I

OPERATION

31.

Adjust

No

the

D.330-1

hand

brake

: K ettto7~i72g

arIft

jilliug

Set the clearance

between brake pads and
discs to 0.1 mm by means of the adjusting
screws ( insert a 0.1 mm shim between pad
and disc 1 and tighten the locknuts.
CAUTION
: Allowance
must be made for the
run-out of the discs.

37. Check that the circuits

gears change correctly.

to

do not leak and that the

).

39. Fit the front wheels

inlet duct assembly,
wheel.
40.

Check

the

clutch

and wings,
the radiator
air
crossmember
and the spare

clearances

J.

brakes.
.

Tighten
the pressure
regulator
release screw.
Run the engine to restore pressure
in the circuits.

Check the adjustment

of the clutch drag speed
and of the clutch re-engagement
control (br,A
rchicles

Stop the engine.

calipers

38. Link up the oil cooler air duct and fit the closing
panel of the front suspension
unit ( IE tvhiclcs

Start the engine, prime the HP pump and connect

the pump inlet pipe to the tank.
front

up the air thermal

33. Fill the cooling

circuit.
Make sure that the
release screw on the pressure regulator
is
slackened.
Connect the earth cable to the battery.

the

330-l

centre the hydraulic

brake units.
Tighten
the screws holding the brake
130 - 140 mZY ( 13 to 14 m.kg 1.

Fit the fan ( connect the leads to the thermal

switch and the electric
fan ( r~rl~icles type DS23

Bleed

D.

36. Slacken the screws holding the main brake calipers.

Have an assistant
depress the brake pedal to

32. Fit the air filter and connect

sensor ( II: tvbicles
).

Op.

gearhor.

41.

Adiust

the

secondary

headlamps.

MANUFACTURING

DRAWINGS

FOR

TOOLS

NOT

MR.

630-22,

90

ex

MR.

3404-50

010

SOLD

Detoil

1969-T

Bis

a
II
Itxl;

I
I

/
1

the

necessary

weld

inside

the

yoke

if

/-

II
lidI

Detail

A : file

Steering

i
I

Developed

length

: 40

mn

OPERATION N D. 100-3 : Overhauling the engine.

Op. D. 100-3

1. OIL CIRCULATION DIAGRAMS

a) D Vehicles All Types except D.IE
Small
End

Small
End

Small
End

Small
End

Big
End

Big
End

Big
End

Big
End

Front Main
Bearing

N 2 Main
Bearing

Engine Oil Gallery

N 3 Main
Bearing

N 4 Main
Bearing

N 5 Main
Bearing

Timing
Chain

(Crankcase)

Oil Pressure
Switch

Petrol Pump
Pushrod

Timing Chain
Tensioner

Oil pump

Camshaft
Front Bearing

Camshaft
Rear Bearing

Camshaft
Centre Bearing
Inlet valve rocker shaft

Exhaust
Rockers

Push rods
& Tappets

b) D. IE Vehicles
Piston
crown

Piston
crown

Piston
crown

Piston
crown

Small
end

Small
end

Small
end

Small
end

Big end

Big end

Big end

Big end

Main
bearing n 2

Front bearing

Main
bearing n 3

Main
bearing n 4

Main
bearing n 5

Timing
chain

Engine Oil Gallery (Crankcase)

Petrol pump
push rod

Pressure
switch

Chain
tensioner

Oil pump

Oil cooler
Front bearing
camshaft

Central bearing
camshaft

Rear bearing
camshaft

Oil cooler gallery

Inlet rocker shaft
1

Exhaust
rockers

Rocker stems
and push rods

NOTE : The cooler is no longer fitted to DJ.IE vehicles (as from 9/1970).

OPERATION

No

D.

loo-3

: Olwhnrrli,rg

II.

1.

E ngine

casings

the

etIgina.

PARTICULAR

FEATURES.

a) Cylinder
block :
- The engine casing and the crankshaft
bearing caps are matched.
- The crankshaft
bearing caps are marked from the front of the engine (flywheel
end ) with the
numbers l-213-4.
- Crankshaft
main journal diameter
: ..................................
.. . .. . ... .. . .. .. .. .. .. .. . .. . 68.7 + 0.05 mm
Overall
flatness
of the seating surface for the cylinder
head : . . .. .. ... ... .... within 0.005 mm
- Tightening
torque on cap securing
screws : ... ... .. .._........ .. .. . .. .. ... . ... .. .. .. .... .. .. .. 90 to 100 rn!I> ( 9 to 10 m.kg)
b) Engine sump :
Tightening
torques :
- Securing
screws : .................. .. .. . ... . . .. .. .. .. .. .... .. .. .. ... .. ... .. .. .. .. .. .. ... .. ... .. .. .. .... .. .... 14 to 19 mAN (1.4 to 1.9 m.kg)
- Drain plug : ._........_._._...................................... . ... .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. ... .. .. ... ... .. .. 35 to 45 rn,jN ( 3.5 to 4.5 m.kg )
- Tightening
torque on screws securing clutch housing closing
plate : . ... .... 9 to 12 m/IN (0.9 to 1.2 m.kg)
c) Timing
gear cover :
- Tightening
torque on screws

2. Crankshaft

and

connecting

and nuts

rods

............

. .

14 to 19 m,\N ( 1.4 to 1.9 m.kg )

:
l

a) S-bearing

crankshaft

:
First

- Journal

possibility

: ._......... . . .. .. .. ... . .. .. .. .. .. .. .. .. . ... .. .. .. ..

64 .04 - 0.005
oo mm

diameter
Second

possibility

First
- Diameter

of crank

possibility

: . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 54

+ 0.010

. o.oo5 mm

0.010
- 0.005

mm

pins
Second

- Bearing shells
Inner diameter

: ,_........._..... .. .. .. .. .. .. .. ... . .. .... ._...... 63.54

:
( two possibilities

- Width

: ,_.,.,...........,.....................................

- Outer

diameter

( shells

not under

possibility

: ._.............,.............

. . .... .. .. ... . 53.5

) : ._..._..._... .. .. .. . .. .. .._....._............ _.....,_..._ ..._ 64.04

. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

strain

).,...................................,...................

NOTE : The bearing shells are made of aluminium-tin

alloy in all engines
Borg-Warner
gearbo,x, whose bearing shells are in copperlead.

28.6

+ 0.010

I o oo5 mm

and 63.54

mm

t 0.100
0.150

68.705

t A*;::
.

except

those

mm

mm
fitted

with

.. 0.045 to 0.160 mm
- Crankshaft
end-float
: ..........................,.........................................................
NOTE : The end-float
is adjusted
by changing
the lower half-thrust-rings
of the central bearing,
except for
engines
fitted with a Borg-Warner
gearbox which have two half thrust-rings
( upper and lower ) placed on
each side of the central bearing.
3.10 to 3.14 mm
- Half-thrust
rings for central bearing ( two possibilities
) : ,.....................
1 3.14 to 3.18 mm
90 to 100 m,ZN (9 to 10 m.kg)
- Tightening
torque on bearing fixing screws : ............................,.................
b) Connecting
- Distance
- Bore

rods :
between

centres

of small end bush

- Clearance

of gudgeon

of small

end and big end : ._........... .. .. .. .. .. .... .. .. .. .. 160 * 0.05 mm

+ 0.009
. 0.003

mm

to 0.018

mm

: ._................. . . .. .. .. .. .. ... ... .. .. .. .. .. ... . ... . .. .. .. .. .. .. .. .. .. .. .. .. 25.005

pin in small

end : ,............... .. .. .. .. .. ... .. ... .. .. .. .. ... . .. .. ..._.. 0.012

- Diameter

of big end : ,_..... ,........... . . .... .. . ..._.... .. .. . .._.......,...,.....,...

.. .. ... . .... .. ... . 57.69

0.005
0.015

mm

OPERATION

b) Piston

rings

D.

100-3

Owrharrling

the e?rgine.

Thickness
Ring

Width

No.

( mm)

Clearance

at gap ( mm )

Compressor

Scraper

Collector

*NOTE

: For the 93.5 dia.

CAUTION
: Certain
rings. When repairs

4.

Liners

and

cylinder

pistons,

the thickness

of the oil collector

engines have been fitted with ordinary

are made, the blade expander type ring

head

gaskets

ring

is

- 0.010
4 _ 0 OI2

mm.

oil collector
rings or with spring loaded
should be fitted to all types of engine.

collector

a) Paper

gaskets for liners :

9/ 1968 : Gasket with extra thickness

fd? 90 mm diameter
liners only
9/ 1968 : Gasket without extra thickness
for 86 and 90 mm diameter
liners
9/1971
: Gasket without extra thickness
for 93.5 mm diameter
liners
b) Cylinder head gasket : Two types of gaskets corresponding
to, the two types of liner gaskets :
- gasket
with circular
crimping
: to be fitted with liner gaskets with extra /hirk~~s.s.
- gasket with ot~al crimpiux
: to be fitted with liner gaskets which have no estra thickness.
IMPORTANT
replaced.
c) Pistons

5. Cylinder

: These

and liners

head

instructions

should

be carefully

observed

when

the cylinder

head gasket

is being

are matched.

90 mm
- Original
thickness
: ....... .............................. ...... ...... ............ .................. ................................................
.... 0.10 mm
- Maximum out of flatness
: ....................................................................................................................
0.10 mm
- Maximum skimming
( surfacing)
: ._...........................................................................................................
a) Valve seat :
120 degress
- Seat angle : Inlet : ._.............................................................................................................................
90 degress
: ._.......................................................................................................................
Exhaust
0.8 to 1 .2 mm
- Width of seats : ._ ..... ...........................................................................................................................
- Nominal
diameter
of seats :
45 mm
IO/ 1968 : ._............................................................................................
Inlet
47 mm
IO/ 1968 : ._ .......................
._ ................................................................
37.5 mm
Exhaust
: ._.......................................................................................................................
b) Valve

guides

First

possibility

Outer
13

dia. of guide
+ 0.059,,
+ 0.039

Cylinder

head bore

13 + 0.007
- 0.013

First
Exhaust

possibility
possibility

13.25

1 i.iz8
.

13 + 0.065
-I 0.045

mm
mm

13.25

8'

13.25

+ 0.065
+ 0.045

13
l

mm

13.25

mm

. 0.013

t- 0.023
0.013

mm

8.99
possibility

0.015
- 0.010

+ ooo7mm

,
Second

bore

mm

Inlet
Second

Guide

+ 0.003
oo23
l

mm

0.015

0.010

mm

OPERATION

No D. 330-3 :

0wrhnuliug

II /r,ur*spcc,r/

Op. D. 330.3

gt,crrbo.v,

FOUR-SPEED GEARBOX
( Hydraulic gear change )

DX a DJ - DL . DV . DT VEHICLES

D. 33.2

FOUR-SPEED GEARBOX
( Manual gear change )
D. 33-3

OPERATION

No D. 330.3 :

Or~erhaulirrg

n li)t~t-.spe~,d

gearhov.

DIFFERENTIAL
D. 34.1

Left-hand

Gears

Right-hand

CrW.Vil
wheel
and pinion

Ratio

12
39

First

side

(325

Speed0 meter

1)

Gear

12

( 3.25

17 (1.94

Second

1)

18

33

Reverse

22

I 1.27

8/35

1 )

(3.25.
x(1.83

Cr0Wl
wheel
and pinion

Fourth

: 1)

11

28 (0,79 : 1 )
13,233.w
22 41

1)

Gears

First

(4.375

/I)\

22
ROVOrBO

Speedometer

1 )

33
( 1.17

(1.21

22

8//35

23
27

(1.83.

1)

1)

Second

7/34
2
(4,857: 1: 16
f /)I ) (2,28.

1 )

Third
1)

Fourth
Reverse

(2.10 1 )

8/ 35

4.375

!I

27 CO.85 1 )
23
13 22 (3.15
1 )

Reverse

39

Third

Fourth

1 )

Ratio

Second

1 )

35

13 x - 22 (3.15:l)
22
41

12

29

Third

10(2.10:1)
1) 21

(4.375:
27(0,85.
23

Gears
First

meter

39

28

Fourth

Speed0 -

39

Second
Third

CroWI
wheel
nd pinio

Ratio

First

side

',Ti

CKWlll
wheel.
tnd pinion

Ratio
12

( 3.25

Speedometer

1 1

37

18

(1.83

1 1

33

7
16
(2.28

1)

OPERATION

- The intermediate
on the gear ).

- The qearbox

sliding

housinq

No D. 330-3 :

reverse

pinion

has been modified

n four-spved

Or~erl~n~rli~tg

and the first/second

to permit

synchronizer

movement

NOTE : It is possible
to fit the new pinions
into a former
is used for setting the reverse qear to H neutral 11.

gearhs.

have been modified

of the new reverse

casing

on condition

( wider

gear intermediate

that the gauge

3188-T

teeth

pinion.

( 3 mm thick

OPERATION

No Dm. 340-3 : Oz~erhnuling u /ilIe-speed

FIVE-SPEED

gearbox.

GEARBOX

DIFFERENTIAL

Op. Dm. 340-3

OPERATION

No

Dm.

340-3

: Oz~erhnuling

c1 fiz)r-speed

GEAR

RATIOS

gearbox.

TRAIN

FIRST

GEAR

SECOND

THIRD

GEAR

FOURTHGEAR

FIFTH

GEAR

REVERSE

GEAR

GEAR

:
Vehicles

Gears

type

DJ

All

Types

and

Crownwheel
pinion

Ratio

Vehicles

DP

Speedometer

type

DT

(optiorz ) *IO/

Gears

First

First

Second

Second

$j

(3..25

; 1 ;

Third

Third
lOi

8/35

Fourth

4.375:1

Fifth
Reverse

2x$.
I

(3.15

: 1 )

y2.10

7/ 34

Fourth
: 1)

Fifth
Reverse

13 x22

2-7

(3.15

41

: 1)

1972

OPERATION

N Dbw. 350-3 : 0

rerllnrrliug

u BORG-14:1RNER

Op. Dbw. 350-3

genrhor.

DESCRIPTION OF THE GEARBOX.

DBW VEHICLES

Rear

biake

Front

- ALL TYPES

D.

-.

35-49

brake
I

sun geai
\

Ring-qear
I

The gearbox comprises

:
- An epicyclic
gear train which provides three forward gears and one reverse gear.
- Two multidisc-clutches,
each operated
by a hydraulic
piston.
- Two band brakes, each operated by its hydraulic
servo piston.
- A free wheel which locks the planet gear carrier to obtain 1st gear.
at the outlet of the epicyclic
gear train, relay the mouvement to the
- Two pinions A ( ratio = 38/33 ) p ositionned
bevel pinion.
- A valve-chest
situated
ih the lower
part of the housing gear provides automatic
control of the clutches
and brakes
for changing
gear.
- A centrifugal
governor which operates
in conjunction
with the valve chest.
- The crown wheel and pinion/differential
assembly
fitted in a separate casing.

POWER-FLOW TABLE

OF THE EPICYCLIC

GEAR TRAIN COMPONENTS.

,

Position

of Selector

lever

Gear

Rear clutch

,, 1 ),

1 st

tc2 11 or (( D H

1st

a 1 n, o 2 u or (( D o

2nd

aD n

3rd

Front

clutch

Rear brake

Front

brake

X
X
X
X

u N I) : neutral

Reverse

Free wheel

X
X

FRONT
Planet

BRAKE
Brake

gear

Rear planet

band
stop

Adjustable
/

gea

Piston

Rear

BRAKE

BANDS

SUN GEARS
EPICYCLIC

GEAR

\
Front

R:a,r

F-loni
I

I&i

CLUTCR
S
7
F;ont
Rea:
,

P.UMP
_~
-oil

OutJet to
cooler

E
,RTQR

I-------

CENTRIFUG
GOVERNOR

1RY SHAFT

SECONDARY

SHAFT
Valve

chest

\
CAM

\
DIFFERENTIAL

Impellor

LIST OF OPERATIONS
IN THE THIRD SECTION OF THE MANUAL No 814-2
Vehicles
Only those

operations

For operations

which

type u DS 21 with
relating

to this

electronic

fuel injection

type of vehicle

are not included

H / DX.IB

and DJ.IE)

are described.

in the following

Operation
Number

system

list,

refer

to (( Operations

relating

to (( D 1) vehicles,

All

Types.

DESCRIPTION

FUEL INJECTION SYSTEM

D.IE

D.IE

144-l

173-1

Work on fuel

injection

system

- Removal
- Removal

and installation
and installation

of electronic
of a throttle

control
spindle

- Removal

and installation

of cold

injector

-Removal
- Removal
- Removal

and installation
and installation
and installation

of full-load
switch
of pressure
sensor
of thermal sensor

- Removal

and installation

of pressure

- Removal
- Removal

and installation
and installation

of injector
of cold start

start

- Removal

and installation

of slow

- Removal
- Removal

and installation
and installation

of injector
of injector

- Removal

and installation

of injection

Petrol

feed system

regulator

( petrol

)
4

time delayed

running

air intake

feed line
feed line
feed line

- RemoOal and installation

of petrol
- Replacement
of petrol filter

unit
switch

pump

thermal

switch

control

( complete

assembly
assembly
assembly

( on cylinder
unit

head

( front part 1
( rear part )
complete

unit

( front

and rear parts

III

SETTING

STRAIGHTENING

VEHICLE

ON STRAIGHTENING

JIG EQUIPMENT

( Fenrick

JIG

2606-T )

Gauge rod dia. 19.85

2 gauges minimum
thickness

2 qauqes maximum
thickness

III - SETTING

STRAIGHTENING

VEHICLE

ON STRAIGHTENING

JIG EQUIPMENT

( Celette

JIG

ENS 30 C )

OPERATION

No 0. 825-l

: Replnceme>lt

o/ roof secured

3. From exterior of vehicle remove ( on each side ) :

- rear indicator flasher reflector ( 10 ),
- rear reflector spring retaining screw (9),
- rear reflector housing (8 ).
4.

Remove

( on

each

side

J:

- self tapping screws ( 11) and free upper rear

pillar trim ( 12),
- screws and washers ( 13 ),
- self tapping screws (14 ) to free retaining panels,
but without removing them,
- self tapping screw ( 16 ) and remove central cover
joint trim ( 15),
- self tapping screws ( 18) and free upper front
windscreen framing units ( 17 ).
- side frame units ( 19),
- fixing screw A ( retaining roof, front frame unit
and side frame unit ).
5. Remove roof, pressing upwards from interior of
vehicle.
6. Remove rear roof trim (21 ).

Op. 0. 825-l

by screws.

INSTALLATION
11. Fit rubber sealing strip ( 20 ) to roof.
12. Extrude two ribbons of sealing compound on to
roof as shown at u a 1) and (( b )).
13. Fit rear roof trim (21 ).
14. Position roof onto body, and with exception of
two left and right hand front screws at A which
also retain the front framing trim, fit fixing
screws (7 ) ( use flat washers ).
Tighten nuts. ( See below for details of fixing ).
15. In interior of vehicle, fit :
- lateral lining ( 5 ),
- headrests ( 4 ) ana self tapping screws ( 3 ),
- upper rear transverse member trim ( 1 ),
- rear courtesy light glasses (2),
- rear seat and backrest.
16. Extrude two ribbons of sealing compound to
ensure watertight seal between roof and quarter
panels.

7. Remove rubber roof sealing strip (20 ).

17. Fit side edging trim ( 19).
PREPARATION
8. Scrape siderail
compound.

clean of all traces of sealing

y 9. Extrude a ribbon of sealing coumpound in front

co
and rear siderail grooves to ensure that roof
3
will be leakproor.
2
g 10. Fit roof trim ( see appropriate
Operatian
).

18. Fit front edging units ( 17) with self tapping

screws ( 18).and nuts and screws A.
19. Fit cover joint ( 15) with self tapping screw ( 16 ).
20. Fit ( on each side J :
- self tapping screw ( 14),
- upper trim ( 12 ) and self tapping screws ( 11 ),
- screw ( 13 ) ( use flat washer ),
- flasher indicator housing ( 8 ),
- rear reflector spring retaining screw ( 9 ),
- rear reflector ( 10).
21. Fit sun visors to both sides and their fixing
screws ( 6 ).
22. Test roof for leaks.
NOTE : If a leak is detected at the forepart of the
roof, run a ribbon of sealing compound as shown
at CC
d )) in illustration opposite ( on eachside
of point X ).