the gaiter.
32 To assemble the wheel side joint. insert the shaft to obtain a
dimension of 88 mm (3.5 in) as shown in Fig. 8.12. Remove the metal
rod without altering this position.
33 To assemble the differential side joint with the metal rod located
under the gaiter, insert the shaft into the tul ip until it abuts. Then
-
Fig. 8.13 Final assembly of differential side joint (Sec 6 )
remove the metal rod (Fig. 8.1 3) .

34 Finally, check the operation of the Joints by hand. Th ey must slide 7 Unscrew the union nut and disconnect the rigid brake pipe from
freely. the rear wheel cylinder. Plug the end of the pipe.
8 Unscrew the nuts securing the backplate and bearing retainer to
the rear axle (photo).
7 Halfshaft ( Estate models) - removal and refitting 9 Withdraw the halfshaft from the rear axle. If it is tight, temporarily
refit the wheel to the drive flange. and pull the wheel outwards to free
1 Chock the front wheels. Jack up the rear of the car and support on the bearing outer track. Alternatively, a slide hammer may be attached
axle stands. Remove the appropriate rear wheel. to th e drive flange. Remove the 0 -ring from the rear axle casing.
2 With the handbrake released. remove the screw s and w ithdraw the 10 To remove the bearing and backplate. refer to Chapter 1O.
brake drum 11 Refitting is a reversal of removal, but note the 'following additional
3 Disconnect the handbrake cable from the shoe operating lever. points:
4 Remove the shoe steady springs. then using a screwdriver. lever the
leading shoe from the lower anchor and unhook the lower return (a) Clean the bearing seating inside the rear axle casing. Renew
spring. With the shoe to one side. use a small drift to drive the the 0-ring. and dip it in rear axle oil before locating it in the
handbrake outer cable from the backplate. mouth of the casing
5 Unclip the rigid brake hydraulic pipe from the rear axle casing. (b) Tighten all nuts to the specified torque
6 Fit a brake hose clamp to the flexible hose for the rear brakes. (c) On comp/et/on. check and lf necessary top up the final drive
Alternatively. it may be possible to restrict subsequent loss of fluid by oll level
tightening the brake fluid reservoir fi ller cap onto a thin piece of ( d) Bleed the rear brake hydraulic circuit with reference to Chapter
polythene. 9.
7.8 Backplate/ bearing retainer nuts (arrowed) on Estate models Fig . 8.14 0 - ring (1) located in the rear axle casi ng (2 ) on
Estate models (Sec 7 )

170 Chapter 8 Rear axle
8 Fault diagnosis - rear u le
Symptom Reason (s)
Noise from rear axle Insufficient lubricant

Worn crownwheel and pinion
Worn differential bearings
'Clonk' on acceleration and deceleration Worn half shaft splines (Estate models)
Worn driveshaft joints (Saloon models)
l ·\

Cha pter 9 Braking system

Contents
Brake disc - inspection. removal and refitung ......... . ............. ... 8 Handbrake warning hght switch removal and ref1111ng .............. 22
Brake pedal - removal and refitting ................................................... 20 Hydraulic system - bleeding .............................................................. 14
Disc caliper (front) - removal, overhaul and refitting ...................... 6 Mas1er c ylinder - removal, overhaul and refitting ............................ 11
Disc caliper (rear) - removal. overhaul and refitting ....................... 7 Rear brake compensa1or - removal, refitting and ad1us1ment ........ 12
D15C pads ( front) - inspection and renewal ......... .... ... ................. 3 Rear brake drum - inspection and renovation .... ... ............ ......... 10
Oise pads (rear) - inspection and renewal ............... ....................... 4 Rear brake shoes - inspect ion and renewal ....... ...... ...................... 5
Fault d1agnos1s - braking system .... ... ... ......................................... 24 Rear wheel cylinder - removal, overhaul and ref11ting .................... 9
flexible and rigid hydraulic lines - 1nspect1on and renewal ........... 13 Routine main1enance ....................... .... ............................................... 2
General description .............................................................................. 1 Stop-lamp switch - removal and refitting ........................................ 21
Handbrake - adjustment ...................................................................... 18 Vacuum servo air filter - renewal ..................................................... 16
Handbrake cables - renewal ................. ... ............... _..................... 19 Vacuum servo un11 - description and 1esti ng ................................... 15
Handbrako lever - removal and refitting 23 Vacuum servo unit removal and ref1111ng ................................ .... 17
Specifications
Type Fron1 disc brakes, rear drum or disc brakes, servo ass1s1ance.
Load-sens111ve rear brake compensator. Cable- opera1ed handbrake on
rear wheels
Brake fluid type/ specification Hydraulic fluid 10 SAE J1703 or DOT 3 (Duckhams Universal Brake
and Clutch Fluid)
Oise brakes
Diameter
Front/ rear ............................................... ~ ................................................ 273 mm (10.75 in)
DISC thickness (new).
Front. non -ventilated ... ·•······~·· N .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12.75 mm (0.502 1n)
Front. venulated ........ ... .......... ....... .... .............................................. 20.0 mm (0 788 in)
Rear .................................................................................................... 12.0 mm (0.473 in)
Otsc thickness (minimum after machining)
Front non -ven1ilated ........................................................................ 11 .26 mm (0.443 1n)
From 11en1ila1ed ..... ... ....................................... -........ . .................. .. 18.5 mm (0 729 in)
Rear ................................................................................................ 11 .0 mm (0.433 in)
Oise 1hickness (minimum before renewal)
Front non·11en11la1ed ...... ......... .... .. .......... .... ... ..................... 10.76 mm (0.424 in)
Front, ven1ila1ed ..................................................................................... 18.0 mm (0.709 In)
Rear .......................................................................................... I 0.5 mm (0.414 in)
Oise 1h1ckntsS veria1ion (ma1umum) ...................................................... 0.02 mm (0.0008 tn)
Oise run -out (ma)(imum)·
On vehicle ................ ... .. .............................................................. 0.07 mm (0.Qq3 in)
On machining hub ... .......................................................................... 0.05 mm (0.002 in)
Oise pad minimum lining 1hlckness .............. ........... ............................. .. 2.5 mm (0.099 In)

172 Chapter 9 Braking system
Drum brakes
Orurr inter 11 11ameter (ntlw ) 255 mm (10.047 m)
Orum internal d1amewr (maximum alter machining) •• 256 mm (10.086 m)
Drum out of round (ma~1mum)
On veh1tlf! 010 mm (0004 m)
On machining hub 0.07 mm (0 003 1n)
MoK1m1m1 drum mrcrnul d1ometer vanauon. sidt: to ·Side 0 20 mm (0 008 m)
Shoo mm1m11111 11111110 thickness 1 0 mm (004 1n)
Vacuum servo unit

Make Iyo OBA or Teves
Diameter 229 mm (90 m)
Torque wrench settings Nm lbf f l

Front r~<i• d ~ I .ub bol ts 50 37
Front caliper moun11n11 bolts
Teves (with loc1<1ng pl.:ite) 85 63
OBA 130 96
Genera l description
The b1akino sy~ti.'11 1s of hydrauhc typo w i th discs at the front and

ther drums or d1~r.~ ;it the rear The handbrake 1s cable -operated on
the rear wh!)els
The hydraul11.: 11cu11 consists of two independent sections. split
front and 1ear so that 1n the event of the failure of one section. the
rema1111no se~t1on is 1111 funcuonal
A load·senslt•ve rear brake compensator reduces the hydraulic
prossu1 to the red1 brakes rn order to prevent 1ear wheel lock up
und<11 heavv apphca11on of the brake pedal w11h the vehicle lightly
lo oded
All moctels are fi ned with a vacuum servo unit
Carry out the followmg procedures at the intervals given in Rou ti ne

ma ntenanc.:: at "'~ from of this manual
Check the brake flt11d level

1 W11h the 11.:h1cle on level gound. check that the level of brake fluid
2 2 Topping -up the brake fluid level
1n 1he reser11011 on the 111.1ster cylinder 1s at or near the maximum mark
No10 1ha1 the level writ drop shghtly as the disc pad and brake shoe
l1mn!}s wear
3 Oise p ads ( fron t ) - inspec t ion an d renewal
2 If nece5~ar\i , 1op up 1he level w1ih the spec1f1ed brake fluid (photo)
II frequent topping up is required the complete hydraulic c11c u11
should be checked for leaks Apply the handbrake. then iack up the front of the car and support
on axle stands Remove the front whetils
Check the hydrau/Jc ClfCUll for leaks and cond1t10n 2 Looking through the aperture at the fr ont of each cahper check the
3 Jack up t~; tron1 ,md rear of 1he 11eh1clo. and support on axle thickness of hnrng on each dr.sc pad To do 1h1s turn the steering on full
stands Remove the front and rear wheels lock 10 1he side being checked
4 Check 1he hydraulic pipes and hoses with reference to Secuon 13. 3 1f the hn1ng on any disc pad is worn below the spec1fted m1n1mum
5 Exarmn.i th~ mas1er cyhnder. rear brake componsa1or. disc cahpers, (1nd1cated 1f the groove 1n the pad hos disappeared). 11 will be
wheel cylinder~ and vacuum servo unit for damago. or leakage of necessary to renew all four front disc pnds as follows.
brake fluid
6 On compleuon refit the wheels and lower the vehicle to the DBA Caliper
ground 4 Disconnect the wear warning ltgh1 wire at the connector
5 Extract the small clip and pull out the upper sltdrng key using pliers
Check operation of the handbrake 6 Using a lever against the front suspension strut. push the caliper
7 Full\/ applv the handbrake. and check 1hat the rear wheels are outwards. then withdraw the outer pad alter lilting 11 slightly to release
locked 1he lower edge of the backing plate
8 Chod 1ha1 the handbrake 1s fully applied between 4 and 7 notches 7 Push back the caliper. and withdraw the inner pad
on vuh1cles with rear drum brakes. and between 7 and 13 notches on 8 Clean aw ay all dust and dirt from the caliper. Do not inhale the
11eh1cles wrlh rear disc brakes If not. adiust the handbrake as described dust. as it may be Injurious to health Check for brake fluid leakage
•n Section 18 around the piston dus1 seal and If evident, overhaul the cahper as
descnbed in Section 6 Check the brake disc for w ear. and also check
Renew the /Jydraullc brake flwd that the rubber bellows on the cylinder sl1d1ng rods are 1n good
9 Unscrew 1he 1 111 •r cap from the brake fluid reservoir and use a condrtron
•vrmge 10 rcmovv thv fl uid from both compartments 9 Clean the backs of the new disc pads and apply a 1t11le anu -squeal
10 F1ll 1he reservoir with fresh hydrauhc fluid and proceed to bleed the brake grease Also apply the grease to the lower pad locating hp on the
sys1em 11s de~c:r1bt!d in Section 14 Al least 5 or 6 depressions of the caliper
t>rako pedal will b11 necessary to clea1 the old fluid from each cylinder 1O Using a block of wood, press the caliper piston fully rn 10 11s
Also hlend 1h1 r.lu rc:h hycfraul1c crrcu11 as descrtbed In Chapter 6 cylinder I

0
Fig. 9.2 Removing the OBA type front disc
pads (Sec 3)
Fig. 9.1 OBA type front disc pads (Sec 3) 1 Warnmg light wire
2 Clip
1 Disc pads 3 Clip 3 Sltding key
2 Anti-rattle sprmgs 4 Slidmg key 4 Pads
5 Suspension strut
6 Caliper
11 With the caliper pushed Inwards, insert the inner pad (the one wi th
Ille pad wear wire) . then push the caliper outwards and insert the outer
pad
12 Check that the pads are correctly located on the caliper lip, then tap
1n the upper sliding key 10 Jock them Fit the sliding key clip.
13 Recon nect the pad wear warn ing light wire.
Teves caliper
14 Disconnect the wear warning light w ire at the con nector (photo) .
15 Eictract the spring clip from the holes in the ends of the pad pins
(photo)
16 Remove the pad pins and the anti-rattle spring (photos)
17 Using a lever against 1he front suspension stru t, push 1he caliper
slightly outwards, then push the caliper inwards again. W ithdraw the
nner pad (photo).
18 Push the caliper fully outwards Disengage the outer pad from the
boss, and wuhdraw it from the caliper (photos)
19 Clean and check the caliper and disc as described 1n paragraph 8.
Check that the caliper piston cut-out 1s posi11oned as shown in Fig.
9.3 A piece of ca rd cut to the 20· angle may be used Instead of the Fig. 9.3 Diagram showing correct position of Teves
special Peugeot tool (photo) If necessary, use internal expanding front brake caliper piston cut- out (Sec 3)
circl1p pliers to repos111on the piston do not use ordinary pliers on the
outer surface of the piston. 1 Caliper 2 Setting tool
Arrow indicates f orward rotation of disc
3.14 D1sconneo1tng the pad wear warning 3.15 Pad pin reta1n1ng spri ng clip (arrow ed) 3.16A Removing the upper pad pin ...
light wire JI

20 Clean the backs of the new disc pads. and apply a ltttle anu -squeal the bracket(s) from the caliper, and pull out the pad retaining fork.
brake grease 6 Usrng pliers. withdraw both dtScs pads.
21 Using a block or wood, press the caliper piston fully into hs 7 Using a screwdriver or similar tool in the cen tral groove. turn the
cylinder caliper piston clockwise 1/sth of a turn (45•) . With a block of wood.
22 With lhe caliper pushed outwards. rnsert the outer pad. and engage push the piston fully into its cyltnder. then turn the piston 1/sth of a
•tS backing plate w ith the boss. turn (45•) anti -clockwise.
23 Push the caliper rnwards and Insert the Inner pad. 8 Clean away all dust and dirt from the caliper Do not inhale the
24 Insert one pad pin through the ca liper and pads. then hold the dust, as it may be Injurious to health Also clean the handbrake
anti -rattle spring 1n position (photo) and rnsert the second pad pm. mechanism on the inside of the caliper. Check for brake flu id leakage
25 Fit the spring cltp to the pad pins. around the piston dust seal and, ir evident, overhoul the caliper as
3 168 lower pad pin, and anti -rattle spring 3. 17 Removing the inner pad 3.1 SA Removing the outer pad. Note the
(arrow ed) cut· Out (arrowed) ..•
3.188 . which engages with the boss 3.19 Using a piece of card to check the 3.24 Fitting the anti-rattle spring
(arrowed) on the ca liper position of the caliper piston cut- out
26 Feed the wear warnrng ltght wire under the spring clip loop, and
press 11 in to the con nector
OBA and Teves calipers

27 Repeat the operauons on the opposite disc caliper.
28 Depress the footbrake pedal several umes, in order to pos1tton the 14
pads against the discs 5,
29 Check. and 1f necessary top up, the brake fluid level in the master
cylinder reservoir 6
30 Refit the front wheels and lower the car to the ground.
. ...
.-r,;
4 Disc pads (rear) - inspection and renewa l
Chock, the front wheels, then jack up the rear of the car and support
on axle stands. Remove both rear wheels and release the handbrake.
2 Check the thickness of lining on each disc pad, and if worn below
the spec1f1ed minimum (indicated if the groove in the pad has
disappeared). renew all four rear disc pads as follows.
3 Disconnect the wear warning light wire at the connector. Fig. 9.4 Rear disc pad and ca liper components (Sec 4)
4 On late models, eXlract the small spring clip from the pad retaining
fork. Unchp and remove the thrust spring plate. Unhook the ends of the 1 Cyllnder 5 Thrust spring plate
damper spring Pull out the pad retaining fork. and remove th e damper 2 Specer rod 6 Damper spring
spring from tho coltper 3 Celiper frame 7 Spring clip
5 On early models. unchp and remove the thrust sprin11 plate. Unbolt 4 Pad 1etaining fork
Il

Chapter 9 Braki ng system 175
desoribed in Section 7 Examine the brake disc for scoring and, if

excessive. renew the disc. Check that rt is possible to slide the calip er 1n
and out by hand.
9 It IS 1ecommended that the pad retaining fork and spring are
renewed every time the pads are renewed.
10 Clean the backs of the new disc pads, and apply a little anti- squeal
brake grease. Also apply the grease to the pad contact points on the
caliper and pad retaining fork.
11 Push the caliper fully outwards. then insert the disc pads.
12 Reht the retaining fork components in reverse order. On later
models. make sure that the ends of the damper spring engage the slots
in the caliper.
13 Reconnect the wear w arning light wire.
14 Repeat the operations on the opposite d isc caliper.
15 Depress the footbrake pedal several tin;ies in order to position the
pads against the discs. Check the handbrake travel, and tf necessary
ad1ust rt as described in Section 18.
16 Check. and if necessary top up, the brake fluid level in the master
cylinder reservoir
5 Rear brake shoes - Inspection and renewal

Fig . 9.6 Using a screwdr iver to retract the rear brake shoes
1 Chock the front wheels, then jack up the rear of the car and support (Sec 6)
on axle stands. Release the handbrake.
2 The lining thickness on the leading brake shoes may be checked 1 Plug 2 Handbrake operating lever
without removing the brake drums. Prise out the plugs from the top
front of the backplates. and use a torch to check the lining thickness
(photo). If it is at, or near, the specified minimum. remove the drums
and make a more thorough Inspection.
3 Remove the rear wheels, then unscrew the cross-head screws and
withdraw the brake drums. If the screws are tight, use an impact driver
to remove them (photos). If the drum is tight on the brake shoes, prise
out the plug from the lower rear of the backplate, and use a screwdriver
to press tn the handbrake operatmg lever. This will allow the lever to
retract more. If the drum is still tight, back off the adjusting nuts on the
handb1eke cables.
4 On models where the lower shoe return spring is located behind
tile anchor plate. use a screwdriver to unhook and remove the sprmg
(photo).
5 On models fined with early OBA shoes, refer to Fig. 9.7 and check
that the clearance ·a· is between 0.9 and 1.1 mm (0.035 and 0.043 in) .
II not determine wh ich components are worn, and renew them.
6 Unhook the upper shoe return sprmg (photo) .
Glfling brakes
7 Move the shoes apart as far as possible, and remove the automatic
adjusting arm and spring.
8 Remove the spacer cup from the leadmg shoe.
9 Remove the au tomatic adjusting strut from the shoes.
10 Usmg pliers. depress and twist the steady spring cups through 90' .
Remove the springs.
11 Remove the leading shoe. Remove the trailing shoe, and
disconnect the handbrake cable. Fl g . 9.6 Using a screwdriver to unhook t he rear brake shoe
l ower return spring (Sec 6)
Early DBA brakes
12 Remove the steady spring from the leading sh oe. To do this, use a
rpewd1111er or shon length of dowel rod to unhook the bottom of the
spnng from the anchor plate.
13 Move the automatic ad1ustmg lever towards the centre of the hub,
then twist the leading shoe to release the ad1usting lever from the link.
Remove the leading shoe.
14 Disconnect the handbrake cable from its lever.
15 Remove Ille steady spring. and withdraw the trai ling shoe together
with the hnk.
16 Note how the levers and link are fitted to the brake shoes, then
prise off the reta ining cli ps and remove them
later OBA brakes

17 Remove the shoe steady springs, using a screwdriver or short
length of dowel rod to unhook the springs from the anchor plates
(photo).
18 Remove the leading shoe. and disconnect the lower return spring,
19 D1S<:onnect the handbrake cable from its lever. then remove the Fig. 9 .7 Checking the c learance 'a' between the l ink (1 ) and
tra1hng shoe. together w ith the link. le~'Y' (2) on early OBA rear brake shoes (Sec 6)

175----~----~--------~~------------~~----~------------------------,
Fig. 9.8 Girling rear brake assembly (Sec 5)
1 A utomatic adjuster 2 Steady springs
Fig. 9.9 Early OBA rear brake assembly

(Sec 6)
1 Automatic adjuster 2 Steady springs Fig. 9.10 Components of the later OBA rear b rake assembl y
( Sec 6)
1 leading shoe 4 Control lever

2 Strut 5 Automatic adjuster
3 Trailing shoe 6 Handbrake operating lever

Ch apter 9 Bra k ing system 177
5 2 Removing the plug from the rear 5.3A Using an Impact driver to remove the 5.3B Removing the brake drum
backplate to check the lining wear brake drum screws
S 1C To retract the hr~ke shoes. pnse out 5.30 ... and msen a screwdriver (arrowed) 5.4 Lower shoe return spring (later OBA
this plug ... against the handbrake operaung lever brakes)
5.6 Upper shoe return spring (later OBA 5.17 Shoe steady spring - arrowed (later
brakes) OBA brakes)
20 Note how the levers and link are fitted to the brake shoes, then when turned clockwise. but locks firmly when turned anu-clockwise.
pr1se off the retaining clips and remove them. Disengage the adjuster Apply a little brake grease to the threads, then ful ly screw the bolt into
lover spring the nut, and fit the plastic tube over the exposed thread. The tube is
17 .0 mm (0.67 in) long on Saloon models. and 24.0 mm (0.95 in) long
on Estate models.
All brakes 24 Engage the adjuster arm In the nut groove and In the lever tab.
21 Brush the dust and din from the shoes. drum and backplate Do not Reconnect the spring.
mhale •t. as It may be injurious to health. Check for brake fluid leakage 26 Fit the adiuster lever to the new leading shoe, using new retaining
around the wheel cylinder dust seals and. 1f evident, overhaul the ell ps. Note that on some early Estate models, the lever was fitted to the
wheel cylinder as described on Section 9. Examine the brake drum for inner face of the shoe. This arrangement must be changed. by
,;coring and. if excessive, renew the drum. or have it reground as swapping the adjusters (or leading shoe assemblies) side for side
descnbed 1n Section 10. between the left-hand and right-hand rear brakes.
21 Smear a l111le brake grease onto the pressure pads on the backplate 26 Fit the handbrake lever to the new trailing shoe, locate the hnk. and
lock by sliding th e spring plate through the cut-out. and snapping the
later OBA brakes tab in the rQle provided.
23 Unscrew the special bolt from the self-adjusting lever. and 27 Locate flie trailing shoe on the backplate, engage the handbrake
thoroughly clean the nut and bolt Check that the nut gently locks cable. then rhfit the steady spring.

Fig 9 .11 Self- adjusting lever o n the lat er OBA rear brake
assembl y ( Sec 5)
1 Special bolt 3 Control /ever

2 Rewrn spring 4 Pivot and stop on fever
Fig . 9.1 2 Handbrake operating lever f itted t o t he trail ing
shoe - later OBA assembl y (S ec 5)
28 Except on later Estate models. locate the leading shoe and refit the
steady spring Fit the lower return spring, using a screwdriver to 1 Lever 3 Spring plate
engage the hole in the shoe. 2 Strut a Location hole
29 On later Es tate models. engage the lower return spring before
pos11lon1ng the leading shoe on the backplate. Refit the steady spring. 36 Locate th e trailing shoe on the backplate, and reconnect the
handbrake cable. Refit the steady spring.
Early DBA brakes 37 Reconnect the lower return spring. using a screwd11ver to lever 11.
30 Fit the levers and link to the new shoes, using new retaining clips. 38 Set the nut on the automatic adjusting strut so that there is 5.0 mm
31 locate tlie trailing shoe on the backplate, reconnect the tiandbreke (0.2 m) of thread on the fork side of the nut. Fit the strut to the shoes.
cable. then refit the steady spring. Note that the nut on the right-hand brake has a left-hand thread, and
32 Locate the lead ing shoe on th e backplate. Move the automatic vice- veru.
ad1ustmg lever tow ards the hub, then twist the shoe to engage 11 w ltli 39 Fit the spacer cup to the leading shoe. with Its dome outside.
the link. lever down th e pawl. and set the ad1usting lever at the 40 Engage the automatic adjusting arm on the strut fork, locate it on
beginning of the serrations. the spacer cup. then refit the spring behind the shoe web.
33 Refit tlie steady spring to the leading shoe
34 Flt the lower return spnng, using a screwdriver to engage the hole All brakes
1n the shoe 41 Refit the upper shoe return spring (photos).
42 Refit the brake drums. followed by the rear wheels.
Glfling brakes 43 Depress the footbra ke pedal several times in order to opera te the
35 locate the leading shoe on the backplate. and refi t the steady automatic adjuster.
spring Engage the lower return spring w ith the hole in the leading 44 Adjust the handbrake as described In Section 18. and lower the car
shoe. to the ground.
5.41 A La ter OBA sell -adjusting mechanism. with fi tted upper shoe 5.41 B View of lat~( OBA rear brake shoes
return sp11ng

Chapter 9 Braki n g system 179
6 Oise ca l i p er ( f ro nt) - removal. overh aul an d refi t t i ng
Remove the fron t disc pads as described in Secuon 3

2 Fit a brake hose clamp to the flexible hose connected to the caliper
Alterna1111ely. it may be possible to ughten the brake fluid reservoir filler
cap onto a th in piece of polythene sheet. 1n order to reduce the loss of
fluid when disconnecting the cahper
3 Loosen only the flexible hose union connection at the caliper.
4 Where applicable. bend back the lockwasher Unscrew the two
mounting bolts. withdraw the caliper from the disc. then unscrew the
caliper from the flexible hose. Plug the end of the hose.
5 Clean the exterior of the caliper
6 On the OBA type. unbolt the caliper frame from the cylinder.
7 Pnse the dus t cover and nng from the end of the cylinder.
8 Withdraw the piston from the cylinder If necessary, use air pressure
from a foot pump in the fluid inlet to force the piston out.
9 Prise the seal from Inside the cylinder. taking care not to damage
the cylinder wall
10 On the OBA type, remove the guides and rubber dust covers from
the housing. A stop plate (Fig. 9.15) 1s fitted to early models, and a
lockplate ( F19. 9 16) is fitted to later models.
11 On the Teves type. ext ract the damper spring from the cylinder.
12 Clean all the components. using methylated sp1nt or clean brake
fluid. then examine them for wear and damage. Check the piston and
fig 9.13 Initial setting on Gir lin g au t omat ic adj ust ing strut cylinder surfaces for scoring. excessive wear. and corrosion. and 1f
(Sec 5) evident. renew the complete caliper assembly. II the components are in
good cond111on. obtain a repair kit of rubber seals.
1 Ad1us1mg nut and fork 3 Return spflng 13 Dip the new seal in fresh brake fluid. then locate 1t 1n the cylinder
2 Pushro d a 5.0 mm (0.2 in) groove. using the l ingers only to manipulate It
14 Di p the piston in brake fluid. and insert i t in the cylinder. twisting it
as necessary to locate 11 in the seal.
/..{ .12!)42
Fig. 9.14 Teves fro nt d isc c alip er ( Sec 6 )
1 Mounting boll 3 Lockwasher 5 PJston seal 7 Dust cover

2 Bleed SCltlW 4 Ca/Jpet llSSQmbly 6 Piston 8 Rrng

~~
./
,/
/
/_·~~---....-
~
Fig 9.15 OBA fro nt d isc caliper and stop plate {Sec 6 ) Fig. 9.16 OBA front disc c aliper and lockplate (Sec 6 )
15 Fn the dust cover and ring over the end of the piston and cylinder. fluid. then examine them for wear and damage. Check the piston and
16 Lubricate the sliding guides with brake grease. cylinder surfaces for scoring. excessive wear. and corrosion, and if
1 7 On the Teves type. refit the damper spring eviden t, renew the complete caliper assembly. If the components are in
18 On the OBA type. refit the guides. rubber dust covers and plate good condition. obtain a repair kit of rubber seals.
Refit the caliper frame and tighten the bolts. 14 Dip the new seals in fresh brake fluid. then locale them in the
19 To refit the caliper. first screw 11 onto the flexible hose. and locate It cylinder grooves. using the fingers only to manipulate them.
over the brake disc so that the hose 1s not twisted 15 Dip the pistons in brake fluid. and insert them 1n the cylinder.
20 Clean the mounting bolt threads, and apply locking fluid where a Before engaging th e pistons, make sure that the ratchet teeth are
lockwashe1 is not fitted aligned with the piston grooves. When completely entered, turn the
21 Insert the bolt5. and tighten to the specified torque. Where fined . direct piston ' lath of a turn (45' ) an ti-clockwise to engage the ratchet
bend the lockwasher onto the bolt head tlats. teeth
22 Tighten the flexible hose union on the caliper. Check that the hose 16 Frt the dust covers and rings.
Is clear of the strut and surrounding components and, if necessary, 17 Lubricate the grooves in the cylinder w l1h brake grease.
loosen the ng1d pipe union on the body bracket. reposition the hose. 18 Locate the plastic spacer in the frame. then fit the cylinder and
and ret1ghten the union. i nsen the spacer rod.
23 Remove the brake hose clamp or polythene sheet. 19 To refit the caliper. first locate it over the brake disc.
24 Ref11 the disc pads, as described 1n Section 3. 20 Clean the moun ting bolt th reads, and apply a llllle locking fluid,
25 Bleed the hydraulic system as described in Section 14. Insert the bolts, and tighten them securely.
21 Reconnect the handbrake cable to the bracket and lever
22 Tighten the hydraulic line union.
23 Remove the brake hose clamp or polythene sheeL
7 Disc caliper (rear) - removal . overhaul and refitting 24 Refit the disc pads as described in Section 4
25 Bleed the hydraulic system as described in Section 14.
26 Check. and If necessary adiust, the handbrake as described in
Remove the rear disc pads as described in Section 4 . Section 18.
2 F11 a brake hose clamp to the tlexible hose leading to the caliper.
Alternauvely. It may be possible to tighten the brake fluid reservoir filler
cap onto a thin piece of polythene sheet, in order to reduce the loss of
8 Brake disc - Inspection. removal and refitting
fluid when d1sconnecung the caliper.
3 Unscrew the hydraulic line union connection at the caliper
4 With the handbrake released. apply the caliper lever and disconnect Remove the disc pads as descnbed in Sec11on 3 or 4, as
the cable Withdraw the outer cable from the bracket. appropriate.
5 Unscrew the socket-headed mounting bolts. and withdraw the 2 Using a dial gauge or feelers and a fixed block, check that the disc
caliper from the disc. then plug the hydraulic line to prevent loss of run-out is w ithin the specified limit. Do not confuse wheel bearing
fluid endfloat with disc wear.
6 Clean tht> exterior of the caliper. 3 Check the condition of the disc for scoring. Light scoring is normal,
7 Turn the piston I /sth of a turn ( 45') clockwise. then press 1t fully and may be removed by fitting genuine Peugeot disc pads, which have
inwards a thin coating of abrasive material for cleaning the disc during Initial
8 Extract the spacer rod. and remove the cylinder from the frame. applications of the brake. If scoring is excessive, either renew the disc
Note that early spacer rods are round in section. whereas later rods are or have it reground w nhin limits by an engineering works.
oval they are therefore not interchangeable. 4 To remove a disc. first remove the hub as described in Chapter 10.
9 Recover the plastic spacer from the frame. 5 M ark the disc and hub In relation to each other.
10 P11se the dust covers and nngs from the ends of the cylinder. 6 Mount the hub in a soft-iawed vice. unscrew the bolts and separa te
11 Withdraw 1he pistons from the cylinder. If neoessary, use air the disc.
pressure from a foot pump In the fluid inlet to force the pistons out. 7 Refitting is a · reversal of removal, but make sure that the
12 Pose the seals from inside the cyl inder, taking care not to damage disc-to -hub mating·surfaces are clean, and apply a little locking fluid to
the cyllnde1 wall the threads of the bolts. before inserting and tightening them to the
13 Clean ell the components, using methylated spmt or clean brake specified t orque

-----------------------------------------------------------------------------1s1
Fig. 9.17 Rear disc c aliper c omponents (Sec 7)
1 Spacer 1od (late) 5 Bleed scre w 9 Dust cover 13 Piston seal

2 Spoce1 1od (early) 6 Cahper spring kit 10 Handbrake 1eturn spring 14 Dust cover
3 Moun11t1g bolt 7 Plastic spacer 11 Piston assembl y 15 Ring
4 Caliper assembly 8 Ring 12 Piston seal

182 Chapter 9 Braki ng system
Fig. 9.18 Rear disc c aliper handbrake self -adjust ing

mechanism (Sec 7)
A
A Direct piston positioned for retrection
8 Direct piston turned 1/sth of a turn (48) to engage
ra tchet teeth
H.12.J44
2 If the drums are grooved. owing to failure to renew worn hn1ngs. or

9 Rear w heel c y linder removal. overhau l and refitting alte< a very high mileage has been covered, then 11 may be possible to
regrind them, providing the maximum internal diameter 1s not
1 Chock the front wheels. then 1ack up the rear of the car and support exceeded
on axle stands Release the handbrake 3 Even 1f only one drum 1s 1n need of grinding, both drums must be
2 Remove the rear whee1and brake drum reground to the same size 1n order to maintain even braking
3 Note the locauon of the brake shoe upper return spnng then characteristics
unhook and remove 11 4 The drums should be checked for excessive out-of -round w ear.
4 Pull the handbrake lever on the tra1l1ng shoe fully forwards, so that which may cause brake judder. If outside the specified hm1ts, either
the upper ends of the shoes are clear of the wheel cyhnder Wedge the renew or regrind the drums
lever in this pos1t1on w 11h a block of wood
5 Fu a brake hose clamp to the flexible hose suppl ying the wheel
being worked on Alternatively, ughten the brake fl uid reservoir cap 11 M aster cylinder - remova l. overhaul and refitting
onto a thin piece of polythene sheet
6 Unscrew the hydraulic pipe union nut from the rear of the w heel
Unscrew the filler cap lrom the brake fluid reservoir ( photo). and
cyltnder
draw out the flu id using a syringe.
7 Unscrew the two mounting bolts, and withdraw the wheel cylinder
2 Disconnect the clutch master cylinder supply hose from the
from the backplate Take care not to spill any brake fluid on the brake
reservoir
shoe linings
3 P11se the reservoir from the brake master cylinder. and remove the
8 Clean the extenor of the wheel cylinder.
seals.
9 Pflse the rubber dust covers from the wheel cylinder body. 4 Unscrew the union nuts securing the rigid brake lines to the master
10 Extract the pistons. seals, and return spring, keeping each
cylinder, and pull out the Imes Cap the pipe ends to prevent loss of
component 1den11f1ed for locatton. On the Girling type. pnse the seals
flu id.
from the piston grooves On the OBA type, the seals are loose. and the
5 Unscrew the mounting nuts and withdraw the maS1er cylinder from
return spring may have end seatings
the servo unit
11 Check the surfaces of the cylinder bore and pistons for scoring and
6 Clean the extenor of the master cylinder
corrosion and 1f evident. renew the complete wheel cyl inder. If the 7 Pnse the c1rclip from the mouth of the cylinder, and remove the
components are 1n good cond111on, d iscard the seals and obtain a
washer Unscrew the stop pin
repair ku. which w ill contain all the necessary renewable components. 8 Remove the pnmary and secondary piston components, noung
12 Clean the p1S1ons and cylinder w ith methylated spirit or clean brake
their locattons If necessary. tap the cylinder on a block of wood.
fluid then dip each component 1n fresh brake fluid and reassemble in
9 Clean all the components in methylated spirit. Check the surfaces
the reverse order to d1smanthng, making sure that the lips of the seals
of the cylinder bore and pistons for scoring and corrosion, and. if
face into the cyhnder When completed, w ipe clean the outer surfaces evident, renew the complete maSler cyhnder. If the components are 1n
13 Clean the backplate and refit the wheel cyhnder, using a reversal of
good cond111on. remove and discard the seals and obtain a repair ki t,
the removal procedure
which will con tain ell the necessary renewable components. Note that
14 Make sure that the brake hose clamp or polythene sheet 1s
genuine Peugeot kits include the pistons In add111on to the seals.
removed then bleed the hydraulic system as described 1n Section 14,
10 Dip the new seals In fresh brake fluid, and fi t them to the pistons,
using the fingers only to manipulate them.
11 Reassemble the master cylinder 1n the reverse order to dismantling.
10 Rear brske d r um - inspection and renovation and make sure that the circllp Is fully engaged w ith the groove in the
mouth of the cylinder.
1 Whenever tho brake drums ore removed , inspect them for w ear and 1 2 Refitting is a reversal of removal. but on com pletion, bleed the
damage complete hydrauljq system as described in Section 14.

,--------------------------------------------------------------------183
Fi g . 9.19 Girling rear wheel cylinder c omponen t s ( Sec 9)
1 Dust covers 4 Return spflng

2 Pistons 5 Bleed screw
3 Seals 6 Wheel cvlinder bortv
___,
.
f
Fig. 9.20 B ra ke master cylinder c omponents (Sec 11)
1 M ounting nut
2 M aster cylinder bodv
3 Stop pin washer
4 Spring
5 Spnng seat
6 Seal
7 Secondary piston
8 Seal
9 Seal
10 SpNng
11 Spring seat
12 Seal
13 Primary piston
14 Seal
15 Washor
16 Circlip

12 Rear brake compensator - removal. refitting and

adjus tment
N ote: A twm brake hydroul1c pressure gauge will be requlfed to od1ust

the compensa101 on Estate models
1 Chock 1he front wheels. 1hen 1ack up 1he rea1 of the vehicle and
suppon on axle stands
2 The compensator is located on 1he rear underbody. inboard from
1he left- hand rear wheel (photos) F11s1 unhook the actuaung spting
J Remove the brake fluid reservoir hlle1 cap and lighten 11 down onto
a thin piece of polythene sheet. m order to reduce the loss of fluid
when d1sconnecung the hydraulic pipes
4 Unscrew the union nuts and disconnect the ng1d hydraulic pipes
from the compensator. Plug the ends of the pipes
5 Unscrew the mounting bolts or nu1s. and withdraw the
compensator.
6 Ref11tmg 1s a reversal of removal. but bleed the hydraulic system as
described m Section 14, and adjust the compensator as follows
7 With the vehicle a1 kerb weig ht (including the spare wheel and a
full tank of fuel) pos1t1on it over an 1nspec11on pit or on ramps
Saloon models
8 Attach a 5 kg (11 lb) weight to the compensator lever on the notch
beneath the sprmg
Fi g . 9.21 Exploded view o f the rear

brake compe nsat or on Saloon models
( Sec 12)
1 Bush
2 Cap
~
3 Bush
4 Compensator body
5 Cup
6 Clamp
7 Bolt
8 Actuatmg spring
9 Rockmg lever
® 10
11
Bolt
Pull off sprmg
@ 12 Cltp
13 Arm
® 'l 12~4f) 14
15
Ad111stmont screw
Clevis pin
ll

Fig. 9.22 Rear brake compensator o n Est ate models ( Sec 12)
1 Mountmg nut
2 Body
3 Control sprmg
4 Pivot wheel
5 Bolt
9 Fully push 111 the compensator piston.

10 Select a 0.8 mm (0.032 1n) feeler blade for disc brake models,
and a 1 3 to 1.8 mm (0.051 lo 0.071 1n) feeler blade for drum brake
models
11 Loosen the locknut, and using a screwdriver, ad1ust the screw so
that 1he correct feeler blade 1s a firm sl1d1ng fit between the piston and
lever Tighten the locknut. If the fuel tank is empty, increase the feeler
blade thickness by 0.2 mm {0.008 In).
12 Remove the weight
Estate models
13 A twin brake hydraulic p1essure gauge Is required to ad1ust the
compensator on Estate models If this is not available. the vehicle
should be taken to a Peugeot garage for the adjustment.
111 Connect one pressure gauge to the bleed screw port on one front
caliper then connect the remaining gauge to the bleed screw port on
one uwr wheel cylinder or caliper. as applicable
15 Bleed the pressure gauge, then have an assistant apply the brake
pedal to obtain a pressure of 60 bar (870 lbf/ in•) in the fron t circuit.
The pressure in the rear circuit should be 43 :I. 1 bar (623 ± 15 lbf/in')
wllh an empty 1uel tank, or 45 :I. 1 bar (652 ± 15 lbf/in') with a fu ll
fuel tank
16 II ad1ustment Is necessary. repos1uon the spring fixed point away
from the compensa tor to increase the pressure, or towards the t 2.2A Rear brake compensator (Saloon model)
compensator to decrease the pressure.
t 7 W11h the brake pedal released. refit the bleed screws. and if
necessary bleed the relevant calipers
13 Flexible and rig id h ydraulic lines - inspec tion and

renewal
1 Examtne all the unions for signs of leakage. Check the flexible
hoses for leaks, fraying and chafing
2 The ng1d brake pipes must be examined carefully and methodicall y.
Clean them wtlh a wire brush. and check for signs of dents, corrosion
or 01her damage. Where 1he depth of corrosion is significant. the pipes
should be renewed This 1s mos1 likely in those areas underneath the
vehicle body where the pipes are exposed and unprotected.
3 II ilny sectlon of pipe or hose is to be removed, first unscrew the
brake fluid reservoir rlller cap. then place a piece of polythene sheeung
over the reservoir neck and secure using a strong elastic band. This will
mm1m1se brake fluid loss when the pipe or hose 1s removed .
J Brake pipe removal is usually quite strmghtforward. The union nul s
at each end are undone. and the pipe unclipped from the body. Where
the union nuts are exposed. rhey may be quite ught. and should first be
soaked wuh penetrating oil. II the nuts can not be loosened w11h an
ope!'I ended spanner. a special brake union spanner should be used, or
a1tern1u1vely a pair of self-loclong grips may be used
5 To remove a flexible hose. unscrew the union nut(s) secunng the
11g1d brake p1pe(s). then pull out the retaining cllp(s) and withdraw the
12.2 B Rear brake compensator (Estate model)
hose from the bracket(s) (photos). If a front hose is being removed. It
i;,1n now be unscrewed from the brake caltper
6 Brake pipes can be obtarned Individually or 1n sets from most
oc:cessory shops or garages, w11h the end flares and union nu ts in
place The pipe 1s then bent to shape. using the old pipe as a guide. pipes are secure in their clips After f1ttrng, remove the polythene
7 Fttttng the pipes and hoses 1s a reversal of the removal procedure. sheeung andi ~leed the brake hydraulic system as described In 1he next
Make sure tha1 the hoses are no1 kinked when in positron. and tha t the Section ·

13.5A Front flexible brake hose (arrowed) 13.58 Rear flexible brake hose (arrowed) 13.SC Rear flexible brake hose (Estate
and body bracket (Saloon model) model)
container. which can be pos1t1oned so that the air bubbles can actu ally
14 Hydraulic system - b leeding
be seen being e1ected from the system.
17 Tighten the bleed screws. remove the tube and repeat the
II the master cylinder has been removed and refitted, then the operations on the remaining brakes.
complete system (both front and rear circuits) must be bled If a 18 On completion, depress the brake pedal. If 11 stlll feels spongy.
component of one circ uit has been disturbed, and there has been only repeat the bleeding operations as air must still be trapped in the system.
minimal loss of fluid, then only that particular circuit need be bled.
2 Before bleeding the rear hydraulic circui t on Saloon models, Bleeding - using a pressure bleeding kit
pos111on a 5 mm (0.2 m) thick spacer (such as an open -ended 19 These kits too are available from motor accessory shops. and are
spanner) between the rear brake compensator piston and adjusrment usuall y operated by air pressure from the spare tyre
lever If the rear wheels are not supporting the weight of the car, insert a 20 By connecting a pressurised container to the master cylinder fluid
th icker spacer. so that the piston is fully in its housing. reservoir, bleeding is then ca rried out by simply opening each bleed
3 If the complete system is being bled. bleed the rear righ t -hand screw m turn and allowing the fluid to run out, rather like turning on a
brake, followed by the rear left-hand brake. the front left- hand brake, tap, until no air is visible in the expelled flu id.
and the front right- hand brake. 21 By using this method, the large reserve of hydraulic fluid provides a
4 Unless the pressure bleeding method is being used, do not forget to safeguard against air being drawn into 1he master cyhnder during
keep the fluid level in the master cylinder reservoir topped up, to bleeding, which often occurs if the fluid level in the reservoir 1s not
prevent air from being drawn into the system, which would make any maintained.
work done worthless. 22 Pressure bleeding 1s particularly effecuve when bleeding 'difhcult'
5 Before commencing operations. check that all system hoses and systems, or when bleeding the complete system at time of routine fluid
pipes are m good condition. w ith all unions tight and free from leaks. renewal.
6 Take great care not to allow hydraulic fluid to come into contact
wuh the vehicle paintwork, as 11 is an effective pamt stnpper. Wash off All methods
any spilled fluid immediately w ith cold water. 23 When bleed Ing Is completed. check and top up the fluid level 1n the
7 Before commencing work, destroy the vacuum in the servo unit by master cyl inder reservoi r.
giving several apphcat1ons of the brake pedal in quick succession. 24 Check lhe feel of the pedal. If 11 feels at all spongy. air must still be
present 1n 1he sys1em, and further bleeding is indicated. Failure to bleed
Bleeding - two-man method S<llislactorily, after a reasonable period of 1he bleeding operauon. may
8 Gather together a clean jar and a length of rubber or plastic tubing be due to worn master cylinder seals.
which will be a tight fit on the brake bleed screws.
9 Engage the help of an assistant.
10 Push one end of the bleed tube onto the first bleed screw, and
immerse the other end in the jar, which should contain enough
hydrauhc fluid to cover the end of the tube.
11 Open the bleed screw one half a turn, and have your assista nt
depress th e brake pedal fully, and slowly release it. Tighten the bleed
screw at the end of each pedal downstroke, to obviate any chance of
air or fluid being drawn back 1.nto the system.
12 Repeal this operation until clean hydraulic fluid. lree from air
bubbles can be seen com ing througn into the 1ar. Tighten the bleed
screw at che end of a pedal downstroke, and remove the bleed tube.
13 Bleed the remaining screw s in a similar way.
Bleeding using one- way valve kit

14 There are a number of one-man, one-way brake bleeding kits
avaltable from motor accessory shops. It is recommended that one of
these kus 1s used wherever possible. as it will greatly simplify the
bleeding opera11on. and also reduce the risk of air or fluid being drawn
back Into 1he system. qu11e apart from allowing one to do the work
without the help of an assistant
15 To use the ktt. connect the tube Lo the bleed screw and open the
screw one half a turn (photo).
16 Depress the brake pedal fully. and slowly release II. The one-way
valve in the kh will prevent expelled air from returning at the end of 14.15 Loosening the bleed screw on a front brake ca liper
each podal downstroke. Repeat this operation several 11mes LO be sure
of e1ec11ng all arr from 1he system. Some kits include a translucent

26 011>Card brake fluid which has been expelled. 11 1s almost certain to 3 Using a scrrber or similar tool. pick out the filler, and cut 1t to
bE- con1amina1ed with moisture. air and dirt, making ii unsu11able for remove ii 11 not renewing the dust excluder
funher use Clean fl uid should always be stored in an airtight container, 4 Fu the new air triter. using a reversal of the removal procedure If
as 11 absorbs moisture readily (hygroscopic) which lowers 11s bo1hng not renewing the dust excluder. cu t the new filter radially bef0<e
point. and could affect braking performance under severe conditions. locating It on the pushrod
16 Vacuum servo unit - description and test ing 17 Vac uum servo unit - removal end refitting
I A vacuum servo uni t 1s luted to the master cylinder, to provide 1 Remove the master cylinder as descrrbed in Section 11
pow81 assistance 10 the driver when the brake pedal 1s depressed 2 0 1sconnec1 the vacuum hose from the non return valve on the
2 The unit operates by vacuum obtained from the 1nduc11on manifold servo un11 (photo)
and compr1ses. basically, a booster diaphragm and a non-return valve. 3 D1sconnec1 the pushrod from the brake pedal by extracting the spl11
3 The servo unu piston rod acts as the master cylinder pushrod The pin and the clevis pm.
d11ver'5 braking effort is transmitted through another pushrod 10 the 4 Unscrew the mounung nuts from 1ns1de tho vehicle, then withdraw
servo unit pu>ton and its built- in control system The servo unit piston the servo unit into the engine compartment Remove the gasket
does not hi tightly in to the container. bu t has a strong diaphragm to 5 Ad1ustment of the servo ou1pu1 pushrod is not possible on 1he
keep 11S edgos In constant contec1 w11h the cylinder wall. so assuring Teves version. On the OBA version. adiustment 1s possible. and the
an airtight seal between the two parts. The forward chamber is held pushrod pro1ec11on from the face of tho unit should be 9 0 mm (0 36
under vacuum conditions created in the inlet manifold of the engine in)
and. during periods when the brake pedal is not in use. the controls 6 Refitting is a reversal of removal. bul fit a new gasket and fully
open a passage 10 the rear chamber. so placing It under vacuum. When tighten the mounting nuts Finally w 11h the brake pedal released
the brake pedal is depressed the vacuum passage to the rear chamber check 1ha1 the clearance between the stop -lamp switch threaded
~ cut off and the chamber opened 10 a1mosphenc pressure. The shank and pedal 1s at least 1 5 mm (0 06 1n). If necessary. loosen the
consequent rush of air pushes the servo piston forward in the vacuum locknuts, ad1ust the switch. then tighten the locknuts
chamber and operates the main pushrod to the master cylinder The
controls are designed so that assistance 1s given under all conditions
and. when the brakes are not required, vacuum 1n the rear chamber 1s 18 Handbrake - adjustment
e&Ulbhshed when the brake pedal is released Air from the atmosphere
en1orrng the rear chamber is passed through a small air filler.
4 Opera11on of the servo can be checked in the following way. With The handbrake 1s normally kept ad1usted by the acuon of the
automatic adiusters on the rear brake shoes (drum brakes) or rear
the engine off. depress the brake pedal several umes. The pedal travel
caliper pistons (disc brakes) . However, the cables may require periodic
should remain the same.
6 Depress the brake pedal fully and hold 11 down. Start the engine ad1us1ment ro compensate for cable stretch
and feel that the pedal moves down slightly 2 With the engine idhng. depress the brake pedal hard several times.
6 Hold the pedal depressed with the engine running . Switch off the This will ensure 1ha1 the brake linings are 1n the normal ad1us1ed
engine. holding the pedal depressed. The pedal should not rise nor fall pos1t1on Switch off the engine
1 ti the foregoing tests do not prove sauslactory, check the servo 3 Chock the front wheels. then 1eck up the rear of the cnr 11nd support
vacuum hose and non -return valve for secunty and leakage. The valve on axle stands. Release the handbrake.
and rubber grommet may be renew ed by prrs1ng them from the servo 4 Working beneath the vehicle. loosen the locknuts at 1he from end
body (photo) of the outer cables (photo).
8 If the brake servo operates properly in tho test, but still gives less
ettecuve service on the road. the air filter through which air flows into Rear drum brake models
tlw servo should be inspected A dirty filter w ill hm11 the formation of a 5 Screw in the adiustment nuts on each cable by equal amountS,
unul the rear brake shoe linings are 1us1 touching the drums. It should
difference 1n pressure across tho servo diaphragm
still be possible to turn the rear wheels by hand. although slight
9 The servo unit itself cannot be repaired. and therefore a complete
resistance should be apparent.
renewal IS necessary i f the measures described are not effective.
6 Check that 1he threaded ends of 1he ad1us1ment ferrules on each
cable proiect by equal amounts If not. roposi11on the ad1us1men1 nuts
then repeat the procedure given 1n paragraph 5.
16 Vacuum servo air filter - renewal 1 Unscrew each ad1us1men1 nut by half a turn
8 Fully apply the handbrake lever, and check that the level travel 1s
1 Remove the ngh1-hand lower facia panel. between 4 and 7 notches W11h the lever off. check that both rear
2 Reach up behind the footpedals, and pull the dust excluder off the wheels tum freely.
servo onto the pushrod If the dust excluder 1s supplied with the new
a r filte1 as a kit. disconnect the push rod from the pedal and remove the Rear disc brake models
8kCIUdtlr 9 Check that w ith the handbrake lever released. both levers on the
15 7 Removing the non- return valve from 17.2 Disconnecting the vacuum hose 18 4 Handbrake cable adjustment nut (A)
the servo ·I and locknut ( B)

rear calipers are resting on their nylon pads.

10 Progressively screw tn the adjustment nuts on each cable by equal
amounts. until the rear caliper levers 1ust lift from the nylon pads.
11 Check that the threaded ends of the ad1ustment ferru les on each
cable pro1ec1 by equal amounts. If not, reposition the adjustment nuts.
th en repeat the procedure given In paragraph t 0.
12 Unscrew each ad1ustment nut by half a turn.
13 Fully apply the handbrake lever. and check that the lever travel rs
between 7 and 13 notches. With the lever off. check that both rear
wheels turn freely
All models
14 Retighten the adjustment lockouts.
15 Lower the car to the ground.
19 Handbrake c ables - renewal
Chock the front wheels. then 1ack up the rear of the car and support
on axle stands Remove the rear wheels.
2 Fully release the handbrake.
3 On models wi th rear drum brakes. remove the rear brake shoes.
then use a small drift to drive the outer cables from the backplates.
4 On models with rear disc brakes. disconnect the inner cables from
the caliper levers. and withdraw the outer cab les from the brackets.
5 Release the outer cables from the underbody clips and springs
(photo).
6 Working inside the vehicle. remove the centre console, then
disconnect the cables from the equaliser (photo) On Estate models
fmed with a bench seat. the equaliser is connected to the handbrake
lever by an additional cable.
7 Withdraw the cables from under the vehrcle.
8 Flt the new cables. using a reversal of the removal procedure.
Finally ad1us1 the cables as described in Section 18.
20 Brake pedal - removal and refitting
Remove the lower facia panel from the steering column. tn order to
gain access 10 the pedal bracke t.
2 Extract the spring clip, withdraw the clevis pin. and disconnect the
pushrod from the pedal
3 Unscrew the self -locking nut from the pivot bolt. and remove the
thrustwasher
4 Pull out the bolt and remove the brake pedal. If the bolt is fitted
from the rig ht-hand side. It will also be necessary 10 remove the clutch
pedal on manual gearbox models.
5 Examine the pedal bushes for wear, and renew them if necessary.
6 Refi111ng is a reversal of remova l. but lightly grease the bushes and
clevis pin. and renew the self- locking nut. Check, and if necessary
adiust. the stop· lamp switch as described in the next Section.
21 Stop- lamp swit ch - removal and refitting
Remove the low er lacia panel below the steering column.

2 Disconnect the wiring from the stop-lamp sw itch on the pedal
bracket (photo)
3 Unscrew the lower adjustment locknut. and remove the sw itch
from the pedal bracket.
4 Refitting 1s a reversal of removal. but adjust the lockouts so that the
clearance between the threaded shank and pedal is at least 1.5 mm
(0 06 1n) Check that the stop -lamps operate correctly with the ignition
sw itched on.
22 H andbrake warning light switc h - removal and refi tting
Remove the ce ntre console.

2 With the handbrake applied, remove th e mounting screw.
w tthdraw the sw uch and disconnect the wiring (photo). 2 1.2 Brake stop-lamp switch (arrowed)
3 Refm1ng 1!> a reversal of remova l.

Fig 9 23 Brake pedal components (Sec 20)
I Nut
2 Washer
3 Bush
4 Spacer
5 Pedal
6 Bush
7 Bolt
8 Spnng clip
9 Clovis pin
10 Stop ·lamp switch
11 Locknut
12 Pad
J..1.12949
23 H andbrake lever - removal and ref i tting
1 Remove the centre console.

2 With the handbrake released. disconnect the handbrake cable(s)
3 Unscrew the mounting bolls and nut. and remove the handbrake
22 2 Handbrake warning ltght switch (arrowed ) lever assembly from the floor.
4 Refuting i~ .\a reversal of removal. but adiust the handbrake as
.
described in 5b'¢tion 18.

24 Fault diagnosis - braking system
Symptom Reason( a)
Pedal travels a long way before the brakes operate Air in hydraulic system
Rear drum brake self· adiusting mechanism faulty
Stopping ab1l1ty poor, even though pedal pressure is firm Linings, discs or drums badly worn or scored
One or more wheel cylinder or caliper pistons seized, resulting in some
brake shoes/pads not pressing against the drums/ discs
Brake linings contaminated w ith 011
Faulty servo unit
Veh icles veers to one side when the brakes are applied Brake linings on one side contaminated with 011
Hydraulic wheel cylinder/caliper on one side partially or fully seized
A mi xture of lining materials fitted between sides
Pedal feels spongy Air in hydraulic system
Pedal feels springy when the brakes are applied New brake linings not bedded in
M aster cylinder or rear brake backplate mounting bolts loose
Excessive wear of discs or brake drums
Pedal travels righ t down with little or no resistance, and

brakes are virtua lly non-operative Leak in hydraulic system, resulting in lack of pressure for operating
wheel cylinder/caliper pistons
If no signs of leakage are apparent, the master cylinder internal seals
are failing to sustain pressure
Binding. 1uddering, overheaung Rear brake shoes fitted incorrectly

Broken rear brake shoe return spnng
Disc/ drum distorted
Handbrake cable(s) seized
Lack of servo assistance Vacuum hose leaking

Non-return valve defecuve or incorrectly fitted
Servo internal fault

Chapter 10 Suspension and steering

Contents
Fault diagnosis - suspension and steering ........................................ 28 Rear hub bearings (Saloon models) - renewal ................................ 15
Front anti-roll bar - removal and refitting ......................................... 3 Rear shock absorber - removal and refitti ng ..................................... 13
Front hub bearings - renew al .. ............ ................ ............................ 8 Rear suspension trailing arms (Saloon models) - removal
Front lower suspension arm - removal and refitting .. .................... 6 and refitting ......... .......... ...... ........ .... ........................... ..• 12
Front lower suspension ball101nt - renewal ....................................... 7 Routine maintenance .. ... ...................... .... .... ............................. ... 2
From radius arm - removal and refitting ....... .. ....................... 5 Steering angles and front wheel alignment ..................................... 26
From suspension srrut - removal, overhaul and rellmng ........•....... 4 Steering column and lock - removal and refmmg ......................... 18
General descriptton ................. ............ ............ ...... ..... ...... ...... ..... ...... .. 1 Steering gear - overhaul .................................................................. 20
Panhard rod (Estate models) - removal and refining ...................... 14 Steering gear - removal and refitting ................................................. 19
Powet steering flu id - draining and refilling .... .... .. ................... 24 Steering rack bellows - renewal ......................................................... 22
Power steering pump - removal and refitting .. ... .......... .... ....... . 25 Steering wheel - removal and refitting ............................................ 17
Rear anti-roll bar - removal and refining ................. ................... 9 Track rod - removal and refitting ................. ...............•••.•• .. 23
Re.ir coil springs (Estate models) - removal and ref1111ng ............. 11 Track rod end - removal and refnung ................................................ 21
Rear coil springs (Saloon models) - removal and refitting ............ 10 Wheels and tyres - general care and mamtenance ......................... 27
Rear hub bearings ( Estate mo~ls) - renewal ............................... 16
Specifications
front suspension
Type ........................................................................................ Independent, M cPherson stru ts. coil springs, rad ius arms. anti-roll bar
Coil spring free length
Standard - without air cond1ttoning .................................................... 575 mm (22.7 In)
Standard - with air conditioning ......................................................... 553 mm (21 .8 in)
Heavy duty - w ithout air condlttoning ................................................ 485 mm (19.1 In)
Heavy duty wnh air cond111oning .. •......................................... 498 mm (19.6 in)
Hub bearing lubricant type/spec1f1cation .............................................. M ulti-purpose lithium-based grease ( Duckhams LB 10)
Rear suspension
Type
Saloon models ........................................... ,.......................................... . Independent, trailing arms, coil springs, telescopic shock absorbers,
ant i-roll bar
EsUltt models ......... R1g1d axle, coil springs. telescopic shock absorbers. Panhard rod,
anti -roll bar on most models
Coll 5P' ng free length·
Standard .................................................................................................. 4 19 mm (16.5 in)
Heavy duty ..................................................................................... ,....... . 413 mm (16.3 i n )
Steering
Type Rack and pin ion , steering column and in1ermed1ate shaft, power
assistance on some models
Lubncnt1on
Steenng rack lubricant type/specification .......................................... L1th1um - based molybdenum d isulphide grease (Duckhams LBM 10)
Pow«tt steering fluid capacity .............................................................. 0.7 litres ( 1.2 pints)
Power steering fluid type/specification ............................................... Dexron II ATF ( Duckhams D -Me1ic)
T rial ve rsion of ABC Ambe r PDF Merger, http:/Atvww.processtext.com/abcpdfmg.html

192 Chapter 1 O Suspension and steering
Steering (cont)
Turns lock to lock:
Manual steering ...................................................................................... 4.5
Power -assisted steering ....................................................................... .. 3.0 or 3.4
Front wheel alignment (at ke(b weight):
Toe-in
Saloon models .................................................................................. 3.0 ± 1.0 mm (0.118 ± 0.04 In)
Estate (except GTI) .......................................................................... 3.6 ± 1.0 mm (0.138 ± 0 .04 In)
Estate (GTI} ...................................................................................... 2.0 ± 1.0 mm (0 .079 ± 0.04 in)
Camber.
Saloon models .................................................................................. - 0•45• ± 30'
Estate (except GTI) ........................................................................ .. - 0·30· ± 30·
Estate (GTI) ...................................................................................... - 0'55' ± 30'
Castor.
Saloon models .................................................................................. 2' 40' ± 30'
Estate models .................................................................................... 2· ± 30'
Steering axis inclination:
Saloon models .................................................................................. 9' 15' ± 30'
Esta te (except GTI) .......................................................................... 9• ± 30'
Estate (GTI) ...................................................................................... . 9' 25' ± 30'
Rear wheel alignment ( Saloon models) :
Toe -in ....................................................................................................... 3.0 ± 1.0 mm (0.118 ± 0.04 in)
Camber .................................................................................................. . - 1· ± 30'
Roadwheels
Type .... ....................................................................................................... Pressed-steel or light alloy
Size:
Steel .............. ,.......................................................................................... 5'/ zJ14 FH 4.30 or 4.23
Alloy - Saloon (except GTI) .............................................................. . 6J14 FHH 20
Alloy - Saloon ( GTI) ............................................................................. 6J15 FHH 25
Alloy - Estate (except GTI) .................................................................. 5' /2J1 4 FHH 30
Allov Estate (GTI ) .............................................................................. . 6J14 FHH 20
Tyres
Size ............................................................................................................. 175 R14S, 185/70 R14T. 185 R14S. 195/70 R14T, 195/ 60 R15H. or
205/70 R14S
Pressures - bar ( lbf/ in'): Front Rea r
175 R14S ................................................................................................ 1.8 (26) 2.0 (29)
185/70 R1 4T .......................................................................................... , .8 (26) 2.1 (30)
185 R14S ................................................................................................ 1.9 (28) 2.1 (30)
195/ 70 R14T .......................................................................................... 1.9 (28) 2.3 (33)
195/60 R1 SS .......................................................................................... 2.0 (29) 2.1 (30)
205/70 R14S ......................................, .................................................. . 2.0 (29) 2.2 (32)
Torque wren ch settings Nm lbf ft

Front suspension
Lower balljoint housing nut (early Saloon) ............................................. 45 33
Lower ball101nt housing (la ter. Saloon, and Estate) ................................ 170 125
Lower balljoint nut (later Saloon. and Estate) ......................................... 45 33
Suspension strut upper mounting bolts .................................................... 10 7
Shock absorber cover nut ........................................................................... 80 59
Shock absorber piston rod nut ................................................................... 45 33
Lower suspension arm pivot pin ................................................................ 45 33
Anti-roll bar link bolt ................................................................................... 45 33
Radius arm nu t ............................................................................................. 45 33
Wheel nuts - steel wheels .......................................................................... 60 44
Wheel nuts - alloy wheels .......................................................................... 95 70
Rear suspension
Hub nu t ........................................................................................................ . 250 185
Crossmember nuts (Saloon) ...................................................................... . 65 48
Trailing arm pivot bolt ................................................................................ . 55 41
Hub carrier/ backplate ( Estate) ................................................................. .. 55 41
Shock absorber upper mounting (Saloon) ............................................... 12.5 9
Shock absorber lower mounting (Saloon) ............................................... 45 33
Shock absorber upper and lower mountings (Estate) ............................ 57.5 42
Steering
Track rod end to steering arm .................................................................... 35 26
Track rod locknut ......................................................................................... 45 33
Intermediate shaft couplings ..................................................................... . 25 18
Steenng gear ................................................................................................ . 33 24
Track rod Inner balljoint .............................................................................. 50 37
Power-assisted steering ram ....................................................................... 50 37
Power-assisted steering pump union ....................................................... . 25 18
J .\

1ncorporattng trailing arms. coil springs. telescopic shock absorbers

1 General description and an anu-roll bar. The tra1hng arms are attached to a lower
crossmember. and an upper crossmember accommodates the shock
absorbers upper mountings and coil spnng seats.
The front suspension 1s of independent type. incorporating On Estate models, a hve axle 1s fitted , being supported at the front
McPherson struts with integral shock absorbers. and coil spnngs. The by the torque tube. Lateral movement 1s controlled by a Panhard rod.
lowei ends of the suspension struts are attached to the suspension Coil springs. telescopic shock absorbers and an an11-roll bar are fitted .
arms by ball101nts. and vertical movement is controlled by radius arms. Rack-and-pinion steering 1s fitted. incorporating a steering column
An an11 -roll bar is fined and intermediate shaft. Power-assisted steering is fitted to some
On Saloon models, the rear suspension is of independent type, models.
Fig. 10.1 Front suspension components ( Sec 1)
1 Rear crossmember 2 Front suspension strut and 3 Front lower suspension arm 5 From crossmember
stub axle 4 Radius arm
Fig. 10.2 Rear suspension components on Saloon model• (Sec 1 )
1 Coil spring 3 Upper crossmember 5 Suppodt:\ 7 Final dtive unit

2 Shock absorber 4 Tralllng arm 6 lower crossmember 8 Propeller shaft link tu/HI

194
=====--~~
Fi g . 10.3 Rear suspension co mpo nents on Estate models (Sec 1 )
1 Fmal dflve unit 3 Coil spring 5 Anti· roll bar 7 Tie·bar

2 Panhard rod 4 Shock absorber 6 Rear axle 8 Torque rube
Fi g . 10.4 Steering components - LHD shown. R HO similar (Sec 1 )
1 Stee1mg wheel 3 Intermediate shaft 5 Steermg gear 7 Power steering fluid

2 Steer1ng column 4 Track rod 6 Power steer/19 pump reservoir

Chapter 10 Suspensio n and steeri ng 195
2 Routine maintenance 3 Front anti- r oll bar - removal and refitti ng
Carry out the following procedures at the intervals given in Routine Apply the handbrake, then jack up the front of the vehicle and
maintenance at the lront of chis manual. suppon on axle stands.
2 Unscrew and remove the bolts securtng the anti- roll bar links to the
Check tyre condition and pressures lower suspension arms (photo) .
1 With the vehicle supported on axle stands. check that the tyre tread 3 Support the anti-roll bar, then unscrew and remove the front
on each tyre is not worn below the legal hmlt mounting bolts and withd raw the bar from under the vehicle (photo) .
2 Check all tyres for damage. and for any flints or nails embedded in Recover the clamps end spacers.
the tread 4 Remove the rubber bushes from the anti-roll bar.
3 With the (kerb) weight of the vehicle on the tyres. check and ad1ust 5 Disconnect the links from each end of the anti -roll bar. On some
the tyre p<essu res. models, a venically -positioned nut together w ith spacer and rubber
bushes 1s used, whereas on o ther models. a honzontally- poslt1oned
Check power steering fluid level bolt is used.
4 Visually check the power steering system pipes and hoses for signs 6 Refitting is a reversal of removal. but delay tightening the nuts and
of leakage. bolts until the weight of the vehicle is on the suspension. Refer to the
5 The fluid level must be checked with the fluid cold. at least two or torque wrench settings quoted in the Specifications Section at the start
three hours after switching the engine off. of this Chapter.
6 If necessary, top up the reservoir on the right-hand side of the
engine to the 'Cold ' ('Froid') mark. On complet ion. tighten the filler
c.:ip onto the reservoir
4 Front suspension strut - removal, overhaul and refi tting
Check front hub bearing adjustment
7 Jack up the front of the vehicle and support on axle stands. 1 Apply the handbrake. then jack up the front of the vehicle and
8 G11p the top and bottom of the tyre. and attempt to rock the wheel support on axle stands positioned under the body charnel sections.
If movement w ithin the bearing is perceptible. adjust it with reference Remove the appropriate front wheel .
to Section 8. 2 Unscrew the brake caliper moun11ng bolts. wahdraw the caliper
from the disc. and suppon it to one side on an axle stand wnhout
Check suspension and steering ba//joints straining the flexible hydraulic hose. There is no need to remove the
9 With the vehicle raised, attempt to move the front lower suspension disc pads. or to disconnect the hydraulic hose. On some models, the
arms up and down. If there 1s any no11ceable movement within a caliper moun11ng bolts may be locked with locktabs, which must be
ball1oint. renew 1t. bent back before loosening the bolts.
10 Similarly check the steering track rod end balljoints for wear. 3 Unscrew the nut securing the steering track rod end to the hub
carrier arm. then use an extractor tool to release the track rod end.
Check suspension rubber bushes 4 Unscrew the pivot pin nut from the inner end of the lower
11 With the vehicle raised, check all suspension rubber bushes for suspension arm (photo). Using a wooden mallet. drive the pivot pin
damage and deterioration, including anti-roll bar, shock absorber. and rearwards to release the splined section beneath the head, and remove
Pantlard rod mountings. It
5 Unscrew and remove the bolt securing the anu -roll bar link to the
Check shock absorbers lower suspension arm.
12 Check the action of each shock absorber by pressing down on the 6 Unscrew the nut securing the radius arm to the lower suspension
appropriate corner of the vehicle After quickly releasing the vehicle. arm. Remove the cup and rubber bush.
the body shou ld rise. then stabi lise. If there are several oscillat ions. the 7 Release the lower suspension arm from the crossmember and
shock absorber shou ld be renewed . radius arm.
8 Suppon the front suspension strut with a trolley jack.
Check power steering pump drivebelt 9 Working inside the engine compartment. unscrew the three bolts
13 Inspect the pump drivebelt for cracking. glazing or fraying, and from the strut upper moun11ng.
renew 1f necessary. as described in Secuon 25 or Chapter 2. 10 lower the trolley 1ack. and withdraw the stru1 from under 1he front
14 Check the pump drivebelt tension. and adjust if necessary, as wing (photo)
desc11bed 1n Sec1ion 25. 11 Clean away all external dirt from the strut and coil spring.
3 2 Anti -roll bar link bolt (arrowed) 3.3 Anti-roll ~ar front mounting (arrowed)

196 Chapter 10 Suspension and steering
4.4 Lower suspension arm inner pivot pin (arrowed) 4.10 Front suspension strut viewed from under the front wing
12 Ftt spring compressors to the coil spring, and 11ghten them evenly
unul the sprtng 1s released from the upper mounting.
13 Unscrew the piston rod nut. If necessary using a screwdriver 10
hold the rod stationary
14 Remove the washer, rebound ltmt1er, beartng assembly, cup and
spring seat.
15 Remove the coil spring The spring can remain in the compressed
state ready for refiulng to the strut If the spring is to be renewed,
release the compressors very gently and evenly. until they can be
removed and tmed to the new sprtng.
16 II necessary. remove the gaiter and bump stop from the piston rod.
Note the locati on of each component to ensure correct refitting
17 Check the S1rut for signs of fluid seepage at the piston rod seal.
Temporartly refit the upper mounting to the piston rod, and, with the
bottom of the stru t gripped In a vice. fully extend and retract the piston
rod II the resistance ts not firm and even in both directions. or if there
are signs of leakage or damage, the strut must be renewed or
overhauled
18 To ovethaul the strut , ftrst mount 11 vertically in a vice.
19 Unscrew the nut and withdraw the shock absorber, while keeping
the cyltnder tn the strut.
20 Wtthdraw the cylinder. and tap the compensator valve from the Fig. 10.5 Front suspension strut upper mounting
bottom of 11 components (Sec 4)
21 Dram the nu1d from the strut Lever off the rebound stop
1 PIS(on rod nut 4 Bearing assembly
2 Washer 5 Cup
3 Rebound limiter 6 Spnng seat
Fig. 10.6 Withdrawing the shock a,bsorber cylinder from the

front suspensi on strut ( Sec 4) Fi g . 10.7 ~evering off the rebound st op ( 1) (Sec 4 )
l

22 Clean the components thoroughly, and renew the parts indicated

1n Ftg 10.8
23 Fit the rebound stop, engaging Its slots, and using ll suitable
h,rbncant if necessary on the strut screw threads
24 Onve the new compensator valve into the cylinder. using a hide or
wooden mallet.
25 Insert the cylinder 1n the strut. then pour in 3.35 cc of suitable flUrd
consult your Peugeot dealer.
26 Insert the shock absorber slowly, being careful not to damage the
seal
27 Frt the upper beanng 3.0 mm (0.118 in) below the upper edge of
the strut
28 Smear the upper seal w ith the above-mentioned fluid, and locate i t
on the bearing. S1m1larly fit the rod seal.
29 Refit and tighten the nut, using a crowfoot spanner and torque
wrench to tighten it to the specified torque.
30 Pull out the piston rod as far as possible.
31 Refit the gai ter and bump stop.
32 Locate the coif spring (compressed) on the strut.
33 Rein the cup and spring seat. bearing assembly, rebound limiter
and washer. and a new piston rod nut. Tighten the nut to the specified
torque.
34 Carefully release the spring compressors. making sure that the coil
spring locates correctly in the seatings. Push the rubber gart er over the Fig. 10.8 Shock absorber overhaul comp onents (Sec 4)
shock absorber retain ing nut.
35 Lift the front suspension unit into position under the front wing, 1 Compensator valve assembly 5 Upper nut
and support it on a trolley jack 2 Sealing ring 6 Gaiter
36 With the rebound limiter parallel wi th the vehicle centre-line. insert 3 Bealing seal 7 Cover nut
the three strut upper mounilng bolts, and tighten them to the specified 4 Rod seal
torque Where applicable, fit the earth lead to the outer bolt.
37 F11 the lower suspension arm onto the radius arm. Refit the rubber
bush and cup. and screw on the nut finger-ught.
38 lnseri the bolt through the an11-roll bar hnk and lower suspension
arm. and screw on the nut finger- tight
39 Locate the lower suspension arm in the crossmember. and insert
the pivot pin from the rear w11hou1 engaging the splined section.
Sc1ew on the nut finger-tight.
40 Fn the steering track rod end to the hub carrier arm Screw on the
nut and tighten to the specified torque.
41 Refu the brake caliper and tig hten the mounting bolts to the
spec1f1ed torque given 1n Chapter 9. Bend over the locktabs where
~pplicable
42 Apply 1he brake pedal several times to reset the disc pads.
43 Refit the front wheel and lower the vehicle 10 1he ground {photo).
44 Move 1he vehicle a few yards backwards and forwards to settle the
suspension. then drive in the lower suspension arm pivot pin to engage
thesphnes, and tigh ten the nut to the specified torque. Also tighten the
anu-roll bar link bolt and radius arm nut to the speci fied torque.
6 Front radius arm - removal and refitting 4.43 Tightening the wheel nuts
1 Apply the handbrake. then Jack up the front of the vehicle and
support on axle stands. Remove the appropriate front w heel.
2 Unscrew and remove the bolt securing the anti-roll bar link to the
lower suspension arm.
J Unscrew the nut securing the radius arm to the lower suspension
arm (photo) Remove the cup and rubber bush.
4 Unscrew the pivot pin nut from the Inner end of the lower
suspension arm. Using a wooden mallet. drive the pivot pin rearwards
to release the splined section beneath the head, and remove 11
6 Release the lower suspension arm from 1he crossmember and
radius arm.
6 Unscrew the front nut from the radius arm. Remove 1he cup and
rubber bush
7 Whhdraw 1he radius arm from the fron t bracket
8 Remove the inner rubber bushes. cups and thrust washers
9 Examine the rubber bushes for damage and deteriora11on, and
renew them If necessary Fig. 10.9 Cross -section of radius arm component• (Sec 6)
10 Rel1tt1ng 1s a reversal of removal, but check that the thrust washers
and cups are located as shown 1n Fig. 10.9, and delay tightening the 1 Radius arm 3 Cep
nuts and bolts until the weight of the vehicle is on the suspension. 2 Thrustw asher 4 Rubb~bush
J;)

198 Ch apter 10 Susp ensi o n and steering
5 Release 1he lower suspension arm from 1he crossmember and

rad ius arm.
6 On early Saloon models having a vehicle iden1iflca1ion number
(VIN) up 10 1.341 .364. unscrew the lower ballioint housing nut from
1he arm. 1ogether with the grease nipple. Unscrew the ball securing
nut, then tap the arm from the bottom of the strut. Use a puller if
necessary
7 On later Saloon models, and all Estate models, unscrew 1he low er
ball1oint nut. and use a balljo nt separator tool to release the arm.
8 Refmmg 1s a reversal of removal. but delay ttghtemng the radius
arm. an11 - roll bar link. and inner pivot nuts and bolts until the weight of
the vehicle 1s on the suspension On early Saloon models, grease the
ball101nt through the grease nipple.
7 Fr ont lower suspension balljoint - renew al
1 Remove 1he front suspension s1ru1 as desc11bed in Section 4.

2 Remove 1he lower suspension arm with reference to Sec1ion 6
Early Saloon models (up to VIN 1.341.364)

3 Unchp the ball1oint boot from 1he groove in the lower suspension
arm.
5 3 Radius arm rear nut (arrowed) 4 Remove the ball and lower half-beari ng from the arm
5 Remove the upper half-bearing from the arm.
6 Clean 1he ball1oint cavity in the lower suspension arm. and obtain a
ball1oint repair kit. Th is will include a rubber bool and clip, upper and
6 Front l ower suspension arm - removal and refitting lower half- bearings. ball, ball nut, housing nut. and grease nipple
7 Grease the half-bearings and ball. then locate them in the low er
Apply the handbrake, then jack up the front of 1he vehicle and suspension arm.
support on axle stands. Remove th e appropriate fron1 w heel. 8 Flt the rubber boot in the groove. and secure with the clip.
2 Unscrew and remove the bolt securing 1he an11- roll bar link to the
low er suspension arm. Later Saloon models. and all Estate models
3 Unscrew the nut securing the radius arm to the lower suspension No t e: To unscrew the bat/joint housing, 11 special tool w ill be required.
arm. Remove the cup and rubber bush but it may be possible to use 11 home -made alternative - rein to
4 Unscrew 1he pivot pm nut from the inner end of the lower paragraph 11.
suspension arm using a wooden mallet, dnve lhe pivot pin rearwards 9 Mount the strut in a vice.
10 release the sphned section beneath the head. and remove iL 10 Bend back the tabs of the lockwasher.
Fig 10 10 Cross- section t hrough front suspension lower Fig. 10.11 Cross -section through front suspension lower
balliolnt on early Sal oon m odels ( Sec 7) balljoint on lat er Saloon. and Estat e models (Sec 7)
f Strut c Ball 1 Strut 5 Lockwasher

2 B•ll pm d Nut 2 Internally- threaded bat~·omt 6 Sell-locking nut
3 811//1omt 11sstJmbly · e Housing nut housmg 7 Locatmg lugs
a Rubber boot 4 Lower suspenslon arm 3 Lockmg splmes 8 Lower suspension arm
b Half ·boarfngs 5 Grease nipple 4 811fl1oint

Chapter 10 Sus pension and steering 199
11 A special tool is now req uired in order to unscrew the ball1oint

housing If Peugeot tool 8.0616 F (Fig. 10.12) cannot be obtained 8.0616F
from a Peugeot garage or tool hire agent, a similar tool may be made
from metal tubing or an old box spanner.
12 Using the special tool. unscrew the ball1oint housing from the
bottom of the strut considerable force wi ll be required.
13 Clean the cavity in the strut, and obtain a new ball1oint housing
and lockwasher.
14 Apply a llule grease to the threads of the new ball1oint housing.
Locate the new lockwasher on the ball1oint housing, With the special
tabs in the cut· outs.
15 lnsen the ball1oin1 housing 1n10 the strut, and ttghten. using the
special tool. to the specified torque - considerable force will be
required
8 . 096 H
All models Fig. 10.12 Tool f or removing the later front lower
16 Refit the from suspension strut and lower suspension arm, with suspensi on bellj o lnt (Sec 7)
reference to Sections 4 and 6 respectively
use a puller to remove it. Prise out the oil seal, and remove 1t from the
hub.
6 Using a sofl metal drift, drive the outer tracks from the hub
8 Front hub bear ings - renewal
7 Scoop the grease from the hub, and clean all the components.
Obtam a new hub nut and oil seal in addition to the new bearings.
1 Apply the handbrake. then 1ack up the front of the vehicle and Check that the stub axle threads are not damaged.
support on axle stands. Remove the appropriate front wheel 8 Smear a little grease on the outer track seatings inside the hub.
2 Unscrew the brake caliper mounting bolts, withdraw the cahper 9 Using suitable diameter metal tubing. press or drive the bearing
from the dtsc, and support rt to one side on an axle stand without ou ter tracks fully mto the hub.
stram1ng the flexible hydraulic hose There is no need to remove the 10 Fit the mner race, then drive in the oil seal squarely using a block ol
disc pads. or to disconnect the hydraulic hose. On some models, the wood, until flush with the edge of the hub.
caliper moun ting bolts may be locked with lockrabs. which must be 11 Apply some grease in the cavity between the bearing outer tracks.
bent back before loosening the bolts. and smear a little grease on the oil seal lips.
3 Carefully tap the hub cap from the hub (photo), and prise the 12 Locate the front hub on the stub axle, together with the remaining
O·ring seal from the groove inner race, and push the assembly fu lly into position.
4 Unscrew the hub nut. and remove the special thrust washer. 13 Fit the thrustwasher, followed by the new hub nut.
5 Withdraw the front hub, taking care to catch the inner race as it 14 Tighten the hub nut to 40 Nm (30 lbf ft). at the same time rotating
comes otf the stub axle. If the other inner race remains on the stub aide, the hub to settle the bearings.
Fig. 10.13 Fr ont hub bearin g co mpo nents (Sec 8)
1 Hub cap 3 Hub nut 5 Outer bearing 7 lnnc1 beating

2 O·nng 4 Thrustwasher 6 Hub and disc 8 011 seal

200 Chapter 10 Suspension and st eer i n g
10 Rear coil springs ( Saloon model s) - removal and

refitting
1 Before commencing work, it is recommended that the guide pms

described in Chapter 7, Section 3 are obtained in order to support the
rear crossmember. Long bolts and washers may be used instead.
2 Chock the front wheels, then jack up the rear of the vehicle and
support on axle stands positioned on the underbody Remove the rear
wheels.
3 Unscrew the nut and release the exhaust tailpipe mounung.
4 Unscrew and remove the nuts and bolts secunng the anti-roll bar
mountings to the underbody.
5 Unbolt the exhaust front silencer heat shield from the underbody.
6 Where applicable, unbolt the bump stop and bracket from the
bottom of the propeller shaft link tube and crossmember.
7 Suppon the final drrve unit on a trolley jack. then unscrew either
the side mounting bolts or lower link mountmg bolt. and lower the tmal
drive unit so that the link tube rests on the rear crossmember.
8 Loosen, but do not remove, the nuts of the rear suspension arm
pivot pins.
9 Support the rear crossmember w11h a trolley 1ack.
1O Workmg inside the car. remove the rear seat to give access to the
8.3 Removing the front hub cap rear crossmember mounting nuts (photo). Unscrew the front nut on
each side. then hit the tab washers and remove the centre plug. Screw
the gulde pins or long bolts into the rear crossmember threaded holes.
Leave the tommy bars in the guide pins 10 support the rea1
15 Loosen the hub nut. then re-lighten to 10 Nm (7 lbf ft) . crossmember.
16 Loosen the hub nut a funher 45• (1 /e th of a turn) . then lock the 11 Unscrew the rear nuts, remove the tab washers. then lower the rear
nul by punching the shoulder m10 the groove In the stub axle. Usmg a crossmember unti l the tommy bars or washers contact the noor.
screwdove1 check that 11 Is possible 10 move the thrustwasher side to 1 2 Suppon the two rear suspension arms w ith a trolley jack and length
side beneath the hub nut. of wood
17 Fil the 0-rtng seal, then tap the hub cap onto the hub. 13 Using an Allen key. unscrew and remove the rear shock absorber
18 Refit the brake caliper. and lighten the mounting bolls to the lower mounting bolts.
specified torque given m Chapter 9 Bend over the locktabs where 14 Open the bootlid, remove 1he plastic covers, and unscrew the rear
applicable shock absorber upper mounting nuts.
19 Apply the brake pedal several umes ro reset the disc pads. 15 W11hdraw the shock absorbers down through the rear suspension
20 Refit the front wheel and lower the vehicle to the ground. arms.
l 6 Lower the rear suspension arms until the rear coil springs can be
lifted out (photo).
17 Refitting is a reversa l of removal, but note the followmg adduional
pomts:
9 Rear anti-roll bar - removal and refitting
(a) Check rhat the upper rubber spring seats are correctly locared
in the upper suspension crossmember
1 Chock the front w heels. Jack up the rear of the vehicle and support (b) When refitting the lower crossmember mounting nu1s. check
on axle stands Remove the rear wheels that flat washers are located under the tab washers. After
tightening the nurs. bend up the tab washers to lock the nuts
Saloon models (c) Where filled. centralise the bump stop with reference to
2 Unscrew the anll·roll bar-to- rear suspension arm link nuts, and Chapter 7. Section 3
remove the cups and rubbe1 bushes { photo). (d) Delay tightening the suspension arm p ivot pins and ami-roll
3 Unscrew the nuts and remove the clamp plates from the rubber bar mountings untJ/ the weight of rhe vehicle 1s on the
mounnngs on 1he underbody (photo). suspension
4 Unhook the rear brake compensator spring. Release the links from
the suspension arms, and withdraw the antr-roll bar from one side of
the vehicle
5 Unbolt the links and remove the cu ps and rubber bushes. Mark the
11 Rear ooil springs (Estate models) - r emoval and refitting
rear brake compensa tor arm m relation to the bar 10 ensure correct
operauon of the com pensator. then unscrew the bolt and remove the
arm 1 Chock rhe from wheels. then 1ack up the rear of the vehicle and
support on axle stands positioned on the underbody. Remove the rear
Estate models wheels and release the handbrake
6 Unbolt the anti-roll bar lmks from the underbody ( photo) 2 Unscrew and remove the bolts securing the anll-roll bar links to the
7 Unscrew the nuts and bolts, and remove the clamp plates and underbody, and withdraw the links trom the brackets.
spacers from the rubber mountings on the bottom of the rear axle 3 Pull ou t the spring plate securing the Hexlble brake hose to the
(photo) Lower the anti -roll bar. and withdraw It from under the torque tube Do not disconnect the rigid brake line from the flexible
vehicle. hose,
8 Unbolt the !mks lrom the anti- roll bar, and remove the rubber 4 Release the r1g1d brake hne support, also uncllp the rear brake
mounung bushes com pensator supply line from the underbody.
5 Unbolt the compensator spring from the torque tube. and the
All models compensator trom the underbody, but do not disconnect the hydraulic
9 Check the mounting ru bbers for damage and detenorauon. and lines.
1enew them as necessary. On Estate models, the hnk bushes may be 6 Unbolt the hydraulic line three -way union from 1he top of th e rear
renewed separately by using metal tubing, thick washers and a long axle casing, but do not disconnect the Imes
bolt and nut to remove and fit them. 7 Unscrew and remove one of the nuts securing the front seat
l 0 Relnung 1s a reversal of removal, but delay lightening the mounung reinforcement bar 10 the underbody. Loosen the remaining nut and
bolts unul the weight of the vehicle is on the suspension. swivel 1he bar toJtte side of the torque tube.

9 2 Rear an11-roll bar lower mounting 9.3 Rear anu - rol l bar mounung on 1he 9.6 Rear anu - roll bar mounting on the
(Saloon models) underbody (Saloon models) underbody (Estate models)
9.7 Ruar anti -roll bar mounting on the rear 10.10 Rear crossmember mounung nuts 10.16 Rear coil spnng (Saloon models)
&Kie (EMate models) (Saloon models)
8 Using a trolley jack. raise lhe rear axle slightly, then unscrew and support on axle stands Remove the appropriate rear wheel
remove both rear shock absorber lower mounting bolts. 2 Posuion a trolley jack under the outer end of the trailing arm
9 Lower the rear axle unul the rear coil springs can be lifted ou1 ( Saloon models), or under the rear axle (Estate models). Raise the i ack
(photo) sligh tly, so that the shock absorber 1s not fully extended.
10 Ref1111ng 1s a reversal of removal. but tighten all nuts and bolts to 3 Using an Allen key. unscrew and remove the shock absorber lower
1he specified torque. Make sure that the coil spring ends locat.e mounung boll, noting which way round It 1s fttted (photos).
co11ectly m the seatings. 4 On Saloon models. open t he bootlid. remove the plastic cover, and
unscrew the shock absorber upper mounting nut (photo). The shock
absorber may then be wilhd rawn downwards through the trailing arm.
5 On Estate models, unbolt the shock absorber upper mounung
12 Rear suspension trailing arms ( Saloon models) - removal bracket from the body (photo) and withdraw the shock absorber
end refitting downwards, then unbolt the shock absorber from the bracke1.
6 Examine the mouniing rubbers for damage and deterioration. and
renew them if necessary. Use metal tubing. washers and a long bolt to
I Remove lhe appropriate driveshaft as described in Chapter 8,
renew the mounting rubber in the eye of the shock absorber.
Section 5
7 Ref1mng 1s a reversa l of removal, but 11gh ten the nuts ond bolls to
2 Unscrew the nut securing the antt -roll bar link to the rear
the specihed torque.
suspension arm, and remove lhe cups and rubber bushes
3 Pos1t1on a trolley 1ack direc1ly beneath the coil spring and shock
absorber and raise the arm slightly
4 Unscrew and remove the p ivot bolts from 1he front of the
S1Jspens1on arm (photo) Prise 1he arm lrom 1he crossmember.
5 Open the bootlid. remove the plastic covers. and unscrew the rear 14 Panhard rod (Estate models) - removal and refitting
)hock absorber upper mounting nut
6 Lower the rear suspension arm. and remove the coil spring.
7 Unbolt tha shock absorber !tom 1he suspension arm. Chock the front wheels. then jack up tha rear of the vehicle and
support on axle stands.
8 Ref1mng is a reversal of 1emoval, bul delay 1lgh1ening the pivot
bolls unul the weight o f the vehicle Is on the suspension Make sure 2 Unscrew and remove 1he bolt secu11ng the Panhard rod to the rear
axle.
1hat the coil spnng sear 1s correctly located In the crossmember.
3 Unscrew and remove the bolt securing the Panhard rod to the
underbody, and remove the rod from under the vehicle.
4 Examine the mounung bushes for damage and deter101a11on If
necessary, lhe bushes may be renewed using metal tubing. washers
13 Rear shock absorber - removal and refitting
and a long bol t to extrac t and Iii 1hem.
5 RefHllng 1s a reversal of remova l. but delay tightening the mounting
I Chock the front wheels, then 1ock up the rear of the vehicle and bolts un ttl the weigh t of the vehicle is on the suspension
I

' l
'..)'~--·. I~
•
- .,,,.
'
~ -
'
-~
.·
.,, -
- -·-·__.--- ·-
-
' ..J
_, .
)
. ··-
t 1 9 Rem coil spring (Estate models) 12.4 Rear suspension !'ailing arm pivot bolt 13 3A Rear shock absorber lower mounti ng
- arrowed {Saloon models) on Saloon models
13 36 and Estate models 13.4 Rear snock absorber upper mounting 13.5 Rear shock C1uso1ue1 upper mounting
on Saloon models on Estate models {arrowed)
Later models (VIN 7.274.587 on)

15 Rear hub bearings (Sal oon models) - renewal 9 Prise the oll seals from the bearing carrier.
I 0 Extract the bearing retaining ctrclip.
Note ReftJt to the preltmmary note in Section 16
A ll models
Remove the dnveshaft as described in Chapter 8. Sectton 5. 11 Support the bearing carrier on a vice
12 Using a soft metal drift on lhe inner track. drive the bearing outer
Rear disc brake models track from the bearing carrier.
2 Usm1:i a suttable puller press the hub/drive flange from the hub 13 Clean all the components, and examine them for wear and damage.
bearings Obtain new 011 seals in addition 10 the new bearing On early models, 11
3 Where the bearing inner track and 011 seal have remained on the 1s recommended that the bearing retaining nut ts also renewed
hub. pull off the track using a suitable puller To lit the puller. it 1s
;idvamageous to unbolt the disc first- Mark the disc in relation 10 the Early models
hub so that 11 may be refined in the same pos111on 14 Press the oil seal in the bearing retaining nut. using a metal tube or
block of wood
Rear drum brake models 15 Insert the bearing outer track and inner race in the bearing carrier.
4 Since the hydraulic brake line Is still attached to the rear wheel Using a metal tube. dnve the outer track fully into position.
cylinder clnd the brake shoes and backplate are suspended. 11 1s not 16 Flt the bearing re1a1ning nut, and ttghten to 250 Nm (185 lb f ft}
possible 10 use a pul ler from 1he 1ns1de to push out the hub. If it is Stake the edge of the nu1 to lock It.
preferred not to d1srnrb the hydraulic circui t, a metal plate must be 17 Press the outer oil seal in the bearing carrier. using a metal tube or
bolted to 1he inside lace of the bearing carrier {see Fig. 10.16), and a block of wood.
puller attached to 1ha hub from the outside. The plate 1s then used as a
reaction base when pulling the hub from the bearings Later models
5 W11h the hub removed. remove the bolts and withdraw the bearing 18 Insert the bearing in the earner Using a metal tube on lhe outer
carrier from 1he backpla te Refit 1he bolts 10 retain the backplate 1n track. drive the bearing fully into pos1t1on.
pos111on 19 Relit the reta1n1ng circl1p 1n Its groove
6 Refer 10 paragraph 3 1f the bearing inner track tias remained on the 20 Make sure that the inner tracks are loca1ed in the bearing. 1hen
hub press in the inner and outer oil seals, using a metal tube or block of
wood
Early models ( to VIN 1 274.586)
7 Mount the beanng earner 1n a soft·1awed vice, and unscrew the Rear disc brake models
bearing 1e1111n1ng nut using a tool to engage the special slots. A tool 21 Where applicable, refit the brake disc w ith reference to Chapter 9.
may be made from metal tubing for thi s purpose. 22 Support the hub bearing inner track on a me tal tube, then press or
8 Remove th e 011 seals end bearing race. dnve the hub into pos1 t1 on
l

,-------------------------------------------------------------------~ 203
Fig. 10.14 Rear hub bearing component s on early

Saloon models (Sec 1 5)
T Hub nut
2 Hub
3 Outer 011 seal
4 Hub carrier
5 Bearing
6 Bearing retaining nut and 011
seal
7 Stub axle ( w ith straight cut
splines)
F19 10.15 Rear hub bearing co m ponents

on later Saloon models ( Sec 1 5)
T Hub nut
2 Hub
3 Outer 011 seal
4 Hub camer
5 Bearing
6 c,,chp
7 Inner otl seal
8 Stub axle (with helicitl cut
sphnes)
Fig. 10 .16 Removing the hub o n rear drum brake S aloon

models (Sec 1 S)
1 Bolts supporting hub caffier

2 Reac11on plate
3 Bolts
4 Extension
5 Puller plate
6 Nuts
7 Puller bolt
JI

23 At 1h1~ i.tage. then run out of the brake disc may be checked by may also be unbolted from the bulkhead
mounung the hub earner 1n a vice Refer 10 Chapter 9 for more details 8 To remove the s1ee11ng lock, unscrew the retaining bolt, then. w11h
If necessary. the disc may be ro posi11onod in rol111ion to rho hub. in the ign111on koy aligned w11h the small arrow between the 'A' and ' M '
order 10 obtain the correct run · out. posi tions. depress tho plunger In tho housing and withdraw the lock.
9 Refi 111ng 1s a reversal of remova l
Rear drum brake models
24 locate thu bearing camer in tho brake backpla te. after 1empora11ly
removing tht 5upponing bolls
25 Insert thE hub 1n the bearing and. using a long bolt. washers and
nut. druv. the hub fully 1n10 tho bea11ng.
All models
26 Ref11 the dnveshah w11h reference 10 Chapter 8. Section 5.
16 Rear hub bearings ( Estate m o dels) - renewal
Note Prem.iturc failure of the rear hub beaf!ngs can be causod by

heavy efectflcal current flow. as a result of a poor earth return of the
battery f'~gat1ve lead Radial Imes on the bearing outer track are an
md1ca11on f this cond111on. and where evident. the negative
lead to body connection should be cleaned and tightened when
renewing the bear1ngs
1 Remove 1he halfshaft as described in Chapter 8. Section 7

2 Suppon the bearing stop ring 1n a vice. then use a sharp cold chisel
10 make a 5 0 mm (0.2 in) groove across the stop ring.
3 Cut the lrp from the bearing 011 seal
4 Using a su11able puller (long) draw the stop ring from the halfshah
Alternauvely the stop 11ng may be drilled or chiselled free. but 1f 1h1s
method is used. care must be taken not to damage tho halfshaft
6 Romovo tho bearing, using the puller or levers. Remove the brake
backplate
6 Clean the halfshaft and backplate. Obtain a new bearing. 011 seal
and stop ring
7 Dip 1he new 011 seal in engine oil. and press 11 squarely into the
bearing by hand
8 Locate tho backplate and bearing on the halfshah
9 Pos111on a metal tube against the bearing inner track. and mount
the assembly on a vice Tie the backplate to the drive flange 10 prevent
11 being trapped by the bearing
10 Press or drive the halfshaft fully into the bearing
11 Similarly 111 the stop ring against the bearing. noting that the Fig. 10.17 Using a c old chisel to cut the rear hub beari ng
removol recess should be towards the bearing. stop ring on Esta t e models ( Sec 16)
12 Refu the halfshaft with reference to Chapter 8. Secuon 7.
17 Steering wheel - remo val and refi tting
1 Set the front wheels 1n the straight-ahead pos111on

2 Pns1: out the steering wheel centre pad. then use a socket 10
unscrew tho reta1n1ng nut (photo)
3 Mark the hub in relation 10 the inner column. then pull off the
steenng wheel If 11 1s 1igh1. a rocking action may release 11 from the
splines
4 Refining is a reversal of removal. but check that the steering wheel
1s correctly centred w 11h the front wheels stra1ght·ahead. Tighten the
nut while holding the steering wheel nm.
18 Steering column and lock - r emoval and refitting
1 Remove the steering wheel as descnbed 1n Sectton 17

2 Remove the lower trim panel from under the s1ee11ng column
J Mark the universal 101nt at the base of the column in relation 10 the
m1ermed1ete shah. then unscrew and remove the clamp bolt (photo).
4 Remove the comb1na11on swi tches as described in Chapter 12
6 01sconnec1 the 1gn1tion sw11ch wmng mulU· plugs
6 Unscrew the mounting nuts from the upper ond lower brackets,
and withdraw the steenng column from the universal 1oin1 (photos)
7 If necessary. the in1ermed1a1e shah can be removed by unscrewing
the pinch bolt(s) end removing the universal 1om1(s) or flexible
coupling whore applicable (photo) M ark the 1oints 1n rela11on to 1he1r Fig . 10 .18 Fi tting a new rear hub bearing oil seal on Estate
corresponding shafts before disconnecting them. The rubber grommet models (Sec 18)

Ch apter 10 Suspension and steering 205
17 2 Steering wheel retainmg nut 18.3 Steering column lower universal 101nt 18 6A Steermg column upper mounung
- clamp bolt arrow ed nuts (arrowed)
18 6B and lower mounting nuts 18 7 lntermed1a1e shah to power steering

gear flexible coupling
19 Steering gear - removal and refitting

5 Unscrew the pmch bolt from 1he mtermed1ate shaft low er universal
1omt or flexible couplmg
6 Unscrew and remove the two moun11ng bolts.
1 Apply tne handbrake Jack up the from of the vehicle and support 7 Withdraw the steering gear from the 1ntermed1a1e shaft suff1c1ently
on adn st~nds to mark the two shafts m relation to each other to ensure correct
2 On power assisted steering models, drain the fluid by unscrewmg reassembly
the feed and return pipe unions at the steering gear (photo). If the fluid 8 Separate the shahs. and withdraw the steering gear from under the
ts 10 be re used keep 11 '" a clean con tamer Also unscrew the steering vehicle
ram nu1 (ph010) 9 Refiulng is a reversal of remova l, but tighten all nuts and bolts 10
3 Remove both front wheels the specifi ed torque and checktk the front wheel alignment on
4 Unscrew the steering track rod end nuts on each side. then use a completion On power· ass1s1ed steering models, refill the fluid
t>allJomt splmer 10 release the track rod ends. reservoir with rererence to Secuon 24
19 2A fMd and return pipes (arrowed) on the power steering gear 19 2B Power steering ram mounting nu1
I ·l

20 Steering gear overhaul
The stee11ng gear should normally have a very long life before any
wear becomes evident. provided that damage has not occurred to the
rubber bellows resulting 1n inadequate lubr1cat1on.
In view of rhe special rools and gauges required to overhaul the
steering gear 111s recommended that when the need for this arises. the
unit should be changed for a new or factory reconditioned one rather
than dismantle the old one
21 Track rod end remova l and refitting
1 Apply the handbrake. Jack up the front of the vehicle and support
on axle stands Remove the apprOPfiate front wheel.
2 Loosen tho locknut on tho track rod.
3 Unscrow the track rod end nut (photo), an d use a balljoint splitter
tool to separate the taper from the steering arm.
4 Unscrew the track rod end from the track rod. nottng the number of
turns necessary to remove ii
5 Screw the new track rod end in the track rod the number of turns
noted in paragraph 4 If both track rod ends are being renewed. set 21 .3 Track rod end nut (arrowed )
them to tho 1ru1tal d1mens1on shown 1n Fig. t 0.19
6 Clean the taper surfaces, then fit the balljoint to the steering arm
and tighten the nut to the specified torque. If the balljoint taper pin
turns so preventtng the nut from being ughtened, use a 1ack or lever
under the track rod end to f0<ce the pm m its contcal seaL
7 Tighten the track rod locknut
8 Reftt the wheel and lower the car to the ground.
9 Check the front wheel alignment as described in Section 26.
22 Steering rack bellows - renewal
1 Remove the relevant rrack rod end as described in Section 21 .

2 On the lefl-hand side of power steering models, remove the track
rod as described 1n Sectton 23. and also disconnect the power steering
ram from the rack by unscrewing rhe nut
3 Release the cltps from each end of the bellows and w ithdraw the
a
bellows from the steering gear.
4 Fit the new bellows using a reversal of the removal procedure. w ith
reference also to Secttons 21 and 23 as applicable. Check that the Fig. 10.19 Track rod end initial setting dimension (Sec 21)
bellows 1s not twisted before tightening the clips.
a .. 55.0 mm (2. 17 m)
23 Track rod - removal and refitting
Remove the track rod end as described in Secuon 21 .

2 Loosen both bellows cltps, except on the leh-hand side of power
steering models, where the 101nt cover should be removed. On all other
models pnse the bellows from the steering gear
3 Unscrew the ball101nt from the rack The Peugeot tool for this ts
shown on Fig 10 20. ond 11 necessary a similar tool may be made from
steel plate Alternauvelv. use a pair of gnps
4 Wtthdraw rhe track rod and recover the lockwashers.
5 Relttt1ng 11 a reversal of removal, but fit new lockwashers where
applteable and ughten tho inner ball1oint and track rod end nut to the
spec1fted torque Check the front wheel ahgnment as described in
Section 26
24 Power steering flu id draining and refilling
1 With the engine switched off, disconnect rhe battery negative lead.
2 Unscrew the ftller ca p from the reservoir
3 Unscrew the union nut and disconnect the high-pressure pipe from
the rear of the power steonng pump Dram the fluid into a clean
conto1ner Fig . 10.20 Peugeot tool for unscrewing the track rod inner
4 Turn the steering slowly from lock to lock several times in order to balljolnt (Sec 23)
remove rema1n1ng flu id.
5 Raitt the high pressure pipe, ond tighten the union nut. The arm p1~0{1 on tho C -platlJ m ardor to grip thll bal!joint

6 Pour fresh fluid into lhe reservo11 to the ' Hot' ('Chaud') level, then
turn the steering slowly from lock to lock several times. If necessary.
top up the fluid to the 'Cold' ('Froid') level.
7 ConMct the battery nega11ve lead and stan the engine.
8 Wuh the engine idlrng. move the steering slowly from lock to lock
while topping-up the fluid to the 'Cold' ('Froid') level
9 When the level no longer drops. switch off the engine and re lit the
1Hle1 cap
25 Power stee ring pump - removal and r efitting
1 Unscrew the filler cap from the reservoir.

2 Position a container beneath the pump Unscrew the high-pressure
pipe union nut, and also disconnect the low- pressure pipe from the
rear of the pump (photos) Drain the fluid and disconnect the supply
hose
3 Loosen the tension adiustrnent bolt. push the pump towards the
engine. and disconnect the dnvebelt from the pulley (photos). Note
that on some models. 11 is necessary to unbolt the pulley from the
pump
4 Remove the tension bolt and spacer.
5 Unscrew and remove the pivot bolt and spacer. and wnhdraw the
power steering pump from the engine (photo) On some models. 11
may be necessary to unbolt the mounting bracket. On fuel in1ection
models, 11 will be necessary to remove the air filter.
6 II necessary. unbolt the tension link and reservoir bracket from the
engine (photos) .
1 If 11 is requ11ed to renew the pump drivebelL the cooli ng Ian
drivebelt must first be removed . as described In Chapter 2.
8 Rehtung 1s a reversal of removal . but tension the drivebelt as
follows. Ad1ust the pump so that the deflection of the belt. under fi rm Fi g . 10.21 Power st eering fluid reservo ir level marks
thumb pressure. midway between the pulleys. is approximately 1 2.5 {Sec 24)
mm (0 5 rn) - do not over-tension Refill the system with fresh fluid.
with reference to Section 24.
25 2A 01sconnectrng the power steering 25.28 ... and low-pressure return pipe 25.3A Loosen the power steering pump
pump high-pressure pipe .. tension bolt
25 38 and disconnect the drivebelt 25 5 Removir1g the power steering pump 25 6A Pump tension link-to-engine bolt
J ·I

208 Ch apter 10 Suspension and st eer i ng
27 Wheels and tyres - general care and maintenance
Wheels and tyres shou ld give no real problems 1n use provided that
a close eye is kept on 1heiri with regard to excessive wear or damage.
To this end, the following points should be noted.
Ensure that tyre pressures are checked regularly and maintained
correctly Checking should be carried out with the tyres cold and not
immediately after the vehicle has been 1n use. If the pressures are
checked with 1he tyres hot, an apparently high reading will be obtained
owing 10 heat expansion Under no circumstances shou ld an attempt
be made lo reduce the pressures 10 the quoted cold reading in this
instance, or ettect1ve undennflat1on will result.
Underinflalion will cause overheaung of the tyre owing to
excessive flexing of the casing, and 1he tread will not sit correctly on
the road surface. This will cause a consequent loss of adhesion and
excessive wear, not to mention the danger of sudden tyre failure due 10
heat build - up.
Overinflation will cause rapid wear of the centre pan of the tyre
tread coupled with reduced adhesion. harsher ride. and the danger of
shock damage occurring in the tyre casing .
Regularly check the tyres for damage in the form of cuts or bulges,
especially in the sidewalls. Remove any nails or stones embedded in
25 6B Removing the power steering fluid reservoir and bracket the tread before they penetrate the tyre to cause deflation If removal of
a nail does reveal that the tyre has been punctured. refit the nail so that
its point of penetration is marked. Then immediately change the wheel
26 Steering angles and front wheel alignment
and have the Lyre repaired by a 1yre deafer. Do not drive on a tyre in
such a condition. In many cases a puncture can be simply repaired by
Accura1e front wheel alignment 1s essenual to provide good the use of an inner tube of the correct size and type . If in any doubt as
steering and road holding characterlsucs. and 10 ensure slow and even to the possible consequences of any damage found, consult your local
1yre w ear Before considering the steering angles. check tha1 the tyres Lyre dealer for advice.
are correctly in flated. that the)ront wheels are not buckled. the hub Periodically remove the wheels and clean any dirt or mud from the
bearings are not worn or incorrectly ad1usted, and 1ha1 the steering inside and outside surfaces. Examine the wheel rims for signs of
linkage is in good order. w ithout slackness or wear at the 101nts rusting, corrosion or other damage. Lighl alloy wheels are easily
2 Wheel alignment consists of four factors· damaged by 'kerbi ng' whils1 parking. and similarly steel wheels may
Camber is the angle at wh ich the road wheels are set from the vertical. become dented or buckled. Renewal of the wheel is very often the only
when voP.wP.d from rhe front or rear of the vehicle Posotove camber is course of remedial action possible.
the angle {1n degrees) that the wheels are tilted o utwards at the top The balance of each wheel and tyre assembly shou ld be maintained
from 1he vertical to avoid excessive wear, not only to the tyres but elso to the steering
Castor is the angle between the steenng axis and a vertical, when and suspension components. Wheel imbalance is normally signified by
viewed from each side of the vehicle. Posiuve castor 1s indicated when vibration through the vehicle's bodyshell. although in many cases ii is
the steering axis 1s i nclined towards the rear of the vehicle at its upper parucularly noticeable through the s1eering wheel. Conversely, It
end should be noted that wear or damage in suspension or steering
Steering axis inclination is the angle, when viewed from the front components may cause excessive tyre wear. Out-of-round or out -of-
or rear of the vehicle. between vertical and an imaginary hne drawn true tyres. damaged wheels and wheel bearing w ear/maladjustment
between the top and bot1om strut mountings. also fall into this category. Balancing will not usually cure vibration
Toe is the amount by which the distance be1ween the front inside caused by such wear
edges of the roadwheel rims d1Hers from 1hat between the rear i nside Wheel balancing may be carried out w ith the wheel either on or off
edges. If the distance between the front edges 1s less than that at the the vehicle. If balanced on the vehicle. ensure that the wheel - to-hub
rear. the wh eels are said to toe -in. If the distance between the front relauonship is marked i n some way prior to subsequent wheel removal
inside edges is greater 1han that at the rear. th e wheels toe-out so that it may be refined in its original position.
General tyre wear is influenced to a large degree by driving style -
Note: Camber. castor and steering axis inclination are set during
harsh braking and acceleration or fast cornering wfll all produce more
producllon. and cannot be adjusted. Where the angles differ from
rapid tyre wear. Interchanging of iyres may result in more even wear,
those spec1fwd. suspect co/li s1on damage or severe wear m the steering
but this should only be carried out where there is no mix of tyre types
or suspension components
on the vehicle. However, it is worth bearing in mind t!'tat if this is
3 To check the front wheel alignment, first make sure tha1 1he lengths completely effective, the added expense of replacing a complete set of
of both track rods are equal, when the steering 1s in the straight-ahead lyres simultaneously is incurred, which may prove financially restrictive
positi on, Ad1ust 1f necessary by releasing the track rod locknu1s and for many owners.
turning the 1rack rods. Reposition the bellows if necessary, so 1hat 11 is Front tyres may wear unevenly as a result of wheel misalignment.
not twisted The front wheels should always be correctly aligned according to the
4 Obtain a tracking gauge These are available 1n various forms from senings specified by the vehicle manufacturer.
accessory stores. or one can be fabricated from a length of steel tubi ng, Legal restrictions apply to the mixing of tyre types on a vehicle.
suitably cranked 10 clear the sump and bellhousi ng, and having a Basically this means that a vehicle must not have tyres of differing
setSCrew and locknut at one end construction on the same axle. Although it is not recommended to mix
5 Wuh 1he gauge, measure the distance between 1he two wheel inner tyre types between fronl axle and rear axle, the only legally permissible
rims (at hub height) at the rear of the wheel. Push the vehicle forwards combi nation is crossply at the front and radial at the rear. When mixing
to rotate the wheel 1hrough 180' {half a 1urn). and measure the radial ply tyres. textile braced radials must always go on the front axle,
distance between the wheel inner rims. again at hub height, at 1he front with steel braced radials at the rear. An obvious disadvan tage of such
of the wlieel This last measurement should ditter from the ftrst by 1he mixi ng is the necessity to carry two spare tyres to avoid contravening
appropriate 1oe-in figure (see Specif1cat1ons) . the law in 1he event of a puncture.
6 Where the 1oe- in is found to be incorrect. release 1he track rod In tlie UK. the M otor Vehicles Construction and Use Regulations
lockrluts. and turn the track rods equally Note tha1one turn of the track apply to many aspects of tyre fitting and usage. It is suggested that a
rod will make a 3.0 mm (0 118 in) difference 1n the wheel alignment copy of these regr.lll1tions 1s obtained from your local police If in doubt
Tighten the lockn uts before checking 1he alignment again. and as to the current legal requirements with regard to wra condition,
reposluon the bell ows if necessary minimum tread depth, e1c.

28 Fault diagnosis - suspension and steering
Symptom Reason( s)
Car pulls to one side Worn front suspension lower ball1oin1

I ncorrec1 tyre pressures
Excessive pitching or rolling Weak shock absorbers
Wheel wobble or v1bra11on Unbalanced wheels

Damaged wheels
Worn wheel bearings
Excessive ryre wear Incorrect wheel alignment

Worn front suspension lower ball101nt
Unbalanced wheels
Strff steermg Seized track rod end ball1omt

Loss at steering gear lubricant
Low tyre pressures
Excessive movement of steering wheel Worn track rod end ball101nt

Worn rack and pinion

Chapte r 11 Bodywork and fittings

Contents
Air cond111on1ng system description end precautions .................. 27 Front grille removal and refitting ..................................................... 8
Air conditioning system maintenance ............................................. 28 General description ..•........ ........... ...........•............ ......................... .... 1
Bonnet removal and refitting ........................................................... 6 Heater - removal and refitting ............................................................. 25
Bonnet locks and cable release - removal and refiwno 7 Hearer blower - removal and ref1111ng ................................................ 26
Boot lid dismantl ing and reassembly .............................................. 14 Heater matnx - removal and refitting ................................................. 24
Boot hd removal and refitting .......................................................... 13 Maintenance - bodywork and underframe ........................................ 2
Bumpers - remova l and refitting ......................................................... 9 Maintenance - upholstery and carpets .............................................. 3
Centre console and heater control panel (1986-on models) - Maior body damage - repair ............................................................... 5
removal and refitting ........................................................................... 22 Minor body damage - repair ............................................................... 4
Door - dismantling and reassembly ......................•......................,..... 12 Seat belts - removal and refitting ....................................................... 29
Door - removal and refining ............................................................... 10 Seats - removal and refitting ............................................................... 18
Door trt m panel - removal and refitting ............................................. 11 Sunroof - general ....................... ....... .... ....... ..... ....... ............................. 19
EKtenor m11ror removal and refi11ing ................................................ 20 Tailgate - dismantling and reassembly ............... ........... ................... 16
Fecia panel (1986-on models) - removal and refitting ................... 23 Tailgate - removal and refitting ........................................................... 15
Facia panel and centre console (pre-1986 models) - removal Windscreen and rear window glass removal and refittmg -
and ref1t11ng .. ..................................................................... 21 general ................................................................................................... 17
1 General descript ion
The bodyshell is of one-piece design, with the front and rear

sections designed to crumple In a controlled manner, and absorb the
impact of a crash The central passenger compartment forms a safety
cell
The complete body is given en extensive anti- corrosion treatment
du11ng manufacture. Including stone-chip protection and wax injec-
tion Peu11eot guarantee the body against perforation as a result of
corrosion for a period of six years, provided the car 1s given periodic
Inspections by a Peugeot dealer
The heater uses heat from the engine coolant to heat the passenger
compartment and coolant flow is controlled by a thermostatic valve.
The heater flaps are activated by vacuum rams via the control panel.
The system uses engine vacuum from the Inlet manifold, and e vacuum
reservoir is provided on the left-hand side of the engine compartment
(photo)
2 Maintenance bodywork and underframe
The general condition of a vehicle's bodywork is the one thing that

slgn1f1cantly affects i ts value. Maintenance is easy but needs to be 1.3 Heater control vacuum reservoir
regular Neglect. particularly after minor damage. can lead quickly to

Chapter 11 Bo dywo rk and f i ttings 211
fu11her de1et1ora11on and cosily ropa1r bills It IS important also to keep Car Bodywork Reparr Manual This mcorporates mlormat1on on such
wa1ch on 1hose par1s of 1he vehicle not 1mmed1ately v1s1ble. for asptJcts 11s rust treatment. p11mtrng 11nd gl11ss fibre reparrs. as well 11s
instance 1he underside 1ns1de all 1he wheel arches and the lower pan details on more amb111ous repalfS mvolvmg weldmg and panel beatmg
ol 1he engine compartment
Th<t basic maintenance rout1ne for the bodywo1k 1s washing Repair of minor scratches m bodywork
pteftfably with a lot of water from a hose This will remove all the If the scratch 1s very superf1c1al. and does not penetrate to the metal
loose solids which may have stuck to the vehicle It 1s important to of the bodywork. repair 1s very simple Lightly rub the area of the
flush th- off in such a way as to prevent grit from scratching the scratch with a paintwork 1enovator or a very fine cutting paste to
hn15h The wheel arches and underframe need washing 1n the same remove loose palnt from 1he scratch and to clear the surrounding
v.iy to remove any accumulated mud which will retain moisture and bodywork of wax pohsh Rinse the area with clean water
ttnd to encourage rust Paradoxically enough. 1he best time to clean Apply touch-up paint to the scratch using a fine paint brush,
the underframe and wheel arches is in wet weather when the mud 1s continue to apply frne layers of pa1n1 unul the surface of the paint rn the
thoroughly wet and soft In very wet wea ther the underframe 1s usually scra tch 1s level with 1he surrounding paintwork Allow the new paint at
cleaned of large accumulat ions automat1cally and 1his is a good time least two weeks to harden then blend II Into lhe surrounding
for mspect1on paintwork by rubbing tho scratch area wit h a paintwork renova tor or a
Periodically, except on vehicles w 11h a wax -based underbody very frne cutting paste Finally, apply wax polish
ptotec11ve coa11ng, 11 1s 11 good idea 10 nave the whole of the Where t he scratch hos penetrated right through 10 1he metal of the
underframe of the veh icle steam cleaned. eng ine compartment bodywork, ca using the metal to rust, a different repair techn ique is
included so that a 1horough 1nspect1on can be carried out to see what requ ired . Remove any loose rust from th e bottom of the scratch w ith a
minor repa11r. and renovauons me necessary. Steam cleaning is penkni fe. then apply rust lnh1b1tmg pain t to prevent the formation of
a11a1lable at many garages and is necessary fo r removal of the rust 1n the f uture. Using a rubber or nylon applicator fill the scratch
accumulauon of oily grime which sometimes is allowed to become w 11h bodystopper paste If required , this paste can be mixed w ith
thick 1n certain areas If steam clean ing fac1ht1es are not available. there cellulose thinne1s to provide a v ery thin paste which is ideal for filhng
are one or two excellent grease solven1s available which can be brush narrow scra tches. Before the stopper-paste rn the scratch hardens.
applied The drn can then be simply hosed off Note that these wrap a piece of smooth con on rag around the top of a lrnger. Dip the
methods should not be used on vehicles with wax -based underbody finger rn cellu lose thinners and then quickly sweep it across the surface
p1otect1ve coating or the coating will be removed. Such vehicles of the stopper-paste 1n t he scratch; this will ensure that the surface of
should be inspected annually, preferably 1ust prror to winter. when the the stopper-paste is slrghtly hollowed. The scratch can now be painted
underbody should be washed down and any damage to the wax over as desc11bed earlier 1n t his Secuon
coating repa11ed Ideally a completely fresh coat should be applied It
wou ld also be worth considering the use of such wax-based
protection for 1n1ect1on rnto door panels sills, box secuons, etc. as an Repair of dents in bodywork
add111onal safeguard against rust damage where such protectton 1s not When deep denting of the vehicle's bodywork has taken place, the
provided by the vehicle manufacturer first task is to pull t he dent out. unul the affected bodywork almost
Alter washing paintwork w ipe off with a chamois leather to give an attains Its 011ginal shape Thero is httlo point m trying to restore the
un ?Otted clear l1n1sh A coat of clear protective wax pohsh w ill give original shape completely as tho metal in the damaged area will have
added protection against chemical pollutants in the air If the stretched on impact and cannot be reshaped fully to its original
pa1ntw0<k sheen has dulled or oxidised. use a cleaner/ polisher contour It is better to bring tho level of the dent up to a pom1 which 1s
combtMt•on to 18Store the b11lhance of the shine. This requ11es a lntle about % rn (3 mm) below the level of the surrounding bodyw ork In
effort but such dulling is usually caused because regular washing has cases where the dent is very shallow anyway. 11 1s not worth trying to
been neglected Care needs to be taken with metallic paintwork. as pull 11 out at all If the underside of the dent 1s accessible. 11 can be
special non abrasive cteaner/ pohsher is required to avoid damage 10 hammered out gently from behind, usrng a mallet w11h a wooden or
the f1n1sh Alwavs check 1ha1 the doo1 and venula tor opening drain plasuc head Whilst dorng this. hold a su11able block of wood firmly
holes and pipes are completely clear so that water can be drained out against the outside of the panel to absorb the impact from the hammer
Bright work should be 11eated in the same way as paint work. blows and thus preven1 a large area of the bodywork from being
Wmdscreens and windows can be kept clear of the smeary film wh ich 'belled-ou1'.
often appears by the use of a proprietary glass cleaner. Never use any Should the dent be 1n a secti on of the bodywork which has a
form of wax or other body or chromium polish on g lass. d ou ble skrn or some other factor making it inaccessible from beh ind, a
different techn ique Is called for. Drill several small holes through the
metal inside the area - par1icu larlv In the deeper sect ion Then screw
3 Maintenance - uphols t ery and carpets long self· tapping screws into t he holes just sufficien tly for them to
gain a good purc hase 1n the metal. Now t he dent can be pulled out by
pulling on the protruding heads of the screw s w ith a pair of pl iers.
Mats and corpe1s should be brushed or vacuum cleaned regularly to The next stage of th e repair is th e removal of the paint from the
keep them free of gnt If they are badly stained remove them from the damaged area. and from an inch or so of the surrounding 'sound'
vehicle for scrubbing or sponging and make quite sure they are dry bodywork. This 1s accomplished most easily by using a w rre brush or
before refitting Seats and rn tenor tum panels can be kept clean by abrasive pad on a power drill although 11 can be done iust as
wiping with a damp clo1h If they do become stained (which can be elfect1vely by hand using sheets of abrasive paper. To complete the
more apparent on light coloured upholstery) use a little hqu1d preparation for hlhng score t he surface of the bare metal with a
dt111rgent and a soft nail brush to scour t he g11me out of the gram of the screwdriver or the tang of a file. or altematrvely. dnll small holes rn the
material Do not forget to keep the headlining clean in t he same way as affected area This will provide a really good 'key· for tho filler paste.
the upholstery When using hqurd cleaners inside the vehicle do not To complete the repau see the Section on filling and re·spraying
~ -wet the surfaces being cleaned Excessive damp could get into
the seams and padded 1nte11or causing stains. offensive odours or even
rot If tllil ·n&1de of tho vehicle gets wet accidentally 11 1s worthwhile
Repair of rust holes or gashes in bodywork
Remove all paint from the aflec1ed area and from an inch or so of
1ali1ng somo trouble to dry 1t out properly, particularly where carpets
the surrounding 'sound' bodywork. using an abrasive pad or a wrre
lie invOllflld Do not leave 011 or electr1c heaters ms1de the vehicle for
brush on a power drtll If these are not available a few sheets of
t/llJ pu1pose
abrasive paper will do the iob iust as effectively W rth tho palt'lt
removed you will be able to gauge the seventy of the corrosion and
therefore decide whether to renew the whole panel (if this is possible)
• Mrnor body d amage - repair
or to repair the affected area. New body panels are not as expensive as
most people think and 11 is often quicker and more satisfactory to fit a
Tl,, pl1otogr11p/11c sequences on pages 214 and 215 illustrate the new panel than to attempt to repair large areas of c orrosion.
opr11t1ons di:tallod 111 the lollowmg sub· sections. Remove al l fitt ings from the affected area except those which w ill
Note Fot mo1e detadod mlotmation about bodywork repair, the act as o gulM to the original shape of the damaged bodywork (eg
Haynes Publisl1mg Group publish a book by Lmdsay Porter called The headlamp shell& etc) . Then, using tin snips or a hacksaw blade, remove

212 Ch apter 11 Bo d ywork and f it ti ngs
all loose metal and any other metal badly affected by corrosion. Before commencing to spray. agitate the aerosol can thoroughly,
Hammer the edges of the hole Inwards In order to create a slight then spray a test area (an old tin. or similar) until the technique is
depression for the filler paste. mastered. Cover the repair area with a thick coat of primer; the
Wire brush the affected area to remove the powdery rust from the thickness should be built up using several thin layers of paint rather
surface of the remaining metal. Paint the affected area w ith rust than one thick one. Using 400 grade wet-and-dry paper. rub down the
lnh1blt1ng paint, 1f the back of the rusted area is accessible treat this surface of the primer until it is really smooth. While doing this, the work
also area should be thoroughly doused with water. and the wet- and-dry
Before filling can teke place 11 will be necessary to block the hole in paper periodically rinsed in water. Allow to dry before spraying on
some way This can be achieved by the use of aluminium or plastic more paint.
mesh, or oluminrum tape. Spray on the top coat, again building up the thickness by using
Aluminium or plastic mesh is probably the best material to use for a several thin layers of paint. Start spraying in the centre of the repair area
large hole Cut a piece to the approximate size and shape of the hole to and then, using a circu lar motion, work outwards until the whole repair
be frlled. then posnlon it 1n the hole so that Its edges are below the level area and about 2 inches of the surrounding original paintwork is
of ihe surrounding bodywork. It can be retained in position by several covered. Remove all masking material 10 to 15 minutes aher spraying
blobs of filler paste around its periphery. on the final coat of paint.
Alumin ium tape should be used for small or very narrow holes. Pull Allow the new paint at least two weeks to harden, then, using a
a piece off the roll and trim II to the approximate size and shape paintwork renovator or a very fine cutting paste. blend the edges of the
required. then pull off the backing paper (if used) and stick the tape paint into the existing paintwork. Finally, apply wax polish.
over the hole; it can be overlapped if the thickness of one piece is
insufficient Burnish down the edges of the tape with the handle of a Plastic components
screwdriver or similar. to ensure that the tape ts securely attached to the With the use of more and more plastic body components by the
metal underneath. vehicle manufacturers (eg bumpers. spoilers. and in some cases major
body panels). rectification of more serious damage to such items has
Bodywork repairs - filling and re-spraying become a matter of either entrusting repair work to a specialist in this
Before using this Section. see the Sections on dent, deep scratch, field, or renewing complete components. Repair of such damage by
rust holes and gash repairs. th e DIY owner is not really feasible owing to the cost of the equipment
Many types of bodyfiller are avaiiable. but generally speaking those and materials required for effecting such repairs. The basic technique
proprietary kits wh ich contain a tin of filler paste and a tube of resin mvolves making a groove along the line of the crack in the plastic using
hardener are bes! for this type of repair. A w ide, flexible plastic or nylon a rotary burr In a power drill. The damaged part is then welded back
applicator will be found invaluable for imparting a smooth and well together by using a hot air gun to heat up and fuse a plastic filler rod
contoured finish to the surface of the filler. into the groove. Any excess plastic is then removed and the area
M ix up a little filler on a clean piece of card or board - measure the rubbed down to a smooth finish. It is important that a filler rod of the
hardener carefu lly (follow the maker's instructions on the pack) correct plastic is used, as body components can be made of a variety of
otherwise the filler will set too rapidly or too slowly. Using the different types (eg polycarbonate. ABS, polypropylene).
applicator apply the filler paSJe to the prepared area; draw the Damage of a less serious nature (abrasions, minor cracks etc) can
applicator across the surface of the filler to achieve the correct contour be repaired by the DIY owner using a two-part epoxy filler repair
and to le.vel the filler surface. As soon as a contour that approximates to material. Once mixed In equal proportions. this is used in similar
the correct one 1s achieved. stop working the paste - if you carry on too fashion to the bodywork filler used on metal panels. The tiller is usually
long the paste wil l become sticky and begin to ' pick up· on the cured in twenty to thirty minutes. ready for sanding and painting.
applicator. Continue to add thin layers of filler paste at twenty-minute If the owner Is renewing a complete component himself. or if he has
intervals until the level of the filler is iust proud of the surrounding repaired it with epoxy filler. he will be left with the problem of finding a
bodywork. suitable paint for fi nishing which is compatible with the type of plastic
Once the filler has hardened. excess can be removed using a metal used. At one time the use of a universal paint was not possible owing
plane or file. From then on, progressively finer grades of abrasive paper to the complex range of plastics encountered In body component
should be used, starting with a 40 grade production paper and applications. Standard paints, generally speaking, will not bond to
finishing with 400 grade wet-and-dry paper. Always wrap the abrasive plastic or rubber satisfactorily. However. it is now possible to obtain a
paper around a flat rubber. cork. or wooden block - otherwise the plastic body parts finishing kit which consists of a pre-primer
surface of the filler will not be completely flat, During the smoothing of treatment. a primer and coloured top coat. Full instruct.ions are
the filler surface the wet-and-dry paper should be periodically rinsed In normally supplied w ith a kit, but basically the method of use is to first
water. This will ensure that a very smooth finish is imparted to the filler apply the pre-primer to the component concerned and allow it to dry
at the final stage. for up to 30 minutes. Then the primer is applied and left to dry for about
At this stage the 'dent' should be surrounded by a ring of bare an hour before finally applying the special coloured top coat. The result
metal, which 1n turn should be encircled by the fmely 'feathered' edge is a correctly coloured component where the paint w ill flex w ith the
of the good paintwork. Rinse the repair area with clean water. until all plastic or rubber. a property that standard paint does not normally
of the dust produced by the rubbing-down operation has gone. possess.
Spray the whole repair area with a light coat of primer - this w ill
show up any imperfections in the surface of the filler. Repair these
lmperfecuons with fresh filler paste or bodystopper, and once more 5 Majo r body damage - repair
smooth the surface with abrasive paper. If bodystopper is used, it can
be mixed with cellulose thinners to form a really thin paste which is
The construction of the body is such that great care must be taken
ideal for filling small holes. Repeat th is spray and repair procedure until
when making cuts. or when renewing major members, to preserve the
you are satisfied that rhe surface of the filler, and the feathered edge of
basic strength and geometry of the structure, for safety reasons. In
the paintworl< are perfect. Clean the repair area with clean water and
addition. the heating of certain areas, particularly during w elding, is
allow to dry fully.
not advisable.
The repair area is now ready for final spraying. Paint spraying must
In view of the specialised knowledge necessary for this work. and
be carried out in a warm, dry. windless and dust free atmosphere. This
the alignment jigs and special tools frequently required, the owner Is
cond11lon can be created artificially If you have access to a large indoor
advised to consult a specialist body repairer or Peugeot dealer.
working area. but if you are forced to work 1n the open, you will have to
pick your day very carefully. If you are working indoors, dousing the
floor in the work area w ith water will help to settle the dust which
wou ld otherwise be in the atmosphere. If the repair area is confined to 6 Bonnet - removal and r efitt ing
one body panel, mask off the surrounding panels; this will help to
minimise the effects of a slight mis-match in paint colours. Bodywork 1 Open the bonnet and support with the stay.
fittings (eg chrome strips, door handles etc) will also need to be 2 Using a pencil. mark the position of the hinges on the bonnet.
masked off Use genuine masking tape and several thicknesses of 3 Unbolt the braided earth lead where fitted.
newspaper for the masking operations. 4 Place some c}°it h beneath the rear corners of the bonnet.

5 With the help of an assistant, support the weight of the bonnet, 3 Unscrew the nuts securing the cen tre brackets to the valance
then unscrew the hinge bolts and remove the bonnet from the vehicle (photo), and withdraw the bumper from the vehicle.
(photo) 4 Refitting is a reversal of removal.
6 Refitung 1s a reversal of removal, but check that the bonnet is
cen tral w ith in its aperture. II necessary, loosen the hinge bolts and Rear bumper
move It within the elongated holes to reposition it. Check for closure 6 Where applicable, unscrew the bolts securing the bumper side
and adjust the bonnet locks and strikers if necessary. sections to the valance.
6 On Estate models, remove both rear hght clusters.
7 Unbolt the main brackets from the valance and withdraw the
7 Bonnet locks and c able release - removal and refitting bumper. If necessary, unbol t the brackets from the bumper (photos).
8 Refitting is a reversal of removal.
1 Remove the steering column lower cowl and low er facia panel.
2 Unbolt the release handle, and unclip the cable (photo).
3 Remove the headlamp units ( Chapter 12). 10 Do or - removal and refitting
4 Disconnect the cables, and unbolt the locks (photo).
5 Unchp and remove the cables. The primary cable leads from the Drive out the roll pin from the door check strap, where this is
release handle to the right·hand lock. and the secondary cable separate from the hinge.
interconnects the two locks. 2 Where applicable, remove the twin panel and disconnect the
6 Refitting is a reversal of removal, but finally apply a little grease to central locking and loudspeaker wiring.
the 1aws of each lock ( photo). 3 Support the door in the fully-open position by placing blocks. or a
jack and a pad of rag , under 11s lower edge.
4 Either dnve out the hinge pivot pins (aher removing the plastic
8 Front grille - r em ova l and refitting caps) or unbolt the hinges (photo).
5 Withdraw the door from the vehicle.
Using a screwdriver through the slots in the radiator grille, remove 6 Refi tting is a reversal of removal, but where necessary adjust the
the cross- head screws. striker to ensure correct closure of the door (photo).
2 u~ the front grille from its location ( photo).
3 Refining is a reversal of removal.
11 Door trim panel - removal and refitting
9 Bumpers - r emoval and refitting 1 On models with manually-operated windows. fully close the
window and note the posit ion of the winder handle.
Front bumper 2 Using a piece of cloth, release the winder handle cfip and withdraw
1 Unscrew the bolts securing the side brackets to the valance. the handle. Remove the spacer (photos).
2 Remove the parking/ direction indicator lamps with reference to 3 On early models, slide the escutcheon from the interior handle
Chapter 12 (photo).
6.5 Removing the bonnet 7.2 Bonnet release handle (arrowed) 7.4 Bonnet lock
7.6 Apply a hule gre.ase to the bonnet locks 8.2 Removing the front grille 9.3 Front bumper bracket
I :I

Th is sequence of photographs deals with the repair of the dent In the case of a dent the first job - after removing surrounding
and paintwork damage shown in this photo. The procedure will irim - ls to hammer out the dent where access ls possible. This
be similar for the repair of a hole. II should be noted that the will minimise filling. Here. the large dent having been
procedure-.. given here are simplified - more explicit instructions hammered out. the damaged area is being made slightly
will be found in the text concave
Now all p aint must be removed from the damaged area. by In the case of a hole caused by rusting. all damaged sheet-metal
rubbing with coarse abrasive paper. Altematlvelv. a wire brush should be cut away before proceeding to this stage. Here. the
or abrasive pad can be used in a power drill. Where the repair damaged area Is being treated with rust remover and Inhibitor
area meets good paintwork. the edge of the paintwork should before being filled
be ·feathered· using a finer grade of abrasive paper
Mix the body filler according to its manufacturer's instructions •.• applying the filler. Filler should be applied w i th a tlexible
In the case of corrosion damage. it wlll be necessary to block off applicator, as shown, for best results; the wooden spatula being
any large holes before filling this can be done with aluminium used for confined areas. Apply thin layers of filler at 20- mlnute
or plasuc mesh. or aluminium tape Mako sure the area is intervals. untll the surface of the filler is slightly proud of the
absolutely clean before ... surrounding bodywork

Initial shaping can be done with a Surform plane or

•
The whole repair area can now be sprayed or brush-painted
Dreadnought file. Then, using progressively finer grades of wet- with primer. II spraying, ensure adjoining areas are protected
and-dry paper. wrapped around a sanding block. and copious from over-spray. Note that at least one inch of the surrounding
amounts of clean water, rub down the filler until really smooth sound paintwork should be coated with primer. Primer hes a
and flat Again, feather the edges of adjoining paintwork 'thick' consistency. so will find smell imperfections
Again. using plenty of water, rub down the primer with a fine When the stopper has hardened. rub down the repair area again
grade w,et-and-dry paper (400 grade Is probably best) until it Is before applying the final coat of primer. Before rubbing down
really smooth and well blended imo the surrounding paintwork. this lest coat of primer, ensure the repair area is biemish-free -
Any remaining imperfections can now be filled by carefully use more stopper if necessary. To ensure that the surface of the
applied knifing stopper paste primer is really smooth use some finishing compound
The top coat can now be applied. When working out of doors. After a period of about two weeks. which the paint needs to
l)lck a dry worm and wind free day. Ensure surrounding areas harden fully. the surface of the repaired area can be 'cuf with
are protected from over-spray. Agitate the aerosol thoroughly. a mild cutting compound prior to wax polishing. When carrying
then spray the centre of the repair area. working outwards with out bodywork repairs, remember that the quality of the finished
a circular motion. Apply the paint as several thin coats lob Is proportional 10 the time and effort expended
I :I

9 7A Rear bumper bracket 9.78 Bolt (arrowed) securing bracket to rear bumper
10.4 Door hinge incorporating check strap 10.6 Adjusting the rear door striker
11 2A Using a piece of cloth to release the clip on the window 11 .28 Window winder handle and clip
winder handle
I :I

11 2C Removing 1he spacer for 1he window winder handle 11 3 Removing the mtenor door handle escutcheon
4 Slide 1he cover from the locking knob (pho10)

5 Remove 1he screws from the armrest. then withdraw 11. On later
12 Door dismantling and rea ssembl y
model~ also remove the interior handle cover (photos)
6 On la1er models, remove lhe panel cen1re screws (photo) 1 Remove the trim panel as described m Secuon 11. then carefully
7 Using a wide-bladed screwdriver or special removal tool , release peel off the plasuc sheeting (photos)
1ho panel clips from the inner door. and withdraw the trim panel 2 Pull off the locking knob (photo)
(photos) 3 To remove the outer handle, unscrew 1he nuts and remove the
8 Rehmno 1s a reversal of removal. but first make sure thal the clips re1alning plate Disconnec1 the opera1lng rod and withdraw the handle
ant correctly located in the pa net from the outside (photos)
11 4 Removing the locking knob cover 11 SA On early models. remove the upper 11 58 lower screws •
screw ..
11 SC and armrest 11 .50 On later models, remove the 11.5 E . armrest .

screws ...
JI

11 SF •• and interior handle cover 11 .6 Door trim panel centre screw removal 11 7 A Prise the clips free ...
11 .78 and remove the door trim panel 12.1A Door panel plastic sheeung 12.1 8 View of the door w ith the plastic
sheeting removed
12 2 Removing the locking knob 12.JA Unscrew the nuts ... 12 38 .. remove the retaining plate ..
12 3C and withdraw the ou ter door 12.4 Inner door handle 12.6A Pull ou t the spring clip ...
handle

Chapter 11 Body wor k and fittings 219
4 To remove the inner handle, dnll out the retaining rivet. disconnect unscrew the Torx screws retaining the lock ( photo).
the rod and withdraw the handle (photo). 8 To remove the central locking unit on cars so equipped, unscrew
5 To remove the private lock, pull ou t the spring clip and disconnect the mounting bolts, disconnect the w111ng and w ithdraw the unit
the rod (photos). (photos).
6 To remove the w indow regulator, disconnect the wiring plug w here 9 To remove the door glass, unbolt the side channels (photo). Tilt the
electric windows are fmed, then unscrew the mounung nuts. slide the glass and w ithdraw 11 upwards.
lilting arm(a) from the channel, and withdraw the regulator through 10 Reassembly of the door Is a reversal of removal. When refitting the
1he access panel (photos) door glass. adiust the side c hannels so that the glass moves smoothly
7 To remove the door lock. disconnect the operating rods, then withou t excessive play
Fig . 11 .1 Fro nt door w indow reg ulator components - manually operated w indow (Sec 12 )
Packing 3 Regulator 5 Handle

2 Window channel 4 Spacer 6 Guide
j .\

220 Chapter 11 Bodywork and fittings
12 58 and withdraw the private lock 12.6A D1sconnec11ng the wiring from the 12 66 W indow regulotor and moun11ng nut
electric wi ndow motor
12 6C Erecm c window moror 12.60 Rear door w111duw rtoyulcsto1 1 2 6E Rt19u l111or lifting orm ond window
moun ting nu ts glass channel
12 7 Door lock Tone screws arrowed 12.SA Unscrew the bolts .. 12 88 ... and remove the control locking
unit
necessary. so that the lock engages 11 correctly

13 Bootlid - remova l a nd ref itting
1 Open the bootl1d. and use a pencil to mark the position of the
14 B oot lid - d ism antling and reassemb ly
hinges
2 Disconnect the wmng to the rear number plo te hghts.
3 Have an assistant suppon the boothd then unscrew the bolts and 1 Prtse the tnm from the inside of the boothd
hh 1t from the ve hicle ( photo) 2 Working from inside the boothd. pull out the spring clop and
4 To remove the hydraulic stay, disconnect the upper socket. ond withdraw the private Jock (photos)
unhoo~ the prston rod from the lower mounting (photo) 3 Unbolt and remove the lock (photo )
5 Ref1111ng 1s a reversal of removal . but check that the boothd is 4 Refltung is a reversal of removal. but adjust the lock so that the
ceniral w11 h1n its aperture. If necessary. loosen the hinge bolts ond bootl1d w eatherstrip Is compressed suff1c1ently 10 prevent entry of
move it within tho elongatod halos to repos111on 11. Ad1ust th e strtkor 1f water. AdJUSt the striker 11 necessary so thot tho lock engages correctly
·I

12 9 A door glass side channel retaining 13.3 Bootlid hinge bolts 13.4 Bootlid stay (arrowed)
boll
14 2A Pvll out th8 spring chp (arrowed) ... 14.28 ... end withdraw the private tock 14.3 Removing the bootl id lock
15 3A 01seonnecung the strut from the 15.38 ... and body 1 5.4 Tailgate hinge - Allen key bolt
iallgdtf (arrowed)
so that the lock lever engages it correctly (photo).

15 Tailgate - remova l and refitting
I Support the tarlgate in the open posrtton

16 Tailgate - dismantling an d reassembly
Disconnect the wiring for the· rear number plate lights.
3 Note which way round the hydraulic struts are fitted, then
1.ll!lCOnneot them by pnsmg out the plastic chps with a smell 1 Using a wide-bladed screwdriver or special toot (photo). prise the
screwdriver The struts may also be disconnected from the body trim from the inside of the ta ilgate
(photo) 2 Remove the rear window wiper motor as described in Chapter 12.
4 With the help of an assistant, pull back the weatherstrip, and use an 3 Unbolt the lock and disconnect the operating rod by prising 11 out
All11n key to unscrew the bolts securing the hinges 10 the brackets (photo)
1photo) Wuhdraw the tailgate from the vehicle. 4 Unscrew the pinch -bolt and disconnect the operaung rod from the
5 If necessary, remove the trim and unscrew the nuts to remove the private lock,~photo) .
rubber guides (photos) 5 Reasseml)ly is a reversal of dismantling, but adjust the operatlng
6 Refitting 1s a reversal or removal, but ad1ust the striker 1r necessary. rod to ensure correct movement or the lock lever.

15.5A Removing the trim ... 15.5B ... for access to the rubber guide l 5.6 Tailgate striker
1 6 1 Pt1s1n9 off 1ho 1ailg::110 ttom 16.3 Tailgate lock - operating rod arrowed 16.4 Opereung rod and pinch · boh
(arrowed) on the ta ilgate private lock
mounting Torx belts (photo) .

17 Windscreen and rear window glass remova l and refitting
2 Move the seat fully rearwards, and remove th e front sliding track
- general
mounting bolts.
3 Remove the seat from the vehicle.
Removal and fitung of the windscreen and rear window glass 1s a
specialist 1ob req uiring the use of equipment not normally available to
the home mechanic, and therefore it 1s recommended that the work is Rear seat
enttusted to a w indscreen replacement company or Peugeot dealer. 4 Press the rear seat cushion down and rearwards to disengage it
from the central mounting bracket. then lift it forwards (photos) .
5 Bend up the tabs retaining the bottom of the backrest, then lift the
18 Seats remova l and r efitting backrest from the upper hooks (photos).
Front sears Front and rear seats

1 M ove the seat fully forwards, and remove the rear sliding track 6 Refitting 1s a reversal of removal.
18 1 Front sea t rear mounting Tone bolts 18.4A Disconnecting the rear seat 18.4B •.. from the mounting bracket
cushion ...

18.6A Rear seat backrest lower mounting 18.56 ... and upper hook 18.SC Rear view of the backres1
tab (arrowed) ...
19 Sunroof - general 3 Remove the loam seal (photo)

4 Support 1he mirror. then unscrew the screws and withdraw the
mirror from the door (photo).
l The sunroof fitted to some models is electrically operated, with a 5 Retitling is a reversal of removal.
control switch on the centre console. The electric motor operates a
gear on a cable rack, which opens and closes the sunroof.
2 Access to the electric motor 1s gained through the boot. Electrically operated
3 It 1s recommended that removal and refitting, and any adjustments 6 Remove the door trim panel as described in Section 11 .
to the sunroof, be entrusted to a Peugeot dealer. 7 Carefully prise off the plastic cover (photo).
8 Peel back the door Inner sheeting, and disconnect the mirror wiring
plug.
9 Support the mirror, then unscrew the screws and withdraw the
20 Exterior mir ror - removal and refitting
mirror from the door while feeding through the wiring (photos).
1 0 If necessary, the glass may be removed using a thin screwdriver
Manually operated through the hole in the housing. Turn the inner glass retaining clip by
1 Remove the door trim panel as described in Section 11. to-and-fro action (photos).
2 Carefully pnse off the plastic cover (photo) . 11 Rehmng is a reversal of removal.
Fig . 11 .2 Sunroof components (Sec 19)

T Sliding panel 5 Front slider support 9 Guide rail 12 Side moving crossmember
2 Cenue moving crossmember 6 Front slider 10 Side rail 13 Intermediate slide
3 Operaung rack cable 7 Control cable sleeve 11 Rear rocker and slide 14 Frame secur1ng bracket
4 Front trim piece 8 Electric motor
JI

224 C hapter 11 Bodywork and fittings
20 2 Remove the plasttc cover ... 20.3 ... foam seal ... 20.4A ... then unscrew the screws ...
20.48 and w11hdro:iw the manually 20.7 Remove the plastic cover ... 20.9A ... un:sc1ew the screws ...
operated exterior mirror
20 98 and withdraw the electrically 20.1 OA Using a screwdriver to re lease the 20.108 ... and remove the minor glass
operated exterior mirror internal chp ...
centre panel screws. Remove the centre panel ( photos).

21 Facia panel and c entre c ons ole (pre-1986 models) -
9 Remove the front door w indow and sunroof switches from the
removal and refitting
centre console.
10 Withdraw the cover from the handbrake lever (photo) .
1 Remove the instrument ppnel (Chapte1 12) 11 Ltft the centre console over the handbrake lever and remove the
2 Remove the d1911al clock (Chapter 12). console from inside the vehicle (photo).
3 Prise out the air vents ( photo). 12 Remove the air ducting from 1n front of the gearstick (photo).
4 Remove the radio (Chapter 12). 13 Prise ou t the plasuc check strap from the front of the glovebox
5 Unscrew tho screws and withdraw the radio surround (photos). (photo).
D1sconnec1 1he wiring from th e cigar lighter. 14 Unclip and remove the g lovebox (photos).
6 Pull the knob from the gearstick. then prise out and remove the 15 Remove the screws from each side of the heater control panel.
galte ( phOIO) 16 Remove the steering wheel and co lumn cowls (Chapter 10)
7 Mova the front sea ts forwards and unscrew the centre console rear 1 7 Remove the headlamp beam adjuster from the lower facia panel
mountmg screws alter prtsmg out the plugs (photos). 18 Unbolt the lower facta panel and disconnect the Instrument
8 Unscrew the cen tre console front mounting screws and the fac1a Illumination rheostat and 1gniuon key lllummauon bulb (photos)

21 3 Removing the air vents 21 SA Unscrew the screw s .. 21.SB .. and withdraw the radio surround
21 6 Removmg 1he gears11ck gaiter 21.7A Remove the plugs ... 21.7B ... and unscrew th e cemre console
rear moun11ng screws (Saloon model
shown)
21 8A Unscrew rhe front screws 21 .SB .. and facia cenrre panel screw s ... 21 .SC ... and remove the centre panel
21 10 Removing the handbrake lever cover 21 .1 l Centre console front section ready 21 . 12 Air duct ing (;irrowed)
for removal
'\

19 Lift out the ashtray ( photo).

20 Pull off the heater control lovers (photos) 22 Centre co nsole and heater control panel (1986- on
21 Remo11e the hazard warning and lighting switches (Chapter 12) models) - removal and refitting
22 Remo11e the screws and hit ofl tho heater control panel (photos).
23 Ri>rnove the glovebox 1llumlnation lamp switch (Chapter 12). and 1 Remove the electric window switches from the rear of the centre
remo11e the fac1a printed circuit board (photos) console (Chapter 12).
24 Remove the fusebox and stee11no column switches (Chapter 12) 2 Remove the screws from tho steering column lower cowl, and
25 Prise the covers from the fac1a panel mounting screws. and remove suspend the cowl leaving tho wiring attached.
the screw s Three bolts are located along the front of the fac1a. and two 3 Unbolt and remove the glovobox (photo)
beneath the fac1a 4 Remove the ashtray.
26 Withdraw the fac1a from one side of the vehicle. and at the same 5 Remove the radio ( Chapter 12)
11me disconnect the air vent ducts 6 Remove the screws and withdraw the blanking plate (photos) .
27 Rel1tttng •s a reversal of removal but ad1ust the glovebox cater 7 Withdraw the radio surround ( photo)
pos111on If nocessary (photo) 8 Unscrew the centre console· to· heator control panel bolts (photo)
21 13 Glovabox checkstrap (arrowed) 21 .14A Removing the glovebox 21 148 Plasuc chps on the bottom of the
glovebox
21 14C Glovebox hinge points (anowed) 21 1 SA Unboll the lower fac1a panel 21 188 end disconnect the instrument
1lluminat1on rheostat
21 19 Remo111ng the ashtray 21 20A Removing the hooter control 21 208 from the control quadrant
lever .. (arrowed)
' l

21 22A Heater control panel screw removal 21 228 Rear view of the heater contro l 21 23A Removing 1he glovebox lamp and
panel fac1a primed c1rcu11 board
21 23B Disconnecting 1he wmng from the 21.27 Glovebox catch 22.3 Glove box mounting bolt
fac1e printed circuit board
22 6A Remove the screws 22.68 .. and w 11hdraw the b lanking p la1e 22. 7 Removing the radio surround
22 8 Unscrewing 1he cen tre 22.9A Prise out the plasuc cover .. 22.98 ... and unscrew 1he heater control
console-to-heater con trol panel bolts panel screw

9 Prise out the plastic cover and unscrew the screw located above panel (pho10). Disconnec1 rhe wiring and the vacuum pipes, afler
the air vents ( photos) noting their locations,
10 Pull the knob from the gear lever (photo) 18 Retinmg 1s a reversal of removal
11 Pull 1he grip from the handbrake lever ( photo).
12 Remove the screw behind the ashtray (photo ).
13 Remove Iha front electric w indow switches (if fined) and
23 Feela panel (1986 -on models) - removal end refitting
disconnect the wiring {photo).
14 ?rise up the rear of the gear lever surround. then release Iha front
clips (phoros) 1 Disconnect the battery'negallve lead.
15 Remove rhe cover at the rear of the centre console, and unscrew 2 Remove the instrument panel (Chapter 12).
the screws (photo) 3 Prise out the plastic cover above the centre vents.
18 Remove the front mounting screws, 1hen withdraw the centre 4 Remove the ashtray.
console from rhe vehicle (photos). 5 Remove the steering wheel {Chapter 10).
17 Remove 1he mounting screws. and w ithdraw the heater control 6 Remove the radio (Chapter 12)
22 10 Removing the gear lever knob 22.11 Removing the handbrake lever grlp 22.12 Removing the screw behind the
ashtray
22 13 Disconnect 1he wiring from the front 22 14A Lifting the rea1 of the gear lever 22.148 Releasing the front of the gear lever
electnc window sw itch surround surround
22 15 Removing the centre console rear 22 16A Centre console front mounting 22.168 Removmg the centre console rear
cover (Estate model shown) screws (arrowed) section
11

screws, and three screws along the bottom

18 Li ft th e facia panel from the centre tab, and withdraw 11 from one
side of the vehicle
19 Refitting is a reversal of removal . but in particular, make sure that
the wi nng harness Is located correctly
24 Heater matrix - removal and refitting
1 Drain the coohng kystem as described In Chaprer 2

2 Remove the glovebox.
3 Remove the steering column and pedal bracket as described in
Chapters 9 and 10.
4 Disconnect the heater valve control cable (photo)
5 Loosen the cltps and disconnect the coolant hoses from the matnx
(protect the carpets from spilled coolant)
6 Unscrew the mounting bolt and wnhdraw the matrix from the
heater
7 Refilling 1s a reversal of removal but fill the coohng system w•th
teference to Chapter 2.
22 l 7 W11hdraw1ng the heater control panel
7 Unscrew the two upper screws and hit the radio surround from the
lowe1 tabs
8 Open the glovebox. then squeeze in the sides and disconnect the
rod (1f luted) to remove 11
9 Remove the upper screw. the screw 1n the ashtray aperture. and the
th1ee lower screws, and w ithdraw the heater control panel
10 ldont1fy the heater vacuum pipes for location then disconnect
them Similarly disconnect the wiring plugs.
11 Remove the switches from the right-hand side of the fac1a panel by
rdmoving the two screws and d1sconnec11ng the w1r1ng
12 Remove the steering column lower cowl and the lower fac1a panel
Disconnect the headlamp height control and the instrument illum1-
na11on rheostat.
13 Disconnect the glovebox lllum1nat1on light and switch and where
fined the passenger compartment temperature sensor.
14 Pull out the side air vents. and 1f fitted, the loudspeaker grilles.
15 Prise out the fac1a centre fron t cover
16 Release the speedometer cable and wmng harnesses.
17 Unscrew the mounting screws and nuts. There are two upper nuts 24 4 Heater valve and con trol cable (arrowed)
at tne front corners, one screw at the centre front, two side bottom
Fig. 11 .3 Disconnec t ing the c oolant hoses from the heater Fig. 11 .4 Heater matrix mounting bolt (1) - left-hand drive
matrix (Sec 24) vehicle shown (Sec 24)

230 Chapter 11 Bodywork and f itt ings
associated components and any uems within the engine and heating
compartment that necessitate d1sconnec11on of the system.
2 The refrigeration circuit contains a liquid gas (Freon). and it is
therefore dangerous to disconnec1 any part of the syS1em without
specialised knowledge and equipment. If for any reason the system
must be disconnected (engine removal for example). entrust this task
to your Peugeot dealer or a refrigeration engineer.
3 The refrigerant gas muSt not be allowed to come in contact w ith a
naked flame, or a poisonous gas will be created. Do not allow the fluid
to come In contact with the skin or eyes.
4 The system consists of a compressor (belt- driven by the engine). a
condenser (located in front of the radiator). a receiver/dryer, and an
evaporator (located In the passenger compartment). A blower Ian
forces air through the evaporator to provide cooled air inside the
passenger compartment
28 Ai r c on di tioning system - maintenance
Regu larly inspect the condition of hoses and the security of

Fig. 11 .5 Removing t he h ea ter matri x ( Sec 24 ) connections.
2 A sight glass 1s located on top of the receiver/ dryer chamber If
bubbles are evident immediately after switching on the system, a fluid
25 Heater - removal and refitting leak 1s indicated.
3 Keep the fins of the condenser free from flies and dirt, and keep tile
compressor drivebelt in good condition and correctly tensioned (the
procedure is similar to that for the dnvebelt given in Chapter 2).
2 Drain tl'le cooling system (Chapter 2)
4 Water dripping or collecting on the floor under the car Is quite
Pre-1986 models normal, and is the result of condensation.
3 Remove the g1ovebox. lower facia panel, and steering column 5 Run rhe system for a few minutes each week when it is not in
lower cowl regular use.
4 Disconnect the heater hoses (protect the carpet from spillage).
5 Unscrew the heater side flange upper bolts.
6 ldenufy and disconnect the heater vacuum pipes.
7 D1Sconnect 1he heater w iring plugs (pho10), 29 Seat belt s - remov al and r efitti ng
8 Pull oft the hea 1e1 control knobs, 1he11 rt111rovt1 1ht1 scrttws crnd
w ithdraw the heater control panel wahout disconnecting the wiring. 1 To remove the front seat belts. remove the trim from the centre
9 Unscrew the heater mounting bolts from the crossmember, and the pillar, then unbolt the Inertia reel . Also unbolt the upper guide and rear
mounung nu ts on the bulkhead (photo). mounting (photos) .
10 Disconnect the air ducts and remove the heater unit. 2 Unbolt the front S1alk from the body.
11 Ref1tung is a reversa l of removal. 3 To remove the rear seat belts, remove the trim from the luggage
compartment, then unbolt the inertia reel (photo). Also unbolt the
1986- on models upper guide and rear mounting.
12 Remove the fac1a panel as described in Secuon 23. 4 Unbolt the stalk from the body.
13 Unbolt the lac1a support crossmember. 5 Refitting is a reversal of removal - ensure that all mountings are
14 Remove the glovebox illumination lamp. ughtened securely.
15 Disconnect the air ducts from the top of the heater.
16 Unscrew the side support bolts.
17 Disconnect the lower air ducting.
18 D1sconnec1 the heater hoses (protect the carpet from spilled
coolan t). and rhe vacuum pipes
19 Unscrew the mounting bolts and remove the heater unit.
20 Ref1mng IS a reversa l of removal
26 Heater blower - removal and refitting
1 Uncllp the hydraulic brake pipes from the left-hand side of the
bulkl'lead
2 Remove the heater blower cover. The cover 1s made of very brittle
mateual and care must be taken not to break It.
3 Release the air duct from the heater blower.
4 Disconnect the winng plug.
5 Uncl1p the heater blower and withdraw 11 from the bulkhead. On
luel injection models. the throttle housing and air box may be removed
to provide add111onal worl(ing room
6 Ref1111ng is .., reversal of removal.
27 A ir conditio ning system - descr ipt i o n an d prec autions
25.7 Heater wiring plugs (arrowed)

1 When an n1r con ditioning system is fi tted, it Is necessary to observe
special precautions whenever dealing with any part of the system, its

25 9 Heater mounung nut (arrowed ) 29 1A Removing the centre pillar trim on an Estate model ..•
29.18 .. and on a Saloon model 29.1 C Front seat belt inenia reel
29 1D Remove the cap ror access to ... 29.1 E .. the fr~nt seat belt upper guide bolt

29 1F Front seat belt rear mounting 29.3 Rear seat belt inertia reel
J .\

Chapter 12 Electrical system

Contents
Ahernator - bfush renewal .. .................................. ...................... . 7 Heated rear screen general .......... .... .......... .......... ....... ... 29
Al111rnaror descripuon and resting . •. • .... • ..... •••. •............... .. 5 Horn unit removal and rehmng ... ....... ........ 24
Alternator - remova1 and ref1111ng ..••• ....... .... .••.• 6 Instrument 1lluminauon rheostat - removal and refining 15
Banerv - maintenance ..... ...... ................................... •. .... . 3 Instrument panel d1sman1hng and reassembly 17
Battery removal and ref111mg ................ ......... ............................ .. 4 Instrument panel removal and ref1mng .... .. ........................... 16
Bulbs (exterior) - renewa l .............................................................. 19 Radio Interference and CB equipment . . .... .................................. 33
Bulbs (interior) - renewa l ........................................................._..... .. 20 Radio. speakers and aerial - removal ond refining ........................ 28
Central locking system - general ........................................................ 31 Routine maintenance ............ .......... .... .... .... ................................... 2
Cigar lighter renew al and refitting .. ............................................ .. 13 Speedometer cable removal and ref1111ng .... .................................. 18
01g1tal clock removal and refitting . • ...... • ••• .. .... .••• •. 14 Starter motor - descnpuon and tesung ............................ 8
O•m·d•p hghl!ng - general ••• •• ••• ... .. •••• ••• •. 32 Staner motor - overhau I ............................ 10
Fault diagnosis electrical system ............................... ................. .. 34 Staner motor - removal and refitung . .. ................. .. 9
fuw and 1elays general • .••• ......... ................. 11 Switches - removal and refitting ..... .. ...................... 12
Get rol description • . .... ••••.....•••......•••••.... 1 Tailgate wiper motor (Estate models) removal and ref1111ng .. 27
Headlamp beam alignment .... ............... ....... .. .... .•• ........ 22 Washer system - general .......... .. . ... .... ....... .. ............... 30
Headlamp beam load ad1uster - general ........................................ 23 Windscreen wiper motor and linkage remova l and refitting ........ 26
Headlamp unu removal and refitting . .................... ........ ..... 21 Wiper blades and arms - removal and reflt11ng ................................ 25
Specifications
System type 12 volt negative eanh. banerv. alternator. and pre-engaged starter
motor
Battery
Roung .................................................................................... 300 amps (rapid discharge rate to - 1a•c)
Maximum charging rare ............................................................................ . 6 0 amps
Alternator
Flat ng carburettor models ..... ................. • .. ..... ............................ .. 500 watts
Rat ng fuel in1ect1on models .................................................................. 750 watts
M " mum bfush length ...........................................-.... •.......... . 5.0 mm (0.20 tn) beyond holder
Starter motor
Type .................... Pre-engaged
Mm1mum brush length 10.5mm(0.41 1n)
I

234 Chapter 12 Electrical system
Fuses
No Circuit p ro tec ted Rating (amps)
1 Rear loglamps ... ...... ......... .... .............................. . 7.5
2 Rear view mirrors. sunroof. electric w indows.
gtovebox parcel tray. automatic trans-
m1ss1on gear selector. clock 1llum1nat1on,
heated sea ts ... .. .............................................................. 26
3 Windscreen wash/ wipe. heated rear window and
extenor mirror relay, direction indicators,
map reading lamp, courtesy mirror,
temperature con trol ........ ........... .. ..... ............................... 20
4 Hazard warning . ....... .......... . .. ............................... 15
5 Clock. horns. rear interior lamp, bootlamp.
cigar lighter, cen tral door locking. front
interior lamp delay, radio .. .. .. .. .. . ............................. .. 20
6 Spare .......................................................................... .. 25
7 Front interior lamp. central door locking ............................ .. 15
8 Reverse lamp, automatic transmission
inhibitor swi tch ...................................................................... .. 15
9 Heated rear w indow and exterior mirror ............................. .. 25
10 Heater motor ................................. ...................................... 10
11 Stop-lamps instrument panel ... . .. .. .. ....................... .. 15
12 Instrument panel illumination rheostat .. .. . .................. .. 7.5
12A Fac1a panel and switch 1lluminat1on. front
parking lamps. 'lights-on' warning, warning
lamps, rear lamps. number plate lamps .............................. .. 7.5
15 or 126 RH tail lamp ............................... ...................................... . 7.5
13 LH tail lamp ............................................................................. . 7.5
14 Radio ......................................................................................... 7.5
Bulbs Wattage
Front d1recuon 1nd1cator ................................_ ........ ~ .................... ,_.. , 21
Front parking .................. _ .........- ..................................... . 5
Side marker ........................................................................ . 4
Rear direction 1nd1cator ............................................................................... 21
Stop-lamp ................................................................................................. . 21
Tail lamp .... ..................................................................................... .. 5
Rear foglamp . •...................................................................................... 21
Reversing lamp ........................................................................................... 21
Headlamp . .......................................................................................... 55/ 60
Glovebox .......................................................- ........................... 5
Interior lamps . .. ....... _,,...............................~ ..................................... .. 5
Torqu e w r en ch setti ngs Nm lbf ft

Starter motor ......... ................................................................................... . 20 15
Alternator mounting bolt ............................................................................ . 45 33
General descript ion Check functioning of lights

2 Check that the headlight main and dipped beams function
correctly. Also check the parking lights, rear lights. and indicator lights
The elec111cal system is of 12 volt negative earth type. and the major
components are a banery. a belt-driven alternator, and a pre-engaged
starter motor.
The alternator has an integral regulator, which varies the output 3 Battery - maintenance
according to demand lrom the battery and electrical equipment
The electrical system has many semi-conduct or components.
1 The battery may be of conventional or low-maintenance type,
which may be permanen tly damaged 11 excessrve current 1s passed
depending upon the date of production of the car.
through them, or 1f their supply leads are connected the wrong way
2 With conventional batteries, check the electrolyte level regularly,
round It 1s therefore recommended that the battery is disconnected
end add purified water to the cells so that the electrolyte level 1s 10.0
when working on the system. and that particu lar care is exercised to
mm (0. 4 in) above the tops of the plates.
ensure correct electrical connections.
3 With low -maintenance batteries. the electrolyte level should only
require checking after the first four years, and every tw o years
therea fter.
2 Routine main tenance 4 Never attempt to add acid to a battery - this could prove
dangerous. If electrolyte must be added to make up for spillage caused
C1uy ouc tha following procedures at the intervals gJVen i n Routine by careless removal of the battery, always have the 1ob done by your
maintenance at the front of this manual dealer or battery specialist.
5 Keep the battery terminals smeared with petroleum 1elly to protect
Check battery electrolyte level (where applicable) them agarns1 corrosion.
1 Remove the battery cell covets. and check the electrolyte level as 6 Any corrosion occurring on the battery platform or surrounding
described in Section 3. bodyw ork should be treated immediately to neutralise it. Apply sodium
JI

Chapter 12 Elect rical syst em 235

bieatbon.stu or household ammonia. wash off and then paint the
affected areas
7 The battery will nor normally require charging from the mains
supply bur 1f only very shoft 1oumeys are made. with much use being
made of the starter and electrical accessones. then a regular charge
from an ou tside source may be requ11ed
8 An 1nd1ca11on of the state of charge of a battery can be obtained by
checking the electrolyte in each cell. using a hydrometer The specific
gravity range of the electrolyte at a temperature of 20 C. 1s as follows.
Fully charged 1 280
H1lf·charged 1 200
Flat 1 120
9 Before charging the battery. remove 11 from the car as described in
the nekl Secuon
1O Connect the leads correclly. and make sure that no sparks or naked
flames are allowed near the battery during charging, as the hydrogen
beong produced by tho battery cou ld cause an explosion.
4 Battery - removal and refitting
The battery 1s located 1n the front left· hand corner of the engine 4.3 Battery clamp
compartment
2 Loosen the terminal clamp nut and disconnect the negauve battery
le.ld. then s1m1farly disconnect the posmve battery lead. Position the
leads to one side. away from the battery
3 Unscrew the clamp bolt (photo) or nuts. and hit the battery
carefully from the engine companment On some models. the clamp is
l111ed to the base of the battery. but on others. the clamp fits over the
tOll of the battery
4 Refitting is a reversal ol removal but smear the terminals w ith
petroleum 1elly on compleuon Connect the pos111ve battery lead first,
followed by the negative lead
5 Alternator - description and testing
1 The alternator 1s of the rotating field coil design. with an integral

voltage regulator The ou tput windings are wound on the stator. and
the field windings are wound on the rotor A diode rectifier 1s
incorporated in the alternator to provide direc1 current for charging the
batteiy
2 To prevem damage to the alternator semi-conductor components.
do nor run the engine with the alternator 01 battery leads disconnected,
do not connect the battery leads the wrong way round, and always
clisconnect both battery leads before charging it. If using electric
welding equipment on tho vehicle. disconnect both the battery and 6.3 Alternator main cable ( 1) and warning lamp wire (2)
ahernato1 leads
3 To test the alternator first check that the battery 1s rn good
condu on the dnvebelt 1s correctly tensioned and the alternator wiring
~secure
4 Connect a vollme ter across the battery terminals. then run the
engine at 3000 rpm. The recorded voltage should be between 13.3 and
14 81101ts Repeat the test with all accessones and lights on, and check
1hat the voltage 1s sull w1thrn the same hm1ts If not, the alternator
vottage regulot01 is faulty. and should be renewed
5 If the alternator is sull inoperauve. remove the brushes and using
an ohmmeter check that the resistance of the rotor windings 1s
between 3 ond 5 ohms If not. the windings are faulty
8 Alternator - removal and refitting
Disconnect the battery nega11ve lead

2 loosen the pivot and ad1ustment bolts, swivel the alternator
toward< th& engine. then remove the dnvebelt from the pulley
J Un:;crew the nut and disconnect the main cable from ns terminal.
Also d.sconnect the warning lamp wire (photo)
4 Remove the ad1us1ment bolt and spacer. II necessary. the
ac11ustmen1 hnk may be unbolted from the cylinder head or block as
applicable (photos)
5 Remove the pivot bolt, and hit the alterna tor from the engine 64A Remov1n~ the alternator adjustment bolt and spacer
(phoro)

236 Chapter 1 2 Electrical system
6 48 Alternator adjustment link removal 6.5 Removing the alternator pivot bolt
6 Refitting 1s a reversal of removal , but tension the drivebelt as

described 1n Chapter 2.
7 Alternator - brush renewal
Note: Several different eliernetors have been fitted to the model range.
This Section describes brush renewal for the Femsa alternator. but the
procedure for o rher types is similar
1 With the alternator removed from the engine, unscrew the nuts and
remove the plastic cover. Remove the spacers (photos).
2 Unscrew and remove 1he bolt retaining the resistor bar to the
alternator (photo). Loosen the nut at the other end of the bar, and
swivel the bar outwards.
3 Disconnect the wiring from the ·c· terminal on the brush holder
(photo)
4 Note the location of the second w ire on the brush holder, then
remove the screw and withdraw the brush holder (photos).
5 Check 1he condition of the slip rings If they are blackened. clean
them w11h a fuel-moistened rag. II they are deeply scored or grooved. 7. 1 A Unscrew the nuts ...
then the alternator 1s probably well-worn and should be renewed.
6 Check the length of the carbon brushes ( photo). If less than the
specified minimum length, the brush holder must be renewed .
7 Reassembly is a reversal of dismantling.
8 Starter motor - description and testing
The Staner motor is located on the rear left-hand side of the engine,
and 1s bolted to the gearbox It is of the pre-engaged type. w here the
drive pinion 1s brought into mesh with the starter ring gear on the
flywheel/dnveplate before the main curren t is applied.
2 When the starter switch 1s operated, current flows from the battery
to the solenoid. which Is mounted Ol'l the top of the starter motor body.
The plunger in the solenoid moves inwards. so causing a centrally-
pivoted lever to push the dnve pinion Into mesh w ith the starter ring
gear When the solenoid plunger reaches the end of Its travel. 11 closes
an internal contact. and full staning current flows to the starter field
coils The armature is then able to rotate 1he crankshaft. so starting the
engine.
3 A special freewheel clutch is f111ed 10 1he Staner drive pinion, so
that as soon as the engine fires and starts to operate on 11s own, it does
not drive 1he staner motor.
4 When the starter switch Is released, the solenoid 1s de-energised. 7. 1 B ... and remo~J the plastic cover ...
and a spring moves the plunger back to its rest position. This operates

Chapter 12 Electrical syst em 237
71C and spacers (arrowed) 7.2 Unscrewlng the resistor bar bolt 7.3 Brush holder terminal and wiring
(arrow ed)
7 4A Aemovill of 1he second wire from the 7.4B flemoving the brush holder 7.6 Carbon brushes (arrowed) and brush
br~sh holder holder
the pivoted lever. 10 withdraw the drive pinion from engagement w ith 4 Unscrew the mounung bolts. and w ithdraw the starter motor from
the sumer rmg gear. the gearbox (photos).
S If the starter motor fails to turn the engine when the swrtch rs 5 Where filled. remove the cover plate from the gearbox aperture
oP'!rated, there are four possible reasons why: (photo).
6 Refitting is a reversal of removal.
a) The battery is discharged or faulty
f/)) The electlical connections between switch, solenoid. battery
and sta1cer motor are somewhere fat/mg to pass the necessary
current from the bactery, through the starter. to earth
(c) The solenoid has an internal fault
(d) The sta1ter motor 1s electflcally defective
6 To check 1he ba11ery. switch on the headlights. If they dim after a
few seconds, the banery 1s d1schar9ed. If they glow brightly, next
opt'fate 1he lgn1t1on/staner switch If the he11dligh1s dim, this indicates
1hat power 1s reach ing the starter motor. but failing to turn It If the
s1aner turns very slowly, go on to the neict check
7 If 1ne headlights remain b11ght when the switch 1s operated. then
powe1 is not 1eoch1ng the starter motor Check all conneciions from the
bauery 10 the solenoid for security Check that the earth cable between
the engine and body is also connected securely
8 If the solenoid clicks when the swnch is operated. the starter motor
rnvst 11ave an internal fault.
9 To ·check that current 1s reaching the starter motor. connect a
voltmeter to the solenoid- to-motor terminal, and operate the switch II
u ent ts available. the starter mo tor must be removed for further
n~ t1gat1on
9 Starter motor - removal and refitting
I Disconnect the battery negative lead

9.2 Starter mOE!t' solE!nold terminals and w iring
2 Disconnect the wiring from the solenoid term inals (photo)
3 On fuel 1n1ect1on models. unboh the bracket from the front of the
~w1e1 motor

238 Chapter 12 Electr ical system
9.4A Unscrew the bolts (arrow ed) .. 9.46 ... and remove the starter motor
9 4C S1ane1 motor un11 9.5 Removing the starter motor cover plate
10 Starter mot or - overhaul
1 Full overhaul of the staner motor is a specialist 1ob. and best

entrusted to an au to electrlc1an.
2 Exploded view s of the Oucether and Paris- Rhone starter motors are
shown in Figs 12 1 and 12.2 respectively Bosch and Va leo types may
also be filled
11 Fuses and rel ays - general
1 The main fusebox 1s loca ted in the right· hand rear corner of the
engme compartment Access to the fuses and relays Is gained by
removing the cover (photo)
Fig . 12.1 Exploded view of the Ducellier starter motor

(Sec 10)
1 Drlvo end housing 5 Brush endplate

2 Dflve pinion 6 Solenoid
3 Armature 7 A cwating lever
4 Field coils
II

Chapter 12 El ec trical system 239
Fig. 12.2 Expl oded v i ew of the Par i s- Rh One starter motor

( Sec 10) Fig. 12.3 Fuse numbering ( Sec 11 )
1 Dflve end housing 5 Brush endplote
2 Drive pinion 6 Solenoid Refer to Specifications Section
3 Armature 7 Actuating lever for details
4 Field coils
2 The c1rcu1t protected by each fuse are given in the Specif1cat1ons 3 Disconnect the w iring plug If there is a chance that the wiring plug
Sectton. and the fuse numbers are indicated in Fig. 12.3 will fa ll back through the switch aperture. retain the plug with tape or
3 On fuel m1ec11on models. two add1t1onal fuses are located in the string.
he<tltH \;011 l1ul µ<1111:11. Utiltind lint <1Shtr<1y (µhulO) Om1 1:; fur lhtt futtl 4 Refming is a reversal ot removal .
pump ( 15 amps). and the other 1s a spare.
4 Should a fuse blow. replace It only w ith one of identical rating and, Electrically-operated mirrors switch (1986-on models)
11 the new one blows again 1mme1;Hately. trace and rectify the cause. 5 Carefully prise the switch from the door inm panel (photo).
whrch may be a short-circuit. 6 Disconnect the w iring plugs and remove the switch.
S The blade-type fuses may be removed by pulling them d1rectly from 7 Refining Is a reversal of 1emoval.
the fuseboard (photo). On some models. a removal tool is provided
with the vehicle Glovebox illumination tamp switch
6 The relays are located either on the fuseboard or behind the lower 8 Remove the glovebox (Chapter 11 ) .
fac1a panel (photos). 9 Prise the swuch from us locauon. and disconnect the wiring
(photo) .
1O Refitting is a reversal of removal
12 Switches - removal and r ef itti ng
Courtesy light switch
t As a safety precautton. always disconnect the battery negauve lead 11 Unscrew lhe mounting screw. and ease the switch from Its location
before removing a switch. Reconnect the lead after refitting the switch. hole (photo).
12 Tape the wire to the doo1 ptllar. then disconnect it and remove the
Fac1a and centre console switches switch.
2 Carefully prise the switch from the panel (photo) . 1 3 Ref11t1ng Is a reve1sa1 of removal
11 1 Removing the fusebox cover 11 .3 Fuses located behind the ashtrayf 11 5 Removing a fuse
fuel in1ec11on models
A Fuel pump B Spare

11 6A Removing a relay from the fuseboard 11 .68 Relay mounted beneath the 11 .6C Relays mounted behind the lower
headlamp load adiuster bracket fac1a panel
12.2A Removing the rear window locking 12.28 ... the hazard warning swi tch 12.2C ... the rear foglamp switch ( 1986-on
sw itch (pre · 1986 models) ... models) ...
12 20 the front left· hand electric 12.2E . and the rear left . hand elecwc 12.5 Electrically operated mirror sw itch
window sw11ch (pre· 1 986 models) window switch ( 1986-on models) removal ( 1986 -on models)
12.9 Glovebox illumination lamp swHch 12 11 Courtesy light swi tch removal
(arrowed)
j l

Chapter 12 Electr ical system 241
Steering column combination switches

14 Remove the steering wheel (Chapter 10). 13 Cigar lighter - removal and ref itting
1fl Unscrew the screws and remove the steering column lower cowl.
On p1e 1986 models. pull ou t the swi1ch cover from the cowl 1 Disconnect the battery negative lead
(phOIOS) 2 Remove the radio as described in" Secuon 28.
16 Unscrew the mounting bolts, disconnect the wiring plug and 3 Remove the upper screws and lilt out the radio surround.
rl)move the switch (photos) 4 Disconnect the wiring. and uncllp the cigar hghter from the
17 Reftt1ing is a reversal of removal surround (photo).
5 Refitting Is a reversal of removal
Luggage compartment illummation lamp switch
18 Remove the lrtm panel from the left-hand side of the luggage
compartment
19 Pnse the switch from Its location. and disconnect the wiring 14 D i gital c loc k - rem oval and refitt ing
(photo).
20 Rehttmg 1s a reversal of renewal 1 Disconnect the battery negauve lead
12 16A Remove the lower screw 12.158 .. pull out the switch cover 12.1 SC .. and remove the lower cowl
(arrowed) ... (pre-1986 models)
12160 Removing the steering column 12.16A Unscrew the bolts (arrowed) ... 12 168 •.. and remove the steering column
lower cowl on 1986-on models combination sw ttch (pre-1986 models)
12.16C S!eering column combination 12.16D Wmng plug (arrowed) on the 12 19 Luggage compartment illumination
swuch removal (1986-on models) comb1nauon switch (1986-on models) lamp switch removal
.I

Pre- 1986 models 17 Instrument panel - dismantling and reassembly

2 Carefully prise the clock from Lhe fac1a panel (photos).
3 Disconnect the wmng and remove the clock.
1 Pull the rubber knobs from the tnp recorder and clock.
1986-on models 2 Disconnect the printed circuit from the tachometer or clock.
4 Prise the clock from the heater control panel. 3 Unscrew the speedometer screws. the temperature gauge nuts. the
5 Disconnect the wmng and remove the clock. fuel gauge nuts. and the rear casing nuts. noung the locatlon of the
spring washers.
All models 4 Using a screwdriver, (elease the clips and remove the front face.
6 Rehlling 1s a reversal of removal. It will of course be necessary to 5 Carefully lever otl the gauge needles, and remove the rear
reset lhe lime assembly
6 To remove rhe speedometer, release the plastic or metal retainer and
withdraw the unit.
15 Instrument illumination rheostat - removal and refitting 7 To remove the gauges. release the retaining plate and withdraw
them.
8 To remove the tachometer. first remove the oil temperature and
level gauge printed circuit as applicable, then prise off the retaining
2 Unchp the support panel from the lower lac1a panel.
plate.
3 Disconnect the wiring from the rheostat. then depress the plas11c
9 To remove the clock. release 11 from the two posts
clips and remove the rheosta t (photo}.
10 To remove the buzzer {where fitted} . pull the rubber caps from tHe
4 Ref1111ng is a reversal of removal.
two pins and withdraw the unit.
11 Reassembly is a reversal of dismantling, but relit the clock hands at
12 o'clock The remaining hands can only be !med in one pos111on.
16 Instrument panel - removal and refi tting

2 Remove the steering wheel (Chapter 10) . Though not essential.
this w ill provide improved working room.
3 Using a small screwdriver through the small holes each side of the
18 Speedometer c able - removal and refitting
instrument panel. depress the plastic chps to release the panel (photo).
4 Withdraw the instrument panel sufficiently to disconnect the 1 Jack up the tront of the vehicle and support on axle stands.
speedometer ca ble and wiring plugs {photos). 2 Unscrew the retaining bolt and withdraw the cable from the
5 Remove the Instrument panel from Its location {photos) . gearbox.
6 Ref1111ng 1s a reversal of removal. The speedometer cable 1s 3 Remove the instrument panel as described m Section 16.
automa11c<1lly engaged as the instrument panel 1s inserted and the 4 Prise the grommet from the bulkhead. then remove the cable.
guide pins enter their holes 5 Refitting 1s a reversal of removal .
13 4 Cigar lighter removal 14.2A Prise out the d1g1tal clock ... 14.28 ... and remove from the facia
(pre· 1986 models)
1 5.3 lnsrrumeni Illumination rheostat 16.3 Method of releasing the instrument 16.4A Instrument panel removal (pre- 1986
(arrowed) panel clips models)

16 48 Instrument panel removal (1986-on models) 16.4C Disconnecung a wiring plug from the instrumen t panel
16 SA lnstrumeni panel connec1tons (pre -1986 models) 16.SB Instrument panel connections ( 1986-on models}
16SC Instrument panel rear view (pre 1986 models) 16.50 Instrument panel rear view (1986-on models)
J .\

16 SE lnsuument panel front view (1986-on models)

Fi g . 12.4 Instrument panel front face removal (Sec 17)
1 P/asflc clips
Refttung 1s a reversal of removal

19 Bulbs (exterior) - renewal
11 If necessary, the bulbholder and printed c1rcu11 board may be
removed by disconnecting the wiring plug (photo).
Heodlamps
1 Pull the wiring connector from the rear of the headlamp (photo). Rear lamp cluster (Estate)
2 Remove the rubber protector (photo). 1 2 Open the tailgate. then unscrew the upper mounting screw and
3 Release the spring clips and extract the bulb (photos). withdraw the rear lamp cluster (photo)
4 Fit th1t new bulb, taking care not to touch the glass If necessary, 13 Prise up the tabs. and separate the bulbholders (photos).
clean tile glass with methylated spirit befort1 hnmg. Refming is a 14 Ot1prt1i.s <md twist the app1opiiate bulb to remove 11 (photo)
reversal of removal - make sure that the 'TOP' mark on the rubber Ref1tt1ng 1s a reversal of removal.
protector 1s uppermost (photo).
Rear number plate lamp
Front parkmg and direction mdicator lamp 15 On Saloon models, use a small screwdriver to depress the end clip
5 Reach under the from wheel arch and squeeze together the plasuc on the lamp lens, then withdraw the lamp. Unclip the bulbholder, then
ears on the inner end of the lamp (photo) depress and twist the bulb to remove it (photo)
6 Release tho lamp from the bumper by unhooking the outer post. 16 On Estate models, use a small screwdriver to prise off the lamp lens,
7 Uncl1p the appropriate bulbholder, then depress and twist the bulb then depress and twist the bulb to remove 1t (photos).
to remove It (photo). Refuting 1s a reversal of removal. 17 Refitung is a reversal of removal.
Rear lamp cluster (Saloon) Side marker lamp

8 Unscrew the plasuc nuts from inside the luggage companment. 18 Prise out the lens (photo)
and remove the inner cover (photo) 19 Prise out the rub&er grommet, making sure that the bulbholder
9 Withdraw the lamp 1.!nll, and separate the bulbholde1 by releasing does not fall back inside the wing ( photo)
th" plasuc chps (photo) 20 Hold the bulbholder, then depre and twist the bulb to remove II
10 Depress and twist the appropriate bulb to remove 11 (photo). (photo) Ref1run9 is a reversal of remolfal
19 l D1&connoct the wiring .. 19.2 ... remove the rubber protector 19.3A .. release the spring clips ...

19 36 and extract the headlamp bulb 19.4 'TOP. mark (arrowed) must be 19.5 Plastic ·ears· (arrowed) on the front
uppermost on the rubber protector parking and direction indicator lamp
19.7 Removing a fron1 direction indicator 19.8 Removing the rear lamp cluster inner 19.9 Rear lamp cluster bulbholder removal
lamp bulb cover (Saloon) (Saloon)
191 O Removing a rear lamp cluster bulb 19 11 D1sconnec11ng the rear lamp cluster 19 12 Rear lamp cluster upper mounung
(SoloonJ wmng plug (Saloon) screw removal (Estate)
19 l 3A Prise up the 1abs (arrowed) 19 1 38 and remove the bulbholder 19 1A Removing a rear lamp cluster bulb
(Estate) JI (Estate)

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246 Chapter 12 El ectrical system
19 15A W1thdr11w the number plate lamp 19 158 unchp the bulbholder . 19 1 SC and remove the bulb (Saloon
models)
19 1GA Prise off the number plate lamp 19 16 B . for access to the bulb (Estate 19.18 Remove the side marker lens ..
len' models)
19 19 rubber grommet and bulbholder .. 19 20 and extract the bulb
20 Bulbs (interior ) ren ewa l
Roof lamp
1 Using a thin screwdriver, depress tho plasuc ear at one end of the
lamp then remove the lamp (photo)
2 Extract the festoon-type bulb from the metal contacts (photo)
3 If necesSJry unchp the lamp surround (photo)
Map reading lamp
d Using a sc1ewdnve1. rock the lamp to release the tongues
5 Withdraw the lamp and remove the bulb
luggage compartment and glovebox lamps
6 Pnse out the lens (photos).
7 h11 ct the festoon-type bulb from the metal contacts
Fig. 12.5 Removing the roof lamp and map reading lamp
Instrument panel warning lamps ( Sec 20 )
8 Remove the instrument J)<lnel as doscrrbed tn Secuon 16 I I
9 Twist tho hulbholders and 1emove them (photo) Plastic eqrs 2 Reto1mng tongues
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Chapter 12 Electrical system 247
10 Pull the wedge-type bulbs from the bulbholders (photo). Heater control/coinbox/ashtray illumination bulb (1986-
Facia switch on models)
17 Remove the heater control panel with reference to Chapter 11.
11 Prise out the switch bunon (photo).
18 Remove the bulb holder and extract the bulb (photos).
12 Using plastic or rubber tubing, pull out the wedge -tYpe bulb
(photo).
Digital c~ock (1986-on models)
Ignition switch illumination bulb 19 Remove the digital clock as described in Section 14.
13 Remove the lower facfa panel (Chapter 11 ) . 20 Twist and remove the bulbholder. then extract the wedge-type
14 Pull out 1he bulbholder and remove the bulb (photo) bulb (photo) .
Heater control panel illummation bulb (pre-1986 models)
15 Remove the hea1er control panel with reference 10 Chapter 11. All interior lamps/ bulbs
16 Extract the wedge-type bulb from the bulbholder (photo). 21 Refitting is a reversal of removal
20.1 Roof lamp removal 20.2 Roof lamp bulb location (arrowed) 20.3 Roof lamp surround removal
20 6A Luggage compartmen t lamp removal 20.66 Glovebox lamp removal 20.9 Instrument panel warning lamp
bulbholder removal
2010 Waming lamp bulb removal from 20 11 Remove the switch button .. 20.12 .. and use tubfng to remove the bulb
bulbholders
II

248 Chapter 1 2 Electrical system
20 14 lgn1tton sw1tch Illumination bulb 20 16 Heater control panel bulb removal 20 18A Co1nbo>1 bulb removal
removal (pre-1 986 models)
20 186 Ht:altu control illumination bulb 20.20 Digual clock bulb removal (1986 -on
removal (1986-on models) models)
2 The device consists of a master control and control knob, two servo
21 Headlamp unit - removal and refitting
units. and connecttng tubing.
3 To remove the master control, first pull off the control knob
1 Remove the headlamp bulb as described in Section 19 { photo).
2 Unclip the headlamp surround (photo). 4 On Saloon models, remove the lower fac1a panel. then unbolt the
3 Unhook the tension spring from the body bracket (photo). master control mounting bracket (photos).
4 Disconnect 1he earth wtre, where fitted. 5 On Estate models. remove the steenng column lower cowl, then
5 Prtse the inner pivot socket from ns boll, and d1sconnec1 rhe outer detach the master control by removing the screws (photo).
socket (photos) 6 To remove the servo units, release rhe headlamp 1ens1on springs.
6 Withdraw the headlamp unit, and at the same trme d1sconnec1 the then unlock 1he plasuc mounungs (photo)
load correctton servo 7 Refttting is a reversal of removal
7 Unhook the tension spnng from the un11 (photo)
8 Rc!ining 1s a reversal of removal, bur check and 1f necessary ad1ust
the beam alignment as descrtbed in Secuon 22 (photo). 24 Horn uni t - r emo va l and ref i tting
1 Remove 1ha lronr grille as described 1n Ch11pte1 1 1

22 Headlamp beam alignment
2 Disconnect the ba11ery nega1ive lead
3 Disconnect the wonng, and unbol1 the horn unit from its mounting
II 1s recommended that the headlamp beam alignment is earned out { photo).
by a Peugttot dealer. or a service srauon having the necessary opttcal 4 Reh111ng 1s a reversal of removal
beam setting equipment
2 As a temporary measure. the load ad1us1er should be set to its basic
pos1t1on, and the main beams aligned parallel to rhe ground by 25 Wiper blades arid arms - removal and r efitting
focusing on a wall.
3 Hon10ntal movement is ad1usted by the screw located behind rhe
1 Whenever the wiper blades fall 10 clean 1he screen the blades or
headlamp and venical movement by the load ad1uster mounting
(photos) their rubber insen s should be renewed
2 To remove a blade, pull the arm from the gloss. lhen depress the chp
and release the blade from 1he arm (photos)
3 Before removing a wiper arm. stick some masking rape on rhe glass
23 Headlamp beam l o ad adjuster - general
to 1ndica1e its res1 pos111on
4 Fhp up the cover. unscrew the nut. and pull the arm from the
1 A sealed hydraulic beam ad1usung device is filled, so that rhe spindle (pho1os) It may be necessary 10 rock the arm slightly 10 release
hu11dlamp beams may be ad1usted independently from the normal basic II from 1he spindle splines
&e111ng to compensate for variations 1n the voh1cle loading. 5 Refitting is a reversal of removal

21 .2 Headlamp surround removal 21.3 Headlamp tension spring 21 .5A Headlamp inner pivot socket
(arrowed)
21 68 01sconnec11ng the headlamp outer 21 .7 Tension spring con nection to the 21.8 Headlamp refitted 1n Its l ocation
socket (arrowed) headlamp
22 3A Horizontal headl<imp adjustmen t 22.38 Vertical headlamp adjustmen t screw 23.3 Pull off the control knob ...
screw (arrowed) (arrowed)
23 4A remove the lower fac1a panel on 23.46 .. unscrew the bolts ... 23.4C .. and remove the headlamp ad1uster
Saloon models .. mounting bracket

23.5 Headlamp adjuster on Estate models 23.6 Headlamp adjuster servo unit
24.3 Horn unit location 25.2A Removing early type wiper blade
25 28 Aemo111ng later type wiper blade 25.4A Unscrew the spindle nut ..
J\

Chapter 12 Electrical system 251
5 Unbolt the support brackets and main crossmember (photos). and

withdraw the complete linkage
6 Tho wiper motor may be sopara1ed from 1he linkage by disconnec·
ting l he operating rod from the crank lever. then unbolting the uni t
7 Rel1 t1 ing 1s a reversal of removal. but make sure that the washer
lubes ore clipped to the air inlet grille
27 Tailgate wiper ll)Otor (Estate models) r em oval and

refitting
I Remove the wiper blade and arm as described on Sectton 25

2 Remove the tailgate trim panel with reference to Chap1er 11
3 Disconnect the wiring plug and unbol1 the earth wire (photo)
4 Unscrew the spindle nut and recover the washers
6 Unscrew the mounting bolts (photo) and remove the motor
assembly from the tailgate. Note the location of the mountrng rubbers
and spacers
6 Refilling 1s a reversal of remova l.
28 Radio. speakers and aerial removal and ref i tt ing

25 48 and remove the wiper arm
Note· On later models. the radio is security coded This means that 1f
tho elccUlcal supply is disconnected (for example disconnecting the
battery). a coded number must be entered by dep1essmg the number
26 Windscreen wiper motor and linkage - removal and buttons before the radio can bo switched on ngam
refitting
1 Disconnect 1he battery negatrve lead
1 R&move 1he wiper blades and orms as desc11bed In Section 25. 2 Insert radio removal tools. or 1h1n rods, Into the holes on each side
2 Remove the screws and withdraw the fresh air inlet grille of the radio. and depress to release the clips (photo)
Disconnect the washer tubes (photos) 3 Wuhdraw the radio suff1c1ently to disconnect the wiring plug.
3 Remove the remaining screws and withdraw the 1111ermed1ate plate speaker plugs and aerial lead (photo)
(pllOtOS) 4 To remove a front speaker. lust pull the weatherstrip away from the
d Disconnect the wiring from the wiper motor (photo) front door pillar near the speaker onlv Remove the screw s and
26 2A Remove 1he screws • 26 28 and withdraw the fresh air inlet 26 2C Washer tube connection on the inlet
g11lle gnlle
26 3A Remove 1he screws ... 26.38 ... and withdraw the intermediate 26.4 Windscreen w iper motor and w iring
plate plug (arrowed)
•I

26 SA Windscreen wiper ltnkage support bracket and bolt 26 SB Windscreen wiper linkage main crossmember bolt
27.3 Tailgate wiper motor wiring plug 27 S Tailga te w iper moto1 mounung bolts (arrowed)
wtthdraw 1he speaker panel. then d1sconnec1 the w1nng (photos). with a soft brush to a really clean surface Use two strips of masking
5 To remove a rear speaker unscrew the mounting screws, withdraw tape as a gu1do 10 1he 1h1ckness of the element 10 be repatred
1ho speaker and disconnect lhe wmng (photos) 4 Allow the new paint to dry thoroughly before swr1ch1ng the heater
6 Access to the ae11al moun11ng nut 1s gained by removing the roof on
lamp es described in Secuon 20 (pho10) S On cars fitted with heated exte11or rear view mirrors. the mirror
7 Rel1111ng of all components 1s a reversal of removal heaung elemen1 is sw11chcd on when the rear screen sw 11ch is
operated.
29 Heated rear sc reen - general

30 Washer system - general
To prevent damage to the elemen1s of the heated rear window,
observe 1hc following precautions The washer system arrangement varies according to model Some
models have 1ust a windscreen washer. ot hers incorpora te 1he
(•J Clun the 1nteuor surface of the glass with a damp cloth or
headlamp washer with the windscreen. and Estate models have a
chamois leather rubbing in the d11ection that the elements run
tailgate washer system. which 1s either incorporated with the
(b) Avoid sc1atching the elements w ith rings on the fingers or
windscreen system or separate
contact with erttcles in the luggage compartment
2 The windscreen washer reservoir 1s loca ted next to the battery, on
(c) Do not stick adhesive lobels over the elements
the left -hand side of the engine compartment Where the 1ailga1e
2 Should 1he olomont be broken, ii can be repaired using a washer reservo11 is separate, 11 1s loca ted on 1he lefl·hand side of the
conductive silver paint. w11hout the need 10 remove the glass from the luggage compartment ( photos) .
window 3 Ad1us1mont onthe washer Je ts IS ca rried out by inserting a pin in the
3 Tho paint 1s ava1lal)le from many sources, and should be applied jel nozzle. and moving 11 to obtain the desired Jet pa ttern on the screen.

28.2 lnserung the radio removal rods 28.3 D1sconnec11ng the radio wiring
28 4A Pull out the weatherstrip .. 28.48 ... remove the screws ...
28 4C and withdraw 1he speaker panel 28 5A Remove the screws .•

28 58 and withdraw the rear speaker 28.6 Aenal mounting nut
30 2A Windscreen washer reservoir 30 28 Tailgate washer reservoir
31 Central locking system - general luggage compartment, and move the actuator rod by hand (pho10).
1 On models hued with central door locking, 1t 1s possible to lock all

doors including the boot or tailgate. simply by locking the driver's 32 Olm-dip l ighting - general
d001
2 The system uses electric actuators to move the door lock 1 All models manufactured from late 1986 are fined wtth a d1m· d1p
mochanism~ The actuat0ts can be removed by dismantling the doors, hghung system. which essentially prevents 1he vehicle from being
boot Of tailgate as described 1n Chapter 11 driven wuh the s1deltghts alone switched on
3 On some models. the fuel filler flap is also incorporated in the 2 When the 1gn11ton 1s switched on with the sidelights also switched
system on. the relay is energised. closing the internal contacts and supplying
4 An electronic control unit sends the opening and closing current to the dipped beam circuit via the resistor This causes the dip
in forn1at1on to 1he actuators in th e doors and fuel filler flap (photo) . filaments In the ~~adlamps to be illuminated at one-sixth dipped beam
5 In the event of failure of the system, the doors, boot and tailgate b11ghtness. The tMay winding 1s earthed through the headlamp main
may be locked and unlocked manually using the key or locking knob. beam filaments. sd 1hat the relay Is de· energised when the main beam
6 To operate the fuel filler flap monuolly, remove the mm from th e rear Is sw11ched on.

--~~~~~~~~~~~~~~~~------------~------------~------------ 255
Fig. 12.6 Central door locki ng system (Sec 31)
I Control unit 3 Door lock (d11ver·s side) 5 Actuators (without 6 Door lock (passenger side)
2 Acltlator (with switch) 4 Actuator rod switches)
31 4 Crntr;il locktn!l svstom elec1ron1c control unit arrowed (111m removed)

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256 Chapter 12 Elec trical system
(b) If possible, use a good quality roof aerial to obtain maximum

33 Radio Interference and CB equipment height and distance from interference generating devices on
tho veh icle.
Radio/cassette case breakthrough (c) Use of a high quality aerial downlead is important, since
Magnetic rad1auon from dashboard wiring may be sufficiently losses in cheap cable can be significant.
intense to break thrOl!9h the metal case of the radio/cassette player. (d) The polarisation of FM transmissions may be horizontal,
Often this 1s due to a particular cable routed too close and shows up as vertical, circular .pr slan ted Because of this the optimum
1gnit1on interference on AM and cassette play end/or alternator whine 1,
mounting angle at 45• to the vehicle roof.
on cassette play
The f11st point to check 1s that the clips and/or screws are fixing all Citizens' Band radio (CB)
parts of the radio/ cassette case together properly Assuming good In the UK. CB transm1tter/rece1vers work w ithin the 27 MHz and
earthing of the case. see if it 1s possible to re·route the offending cable 934 MHz bands, using the FM mode At present interest is
the chances of this are not good, however, in most cars. concentrated on 27 MHz where the design and manufacture of
Next release the radio/cassette player and locate 11 1n different equipment is less difficult. Maximum transmitted power is 4 watts. and
pos111ons with temporary leads. ff a point of low interference is found, 40 channels spaced 1O kHz apart wuhm the range 27 .60125 to
then 1f possible fix the equipment 1n that area This also confirms that 27 99125 MHz are available.
local rad1a11on is causing the trouble. If re · loca11on 1s not feasible. fit Aerials are the key to effective transmission and reception.
the radio/ cassette player back 1n the orlglnal posuion. Regulations limit the aerial length 10 1.65 metres including the loading
Alternator Interference on cassette play is now caused by radiation coll and any associated circuitry, so tuning the aerial 1s necessary to
from the main charging cable wh ich goes from the battery to the obtain op11mum results. The choice of e CB aerial 1s dependent on
output terminal of the alternator, usually via the -r terminal of the whether 11 is to be permanently installed or removable. and the
starter motor relay In some vehicles this cable is routed under the performance will hinge on correct tuning and the locauon point on the
dashboard, so the solution is to provide a dtrect cable route. Detach the vehicle Common practice is to clip the aerial to the roof gutter or to
original cable from the alternator output terminal and make up a new employ wing mounting where the aerial can be rapidly unscrewed. An
cable of at least 6 mm' cross-secuonal area to go from alternator to alterna11ve is to use the boot nm to render the aerial theftproof. but a
battery with the shortest possible route Remember do nor run the popular solu11on is to use the 'magmount' - a type of mounting having
engine with the alternator disconnected from the battery. a strong magnetic base clamping to the vehicle at any point, usually
Ignition breakthrough on AM and / or cassette play can be a difficult the roof
problem II 1s worth wrapping earthed foil round the offending cable Aerial location determines the signal distribution for both transmis·
run near the equipment. or making up a deflector plate well screwed s1on and reception, but it 1s wise to choose a point away from the
down to a good earth. Another possibility 1s the use of a suitable relay engine compartment to minimise interference from vehicle electrical
to switch on the ignition coil. The relay should be mounted close to the equipment.
Ignition coll. with this arrangement the ignition coll primary curren t ts The aerial is subject to considerable wind and acceleration forces.
not taken into the dashboard area and does not flow through 1he Cheaper units will whip backwards and forwards an~ 1n so. doing wi!I
1gn111on switch A suitable diode should be used since it 1s possible that alter the relauonship w ith the metal surface of the vehicle with which 11
at ignition swnch -off the output from the warning lamp alternator forms a ground plane aerial system. The radiation pattern w ill change
terminal could hold the relay on correspondingly, giving riso to break up of both incoming and
outgoing signals.
Connectors for suppression components Interference problems on the vehicle carrying CB equipment fall
Capacuors are usually supplied with tags on the end of the lead,
into two categories·
while the capacitor body has a flange wuh a slot or hole to flt under a
nut or screw wuh washer (a) Interference to nearby TV and radio receivers when trans·
Connecttons 10 feed w ires are best achieved by self-stripping mming.
connectors These connectors employ a blade which, when squeezed (b) Interference to CB set reception due to electrical equipment
down by phers, cuts through cable insule11on and makes con nection to on the vehicle.
the copper cond uctors beneath.
Chokes sometimes come w ith bullet snap-in connectors fitted to Problems of breakthrough to TV and radio are not frequent, but
the wires. and also w l,th Just bare copper w ire. W ith connectors. can be difficult to solve. Mostly trouble is not detected or reported
suitable female cable connectors may be purchased from an because the vehicle is moving and the symptoms rapid ly disappear at
auto-accessory shop together w ith any extra connectors required for the TV / radio receiver. but when the CB set is used as a base station any
the cable ends after being cut for the choke insertion. For chokes with trouble w ith nearby rece111ers w ill soon result in a complaint.
bare w11es. s1m1lar connectors may be employed together with It must not be assumed by the CB operator that his equipment is
1nsulat1on sleeving as required. faultless. for much depends upon the design Harmonics (that 1s,
multiples) of 27 MHz may be transmitted unknowmgly and these can
VHF/ FM broadcasts tall into other user's bands Where trouble of this nature occurs, low
Recepuon of VHF/ FM in an automobile is more prone to problems pass filters 1n rhe aerial or supply leads can help, and should be fitted 1n
than the medium and long wavebands Medium/long wave trans- base station aerials as a matter of course In stubborn cases tt may be
mitters are capable of covering considerable distances. but VHF necessary to call for assistance from the licensing authority, or, if
transmitters are restricted to line of sight, meaning ranges of 10 to 50 possible, to have the equipment checked by the ma~ufacturers. •
miles, depending upon the terrain. the effects of buildings and the Interference received on the CB set from the vehicle equipment is.
transmitter power. fortunately, not usually a severe problem. The precautions outlined
Because of the limited range It Is necessary to retune on a long previously for radio/ cassette units epply, but there are some extra
Journey. and 11 may be better for 1hose habitually rravelling long points worth no11n9.
distances or living in areas of poor provision of transmitters to use an It 1s common pracuce to use a slide-mount on CB equipment
AM radio working on medium/long wavebands. enabling the set to be easily removed for use as a base station, for
When conditions are poor. interference can arise, and some of the example. Care must be taken thet the shde mount fittings are properly
suppression devices described previously fall off in performance at very earthed and that first class connection occurs between the set and
high frequencies unless spec1f1cally designed for the VHF band slide-mount
Available suppression devices include reacuve HT cable, resistive Vehicle manufacturers 1n the U K are required to provide suppress-
distributor caps, screened plug caps, screened leads and res1st1ve spark ion of electrical equipment to cover 40 to 250 MHz to protect TV and
plugs VHF radio bands. Such suppression appears to be adequately effective
For VHF/ FM receiver installation the following points should be at 27 MHz but suppression of individual items such as alternators/
particu larly noted: dynamos, ~l ocks. stabilisers. flashers. w iper motors, etc. may still be
(a) Eanh1ng of the receiver chassis and the aerial mounting 1s necessary. The suppression capacitors end chokes available from
important . Use a separate earthing w ire at the radio. and auto·elecmcal Sl.f)j:>liers for en tertainment receivers will usually give
scrape pain t aw ay at the oerlal mounting the required results,with CB equipment
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Chapter 12 Electric al system 257
Other vehicle radio transmitters Generally the suppression techniques described previously will
Besides CB radio already mentioned, a considerable increase in the suffice, with only a few difficult cases arising. Suppression is carried
use of transceivers (1e combined transmitter and receiver units) has out to satisfy the 'receive mode', but core must be taken to use heavy
taken place in the last decade. Previously this type of equipment was duty chokes In the equipment supply ca bles since the loading on
fined mainly to military, fire, ambulance and police veh icles. but a large ·iransmit' 1s relatively high.
business radio and radio telephone usage has developed.
34 Fault diagnosis - electrical system
Symptom ReHon{a)
No vol tage at starter motor Battery discharged

Battery defective internally
Battery terminals loose or eanh lead not securely attached to body
Loose or broken connections in staner motor circuit
Starter motor switch or solenoid faulty
Voltage at starter motor - faulty motor Staner brushes badly worn, sticking, or brush w ires loose
Commutator diny, worn or burnt
Starter motor armature faulty
Field coils earthed
Staner motor noisy or rough in engagement Pinion or flywheel gear teeth broken or worn
Staner motor retaining bolts loose
Alternator not charg ing· Drivebelt loose and slipping, or broken

Brushes worn. sticking, broken or diny
Brush springs weak or broken
' If all appears to be well but the alternator is still not charging, take the car to an automobile electrician for checking of the alternator
Banery will not hold charge for more than a few days Battery defec.tive internally
Electrolyte level too low or electrolyte too weak due to leakage
Plate separators no longer fully effective
Battery plates severely sulphated
Drivebelt slipping
Battery terminal connections loose or corroded
Alternator not charging properly
Short in lighting circuit causing continual battery drain
lgmt1on light fails to go out, battery ru ns flat in a few days Drivebelt l oose and slipping, or broken
Alternator fault y
F\Jel gauge gives no reading Fuel tank empt y

Electric cable betw een tank sender unit and gauge earthed or loose
Fuel gauge case not eanhed
Fuel gauge supply cable interrupted
Fuel gauge unit broken
Fuel gauge reg 1sters full all the time Electric cable between tank unit and gauge broken or disconnected
Horn fails to operate Blown fuse

Cable or cable connection loose. broken or disconnected
Horn has an internal fault
Horn emits intermittent or unsatisfactory noise Cable connections loose

Horn incorrectly adjusted
Lights do nor come on If engine not runn ing, battery discharged

Light bulb filament burnt out or bulbs broken
Wire connections loose. disconnected or broken
Light sw itch shoning 0< otherwise faulty
Lights come on but fade out If engine not running, battery discharged
Llgtns give very poor illumination Lamp glasses dirty

Reflector tarnished or dirty
Lamps badly out of adjustment
Incorrect bulb w ith too low wattage fitted
Existing bulbs old and badly discoloured
Electrical wiring too th in not allowing full cu rrent to pass
Lights work erraucally, flashing on and off, especially over bumps Battery termln;..~s or earth connections loose
Contacts in ligh) swi tch faulty

34 Fault diagnosis - elec trical system (cont)
Symptom ReHon(s)
Wiper motor fails to work Blown fuse

Wire connections loose, disconnected or broken
Brushes badly worn
Armature worn or faulty
Field coils faulcy
Wiper motor w orks very slowly and takes excessive current Commutator ditty, greasy or burnt
Drive to spindles bent or unlubncated
Drive spindle binding or damaged
Armature bearings dry or unaligned
Armature badly worn or faulty
Wiper motor w orks slowly and takes little current Brushes badly worn
Commutator dirty. greasy or burnt
Armature badly worn or fau lty
Wiper motor w orks but wiper blades remain static Linkage disengaged or faulty
Drive spindle damaged or worn
Wiper motor gearbox parts badly worn
J·I

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259
Wiring d iagrams commence overleaf
I :I
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200------------------------------------------------------------------------~
I 1 ~
- n t't ) C tn • , . • • f'.A
5! !:! ~ !) ,If: .. ~
:;MO • •••
11 I Ir
I
-
1 2"A
.a ~tL
--
3 ~c
c 26A
-- m
-
~0 -
1- --
C8
8
- _J
-
-
I... l k;
_,...., .. .,.,
:!:I
I!
ii
~1
.. ·- ·-fl ~, l
[ i 80 I ! 'C:::;::::;;:::Z::.:i.:::::Z:::Z::=~:!:::=:=:=::::=z
;;;(""~.I , • • • ·-. MIO ~ a j!
!?-.:i.;._,.....•...,. ..,....,_ ~~till~-- ,._J·-·-·--·~· I .~ 53A
... . . ... .
..... . . .. .... ..
... Lt& -
17 ;.. - - -1.. . .... - · - · - ·'--"
- #- --"".o'---_ 40
Fig. 12.7 Typical wiring diagram for pre-July 1981 505 wj'h c arburettor engine

...
,-----------------------------------------------------------------------------~ 251
69
68
67 70
F7 90
,---i
I
I
I
I
I I
I I
L - - -.J
107
Fi g . 12 .7 Typ ical wiring diagram for pre -July 1981 505 with carburettor engine (continued )

-c:=:=:=:..-:-..:::.:=.:::.::=:=:.=:=.=:=::.
10
Fig. 12.8 Typical wi ring diagram for pre-July 1981 506 Tl and STI

,,,,,...--------------------------------------------------------------------~253
69
68
fil 70
F7 90
Fig. 12.8 Typical w iring diagram for pre -Jul y 1981 505 Tl and STI (continued)

264
27C
2
3
20 15A
Oe t1ll1 of th• h e adl am p wHh/wlp•
Fig . 12.t Typical wiring diagram for July 1981 · on 506 w it lt c a rburettor e ngine

------------------------------------------------------------------------~ 265
:.~
29A 66
64
17
65
·I
~
n-·-~
~·g
. . .so 8li!F.8ID '£·::l·
!iEBiiB --c:==:1 . · r Bffi:l]j] · · ':'
ti.J,1
83A
» -
rc~JB::oo .:::J
. ,:~
83A
. ;:.i 838
-·-·-·-·~··
-·-·-·- ·___, rt~m: .
··--11·-·-·-·...--·-·---------1
. .. C:::::·- ·-·-·-
.... ·--·--·- · - - - - - ~~
r.Ji;-J
Fig. 12.9 Typica l wiring diagram for July 1981-on 505 wj~ carburet'tor engine (continued)

~14
Fl 8
r:!l
L..ilJ
52
~15A
~
51Af°;
19 • • 52A 29
r--
'If.>.·,.
I ~' 1
I
r - -..-;r.
I 99 I ..: I
l--'--'
.Lg., I
L__
36 t 51A
L.___
~ .
Llr
=l
1
~
Wl~
Fig. 12.10 Typical wi ring diag ram fo r Ju ly 1981 -~·~ 606 STI

.:----------------------------------------------------------------------257
• !!! ~82
51A [ H
r.
,-----, ,.---...,
I I
I
I
I
I
I I I
I .. 57
I I
I.._ _ __ JI
I
L___ J L f.
.~. 35 • '?lO. t250
.JJ]
'.,,.tsoA
125 29A
• @""· 154 54
55
,D 66
74
- D 76
64
... l25G
5~
_@:; '1... 588
jl
'J. 53
. .\G • f3 ~-:. C
123E
:n053A ·~ G~
6 4A
9
J 8 834
It~;· JfU!I ,_.....§ ~
j .11 ml ,._.~
m!
= =========='=r"°' -c::::=l-=,,~
r! -..,_.,_~·4·-======================~
J:, .. -L 69
Fig. 12.10 Typica l wiring diagram fo r J u ly 1981[ fn 505 STI (continued )

M811
M671 ~.,
!JV': ~
M75
Clt
M730
i1....
,
,11
tit
I
•
M855
""
"
.. • .4 " - ·.. · · -
M850
M25
M670
Fig. 12.11 Typical wiring d iagram for pre-July 1985 605 SR

H233
w .. 9 . C445
ti
H501
H364
~
C386
r"- \
(f)
~
H30
C3~·
(f)
H500
!I
J
~
Fig. 12.11 Typical wiri ng diagram for pre -July 1985 505 SR (continued)
/ .\

Fig. 12.12 Typical wiring diagra m for pre-July 19PJ 505 GTI

CHI
-
Fig. 12.12 Typical wiring diagram for pre-Ju ly 1986 606 GTI (conti nued )
1:1

212------------------------------------------------------------------------.. . .
Key to wiring diagrams - up to July 1985
1 Headlight 32 lighting - w indscreen wiper/ windscreen washer

2 Front direction indicator switch
3 Front sidelight 32A Windscreen wiper/ .:.,jndscreen washer switch
4 Direction Indicator repeater 32B Lighting/ direction indicator/horn CDntrol switch
5 Stc'lrter relay 33 Headlight flasher relay
SA Neutral safety relay 34 Sidelights
6 Alternator 35 Cigar lighier. front
7 011 pressure switch 35A Cigar lighter. rear
7A 011 level indicator 35B llluminauon, cigar lighter
7B Control bo)(, oil level indicator 36 Clock
7C Checking diode, oil level indicator 37 Direction indicator repeater ligh t
8 Electro·magnetic fan or electric ran 38 Fuel gauge
SA D1sengag1ng fan relay 38A Warning light, low fuel level
SB A ir conditioning electric fan 39 Mai n beam warning light
SC Electric fan relay 39A Dip beam warning light
SD Diodes 40 Hazard warning light
9 Tamperature switch. fan clutch or electric fan 41 Rev counter
9A Temperature switch. fan clutch. cooling system 42 Sidelight warning light
9B Temperature switch, fan clutch, lube system 43 Brake safety warning light
9C Sender unit, oil temperature gauge 43A Brake safety warning light checking diode
10 Horn 44 Coolant temperature gauge
11 Headlight relay 45 Oil pressure warning light
12 Battery 45A Warn ing light, oil temperature
12A Battery cut ·Out 456 Warn ing light. 011 pressure and temperature
13 Starter motor 46 Choke warning light
14 Brake pads 47 Oil and water warning light
15 Sender unit. coolant temperature 48 Preheater warning light
15A Switch, coola nt temperature 49 Charge/discharge warning light
15B Coolant temperature warni ng light switch or coolant 50 Instrument panel lighting
temperature warning light 50A Gearchange gate light
15C Resistor. coolant temperature gauge 50B Rheostat, gearchange gate light
15D Checking diode, coolant temperature warn ing light soc Switch lighting
15E Switch, coolant level 51 Heater lighting
16 Brake fluid reservoir 51A Console lighting
17 Stop switch 51 B Console lighting rheostat
18 Reversing light switch 52 Glove compartment light
19 Starter safety cut-out 52A Glove compartment light switch
20 Idling cut-out or carburettor resistance 53 Front door switch
21 Regulator 53A Rear door switch
22 Coil 54 Interior lighting
22A Coi l relay 54A light under facia panel
22B Coi l resistor 54B Map reading light
22C Coli resistor relay 54C Illuminat ion. courtesy mirror
23 Distributor 55 Handbrake switch
23A Pulse generator 56 Hazard warning light switch
24 Windscreen wiper 57 Sunroof switch
24A Windscreen wiper relay 57A Sunroof motor
24B Windscreen wiper t imer 57E Locking relay. sunroof
24C Rear window w iper SS Steering lock
24D Windscreen wiper unit 58B Ignition switch light
25 Windscreen washer pump 59 Preheat - starter switch
25A Rear window washer pump 59A Preheater plugs
26 Heating/ ventilation fan. front 60 Pump cut-out motor or solenoid valve
26A Rear heating/ ventilation fan 61 Preheater warning light switch
26B Hea11ng/ven11la11on fan switch 62 Prehaater relay
26C Air conditioning blower 63 Direction indicator and horn control
26D Relay, air conditioning blower 64 Boot or rear compartment lighting
27 Hea1ing/ ventila11on switch or rheostat 64A Boot lid or tailgate switch
27A Rheostat resistor or heating/ventilation fan resistor 65 Fuel gauge tank unit w ith or without low fuel
278 Rear heating/ ventilation switch warning
27C Air conditioning control unit 65A External tank unit resistor
2S Choke warning light switch 65B Rheostat. fuel gauge
29 Heated rear window switch 66 Number plate l ight
29A Heated rear window 67 Reversing lights
30 Windscreen wiper/windscreen washer switch 6S Stop-light
30A Rear window w iper/washer switch 68B Stop/tall lamp (twin filament)
31 Direction indicator flasher unit 69 Rear direction Indicator

,-----------------------------------------------------------------------~ 2 73
Key to wiring diagrams - up to July 1985 (con t inued)
70 Tail lamp 1 11 Idling speeo compensation solenoid valve

71 Tailgate switch 11 1A Air conditioning shut off pressure switch
72 Door mounted light 118 Control pre!lsure regulator
73 Left - hand relay window w inder switch 119 Additiona l ait co ntrol
73A Locking relay, LH rear window winder 120 Sensor plate switch
74 Window winder switch, LH front 121 Cold starting miector
74A Locking relay, LH front window winder 122 Thermal time switch
75 Interlock, rear w indow winder 123 Speed regula tor switch
76 Window winder switch, RH front 123A Speed regulator electronic unit
76A Locking relay, RH front window winder 123B Speed regulator servo
77 Window winder switch, RH rear 123C Speed regulator safety switch
77A Locking relay. RH rear window w inder 123D Speed regulator disengagement switch
78 Left -hand window winder rear switch 123E Speed regulator pick-up
79 Right-hand wmdow winder rear switch 123F Speed regulator fuse
80 Window winder motor 123G Safety relay speed regu lator
80A Window winder relay 123H Vacuum capsule
81 Diagnostic socket 1231 Safety relay
81A TDC sensor, diagnostic socket 123J Main switch. speed regulator
82 Door lock sw itch 125 Rad io connection
83 Control box, central door locking 125D Rad io speaker, front RH
83A Actuator, door lock 125G Rad io speaker, front LH
83B Actua tor, fuel liller flap 125AD Radio speaker, rear RH
86 Fuel pump 125AG Radio speaker. rear LH
86A Primary fuel pump 125E Connector, radio speaker
87 Solenoid valve 129 Speed sensor
87A Solenoid valve control switch 142 Tachyme1ric relay. fuel cut-off on ovenun
88 lgmt1on pick-up 142A Relay. fuel injection cut -off on overrun
89 EJectromc unit or amplifier module 1426 Control unit, for delay of fuel in1ect1on cut-off
90 Rear logllghts 150 Warmng light, economy
90A Rear foglight swatch 150A Vacuum pick-up
906 Rear foglight warning light 151 Switch, water detector
91 Relay 151A Warning light, water detector switch
91B Tachyme tric relay 152 Connector. front foglamps
91C Acce.ssory relay 152A Switch, front fog lamps
910 Heated rear window relay 152B Relay, front foglamps
92 Connecting terminal 170 Relay ignition system
92A Connection board 171 Calculator. 19nuion advance
93 Services connecuon board 172 Control unit. knock detector
93A Fusebox No 1 172A Knock detector
93B Fusebox No 2 173 Warning light. LED. knock detector
94 Conductive tailgate stay 174 Relay, capsule venting
95 Brake servo vacuum sw itch 175 Electronic relay
96 Brake pedal travel switch 180 Relay, fuel injection system
97 Headlight washer/ w iper switch 181 Calculator. fuel injec::tion system
98 Headlight washer pump 182 Airflow sensor
99 Headlight wiper motor , 83 ln1ector
99A Headlight wiper relay 184 Throttle sw itch unit
100 Pressure drop indicator 185 Temperature sensor, engme
101 Tachograph 190 Sensor, fuel pressure
102 Flasher light 191 Sensor. turbocharger excess pressure
102A Flasher light switch 192 Gauge. turbocharger pressure
103 Centre interior light 195 100 mbar switch - turbo full-load control. turbo
103A Centre interior light switch in1ecuon 1ntercooler
104 Feed warning light 196 Switch. advance curve selector
104A Feed warning light switch 197 Re.sister, full-load circuit (turbo in1ect1on int ercooler)
105 Atr fan 200 Control unit, voice synthesizer
105A Air fan swatch 200A Filter
106 Warning bell 201 Test button. voice synthesizer
106A Warning bell switch 210 Trip computer
107 Electrical plug 211 Display control
108 Compressor clutch 212 Fuel flow sensor
108A Compressor clu tch switch 213 Digital display
108B Relay. compressor clutch M Earth
, 09 Thermostat +P Supple from 1he battery
109A Protection diode. thermostat + aa Accessory supply
110 Constant pressure unn + ac Supply from the ignition switch
Not all items are fmed to all models

The wifes are not colour- coded
r:\

274
CID
~
CID
..
CID
•
@
CID
.
Fig. 12.13 Typical wiring diagram for July 1985 to J uly 1987 605 withlca rburettor engine - Part A

--------------------------------------------------------------------------275
' ""
' I
"I I G)
<iiD ere
-t::: .
....
I J:::
'---
'"' :~ I CiiD t==

I CID
~d~=
]-.=.]~=·~:,=:Jl=
Ll,~ ~:·...u.......~-"~b'.~
E'~~
' ."
E::: ' ..
r• ~
n C1iii)
:u::=: .. E' @0
~ .. ·'' E
LIJ I !J.!!-
_
tr::::' .._u '"" I i!i=
E~ ~:~
•C~
_, ~
-lj
" '
till f \
GD
I
I '
1111 ... 1¥""' "

I I
.
•
- ,-
OU J-
I
/ cm
-'
''., '" »
""-
"'"'"
:: • I ..
W ILL
GD
~
'' "
""
~
I ,, •I
I cm)
..
""
~. ;
' .
-~
=-
C•
:Ii:::
CID C3iD
I
,,. ..
' "" '"
'· ""
86 505 01
Fig. 12 .13 Typical w iring d iagram fo r July 1985 to July 1987 605 wit h carburetto r engine - Part A (continued)

276
I
II
"
'"
.
,,,.....,,. ~ ' •
GD •
Fig. 12.14 Typical w iring diagram for July 1985 to July 1987 505 with fuel injection engine - Part A
i·

Fig. 12.14 Ty pical wiring diagr am for Jul y 1985 t o J uly 1987 505 wit~:\fue l inject ion engine - Part A (continued)

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Fig. 12.15 Typical wiring diagram for J u ly 1985 to July 1986 505 Saloon - Part B

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Fig . 12.16 Typical w iring diagram fo r July 1985 to July 1986 505 Estate - Part B
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Fig. 12.17 Typical wiring diagram for July 1986-on 505 Saloon - Part B
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Fig . 12.18 Typ ical wiring diagram for J uly 1986-on 506 Estate - Part B
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Fig. 12.19 Typical wiring diagram for July 1988-on 505 with carburettor engine - Part A
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Fig. 12.20 Typical wiring diagram for July 1988- on 606 w i th fuel i njection engine - Part A (continued)
For Part B. see Fig 12 77 or 1i .\18

286
Fuse Fil Sidelights
Lighting switch
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DIPl*f beam
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Fi g . 12.21 W ir ing d iagram f o r dim- dip li ghting
The vehicle is divided into 4 sections. Section codes are given before the component code.
Section c odes
M Engine H Passenger compartment

P Facia C Luggage area
For connecuons between harnesses the Section codes. followed by C, are used to indicate where the connection is
eg MC indicates a connector between the engine and facia harnesses w hich is located in the engine compartment
For earthing points the Secti on code is follow ed by M

eg CM indicates an earthing point in the luggage area
Key to w i ring diagrams - July 1986 on
Component c odes Compo nent codes

1 Cigar lighter, front 49 Unit, fuse board group (FBG)
3 Cigar lighter. rear 50 Ignition coil
5 Distributor, ignition 53 Control box. exhaust emission, for pilot carburettor
9 Idling actuat or (idling solenoid) 54 Emission control unit (ignition advance modulator)
10 Alternator 65 Emission con trol unit {Idle retard)
11 Transistor, heater blow er control (power transistor) 56 Control unit, aut omatic transmission (idle speed)
13 Strut (earth connection) 57 Alarm unit. theft protection
14 Ammeter (battery charge) 58 Control unit. Injection
20 Radio aerial, electric 60 Control unit, air conditioning
25 Horn 61 Electronic unit. brake antilock
25A Horn, low note 65 Control unit. screenw iper
258 Horn, high note 66 Control box. pow er st eering
27 Connector, towing attachment 75 Control unit, ignition, or pick-up amplifier module
28 Dimmer, dipped beams 76 Detector unit. bulb failure
30 Radio 80 Cruise control unit
35 Actuator, fuel output (VP1 5) 85 Indicator unit, oil level
40 Radio balance control, front 86 Indicator unit, coolant level
41 Radio balance control, front/rear 90 Control unit. centra l door locking
45 Battery 95 Infra red signal receiver ( PUP)
47 Diodes unit 96 Control unit, knock detector
48 UM, electric pump group (EPG) 97 Thermostat unit (passenger compartment)
,,\

,,------------------------------------------------------------------------- 297
Key to w ir ing diagram s - J ul y 1985 o n (continued)
Component c odes Component codes

110 Control unit. preheater 229 Sw itch. 1gn111on/ steenng lock
111 Control unit. fuel cut-off on overrun 230 Door switch, LH front
112 Control unit. fuel flow (tnp computer) 231 Door switch. AH front
113 Electronic control unit, advance (Diesel) 232 Door switch LH rear
11 4 Control box. coolant temperature, air conditioning 233 Door swnch, AH rear
115 Preheater plug 234 Control switch. audible warn ing (ignition key 'in')
120 Te1m1nal connector 235 Switch. brake fluid pressure drop
121 Buzzer ( P4. warning. coolant tomperature. oil 236 Switch, brake fluid level
pressure, charge warning light) 237 Switch, coolant level
122 Buzzer, direction indicator ( P4) 238 Switch, water sensing. fuel system
125 Audible warning, seat belt 239 Switch. washer bottle level
126 Audible warning (key in the 1gmtion/steenng lock 240 Limit sw itch, sunroof
with the driver's door open) 241 Switch on accelerator pedal (idle speed)
127 Audible warning, excessive speed 242 Swi tch. idle speed
128 Audible warning (lights on, door open or 'STOP' 243 Swilch, power take- off (P4 )
warning lamp on) 247 Switch. rear differential lock
130 TDC sensor 248 Switch. front d1fferem1al lock
131 Alutude sensor 249 Switch, windscreen wiper lockout (P4)
132 Knock detector 250 Disengaging switch. cruise conttol (brake)
133 Sensor, engine speed 250A Disengaging sw itch, cruise control (clu tch)
134 Sensor. absolute pressure (Diesel) 251 Throttle sw it ch (idling + full load)
135 Sensor. potenuometer (econoscope vacuum ) 252 Level swnch, brake anulock
136 Sensor. demisting the rear glass 260 Conttol. lighting /direction indicators/ horn
137 Pressure sensor inlet manifold 261 Control. lighting/screen wiper/screen w ash
138 Pressure sensor, speedometer cable 262 Control, lighting/screen wiper/ direction
140 Speed sensor. speedometer cable indicator/ horn
141 Speed sensor. trip computer 263 Control, screen w iper/ w ash
142 Sensor, oil pressure 264 Control, lighting/ horn
143 Sensor. No 1 cylinder 265 Con trol. direction indicator/horn
144 Sensor. diesel in1ector needle lifted 266 Switch, cruise control
145 Direction indicator flasher unit 267 Sw itch, cruise control/ direcuon indicator
146 Antilock sensor. LH front wheel 268 Switch, flasher unit ( P4)
147 Ant1lock sensor. RH front wheel 269 Switch, lighting/blackout ( P4)
148 Ant1lock sensor. LH rear wheel 270 Switch, w indscreen w iper ( P4)
149 Antilock sensor. RH rear wheel 275 Control, driver's seat positron
150 Air temperature sensor (air cond1t1oning) 276 Control. rear view mirror LH
151 Load sensor (Diesel) 277 Control, rear view mirror AH
155 Pilot carburettor 280 Supplementary air device (cold start)
160 Battery isolator 281 Corrector. fuel reheaung
165 Instrument panel 285 Capacitor. coi l pos111ve
167 Connector, emission control setting 286 Capacitor. direction indicator flasher unit
169 Switch, Starter/ preheater 290 Tachometer
170 Switch, luggage compartment lamp 295 Compressor
171 Switch. enrichment (LPG) 296 Compressor. air horn
175 Switch. door lock 300 Starter motor
176 Switch, vacuum (LPG) 301 Vapour relief valve (LPG)
177 Swttch. LH front lock (door open detector) 302 Diode. relay protecti on
178 Swttch, RH front lock (door open detector) 303 Diode. rear fogfamps
179 Sw1tch, LH rear lock (door open detector) 304 Protection diode, electronic control unit
180 Swttch. AH rear lock (door open detector) 305 Checking diode. coolant temperature warning ligh1
181 Swttch. luggage compartment lock (lid open 306 Checking diode. brake warning hght
detector) 307 Diode, air condrtloning control
182 Switch, bonnet lock (bonnet open detector) 308 Diode, lighting dimmer
, 85 Switch. stop lamps 309 Diode. electric fan
186 Switch, brake pedal travel 310 Diode, compressor
190 Switch, handbrake 311 Diode. roof lamp
195 Switch, low pressure (Freon) 312 Dtode. speech synthesizer
196 Switch. mean pressure (Freon) 313 Flow sensor
200 Thermal switch (Freon) 329 Solenoid valve. cruise control deceleration
205 Switch, glovebox lamp 330 Solenoid valve, air cond111oning
210 Switch, seat belt 331 Solenoid valve, EGR (pilot carbureuor)
211 Switch. display (tnp computer) 332 Solenoid valve, opening the carburattOf throttle valve
215 Switch. starter inhibitor 333 Solenoid valve. rn1ec11on cut -off on overrun
216 Swttch, reverse lamps 334 Solenoid, em1ss1on control advance modulator
217 Switch. reverse lamps/starter 1nh1b1tor 335 Solenoid. exhaust emission
220 Switch. heating/ venulation fan 336 Solenoid. carbureuor breather
221 Swttch. heating/ venulauon fan (rear) 337 M ain solenoid, brake anulock
225 Switch. choke warning light
I :I

288
Key to wiring diagrams - July 1985 on (continued)
Component codes Component codes

338 Control solenoid, brake antilock 488 Fuse holder (control unit, advance regulator VP15)
340 Solenoid, pump stop 489 Fuse holder. cooljng fan group (CFG)
344 Solenoid, turbine fan 490 Impulse generator \speed)
345 Solenoid valve. fas1 idle s1abiliser 491 Rotating tamp
346 Solenoid, canister 500 Loudspeaker, LH front
347 Solenoid, cruise control 501 Loudspeaker. RH front
348 Advance solenoid, diesel 602 Loudspeaker, LH rear
349 Solenoid valve. temperature control 503 Loudspeaker, AH rear
350 Switches, Illumination 505 Hour meter ( P4)
351 lllum1na11on, Instrument panel 610 Switch: front loglamps
355 lllumina11on, heat1 ng/ ventila11on con trol 511 Switch, rear foglamps
360 Illumination, console 512 Switch, au xiliary driving lamp
361 Courtesy lamp 513 Switch, siren
364 Illumination. cigar lighter 514 Switch, rotating lamp I•
I' 365 lllum1na11on, ashtray 515 Switch, rheostat, instrument panel illumination
370 Illumination, luggage compartment (or tailgate) 516 Switch, parking lights
375 Illumination. glovebox 517 Switch, general (military P4)
380 Illumination. engine compartment 518 Test switch. oil, coolant or charging fault ( P4)
385 Illumination. number plate LH 519 Switch, horn (P4)
386 Illumination. number plate RH 520 Switch, window winder (driver's)
390 lllum1na11on, ignition switch/ steering lock 521 Switch, window w inder (passenger's)
395 Floor 1lluminat1on. driver's side 521A Switch. passenger's window w inder
396 Floor illumination, passenger's side 522 Switch, window winder. LH rear
397 Sill illumination. driver's side 523 Switch, window winder, RH rear
398 Sill 1lluminat1on. passenger side 524 Switch. window w inder, LH rear (in rear
400 llluminauon, gear selector lever compa rtment)
410 Clutch, compressor 525 Switch, window winder, RH rear (in rear
420 ldhng cut- o·H, carburettor compartment}
425 Map reading lamp 526 Child safety switch, rear w indow w inders
440 S1delamp LH 527 Switch, main/dip beams ( P4)
441 S1delamp RH 530 Switch. sunroof
445 Tail lamp cluster LH 532 Switch, heated rear window
446 Tail lamp cluster RH 535 Switch, driver's seat heating
452 Marker lamp, LH rear 536 Switch. passenger's seat heating
453 Marker lamp, RH rear 540 Switch. preheater
455 Door marker lamp LH 545 Switch, central roof lamp
456 Door marker lamp RH 548 Test switch, brake wear warning light
457 Front foglamp RH 549 Diagnostic switch. diesel
458 Front foglamp LH 550 Switch. rear screen w iper
460 Rear foglamp LH 552 Switch, headlamp wiper
461 Rear loglamp RH 555 Switch, fuel supply warning light
462 Reverse tamp 556 Switch. police horn
463 Stop-lamp 557 Switch. rotating lamp
464 Reverse lamp .,. foglamp { rear) 558 Switch, air fan
465 Suppressor filter. tachometer 560 Swi tch, warning bell
466 Fuse holder ( + accessories. brake antilock) 565 Switch, pressure drop
467 Fuse holder (for warning light, brake antilock ) 566 Switch. air conditioning control
468 Fuse holder (power circuit, brake antilock) 567 Switch, cruise control
469 Fuse holder Lambda sensor heater 570 Switch, hazard warning
470 Fuses {fusebox) 571 Test switch
471 Fuse holder {rad io) 572 Switch, lamps (police)
472 Fuse holder ( locks) 574 ln1ectors
473 Fuse holder (dipped beams) 575 Cold start Injector
474 Fuse holder (speech synthesizer) 576 Information display. injection control box
475 Fuse holder (carburettor heater) 580 Fuel tank unit
476 Fuse holder (cruise control) 590 M ap reading lamp
477 Fuse hvlder, supply pump 591 Indicator, coolant temperature
478 Flashing lamps, priority 592 Gauge, turbocharger pressure
479 Fuse holder (pump, brake antilock) 593 Fuel gauge
480 Direcuon indicator lamp, LH front 594 Gauge, engine oil temperature
481 Direction Indicator lamp, RH front 595 Gauge. engine oil pressure
482 D1recuon indicator lamp, LH rear 598 Electronic control unit, ignition
483 D1reci1on indicator lamp, RH rear 600 M otor. screen w iper
484 Side lamp/direction indicator, LH front 601 M otor. window wiper. rear
485 Side lamp/direction indicator, RH front 605 Wiper motor, headlamp LH
486 Suppression filter, speech syn thesizer 606 Wiper motor, headlamp RH
487 Fuse holder (control unit, fuel output VP15) 607 Motor, heater control flap
I :l

,..---------------------------------------------------------------------299
Key to wiring diagrams - July 1985 on (continued)
Component codes Component codes

610 Motor. sunroof 735 Relay, main beams
615 Motor. LH front window winder 736 Relay, auxiliary driving lamps
616 Motor. RH front window winder 737 Relay, dipped beams
617 Motor, LH rear window w inder 738 Relay, heat~ g/ventilation fan, fast speed
618 Motor. RH rear window winder 740 Relay, coll
620 Motor, heal1ng/ ven11la11on fan 741 Relay, coil resistance
625 Actuator. LH front door lock 742 Relay, cold start control
626 Aetuator. RH front door lock 743 Relay, compressor
627 Actuator, LH rear door lock 744 Tachymetnc relay or pump con trol relay
628 Actuator, RH rear door lock 745 Relay, air horn compressor
629 Aetuator. luggage compartment lock 746 Tachymetnc relay (cut-off on overrun)
630 Motor, fuel filler flap lock 747 Relay, CLT
635 Motor, engine cooling fan 748 Relay, ECU. exhaust emission
636 Motor, air cond11tonmg fan 749 Relay, cold cut-off
640 Clock 750 Relay, front foglamps
645 Pressure sw itch. brake servo 751 Relay, rear foglamps
646 Pressure switch. power steering 752 Relay, compressor cut-off (105•)
647 Pressure switch. air conditioning cut-out 753 Relay, pump, brake antilock
650 011 pressure sw11ch 754 Relay, power circuit, brake anulock
651 Vacuum-pressure switch 755 Relay, headlamp wiper
652 Pressure switch. turbocharger cut-out 756 Relay. headlamp wiper timer
653 Fuel throttle enrichment swirch 757 Relay, advance curve selection
654 Advance curve selection switch 760 Relay. heated rear window
660 Trip computer 761 Relay, rear electric window
660A Keyboard. trip computer 762 Relay, front electric window
660B Display, trip computer 763 Relay, sunroof
669 Potentiometer, throttle 764 Relay. sunroof tilt + central locking
669A Potenttometer, accelerator pedal ( Diesel) 765 Relay, front screen wiper
670 Headlamp LH 766 Relay, rear window w iper
671 Headlamp RH 767 Relay, warning light occu l1ation (P4)
672 Headlamp blackout ( P4) 770 Relay, accessories
673 Driving lamp LH 771 Relay, visual warning
674 Driving lamp RH 772 Relay, two-speed (mixture control)
675 Brake pads. LH front 773 Relay, car bu renor heater
676 Brake pads. RH front 775 Relay, starter motor isolator
677 Brake pads, LH rear 776 Relay, cruise control disengagement
678 Brake pads. RH rear 777 Relay, pilot carburettor supply
679 Vacuum pump, cruise control 778 Relay, scavenge pump
680 Washer pump, front 780 Relay. lighting dimmer
681 Washer pump, rear 781 Relay. excessive speed
682 Washer pump, headlamp 782 Relay, ignition supply
683 Fuel supply pump 783 Relay. injection supply
684 Scavenge pump 784 Relay, trip computer/cruise control/speech
685 Coolant pump, heater matrix synthe.sizer information
686 Hydraulic pump, brake anti-lock 785 Relay, brake warning (Australia)
688 Interior lamp. front 786 Resistor, coil
689 Interior lamp, rear 787 Resistor, heating/v~mtilation fan
690 Interior lamp. centre 788 Resistor, two-speed cooling fan
691 Interior lamp. LH front 789 Resistor, lighting dimmer
692 Interior lamp. RH front 790 Hearer. diesel fuel
693 Interior lamp, LH rear 791 Heater, carburettor
694 Interior lamp. RH rear 793 Resistor, preheater ( P4)
697 PUP 794 Resistor, injection matching
700 Pressure switch 795 Rheostat, instrument illumination
705 Connector board 800 Regulator. voltage
706 Services connector board 801 Regulator, control pressure
710 Battery supply socket 810 Side repeater flasher LH
720 Diagnostic socket 811 Side repeater flasher RH
721 Test socket (injection) 812 Rheostat, temperature display
723 Front foglamp LH 814 Rear view mirror LH
724 Front foglamp RH 815 Rear view mirror RH
729 Relay. emission control 817 Heated seat, front LH
730 Relay, starter motor 818 Heated seat, front RH
731 Relay, preheater 820 Bell
732 Relay, fan clutch 829 Servo, power steering
733 Relay. electric fan motor 830 Servo, cruise cotrol
734 Relay. hour meter (P4) 832 Sensor. evaporator

290----------------------------------------------------------------------.. . . .
Key to wiring diagrams - Jul y 1985 on (continued )
Component codes 965 Cold start flap

833 Sensor. blown air 970 Voltmeter
834 Sensor, interior air temperature
835 Sensor, oil level + AA Supply from accessories terminal
836 Sensor. fuel flow (trip computer) + AC Supply from ignition switch
837 Sensor, coola nt level BL Screened cable
838 Sensor, mixture regulator +D Supply from starter motor
840 Sensor high temperature L1 Warning lamp, seat belt
841 Siren L2 Warning lamps, direction indicator
845 Speech synthesizer L3 Warning lamp, low fuel level
846 Sensor, body temperature (exhaust) L4 Warning lamp, main beams
847 Sensor, passenger compartment temperature LS Warning lamp. hazard warning
regulation L6 Warning lamp, side/tail lamps 'on'
848 Lambda sensor L7 Warning lamp, no battery charge
849 Sensor, external air temperature LS Warning lamp, preheater
850 Thermal switch, cooling fan (coolant) L9 Warning lamp, choke control
852 Thermal sw itch, transmission oil L10 Warning lamp, oil pressure
853 Thermal sw itch. 18' C (coolant temperature) L11 Warning lamp, oil and coolant
855 Thermal switch, coolant L12 Warning lamp, coolant temperature
861 Thermal switch, 40' C (coolant temperature) L13 Warning lamp. brake safety
862 Thermal switch, 60' C (coolant temperature) L14 Warning lamp, rear foglamps
865 Thermosta t. electronic (air conditioning) L15 Warning lamp, fuel supply
870 Thermal rime switch (cold start opening) L16 Warning lamp. 'stop·
880 Tachograph L17 Warning lamp, brake flu id/stop-lamps
885 Timer switch. seat bolt L 18 Warning lamp, side lamp failure
886 Timer switch, interior lamp L19 Warning lamp, tail lamp failure
887 Timer switch. headlamp wash L20 Warning lamp, screenwash level
888 Sender unit. oil temperature gauge l21 Warning lamp, coolant level
889 Temperature sender unit, injection L22 Warning lamp, engine oil level
890 Sender unit, coolant temperature gauge L23 Warning lamp, brake pad wear
891 Temperature sender unit, electronic L24 Manual test switch, instrument panel
(heating/ ventilation) L25 Warning lamp, oil temperature
892 Sender unit. engine oil temperature L26 Warning lamp. 'door open'
893 Timer switch. rear screen wiper L27 Warning lamp. tall lamp or rear foglamp failure
893A Timer switch. w indscreen w iper L30 Warning lamp, rear differential lock
894 Temperature sender unit, controlling cooling fan L31 Warning lamp. front differential lock
motors by ECU (liquid cooling) L32 Warning lamp. knock detector
895 Sender unit, exhaust emission L33 Warning lamp. diagnosis
896 Thermal resistor, inlet air temperatu re L34 Warning lamp. water in fuel
897 Tester, anti -lock L35 Warning lamp, dipped beams
898 Sender unit, oil pressure L36 Warning lamp. trailer direction indicator
899 Test unit. variable power steering L37 Warning light, power take-off ( P4)
929 Proportioning valve. cruise control L38 Warning lamp, catalytic converter
930 Fan. electromagnetic clutch L39 Warning lamp. brake anti -lock alert
935 Fan, heating/ ventilation
936 Fan, heating/ ventilation. rear M Earth connections
945 Heated rear w indow +P Supply from battery
950 Fan Not all items are fitted to all models
955 Ram, driver's seat
960 Fan, air conditioning The wires are not colour-coded
I:)

'
Index
A Brake disc
mspec11on, removal and refitting - 180
About th is manual - 5 Brake pedal
Accelerator cable removal and reflt11ng - 188
removal, refitting and ad1ustment 98. 108 Brake shoes ( rear)
Air cleane r 1nspect1on and renewal - 175
el ement renewa l 86. 101 Braking syst em - 171 et seq
removal and refitting 101 Braking sys tem
Air conditioning system brake disc 180
description and precautions - 230 descnptlon - 172
maintenance 230 disc caliper (front) 179
Alternator disc caliper (rear) 180
brush renewal 236 disc pads (front) 172. 173
descnpt1on and testing 235 disc pads (rear) - 174
removal and refitung 235 fault diagnosis - 190
Ancillary co mponents (engine) flexible and rigid hydraulic Imes inspection and renewal - 185
refitting - 58, 73 handbrake - 187 to 189
removal 45. 66 hydraulic system (bleeding) - 186
Antifreeze m i xture. general 78 maintenance, routine - 172
Anti-roll bar ( front) master cylinder 182
removal and ref1tt1ng 195 pedal 188
Automatic transm ission rear brake compensator - 184
fluid draining and refilling 153 rear wheel cylinder 182
gear selector lever ad1ustment - 154 spec1ficat1ons - 171 to 172
k1ckdown cable ad1ustment - 154 stop-lamp swnch - 188
removal and refnt1ng 153 torque wrench setting - 172
vacuum servo air filter renewal - 187
vacuum servo unit 187
B Bulbs ronowol
extenor
Battery front parking and direction indicator lamp - 244
maintenance - 234 headlamps - 244
removal and refitting - 235 rear lamp cluster (Estate) - 244
Big-end and main bearing shells rear lamp cluster (Saloon) - 244
examination and renovation 51 rear number pla te lamp 244
Bodywork and f i ttings 210 et seq side marker lamp - 244
Bodywork and fittings intet1or
a11 conditioning system 230 all Interior lamps/ bulbs - 247
bonnet 212. 213 digital clock (1986 -on models) 247
boothd 220 facia switch 247
bumpers 213 heater control/ co1nbox/ashtray illumination bulb
cen tre console and heater control panel 224. 226 (1986- on models) 24 7
desc11puon 210 heater control panel 1lluminat1on bulb
doors 213 to 217. 219 (pre· 1986 models) - 247
fac1a panel 224, 228 Ignition swnch 1lluminat1on bulb - 247
front gnlle removal and refitting 213 Instrument panel warning lamps - 246
heater 229. 230 luggage companment and glovebox lamps 246
maintenance. routine - 210. 211 map reading lamp - 246
mirror (exteuor) 223 roof lamp 246
repa11 Bumpers
maior damage - 212 removal and refitting 213
minor damage 211 . 21 2
plastic components 212
seat belts 230
seats 222
c
sunroof 223 Camsha ft
tai lgate 221 examination and renovation - 51 . 68
w indscreen and rear window glass - 222 refitting 56
Bonnet removal and ref11t1ng (ZEJ and ZDJ engines) - 62
locks and cable release removal and refitting - 213 Capacities. general - 7
removal and ref1tung 212 Carbu retto r
Bootlid general - 89
dismantli ng and reassembly 220 idle speed and mixture ad1ustment - 89
remova l and refitting 220 removal and refitting 91
Brake comp ensator ( rear) Carburettor (Solex 32- 34 and 34 -34 CI SAC)
removal, overhaul and refitting dismantling. reassembly and adjustment - 96
Estate models 185 Carburetton (Solex 32-35 MIMSA)
Saloon modols 184 dismantling. reassembly and adjustment - 96

292 Index
Carburettor ( Solex 32- 35 TMIMA) 0

dismantling reassembly and ad1ustment 94
Carburettor (Solex 34 BICSA 3) Damage repa ir (body)
d1sman1hny. 1eassembly and ad1us1men1 96 ma1or 212
Carburettor (Solex 34 -34Z1 ) minor 211 , 212
dismantling reassembly and ad1us1men1 - 96 Differenti al unit and rear' axle (Esta te models)
Carburettor ( Zenith 35-40 INAT) removal and refrmng 16~
dismantling reassembly and ad1ustmen1 92 D im -d ip lighting, general 254
Central locking system. general 254 Dimensions, vehicle - 7
Centre console and heater c ontrol panel Oise caliper
removal and relming remova l, overhaul and refitting
pre- l 986 models - 224 front - 179
1986 on models 226 rear 180
Choke cable Oise pads (fron t )
removal relotung and ad1us1ment 98 inspection and renewal
Cigar lighter OBA caliper - 172
removal and ref1 t11ng - 241 Teves caliper - 173
Clock ( digital) Disc pads (rear)
removal and refilling - 241 inspection and renewal 17 4
Distributor
Clutch 125 et seq
dismantling and reassembly - 116
Clutch
removal and refitung - 115
descrrpuon 125
Distributor cap. general 122
fault diagnosis - 130
Distributor drive pinion
hydraulic flexible hose - 130
refining - 73
hydraulic system (bleeding) 130
Door
inspection and renovation 126
dismantling and reassembly - 217
maintenance. routine - 125
removal and refining - 213
master cylinder 127
trrm panel removal and ref1111ng - 213
refrnmg 126
Orivebelt
release bearing and fork assembly - 129
removal. ref111tng and ad1ustmen1 - 79
removal 126
Oriveshaft ( Saloon models)
slave cylinder 1 29
overhaul - 167
specificauons 125
removal and refitting
torque wrench senings - 125
disc brake models 167
Coil ( ignition)
drum brake mpdels - 167
removal 1es11ng and ref1111ng 122
Condenser
removal testing and refin ing - 11 5
Connecting rods (and pistons)
E
exam1na11on and renovauon 60. 68
Electrical system - 233 et seq
refitting 53, 70
Electrical system
Contact breaker points (cassette type)
alternator 235. 236
ad1us1ment 113
battery - 234. 235
removal and refming - 11 4
bulbs - 234. 244. 246, 247
Contact breaker points (standard type )
CB equipment - 256
adJustment 112
central locking system - 254
removal and refitting - 113
cigar lighter - 241
Conversion factors 13
clock (digital) - 241
Cooling system 75 er seq description - 234
Cooling system d1m-d1p lighting - 254
an tifreeze m11Cture - 78 fault d1agnos1s - 257. 258
descripuon 76 fuses and relays - 234. 238
draining flushing and refilling 77 headlamps 244, 248
drrvebelt 79 horn unit - 248
fan thermoswuc h (self-disengaging) - 80 instrument illumina11on rheostat - 242
fault d1agnos1s 82 instrument panel - 242
maintenance routine - 76 maintenance. routine - 234
radiator 79 radio interference - 256, 257
spec1f1ca11ons 75 radio. speakers and aerial 251
thermostat 78 rear screen (heated ) 252
torque wrench settings - 75 specifications - 233. 234
water pump 79 speedometer cable - 242
Crankcase venti lat ion system staner motor - 236, 237. 238
desc11pt1on 46, 67 switches 188. 239. 24 1
Crankshaft tailgate wiper motor (Estele models) - 251
and main bearings. refimng 52, 69 torque wrench semngs - 234
exam1na11on an d renovauon - 51 . 68 washer system. general 262
Cylinder block and crankcase w indscreen wiper - 248, 261
examina1lon and renovation 50 w mng diagrams - 260 to 290
Cylinder head Engine - 28 et seq
dismantling. decarbon1sin9 and reassembly 48. 57 Engine ( Pert A : General )
exam1nat1on and renovation 51 descnpuon
removal end refining - 38. 64, 73 overhead cardshaft engines (ZEJ and ZOJ) - 32
Cylinder lrners/ pistons and c onnecting rods overhead valve engines (XM 7 and XN1) 31
ref1mng - 53. 70 maintenance. routine - 32, 34

specifications 28 to 30 Final drive uni t (Salo on m odel s)

torque wrench settings - 29, 30. 3 1 removal and refitting - 165
Engine (Part B: Over head va lve engines - XM7 and XN1) Flywheel / d ri veplate and st arting g ear
ancillary components - 45, 58 examination and renovation - 51
b1g·end and main bearings shells - 51 refitting - 53. 70
camshaft - 51 , 56 Front suspensiofl
components examination and renovation - 48. 50 to 52 description - 1193
crankcase venti lation system - 46 fault diagnosis 209
crankshaft - 51, 52 front anti-roll bar
cylinder block and crankcase - SO removal and refitting - 1·95
cylinder head - 38, 48. 51, 57 front hub bearings
cylinder IIners - 53 renewal - 1 99
dismantling - 45, 46 front lower suspension arm
flywheel/ driveplate and starter ring gear - 51, 53 removal and refitting - 198
initial stan-up after major overhaul - 58 front lower suspension balljoml renewal
moun tings - 42 all models - 199
011 pump/distributor driveshaft - 52, 56 early Saloon models (up to VI N 1.341 .364) -1 98
operations possible with engine in car - 34 later Saloon models and all Estate models - 198
pistons and connecting rods - 50, 53 front radius arm
reassembly - 52 removal and refitting - 197
refimng - 58 front suspension strut
removal - 42 removal, overhaul and refitting - 195
rocker arm assembly - 52 maintenance. routine - 195
sump - 57 specifications - 191
tappets - 57 torque wrench settings - 192
ummg chain and sprockets - 35. 51, 56
valve clearances adjustment - 35 Fuel and exhaus t s ystems - 83 et seq
Engine (Part C: Overhead c amshaft engines - ZEJ and ZDJ ) Fuel and exhaust systems ( Part A: General)
ancillary components - 66. 73 description - 86
camshaft 62, 68 maintenance, routine - 86
crankcase ventilation system - 67 specifications - 83 to 85
crankshaft - 68, 69 torque wrench settings - 85
cylinder head - 64. 73 unleaded fuel - 86
cylinder liners - 70 Fuel and exhaust systems ( Part B: Carburettor engines)
dismantling - 66, 67 accelerator cable - 98
distributor drive pinion - 73 air cleaner element renewal - 86
examination and renovation (dismantled components) - 68 carburettor - 89. 91
flywheel or driveplate (automatic transmission) - 70 carburettor (Solex 32-34 and 34 -3 4 CISAC) - 96
initial start-up after major overhaul - 73 carburettor (Solex 32·35 M IMSA) - 96
intermediate shaft - 69, 70 carburettor (Solex 32·35 TM lMA) - 94
mountings - 65 carburettor (Solex 34 BlCSA 3) - 96
011 pump - 69. 70 carburettor (Solex 34·34Z1) - 96
operations possible with engine in car - 58 carburettor (Zenith 35-40 INAT) - 92
pistons and connecting rods - 68, 70 choke cable - 98
reassembly - 69 fuel level transmitter removal and refitti ng - 88
refimng - 73 fuel pump cleaning, removal and refitting - 87
removal - 66 fuel tank removal. repair and refitting - 89
rocker gear - 69 manifolds and exhaust system - 98
sump pan - 73 Fuel and exhaust systems ( Part C: Fuel inject ion engines )
urning belt 59. 69, 70. 73 accelerator cable - 108
valve clearances adjustment - 58 air cleaner and element - 101
Engine (Part D : Fau lt d i agnosis) - 74 description and precautions (fuel injection system) - 98
Exhaust system , genera l - 98. 108 fuel filters renewal - 103
fuel level transmitter remova l and refitting - 108
fuel pump removal and refitting - 108
F fuel tank removal. repair and refitting - 108
manifolds and exhaust system - 108
Facia panel K-Jetronic system
removal and refitting components checking
pre-1 986 models - 224 additional air device - 103
1986-on models - 228 cold start injector - 1 02
Fan ther mosw itch (self-disengaging) fuel injectors - 1 03
removal and refitting - 80 mixture regulator - 102
Fault diagnosis - 25 et seq sensor plate - 102
Fault diagnosis thermal time switch - 103
braking system - 190 idle speed and mixture adjustment - 101
clutch - 130 specifications - 85
cooling system - 82 throttle butterfly initial seuing - 102
electrical system - 257, 258 LE2·Jetronic system
engine - 74 airflow sensor remova l and refitting - 107
fuel and exhaust systems - 110 components checking
1gn111on system - 124 airflow sensor - 105
manual gearbox and automatic transmission - 156 engine temperature sensor - l 06
propeller shaft - 162 s~ppl ementary air device - 106
rear axle - 170 fuJ1 l,njector removal and refitting - 108
suspension and steering - 209 idle speed and mixture adjustment - 104

Pug 505 Manual Service

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Models covered by this manual

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Hay nes Publishing Group

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© Haynes Publishing Group 1989

A book in the Haynes Owners Workshop Manual Serles

Printed by J . H. Haynes & Co. Ltd, Sparkford, Nr Yeovil,

All r ight s reserved. No part o f this book may be reproduc ed or

ISBN 0 85696 762 9

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About this manual 5

Introduction to the Peugeo t 505 5

General dimensions. weights and capacities 7

Buying spare parts and vehicle identification numbers 9

General r'epair procedures 10

Tools and working facilities 11

Recommended lubricants and fluids 24

Chapter 2 Cooling system 75

Chapter 3 Fuel and exhaust systems 83

Chapter 4 Ignition system 111

Chapter 5 Clutch 125

Chapter 6 Manual and automatic transmission 131

Cl;lapter 1 Propeller shaft 157

Chapter 8 Rear axle 113

Chapter 9 Braking system 171

Chapter 10 Suspension and steering 191

Chapter 11 Bodywork and fittings 210

Chapter 12 Electrical system .. 233

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Peugeot 505 SR Saloon (1981 model)

Peugeot 505 GR Estate (1981 model)

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Abo ut this manual

Introduction to the Peugeot 505

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General dimensions, weights and capacities

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Jacking, towing and wheel changing

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Buyi ng spare parts and

Vehicle identification number (VIN) II TyptJ apptoval numbar

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General repair procedures

Tools and working facilities

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12 Tools and working facilities

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Torque (moment of force)

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Asbestos Ignition HT voltage

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Models up to July 1984

Cooling system (Chapter 2) Ignition system (Chapter 4)

Electitcal system (Chapter 12) Fuel system (Chapter 3)

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Suspension and steering (Chapter 10) Steering (Chapter 10)

Fuel system (Chapter 3) Fuel system (Chapter 3)