Citroen CX Manual Series 2 PDF

REPAIR MANUAL MAN 058531
CUSTOMER SER VICES SEPTEMBER 1988

AFTER-SALES TECHNICAL DEPARTMENT
cx
:
No. 3:
VEHICLES
MECHANICAL COMPONENTS 1
1
'4-.---
\ \
le-
Automobiles Citroén. SA. au cap/tal de 800.000.000 F

ömö
R.C.S. NANTERRE 8 642 050 199. SIRET 642 050 19900644 APE 3111 Télégramme et Télex: C/TR 614830 F
ADRESSE POSTALE: 92208 NEU/LLY-SUR- SE/NE CEDEX FRANCE
PDF compression, OCR, web-optimization with CVISION's PdfCompressor
1
USE OF THE MANUAL
PRESENTATION
The Repair Manual comes in a binder with a Multo" type mechanism to facilitate the filing of additive sheets
or the removat of a part for operation in the workshop.
fl?
The MECHANICAL COMPONENTS, PART 1 VOLUME (8531) covers operations on the MECHANICAL
COMPONENTS and the BODYWORK which may be carried Out by a general workshop
It is divided into 15 chapters separated by vinyl tab inserts numbered to
Generat Rear axle
Engine Suspension - wheels - tyres
Fuel systemCarburettor Steering
Ignition system Braking system
Clutch Electrical equipment and radio
Gearbox-Drive shafts tij : Heater, ventilation and air-conditioning
Source and reserve of pressure Bodywork

Front axle
111
COMPOSITION OF A CHAPTER
Each chapter includes:

- the list of operations in it,
- the operations in numerical order.
OPERATIONS
The operation references are made up as follow:

- - - --
MA
af
100
b)
- 00
c)
/
dl
1 a
el
al vehicte code letters: MA

bl three figure number identifying the assembly or the assembly part.
D cl figure indicating the type of operation:
- figures 000 indicate the vehicle specification
.O)
the
- the figures 00 indicate the assembly specification
`c"
- the figures 0 indicate checks and adjustments

the figures 1 indicate removals and refittings
arm')
- the figures 2 indicate dismantling and re-assembly

the figures 3 indicate recondiuoning
dl figure /1,.../2.../.. standing for a variant,
e) letter: a, b. standing for an evolution.

fl,
the various operations are presented:

1 either through photos, drawings and texts,
2° or through photos, drawings and symbols.
A GLOSSARY has been placed at the beginning of each volume for this purpose.
ln the glossary (the one in the Mechanical Components volume isdifferent from the one in the Bodywork volumel,
the rneaning for each symbol has been translated into nine languages.
It consists in
a removable set of "plastic" sheets bound with one manc2uvrable metal ring to facilitate the
Omsy
extrac10 ot
one or several pages (and obtain photocopies from them, for instancel.
*
8531
TOOLS
For each chapter, the photos of the special tools required for proper completion of the work, are given at the
.-.
end of the list of operations.
The special tool numbers and photos appear ln the operation description as the work progresses.
The tools referenced OUT followed by 6 figures and ending in the letter "T" are sold by the Rep(acement
-CD
Parts Department to FRANCE and EXPORT networks.

"T"
CDU
The tools referenced with 4 figures followed by the etter are sold to FRANCE by the Société FENWICK,
Département AMA
24, boulevard Biron, 93404 SAINT-OUEN. Tél. 42.52.67.00, and to the EXPORT network by CITRON.
m
:
The tools referenced MR must be made up by the repairer himselt.
TIGHTENING TORQUES:
The tightening torques are expressed in metre Decanewton (mdaN), the official torque measuring unit
fl
.-.
O981 mdaN = 1mkg lformer measuring unit).

(n practice, 1 mdaN = 1 mkg.
UPDATING THE MANUAL WITH ADDITIVES:
Additives should be ordered immediately on receipt of the DOC%JMENTATION BULLETIN announcing that
0
they are issued.

The updated sheets must be added to the existing pages in the manual or replace the corresponding ones. They
fl.
are identified by spots located to the eft of the shortened volume number placed at the bottom right hand side
of the recto page:
2 spots . 8531 additive no. 2, etc.

('')
Example : 1 spot 8531 additive no. 1
IMPORTANT NOTE:
For all technical information, please apply to:
CENTRE TECHNIQUE CITROÉN

Division Aprés-Vente
Service Technique
Chemin Vicinal n° 2 78140 VELIZY
Tél. : 45.37.30.30.

LIST OF OPERATIONS APPEARING IN THE CHAPTER: VEHICLE CONCERNED
°P7
i..
1
V GENERAL INFORMATION ENGINE TYPE L
OPERATION 20 22
25
25
25
Prestige 25
25
Limousine
2%n 25 Salan
2:r 25 Salan
Petro/ Petrol Dese/ Petrol Desel Ambulance
Petrol Petrol Prestige Petrol Diesel Diese/ +
SYMBOLS
/njectuof Turbo Turbo lnjection Turbo
OPERATION Turbo Turbo Fambale Famihale
TEXTS
NUMBER
829A5
H- 829 AS 261 A 500 251659 25/659 25/662 25/662 251660 25/648 25/648 829 A 5 251659 251660 25/648 or
__________________ ___________________________________________________________________________________ /s ________ __________ _________ __________ _________ _________ __________ __________ _________
25/660
0
0
General specification vehicle identification X X X X X X X X X X X X X X
OO(
0
Jacking and towing points X X X X X X X X X X X X X X
Protection of the electrical units A X X X X X X X X X X X X X X
Recommended products A X X X X X X X X X X X X X X
Products to be used on the bodywork A x X X X X X X x x x x x x x
PDF compression, OCR, web-optimization with CVISION's PdfCompressor 8531

*
85318533
CX 25
Pallas D Pallas D AD Turbo Limousine

(AM84) (AM85)
pop
TRD Turbo Turbo
TRD D
AD
MM MM NB ND
______ M25/660 M25/660 M2/648 M25/648
_ 4
A 2,845 m 3,095 m
E
8 4,650 4,900m
E
C 1,360 1,375m
E
D 0,160m
///L
m
11,70m 12,50m
E
F 12,50m 13,40m
E

8531-8533
MA
000/1 (:1011:)
CX25
D RD Turbo Limousine
E
Pailas D TRD Turbo Turbo
RD
TRD
420 kg 435 kg 460 kg

950 kg 970 kg 990 kg
1370kg 1405kg 1450kg
1300 kg
Ill
685 kg 700 kg 725 kg
755 kg 755 kg 790 kg

1140kg 1155kg 1160kg
00
1890kg 1905kg 1920kg
3190 kg 3205 kg 3220 kg
80kg
100 kg
3190kg 3205 kg 3220 kg
12%

CX2O CX25D
CX 25 TRI CX 25 TRD Turbo
CX2ORE CX25RD
MR NJ MN NC
ri
5 8 5 5 8 5
829 AS M 25/659 M 25/660 M 25/648
4 5 4
5 5 5
5 Automatic 5
f+6
_+)
*+8mm TRX
*
85318533
000/1
CX2O CX25
20 25 TRI 25 D 25 TRD
20 RE 25 RD Turbo
530 kg 520 kg 510 kg 530 kg

860 kg 945 kg 965 kg 990 kg
1390 kg 1495 kg 1475 kg 1520 kg
'
i::
///i
1300 kg
''k
695 kg 730 kg 750 kg 750 kg
1030 kg
1065kg 1160kg 1175kg 1175kg
JIjIL 2080 kg
3980 kg
2165 kg
3465 kg
2190 kg
3490 kg
2200 kg
3500 kg
80kg
opp
100kg
3380 kg 3465 kg 3490 kg 3500 kg

o
11%

* 8531-8533
MA
000/1
r Li
-
CX2O CX 25D
590 kg 585 kg
880 kg 990 kg
1470kg 1575kg
1065kg 1175kg
1030 kg 1030 kg
2080kg 2190kg
11%

MA
000/1
2 VF7MANK0000NK0001
4(
0
6
'JIiiiptiiijIi''
0001
lo GkLJ
11

* 8531-8533
* 8531-8533
2
©
'L5II1IIII)
IJ ZF 3HP22
- 50 Km/h, - 50 Km
- 7/85 7/85 -*
:
EO
GENERAL INFORMATION
PROTECTION OF THE ELECTPICAL UNITS
*
*
8531
2 PROTECTION OF THE ELECTRICAL COMPONENTS
PRECAUTIONS TO BE TAKEN WHEN CARRYING OUT AN OPERATION ON THE VEHICLE
actions which may damage the electrica( or the e(ectronic equipment or create
It is essentia( to avoid a short circuit
(with subsequent risk of fire or accident(.
Battery:
a( First disconnect cab(e c(amp from the battery negative terminal, earthed, then from the positive post.
Before tightening the negative clamp to the battery (the negative lead shou(d be connected (ast(, ensure that there
;--
b 1
is no short circuit (bright sparks or arcs).

Small sparks may occur due to the nterior (amp (door open(, door locking device, dock or components having
remained in operation.
cl Make sure that the terminals are properly connected. Clamps and termina(s should be c(ean and correct(y tightened.
C/)
åns
d ( When recharging the battery, disconnect the two clamps first.

e( Do not reverse the negative and positive clamps on the battery. (This could destroy the alternator diodes(,
Fuses:
a Fit the correct type of fuses: use the fuses specified for the protected devices.
`ner
bl Take the added accessories and the functions into consideration.
Charging circuit:
,a Do not run the a(ternator unless it is connected to the battery. Do not disconnect the battery when the alternator
paj
..C
1
is rotating.
bl
---
Ensure that the regulator is correctly earthed.

o°°
mar-
c ( Do not interchange the leads connected to the regulator, (charge detection warning lamp and excitation are specific(.
d Do not connect a suppressor capacitor to the regulator without taking precautions or following proper
,-«
instructions.
e 1 Do Oot use an electric welding equipment on the vehicle without having first disconnected the alternator, the regula-
tor and the battery (insulate the two terminaisl.
fl Do not « check» the operation of an alternator by short circuiting the positive and ground terminals, which may
destroy the diodes.
Starting the engine:

-tom
Do not use a booster or a 24-volt battery. Only use a correctly charged 1 2-volt battery la higher capacity battery may
be utilised(. Otherwise, risk of deterioration of the ignition module or any other electronic control units. If the starter
,-+
is needed for starting the engine, without running it, it is necessary to disconnect datum and flywheel sensors on the
All Electronic Ignition, or the primary lead of the coil on any other type of ignition.
Ignition:
a) Do not connect a suppressor capacitor to the negative terminal of tho coil.
,-,
r-:
b Do not operate the module if ts radiator is not connected to the earth.

Q-6
c Fit the radio suppressor capacitors recommended by the factory.

(l7
d) Never operate the ignition system while the HT circuit is open. Connect the HT leads to earth.
e( Only use rev. counter having a HT sensor, (never puncture HT leads(.
Q.I. buib:
al Never replace a 0.1. bulb with the headlamp switched on. If the headlamps have been in use, allow them to cool down.
bl Do not touch a 0.1. bulb with bare fingers. Any fingerprints must be cleaned with soapy water and the bulb dried
with a dry lint-free cloth.
0
Checks
al Preferably use a high resistance 1> 10 k 0 VI voltmeter or a battery-operated ohm-meter...
919
bl Take care not to use instruments taking their power from the mains.
Electronic components:
al Avoid overvoltages duc to a badly insulated charger, electric arcing or connections to the coil.
O'>
The units such as regulator, ignition module, tachometer, windscreen wiper timer, flasher unit, dock, radio, oil gauge
unit, door lock control unit, etc. comprising electronic components may be deteriorated.
bl The electronic components should not be placed or operated under a temperature exceeding 80°C.
cl Always switch off nstruments or electronic control units before connecting or disconnecting them.

RECOMMENDED PRODUCTS
- CLEANING PRODUCTS
PRODUCT
USE AND SPECIAL FEATURES AND SYMBOL MARK SUPPLIER
R.P. No.
0)>
Cold degreasing agent tor mechanical units specially SOLVANT FL.
D 1 R P D
r`:
designed to be used into cleaning tanks ZC 9865832 U
- Gelified iquid designed for stripping DECAPLOC

D
9865104
-cam
sealing surfaces and non metal gaskets ZC U
D2
- Aerosol can intended for unsticking and DECAPJOINT
R P D
stripping non metal gaskets and sealing surfaces ZC 9875077 U
- Carburettor cleaning product.

Carburettor
CDU
ceaner D 3 RP.D
To be used pure.
ZC 9862011 U
0
II - SEALING COMPOUNDS
20C
PRODUCT
USE AND SPECIAL FEATURES AND SYMBOL MARK SUPPLIER
R.P. No.
- Sealant for joint contact surfaces, screws and nuts.

CURTYLON E 1 CURTY
Clean with acohoI.
- Hydrocarbon resistant product LOWAC E 2 S.E.B.I.S.

* 8531
2 RECOMMENDED PRODUCTS
USE PRODUCT
AND AND SYMBOL MARK SUPPLIER
SPECIAL FEATURES R.P. No.
Z^>
Locking and sealing agent for FRENETANCH
E 3
removable threaded assemhUes. ZC 9865034 U
- Sealant for joint contact surfaces,

locking of screws, fixing studs and
FORM ETANCH
arm
nuts. E4
Sealant for joint contact faces and
ZC 9865036 U
unions.
Bearings, nngs, bushes, liners,

-lo
inserts, pulleys ocking products. SCELBLOC
E 5
Strengthening agent for splined ZC 9865035 U
and pinned connections.
Product for locking and sealing

TCO
FRENBLOC
studs, screws and nuts with maxi- E 6
mum effectiveness.
ZC 9865033
RP.D
Sealant for joint contact faces in FORMAJOINT

E 7
9865037
C31
replacement of traditional gaskets. ZC U
- Sealer for housings: POXY. MATIC ALU

Oro
E 8
Aluminium based 9865565
C71
ZC U
POXY. MATIC ACIER

d'1
Metal based E 9
ZC 9865559 U
- Paste for bonding door linings,

windscreen, etc. AUTO JOINT
NOIR (black) E 10
Sealant for joint contact surfaces.
9865038
C71
ZC U
Remains flexible after drying.
- AUTO JOINT
FCO
Sealant for joint contact surfaces.

BLEU (blue) E 10
Remains flexible after drying. ZC9865 103 U
Fire-proof
Air intake casing heater tubes sea- mastic paste
E 11 Ets BARTHELEMY
ung compound Ref. 1500
(CO LLAF EU)
- Strengthener of fixed assemb(ies

,S3
SCELMETAL E 12 FRAMET
III - PENETRATING OILS

20C
USE PRODUCT
AND AND SYMBOL MARK SUPPLIER
SPECIAL FEATURES ftP. No.
- Aerosol can for rusted parts and

oms
<CD
DEGRIPPANT
F 1 R P D
seized assemblies ZC9865303 U

MA
00/3
IV - GREASES AND LUBRICANTS
PRODUCT
AND SYMBOL MARK SUPPLIER
USE AND SPECIAL FEATURES
R.P. No.
0
95 615 129 R.PD.
High adhesive grease:
Intended mainly for drive-shaft lubrication.

fl'
-
GRAISSE 1495 MOLYDAL
d')
G 1
- Can be used for mechanisms wor k ing un d er di ffi cu t

l
conditions (high pressures, spiashed water( MOLYKOTE

DOW-CORNING
LONGTERM 2
Grease resisting high temperatures:

GRIRCOTT AF G 2 MOLYDAL
- For exhaust manifold ball-joints.
Lubricant for parts working under difficult

conditions: Hl LUB-HTC G 3 FRAMET
Splashed water, high pressure and temperature.
C/)
Grease resisting high temperatures:

--,
- To lubricate the threaded spark plugs fitted to the NO-BIND G 4 CURTY

cylinder head.
Multifunctional lubricant:
MO.
t19
G 5 TEROSON
- Mo(ybdenum disulfide-base product.
Multifunctional grease:
TOTALMULTIS G6 TOTALC.F.R.
For routine works.
PROBA. 270
Special grease:
ALTEMP G 7 R.P.D.
-Designed for anti-roll bar bearings.
7901 973067
Animal grease:
t/7
G8
- Tallow.
Special grease: ESSO

- To be used for fitting the road wheel sensors of the NORVA G 9 RED.
anti-locking brake system. 275
*
8531
ini
MA
4 00/3 RECOMMENDED PRODUCTS
LIST OF SUPPLIERS
SUPPLIER ADDRESS TELEPHONE
BARTHELEMY 61, rue Defrance, 94300 VINCENNES (1) 4328.4287
CURTY 25, rue Aristide-Briand, 69800 SAINT-PRIEST 78.20.81 .24
z
.t)
CFR. (TOTAL) 11, rue du Docteur-Lancereaux,

75381 PARIS CEDEX 08 42.67.15.00
(Si
(1)
FRAMET 10, avenue Eugéne-Gazeau, Z.l.,

60304 SEN LIS CEDEX 44.53.38.88
DOW CORNING S.A.R.L. 36-38, rue de la Princesse, 78430 LOUVECIENNES (1) 39.18.92.50
MOLYDAL 60, rue des Orteaux, 75020 PARIS (1) 43.70.75.50
S.E.B.I.S. 3 5, rue de Metz, 75010 PARIS (1) 47.70.13.08
TEROSON Tour OBJECTIF,

2, rue Louis-Armand, 92607 ASNIERES 47.99.66.66
C/)
C/)
(1)

- EXTRUDABLE SEALING COMPOUNDS
PRODUCT SUPPLIER
USE AND SPECIAL FEATURES AND SYMBOL MARK
m
R.P. No.
(if any)
- Body seam
tid
sealer. 6051 BOSTIK
Air drying products. 8645 A 1 3 M FRANCE
Can be coated with paint. 42 TEROSON
-Sealant for spot welded panel junctions. BOSTIK

1605
Sealant for windows having a rubber sealing strip. A 2
94 TEROSON
Does not dry.
« » Kit complete ZC 9867511 U _______

GURRIT
Cartridge ZC 9867447 U
Polyurethane sealing compound
or A 3 R P D
For bonding and seaflng:
'
BOSTIK
" Kit complete ZCP.830.002
Cartridge ZCP.830.003
-Tightness of the crimpings. ZC 9867264 U A 4 R.P.D

,-r
II - PREFORMED SEALING COMPOUNDS
PRODUCT SUPPLIER
{1J
R.P. No.
(if any)
- Filter ensuring a seal between the bolted panels (wings...)

a..
--{
TEROSTAT 7 TEROSON
Prestik SS. dia = BOSTIK
aven
- Round section
8568 3 M FRANCE
- Round section 1053 da =20 mm CEPAC
TEROSTAT 7 TEROSON
Dimensen
- Box section 8573 1 3 M FRANCE
EX . 2 x 18
Prestik .s. BOSTIK
* 8531
MA
2 00/4
III - ADHESIVES
PRODUCT
SUPPLIER
(jf any)
R.P. No.
ZC 9865561 U
- Meta)/glass bonding )rearview mirror, lower part of
or 8 1 R.P,D.
the door windows).
ZC 9856689 U
1410 SC BOSTIK
- Bonding of trim elements. 1236 B 2 3 M FRANCE
N 66 TEROSON
- Sticking two panels together. ZC 9867263 U

8 3 R.P.D.
Door c)inching. ZCP 830 009
Bonding composite material, SMC and BMC ZCP 830 009

(CIBA)
to meta) B4
0
R.P.D.
ZC 9867448 U
together or to meta)
°-'
(TEROSON) _______ ______________
- Bonding of p)astic (rear view mirror trim). ZC 9865105 U B 5 RED.
- Bonding of monogram, décorative strip... DF 0985 SINGS

86
CEPAC
Dual adhesive surface tape. 4205 3M FRANCE
- Heat me)ting paste. Réf. C130 B 7 CEPAC
IV - GREASES
PRODUCT
SUPPLIER
(_q
(if any)
R.P. No.
- Mu)tifunctiona) )ubricant with a mo)ybdenum

MO. G 5 TEROSON
bisu)fide base.
- Mu)tifunctiona) grease. TOTAL MULT)S G 6 TOTAL C.F.R.

MA
RECOMMENDED PRODUCTS 00/4
V - PROTECTIVE PRODUCTS
PRODUCT SUPPLIER
:.;
(if any)
R.P. No.
- Inner protection of the spot-we(ding seams: Refer to

Conductive primer apphed to the inner face of the ________ Equipment
metal panels to be we(ded. Catalogue
- Refer to
'+--
Protection of underbodies, corrosion nhibitive.

Coating (to be apphed over metal panels a(ready ______ C 1 Equipment
coated(. Cata(ogue
/
- Protection of door crimpings and tai(gate surrounds.

ZC 9867264 U ______ C 2 R.P.D.
App(y over precoated panels.
- Protection for ho((ow sections: Refer to

'''
Product to be sprayed through the orifices Equipment

designed for this purpose. Cata(ogue
See Equipment
- Anti-grave! projection primer. C 3 Bulletin
(on paint(
- Protection against road chippings, CI Beige C 4 TEROSON
*
8531
Achtung Wichtiger Punkt oder Fehlerquete
f..
l
Pas p°a Vigtigt punkt eller fejlmulighed

Atenci6n Punto irnportante o posihle dificultad
Caution Important detail or possihle trap
Punto importante o possibilita di errore

Lj Attenzione
Let op Belangrijk punt, kan gemakkelijk fout gaan l
Atencb Ponto importante ou possihilidade de errar
Varning Viktigt arbetsmoment eller möjlighet till misstag
Attention Point important ou piöge possible

oro
Darauf achten, dass keine Teile herunterfallen oder abspringen
Risiko for at delene falder ud eller forsköbber sig

Riesqo de caida o de proyeccrcn de piezas
CAJ
Q_%
Parts may drop or spring out

6'.
Rischio di caduta o di proiezione di pezzi
Kans op riaar beneden vallen of wegspringen van onderdeln

Risco de queda ou de projeccao de pecas
Risk för att delar faller ned eller spritter ut
Risque de chute ou de projection de pieces

oro
Unhedingt S pezia lschrauben verwenden

r.,
Special - skruer skal anvendes

(É Empleo imperativo de tornillos especiales
Use of special fixing hardware essential

{i7
`c°
Uso obbligatorio di bullonenia speciale

NL Uitluitend speciale bouten gebruiken
® irnperativa de parafusos ou porcas

",C
Utilizac
Specialskruv måste ovillkorligen användas
® Emploi imperatif de visserie
Indien noodzakelijk handeling

D Arbeifsvorgang, falls erfordenlich NL uitvoeren
du rc hfu h ren
@ Arbejdsoperation der udfres hvis det OperacT a efectuar se necessrio
® Operacin a etectuar
Operation to be carnied out if

si es necesario ArbetsrnomenVarhete att utföra
vid behov
neCessa ny
Operazione da effettuare se Opération ä effectuer si nécessaire
necessa rio

Rechis Destro Höger
H j re Rechts
Derecho Direita Droite
Right
Lnks (i Sinstro Vänster
Venstre Links
zqmerdo Esquerda Gauche
Lett
Oben (j Alto Uppa°t
J (R Opad Boven
Atto Aho Haut
Up
Unten ED Basso (j) Nedat
Nedad Onder
Bajo Baixo D Bas
Down
4898
Hinten Dietro ( Posteriore) Bak ( a°t). bakre
________
(j Bag Achter
Trasero Traseira Arriöre
Rear
Vorn Avant ) Anteriore) Fram a°t). fra mre
For Voor
De)antero Diantera 1II Avant
Front
CDU
Ausbau. Ausbauen Staco. Staccare I1 Demontering.

Demontera
®S®
Fjernelse. Fjerne Verwijder. Uitbouwen
Quitado. Quitar Desmontagem.

Des mo nta r.
Removal. Remove Dépose Déposer
O^_
Einbau. Einbauen (j Riattacco. Riattaccare

0
Atermontering.
Åt ermon t era
Anbringelse. Anbringe Monteer.
Cotocacion. Poner EIII Montagem. Montar Pose Poser
Fitting. Fit

4
Losschrauben. = Anzahl der Umdrehungen. 800 Einstellwinkel
E
1 1
Skrue løs. 1 = Antal omdrejninger. 1 80° = Drejningsvinkel

Desenroscar, = Ntméro de vueltas. 80° = Angulo que se debe efectuar
cup
1 1
Unscrew. 1 = Number of turns. 1 80° = Angular value
Q
Svitare. 1 = Numero di giri. 1 80° = Rotazione da effettuare
Losdraaien. 1 = Aantal slagen. 1 80° = ln te stellen hoek
Desaparafusar. 1 = Nimero de voitas. 1800 = Änguio a efectuar
= Antal 80° = Antal grader

c!)
Skruva ut. 1 varv. 1
Dévisser - 1 = Nombre de tours. 180° Angle ä effectuer
Verbot. Nicht verwenden oder wiederverwenden
Forbud. M ikke anvendes eller genbruges
Prohibido. No utilizar o volver utilizar

.Q_
Prohibited. Do not use or reuse
EII Proibizione. Non usare o
Verboden Niet gebruiken of niet opnieuw gebruiken

.II
Proibido No utilizar ou reutilizar

`°.
Förbud Använd eller teranvänd ej
interdiction - Ne pas utiliser ou réutiliser

0t0
Federring Rondella Grower Grower - Bricka
Fjederskive Veerring
Arandela Grower Anilha Grower Rondeile Grower
Spring washer
() Unterlegscheibe Rondella a Contatto Kontaktbricka
Contactring
C/)
Kontakt Skive
Arandela de Contacto Anilha de Contacto Rondeile Contact
Contact washer
®e®
egg
Zahnscheibe Rondelia a Ventaglio Solfjäderbricka
Stjerneskive Karteiring
2.-
Arandela Estreiiada Anilha Recartilhada Rondeiie Eventail
Serrated washer
'..
Flachscheibe Rondeiia Platta Planbricka
Fiad Skive Piatte Ring
Arandeia Piana Aniiha Plana E1III Rondelle Plate
Fiat washer

Losschrauben. 1 = Anzahl der Umdrehungen. 1 800 = Einste)lwinkel
= Antal
7c'
Skrue løs. 1 omdrejninger. 1 80° = Drejningsvink el
Desenroscar. = Ntméro de vueltas. 80° = Angulo qu e se debe efectuar
E
1 1
Unscrew. = Number of turns. 80° Angular value
`c°
1 1
Q = Numero 80° = Rotazione da effettu are

Svitare. 1 di giri. 1
Losdraaien. 1 = Aantal slagen. 1 80° ln te stellen hoek
Desaparafusar. Ntimero de voltas. 80° = Änguto a efectuar

C/:
1 1
Skruva ut. 1 Antal varv. 1 80° = Antal grader
= = Angle
CD,
Dévisser - 1 Nombre de tours. 180° ä effectuer
Verbot. Nicht verwenden oder wiederverwenden

.fl
Forbud. M ikke anvendes eller genbruges
`N° fl
Prohibido. No utilizar o volver a utilizar
Prohibited. Do not use or reuse
( Proibizione. Non usare o
Verboden Niet gebruiken of niet opnieuw gebruiken
No
.0(
Proibido utilizar ou reutilizar
Förbud Använd eller teranvänd ej
$nterdiction - Ne pas utiliser ou réutiliser

v_,
(Federring
ute.
Rondella Grower Grower - Bricka
CD () Fjéd\erskive
ArandéiaGrower
Veerring
Anilha Grower Rondelle Grower

''=
Spring wash
() () fl
oro
020
Unterlegscheibe Rondella a Contatto Kontaktbricka
(j Contactring
:-i
Kontakt Skive
Arandela de Contacto Anilha de Contacto Rondeile Contact

«°.
0
«,,
Contact washer
oro
oro
Rondeila a Ventaglio Solfjäderbricka
Stjerneskive Karteiring
Arandela Estreilada Anilha Recartilhada Rondeile Eventail

t!)
t1>
Serrated washer
oro
o®o
oja
Fiachscheibe Rondelia Piatta Planbricka
Fiad Skive Piatte Ring
Arandela Piana
Fiat washer
Anilha Piana Rondelio Piate
fl
Anzahl der Schraubelemente: Schrauben, Muttern. Stifischrauben usw
Antal dele 1 skruesamlingen
Canlidad de elementos de tornilleria: tornillos, tuerca. esparrago. etc.
Number of threaded components: screw. nut. stud, etc.
Z
Numero di elementi di bulloneria. viti, dadi. prigionieri, ecc.
Z
J
Aantal: bouten, moeren, tapeinden enz.

Nmero de elementos de parafusos ou porcas. porca. perno. etc.
0
Antal förskruvningspunkter: skruv, mutter, pinnbult. etc.
Nombre déléments de visserie: vis, écrous. goujons.. etc.
Sichern bzw, Entsichern Borgen of borg verwijderen

opp
Lse eller frigre Travar ou destravar conforme o caso
Frenar o quitar el freno, segi'in el caso Ls eller avlägsna läsningen
GB Lock or unlock as appropriate

..O
Bloccare o sbloccare, secondo casi Freiner ou défreiner suivant le cas
000 Noodzakeik een nteuw onderdeel
cup
Unbedingt Neuteile verwenden
Ny del skal anvendes Utilizaco imperativa duma pea nova
((0
fwfJ Empleo imperatvo de una pieza nueva Ny del mste ovillkorligen användas
(i')
Use of new part esseritial
Uso obbligatorio di un pezzo nuovo

(' Emploi impératif d'une pice neuve
i'
oro
000
Anolja
(/J
Schmieren Oliare
5J SmØre Oliön
Aceitar Olear Huiler
Oil
oro
Reinigen ...(je nach evontueller Markierung. siehe Tabelle der Klebe-.Schmier-und Dichtmittel)
:ii":
(afhngig af evt. mrkning af produkt)
C:-
FlengØre med ..
siguiendo lo selado eventualmente, ver cuadro

,.-,
de productos)
'_.
Limpiar ... (
Clean (according to symbol, if present, see table of recommendations)

Pulire ( secondo eventuale riferimento. vedere tabella ingredienti)
zoals aangegeven, zie lijts met benodigdheden)

p..
Reinigen .. (
Limpar . ( conforme marca eventual, ver quadro ingredientes)
Reng6r ( enligt eventuell märkning. se listan över olika produkter)
Nettoyer ... ( suivant repére éventuel, voir tableau ingrédients)

Mit chmieren (
gemäss Markierung. siehe Tabehe der Klebe-, Schmier- und Dichtmittel)
Overstryge med { afifingig af referance produkt)
Untar con ) siguiendo lo sealado, ver cuadro de productos)
according to symboL see table of recommendations)

GB Smear with (
Spalmare di ( secondo riferimento. vedere tabella ingredienti)
Insmeren met ( zoals aangegeven. zie lijst met benodigdheden)
Untar com ... conforme marca, ver quadra ingredientes)
Bestryk med ... ( enligt mäkning. se listan över olika produkter)
Enduire de.. suivant repre, voir tableau ngrédients)
Gut o00 Buono Korrekt

C.7
God
OK B ueno Bom Bon
Serviceable
(j
000
EII Siehe Vedere ... riportarsi a. Se ... g tillbaka tIl

Se .. henvisning til . Zie ... verwijzen naar
Ver ... dirigirse a ... Ver ,. reportar- se a.. Voir .. se reporter ä
See refer to
d.'
Sichtprötung oder Pröfung mit der Hand

Kontrollere visuelt eller manuelt
Controlar visualmente o manualmente
Check visually or physically
Controllare visivamente o manualmente

NL Visuele of handmatige controle
Controlar visual ou manualmente

.]G
;(p
Gör en manuell kontroll eller en okulärkontroll
Contröler visuellement ou manuellement
Mit einem Messgerät prbfen Controleren met een instrument
Kontrollere med mleinstrument Controlar com um instrumento
Controlar con un instrumento Kontrollera med instrument
Check with a measuring instrument
Controllare con uno strumento Contröler avec un instrument

fl
ann r a Mehrere Einbaumög li c hk e it en ( 1 - 2 - 3 ) V ersc hill en d e moge li j kh ed e n
______ montage (1 ; 2 ; 3...
( Flere monteringsmuligheder (1; 2; 3...) Vrias montagens possives (1. 2. 3)
iJ Varios montajes posibles (1. 2. 3) Hera monteringsutföranden förekommer
avi
( 3)
(!i
______ Severa! assembly possibilities (1 2,
Diversi montaggi possibili (1; 2; 3) Plusieurs montages possibles (1 - 2 - 3)
Markieren, Biem Wiedereinbau auf Zugehörigkeit der Teile achten
°_'
Afmcerke. Ved genmontering skal delenes rette sammenpasning respekteres
Senlar. Respetar el apareado de las piezas para el nuevo montaje
Mark. The parts must be kept paired for re-assembly
Segnare. Rispettare faccoppiamento del pezzi per il rimontaggio

__
-
1 1 I Merken. Zorg bij montage dt de onderdelen bij elkaar komen
avi
.
CII Marcar. Respeitar o acasalamento das peas para armé- las
Märk ut. Respektera a delarnas märkning vid termonteringen
Repérer- Respecter rappariement des piéces pour le remontage
Einstellen Regolaro Ställ in
________ Justere Mstellen
Regular (j' Afinar Régler
Adjust
Abstand. Spiel Gioco Spel
Spil C! Speling
Jeu
0
Juego Folga
Clearance
Einbau durch Pressen, Vorspannen oder genaues Einpassen

0
Montering med forspnding. prespasning eller itrykning

`fl
paj
Montaje con esfuerzo. precarga o apriete ajustado
Assembly force fit. with preload or interference fit

(Ti Montaggio forzato, precarico o accoppiamento serrato
Montage onder spanning. voorspanning of klemspanning
Armar om esforco, précarga ou encaixe apertado
EII Montering med förspanning. presspassning eller ihoptryckt

(1'n
Montage sous contrainte. précharge ou emmanchement serré

...

Leicht anziehen
Skrue sammen uden fastspaending

Aandraaien zonder vast te zetten
Aconchegar sem apertar

fl
(É Aproxmar sin apretar Skruva utan att dra t
Screw up wrthout tightening
Avvicinare senza serrare Approcher sans serrer
Vorgeschriebenes Anziehdrehmoment
Tilspndingsmoment skal overholdes

Par de apriete quo se debe respetar imperativamente
Observation of tightening torque essential

, Coppia di serraggio da rispettare obbligatoriamente
'"O
Voorgeschreven aanhaalspanning aanhouden
Aperlo a respeitar imperativamente
Åtdragningsmoment som ovillkorligen mste respekteras

Sr.
Couple de serrage ä respecter impérativement
\, Hartlöten
Lodde
Soldar con metal
Braze
Brasare
Soideren
Soldar a metal
Löd
Braser
oro
a,:
(t
Schweissnaht Cordone di saldatura Svetssträng
SvejsesØm Lasrups
Cord'o de soldadura Cordon de soudure

_'0
Cord6ri de soldadura
Fiflet of weld
_0)
Lochpunktschweissen Proplassen
TJ
Stubsvejsning Soldadura por pontos tampo"

Soldadura por puntos de tapdn' Pluggsvetsning
Plug weld
Saldatura con punti a tappo' Soudage par points bouchon'

Einen Gang einlegen ( z. B. 3. Gang)
Stigear(f. eks.:3. gear)

eje mplo: 30)
`..
Ponor una relaci6n de velocidades (
Engage a gear (for example: 3rd)

lnserire una marcia ( esempio: 30)
Schalel een versnelling in ( bijv: de 3 de)
Engatar urna velocidade por exemplo: 30)
c`9
(
(till exempel: an)
cp-
:c0
Lagg en växel 3 :
(II) Engager un rapport de vitesse ( ex. : 38 )
() () Vullen of niveau op hoogte brengen
(É
Ein- oder Auffullen
Fylde eller efterfylde () of bijvuUen

Encher ou por a nivel
fl GB
Lienar o poner a nivel
Ful or top up to evel

Fyll eller korrigera nivån
ED Riempire o effecttuare il rabbocco :1IiIII1 Remplir ou effectuer a mise 'a
Gelenkwelle
Z00
cz
Transmissidn Transmisso
Transmisidn Drivaxel
Ofn
Drive Shaft
Trasmissi6ne Transmission
ZON
tnrichting
Nog
Lenkung
,
***' Styrtj Direco
maj,
C)
6
Direccin Styrsystem
/
____ Steo Direction
('
000
oro
Motor Motor
Motor Motor
Motor Motor
GB Engine
ED Motore Moteur
Cilinderkop
7c-
Zylinderkopf
Z00
(6k Topstykke Cabea

oro
000
Culata Topplock
0 (j
Cylinder Head
Testata Culasse
torn

lo
Getriebe
Gearkasse
Versnellingsbak
Caixa de velocidades
fl
Caja de velocidades
Gearbox
(%)
Scatola cambio BoTte de vitesses
II.
Zwischengetriebe Overbrengingstandwielen
Overføsels - gearhjul Carretos de transferencia
Piones de transferencia Överföringsdrev
Transfer gear assembly
i Pignoneria di movimento Pignons de transfert
Federung und Hadaufhängung Vering

1
Ophngning eller affjedring Suspensé
'j/ Suspensi6n Fjädring
Suspension
Suspenson
ED Sospensione
Bremsen Hemmen
(J
Bremser Travöes
E
(c Frenos
.
Brakes
Freni Freins
Hinterachse: Längslenker Achterbrug: Draagarm

Bagbro: Brearm Eixo traseiro: Brao
Eje trasero: Brazo Bakvagn: Bärarm
Hear axle: Arm
Assale posteriore: Braccio Essieu arri'ere: Bras

`L°
Hinterachse: Radnabe Achterbrung: Naaf

OND
Bagbro: Nav Eixo traseiro.: Cubo
Eje trasero: Buje Bakvagn: Nav

Hear axle: Hub
Assale posteriore: Mozzo Essieu arriére: Moyeu

11
Vorderachse: Unterer Querienker VOorbrUg Onderdraagarm

r
Forbro: Nederste brearm Eixo dianteiro: Brao inferior
Eje delantero: Brazo nférior Framvagn: Undre länkarm
Front axle: Lower arm
Essieu avant: Bras inférieur
C(]
Assale anteriore: Braccio inferiore
Voorbrug: Fusee
Z00
Vorderachse: Achsschenkel
Forbo: Styrebolt MEO Eixo dianteiro: Pivot

.S]
oro
oro
Eje delantero: Pivote Framvagn: Pivot
,a«
_______
Front axle: Swivel assembly
Assale anteriore: Pivot Essieu avant: Pivot
Klasse Klasse
Klasse Classe
oja
Clase Klass
Class
i Classe Classe
Aftappen
Z00
Ablassen
TØmme Esvaziar
oro
Vaciar Töm ur
Dram
Svuotare Vidanger
TI
Entliften
Udlufte () Ontluchten
Purgar
00: Purgar Lutta
Bleed
ED Spurgare (!) Purger

000
Z00
Bearbeiten Bewerken
Bearbejde Trabalhar a maquina
Bearbeta, slipa, etc.

_______ (JÉ
,
Mecanizar
ni Machine
Lavorare Usiner

LIST OF OPERATIONS APPEARING IN THE CHAPTER: VEHICLE CONCERNED 1
ENGINE ENGINE TYPE
2OSafaH 25S:fari
OPERATIONS 25 25 25 25 Safar 25 Safar
20 22 25 Presge 25 Limousine
Petrol Petrol Dieser Petro D FeSe Am b u l ance
Petrol Petrol Prestige Petro Dese Diesel +
(1) Injecbon Turbo Turbo Injection Turbo
OPERATION Turbo Turbo FamihaFe Famihae
'4OI
DESCRIPTION
H-
>- 829A5
H- J)
829 A 5 J6T A 500 25/6b 25/659 25/662 25/662 25/660 25/648 25/648 829 A 5 25/659 25/660 251648 or
_________________________ A ___ ___ ___ ___ ___ ___ 25/660
11 Tools
0 X X X X X X X X X X X X X X
MA 2 litre petrol engine, type 829 A5:

100.00/1 specification and particular features x x x
MA 2.2 litre petrol engine, type J6T A 500:
100.00/2 specificaton and particular features x
MA 2.5 litre engine with petrol injection, type 25/659:
100.00/3 specification and particular features x x x
MA 2.5 litre petrot turbo engine with injection, type 25/662
100 00/4 specfication and particular features J x x
MA 2.5 litre normally aspirated Diesel engine, type 25/660
100.00/5 specification and particular features
;
x x x
MA 2.5 litre Diesel turbo engine, type 25/648
10000/6 specification and particular features x x x
Removing and refitting the engine/gearbox assembly X X X X X
1003
Overhauling a Diesel engine (see BRE 0985.14) 0 X X X X X X
112.3
Overhauling the cylinderhead (see BRE 0985.14)
0 X X X X X X
122.0/1
Checking the valve timing A X X X X
122M/2
Checking the valve timng A X X X X X
122.0/3
Checking the valve timing A X X X X X X
1 221/1
Removing/refitting the timing be(t (on the vehicie) A X X X X
Removing/refitting a timing chain, chain tensioner and timing gear

1221/2 x x x x
Removing/refitting the timing belt (in situ(

122 1/3 X X X X X X

c::: ENGINE ENGINE TYPE
25 25 20 Safari 25 Safari
OPERATIONS 20 22
25
25
Prestige 25 Limousine Petrol Diesel
-
Petrol Petro DeseI Petrol Diesel Ambulance
Petrol Petrol Prestige Petrol Diesel Desel + +
OJ Injecton Turbo Turo Injecton Turbo
OPERATION Turbo Turbo Familiale Familiale
No.
DESCRIPTION ______ _____ _____ ______ _____ _____ ______ _____ _____ ______ ______ _____ ______
829A5
F- 829 A 5 J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829A5 25/659 25/660 25/648 or
______________________________________________________________________________ /\ __ Q_ ________ ________ ________ ________ ________ _________ _________ ________ _________ _________ ________ ________ _________
25/660
MA
Adjusting the valve clearances , X X X X X X X X X X X X X X
124.0/1
MA
133.00/1
Specification and part/cular features of the engine mounting brackets 0 X X X X X X X X X X X X X X
MA
133.0/1
Checking and adjusting the engine support brackets A X X X X X X X X X X X X X X
MA
Specification and particular features of the exhaust system (3 X X X X
180.00/1
MA
Specification and particular features of the exhaust system X X X X X X
180.00/2
MA
Specification and particular features of the exhaust system (3 X X X
180.00/3
MA
180.00/4
Specification and particular features of the exhaust system 0 x x
MA
180.1/1
Carrying out work on the exhaust system A X X
MA
220.0/1
Checking the engine ou pressure 0 X X X X X
MA
220.0/2
Checking the engine oil pressure
0 X X X X
MA
220.0/3
Checking the engine oil pressure 0 X X x x x x
MA
230.00/1
Specification and particular features of the cooling circuit
J X X X
.MA
Specification and particular teatures of the cooling circuit (3 X
230.00/2
MA
Specification and particular features of the cooling circuit (3 X X X
230.00/3
IVA 1 1 1 1
Specification and particular features of the cooling circuit X X

230.00/4

LIST OF OPERATIONS APPEARING IN THE CHAPTER; VEHICLE CONCERNED 3
ENGINE ENGINE TYPE
25 25 20 Safan 1
25 Sa/an
OPERATIONS 25 25 25 Sa/an 25 Sa/an
r_-
20 22 25 Prestige 25 Limousine Petrol Dese
Petrol Petro/ Dse/ Petro/ Dese/ Ambulance
Petrol Petro/ Prestige Petrol Drese/ Diesel + +
Injection Jurbo Turbo
SYMBOLS
CI) nection Tunbo
OPERATION Turbo Turbo Familale Familiale
No.
DESCRIPTION 0 _____ ______ _____ ______ ______ _____ ______ ______ ______ _____ ______ ______ _____ _____ ______ ______
TEXTS
(1)
>< 829A5
u.J >-
- 829 A 5 J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_________________ _____________________________________________________________________________ ________ 25/660

_________ ________ _________ _________ ________ _________ _________ ________
MA
230.00/5
Specification and particular features of the cooling circuit 0 X X x
MA
23OOOI6
Specification and particular features of the cooling circuit
0 x x x
MA Filling and bleeding the cooling circuit
A x x x x x x x x x x
x
230.0/1 x x x x

OUf 50 6602 1
13815
L
OUT 20 6323
T b a r 5602 TJ
a
[our 106004
-,I
1
12827

3312T1 0U1 30 4O61
rTj
OIT
1T.

829.A51
J6 RA 500 (AM 87 )
1[
x 4 1995 cm3
0 88mm
E
1
c 82mm
E
E
V + V 9,2/1 (829A5)
V 9,5/1 (J6 RA 500)
SUPER 98 RON minh
*
- --
40
-----
+ii
,-
j
-
I
-- -------
- - - -
1 1 1
'
-
-
1 1
--

8531
-
-
---
1
-- -- - -
1
16
-15-
z z
z z
E
2 h.
E
E E m
CA)
LO 00
SmdaN
9,3
9,3
c) J
tco
1
6
2

MA
3
EI 829.A5
100.00/1
EEEJIII 0 0 (mm) = 66,668 - 66,687
01 Ø1(mm) Ø2(mm)
52,267 52,286 62,873 62,892
a - b maxi 0,005 maxi 0,005
1,846 1,852 1,878 .

1,884
'
0,06 7 - 0,252
d
1 : 2,80 -, 2,85
II : 2,85 -* 2,90
III 2,90 -* 2,95
IV 2,95 - 3,00
74,5 mm - 75 mm
IC lo 22,992 - 22,9961
lD22,996-23 1
jC lo 23,003 -* 23,0071
D jo 23,007 - 23,0111

* 8531
MA
9.
100.00/1
829.A5
-4-- A Ø 88 - 88,010 0 87,930 - 87.9401

-fr-fl-- A Ø 88,010 - 88,020 D 87,940 - 87,9501
-1-0-fr--- A
Ø 88,020 -. 88,030 D Ø 87,950 -. 87j
0
1,800- 1,820 mm 2,015 - 2,035 mm
4,015 - 4,035 mm
68,75 - 69,35 mm
E
E
0,30 - 0,45 mm
L'l
MINI
6 gr.
MAXI L'l 1,728 - 1,740
L'2 1,978 - 1,990
3,978

MA
100.00/1
829.A5
_________
0 0 ®
Ii
0 0
1'
®
1
0 0 00
____
o 0
0
0
_ d
(SO
o o o o o o o o ®
±O,5mm00
maxi 0,05 mm
0
Tr
0
0
*
8531
ini
MA
10000/1
829.A5
0 4,25
c x 4,5
0
111,40
111,95
00\
00
000
J-[j!H
fl
0

1
rrT2N
829.A5
' '' '' 77 '
"t-
tH !
0,8 bar _________________________________
,:':
TOTAL
XjX GTS Plus GTI Plus
+
J
____J
1
10W40 10W30
__ 5 L
__ j 5,25 L
/ 90°C
_ :::ars L = 101 mm

* 8531
______ J6TA500
1[
x 4 2165 cm3
0 88mm
c 89mm
TT V+v
____
1[ v
9,8/1 mm
SUPER 98 RON minh
*
8531
zm zw
z z
3
h.
E
w
m M
2
E E
al WIE:
9,3mdaN
00
8mdaN
5mdaN
CC)
9,3
F3
L-
n*
6
5
1
3
2

MA
___ 10000I2
E1 J6 TA 500 1
0 0 (mm) = 66,668 66,687
0 1
0 1 (mm) 0 2 (mm)'
56,267 56,286 62,871 62,880
a-b maxi 0,005 maxi 0,005
Tr 1,836 1,841 1,876 1,864
fl Dit] fl
____ ____
ciHtijj419H ---
0,10 - 0,30
2,80 - 2,85
001001
tt : 2,85 - 2,90
lit : 2,90 - 2,95
IV : 2,95 - 3,00
74,7 mm - 75 mm
C 0 22,992 - 22,996
D 0 22,996 - 23
+ 1
145,5 ± 0,05 1
C 0 23,003 - 23,0071
1010 23,007 -* 23,011J
*
8531
ini
4
MA ___
100.00/2
'E1I J6 TA 500 IIID
-il-- A -. 88,010 -
0c0
Ø 88 Ø 87,930 87,940
0)0)0
D
-Ii-fl-- A 88,010 - 88,020 87,940 - 87,950
0
D Ø
-1-fl-fl-- A -
88,020 88,030 0 0 87,950 - 87,960
E
E
0,05 mm
0,30 -. 0,45 mm
L'l
6 gr.
MIN! MAXI L'l 1,728 - 1,740 mm
111
L'2 1,978 -* 1,990
F'1L3 3,978 3,990
- UFLEX

6 J6 TA 500
1
MA
OO00/2
0 0 ® 0 0 ® 0 0 ® 00
fl 0 0
__
0 0
__
0 0 0 0 ® Q
>;
17°
5T
630
*
8531
MA
6 100.00/2
J6TA500
0 4,8
P
+ 0,022
0 0,8
41 1200
9OO)<\ c

100MOAOI2
7
J6 TA 500
mdaN
=LX
JN
/ M 'Y
0,8 bar _______

-;0- -H
1
-- TOTAL
GTS Plus
+ GTI Plus
J 10W40
[:1 5 L
j 5,25 L
III
90°C
800 1,4bar
L = 122 mm
4,45 bars
*
8531
'tI1I j__________
ir 2500 cm3
93mm
C 92mm
V+v
-{-
______ 8,75 Il
v
SUPER 98 RON minh
90
-1 40-
I izo
------ - ---
II II I
- -
I1
____
-- -- --
--- -
II II !1
- -
-
-
-
t
-
1 1
- --
_.a
110
70-
±- - -- -- -- -- -- -- - - - -- -- -- - - - -
_
-----
60- 80
/ -- --
-- -
m.doN
---- 3 0-
- ---- 28-
- - - - - - - - - - - - - - - - - - - - -22-
'
20-
20- --- - -- ------ ----
10-
- r i i : i0: '
206
*
8531
100.00/3
25/659
_
_
10 0
O
C)
10 0
Q
4
5r
3
2

MA
____ 1OOOOI3 3
M25/659
0
0 mm : 71,695 - 71,705
0 Ii (mm) 011 (mm)
57,675 - 57,685 57,685 - 57,695 mm
1 1,819 mm - 1,828 m
A - 2,306 mm 2,312 mm
_______________ 11 1,824 mm -' 1,832 mm
L
T 1,944 mm 1,952 mm
B - 2 , 431 mm - 2 , 437 mm
L 24,4 01/87 22,6 11 1,949 mm - 1,957 mm
Li1JffIffl1LJ3J 0,045 mm - 0,160 mm
3,10-3,14-3,18-3,22-3,26

* 8531
93,00 - 93,01 mm 92,950 - 92,960 mm
3
E
E
93,01 - 93,02 mm 92,960 - 92,970 mm
E
III 93,02 - 93,03 mm 92,970 - 92,980 mm
3
E

MA
100.00(3 5
1
M25/659
U.FIex
= 3,520 3,540 mm L'3 3,440- 3,470 mm
<,7
Ø 25,008 25,014 mm
Ø 25,000 - 24,996
E
Hftl/
81,6mmU Ø 25,001 - 25,006 mm
0
156,80
co
(0
tO
t
156,70
r__
*
8531
ini
6
MA ___
100M013
M25/659 1111
[t'
< x4,2
oms,
90 900
116,5
LC)
_______
0,015
105,5
LID
LC)
0 48,25

ini
6 M2 5/6 59
MA
100OO/3 7
0 ®
0
LN
Maxi 0,1
6*
3o
*
8531
8
M251659 ED
PURFLUX LS 468
H Hj
___________________ ...
_______rIW1_______________
______________ )
ZZ//zzzzzJ
O,8bar ..
__
* wp
TOTAL
+ ___
4,6L
[L + j 5,3L
90°c
_ ::5bars

Ir1II:ili M25/662
M25/666 (AM 87
x 4 2500 cm3
1 [
c 92mm
--
-,
v + v 7,75/1 (M25/662)
Jf 1[ v 8,5/1 (M25/666)
----
-- --
_
SUPER : 98 RON
--
170
--
20 -
oiIIIIIIIIIIIIIII
160 T
11111
ooH
130_
-------- -
1
-4-- A
c,,J
II1IIIIIIII1iIIIII:
1
90 120
111111
-,
--
1-----
so- _ao-
____
---- m.doN
-
m.l
-
;70___
1
-
30-
60 ----28. 2
111±
--- - -- - - )____2 26 26
- _
-
-1
i A
-- i
-- -
24
± -
___ ---
1
-22 22
20-
1
l0_.10__
--- -
20-20
___ - 18-18
1 l
*
8531
N2PW
oOOL
000 L
--.
-

MA
100.00/4
M25/662
0 mm: 71,695 - 71,705
0I 011
57,675 mm - 57,685 mm 57,685 mm - 57,695 mm
1 1,819 mm - 1,827 m
A - 2 , 305 mm - 2 , 313 mm
____________ II 1,824mm-* 1,832mm
L
1,944mm 1,952mm
- -
-
B - 2 , 430 mm - 2 , 437 mm
L: 24,4 01/87 22,6
11 1,949 mm -* 1,957 mm
EflffJfilJJ 0,045 mm - 0,160 mm
3,10- 3,14- 3,18-3,22- 3,26 mm

E
E
*
8531
93,00 -* 93,01 mm 92,945 - 92,955 mm
3
E
Il 93,01 93,02 mm 92,955 92,965 mm
E
III 93,02 93,03 mm 92,965 - 92,975 mm

MA
1OOOOI4
M251662
L'l L i1,978 1,990 mm

Q0.45
L'2 1,990 mm
L'3 F3,44O - 3,470 mm
O1Ii040
0 25,008 -* 25,014 mm
Fri
0 25,000 - 24,996 mm
156,80 mm
78,4 -* 78,6 mm
0 25,002 25,008 mm
156,70
r-'
*
8531
MA
100.00/4 'ilI::Ii
M25/662
0 ®
0
Do©
0
OOOOOO(
B __ __ __
TE 25
0
maxi 0,1 mm
imm(3>
4)
3030'
0
10
0
1- --
450 38030

ini
MA
1OOOOI4
M25/662
Itu
cZ< X 4,2
010
fl9+O015
- 0,010
-
-f fr-
1200
0o
*
8531
MA
8 100.00/4
M25/662
PUR FLUX
LS 468
_
0,8 bar
f
____ TOTAL
r - GTS Plus GTI Plus GTV
v=i
1
10W40 10W30 15W50
t. J - 11/85 11/85 -
_ 4,7L +f5,4L
'i'
90°C
3l0
3bars minh
r, iL
- -
4 5 bars

6 ______
ir x4
0
2500cm3
93mm
--'
1
c 92mm
E
1
V+v
______ 22,25/
v
j.iI1
*
8531
100M0/5
M25/660
_ s.
ti1
_ ____
_
i
4 mdaN
O
C)
C)
-T
450
10 0
10 0
C)
-
r
1
- -t
i
5
4

MA
100.00/5 3
M25/660
0 mm: 71,695 71,705
01 01 ø2
A 54,005 mm 53,990 mm 67,05 mm 67,035 mm
B 53,755 mm - 53,740 mm 66,80 mm - 66,785 mm
E
C 53,505 mm -* 53,490 mm
____ b a-b 0,004 mm
0! 011
57,675 mm - 57,685 mm 57,685 mm - 57,695 mm

E
___________________________________ - 1,820 mm - 1,826 mm

A -
1
1,825 mm _ 1,831 mm 2 , 306 mm 2 , 312 mm

E
11
-
- 1,94 5 mm , 951 mm
E
1 1
B 2 , 431 mm 2 , 437 mm
E
1,950 mm 1,956 mm
E
E
11 -
- 2,070 mm - 2,076 mm
E
1
C _____________________
L: 24,4 01/87 22,6
t
II 2,075 mm - 2,08 1 mm
E
EtLfTIfl4LJJJJ 0,04 5 mm 0,16 mm

dh
-
3,10-3,14-3,18-3,22-3,26

* 8531
4MA 100.00/5 _ M25/660
AEF PdC
93 A 93,01 - 93,02 92,900 92,910 92,897 - 92,912 0,50 - 0,55

Bl 93,25 - 93,26 93,150 - 93,160 93,137 - 93,152
93 , 25 0,47 - 0,52
B2 93,26 - 93,27 93,160 - 93,170 93,147 - 93,162
c'7
Cl 93,50 - 93,400 - 93,410 93,387 -* 93,402
t+')
93,51
f')
93 , 50 0,44 - 0,49
93 , 51 -, 93 , 52 93 410 - 93 , 420 - 93 , 412
0
t!')
C2 , 93 , 397
Dl 93,75 - 93,76 93,650 - 93,660 93,637 93,652

93 , 75 0,41 0,46
D2 93,76 93,77 93,660 93,670 93,647 93,662
2Y_
_ III Hl _
l5gr 7gr
MINI MAXI
MINI MAXI

MA
100M015 5
M25/660
0,45
L1 1978199Omm
L'2 1,978 1,990
(( L'2
L'3
U.FIex
H( 3,978 3,990 mm09»3
4/85 : Li = 2,550 - 2,570 mm L'l 2,478 - 2,490 mm
93,25 93,50 93,75
Q V B Mv
Ø 30,014 mm 30,02 mm 0 29,999 mm - 29,994 mm
77,8 mm - 78 mm

* 8531
8
r
0
r..)
U'
0)
ri
ioii)
ioiiti')

MA
100.00/5 7
M251660
0
0
OO0O0E
L 25
_____ 1163mmmini

*
c3,
8531
0 4,8 cx X 6,5
+ 0,015 + 0,015
0 8 —
0,010 0 8,99 — 0,010
SL ,00
+
0 7,975 —

1OO/5
M251660
JUl
H
' \
1
\
\
\/ ,
/ /7/7 /7 '/7/ /7 " ""

_.iui._J 0,8 bar
_____ TOTAL _____ TOTAL

SUPER DIESEL
15 W 40
RUBIA S 10 W
_____
_____ 15°C - 12°C-"-
L[ 5L
LL t 5,6L
950
1000 25 bars mmi
Bar 0,9 L
4,5 5 bars
*
8531
M25/648 1
ir x4 2500cm3
1L1[ V+v
_____
0
c
93mm
92mm
21/1
v
Diesel
* 8531
__
_______
_
4 mdaN
______
1000
1000
C)
450
Q
Q
--
3
2
i

MA
____ 100.00/6
M25/648
Ø mm: 71,695 71,705
01 02
A 54,005 mm - 53,99 mm 67,05 mm -* 67,035 mm
B 53,755 mm - 53,74 mm 66,80 mm - 66,785 mm
E
E
E
C 53,505 mm -* 53,49 mm
E
a - b 0,OO4mm
øII
57,675 mm -* 57,685 mm 57,685 mm - 57,695 mm
1,816mm-* 1,826mm
A -
1
-
2,306 mm - 2,312 mm
Il 1,821 mm 1,831 mm
E
t
1,941 mm - 1,951 mm
B -
1
2 , 431 mm - 2 , 437 mm
E
L ______ II 1,946 mm - 1,956 mm

E
2,066 mm - 2,076 mm
-
E
L:24,401/8722,6 C _________________
2,071 mm - 2,081 mm
E
II
- 0,045mm-*0,16m
3,10-3,14-3,18-3,22-3,26

* 8531
,J MA I
,
100.00/6
M25/648 El)
l5gr 7gr
MINI MAXI
MINI MAXI

MA
EiI M251648
100.00/6
Li
L2 0 25 - 0,45 mm
L3
015 0,4mm
0 32,014 mm - 32,02 mm 77,8 mm - 78 mm 0 31,999 mm - 31,995 mm
E
E
LO
0
LO
t
E
E
LO
0)
LO

* 8531
6MA 100.00/6 _
_____
M251648
E1IjflJ1LllJ c5mmu
-
2° 52' 4° 12'
33° 08'
lo
1 37° 48'

MA
E111
___ 100.0016 7
M25/648 j
© 0
'-1 o 0
LS 25
117
______ 116,3 mm mmi

E
E
* 8531
MA
8 1 OOOO/6
M25/648
0 4,5 c< X 6,5
8,99
-Y c
U)
121,4 ± 0,25
121,4 ± 0,25
L
c'4 c'.J
o d
-H +
0 7,975 -+00,015 -
0 42
1j
_____ 0,30 0,20

_____ _____

MA
'iF ii 100.00/6
M25/648
__ jJHJH
// 7/ /7 /7 /7 /7
/
-_ 0,8 bar
_____ TOTAL _____ TOTAL

SUPER DIESEL
RUBIA - S - 10 W
_____ 15 W 40
_____1 -.- 15°C - 12°C-'-
--
f 950

* 8531
MA
ENGINE 100.1/1
RECOMMENDED TOOLS
Removing and refitting the power unit assemb!y
6602-T Set of three stands

2517-T.bis Lifting sling.
4061-T VISA anti-roll bar tensioning device
6031-T Attaching bracket (for the petrol turbo engine>
Removing and refitting the drive-shafts
3312-T Lower arm baIl-joint extractor with bosses

or
6323-T Lower arm ball-joint extractor, with or without bosses
6310-T
E5'
Whee! hub locking too(

6320-T Anti-roll bar link rod puller
oms
- Torque wrench (40 m.daN)

- 35 mm accross flats
Bush
REMOV/NG AND REF1TTING

THE ENG/NE/GEARBOX ASSEMBLY
* 8531
MA REMOVING AND REFITTING
2 1001/1 THE ENGINE/GEARBOX ASSEMBLY
2.5 LITRE CX WITH PETROL INJECTION
--i
REMO VAL
Support the car on stands horizontafly, Fig. using 1 Disconnect:

the three stands 6602-T, in order to facilitate the
wiring harnesses (3) from the battery positive lead,
.-«
removal of the power unit assembly and to reposition
it more easily on the stands. Fig. III,
- the ground cable from the gearbox,
the wiring harness from the reversing lamp switch.
"_'
-
Depressurize the hydraulic system.
Dram the brake accumulator. Remove, Fig. III:
Set the height control to the "low" position
- the pressure regulator accumulator,
- pipe (4) between pressure regulator and brake accu-
p..
mulator.
Remove:
- the battery,
- the bonnet, Vehicle with air conditioning optiori:
- the front wheel, - the belt protective cover,
- the spare wheel - the air conditioning compressor drive belt.
the protection plate located under the spare wheel,
Uncouple:
- the air intake casing position accelerator cable,
-3O
Dram the coohng circuit via the dram hose of the

radiator. - the high pressure pump rubber suction pipe,
Take off the crankcase dram plug (1), Fig. II. the high pressure pump outlet pipe (5) and its attach-
ment, Fig. III.
Remove the drive-shafts: Disconnect: Fig. V

(Refer to Op ® MA.372. 1/1).
the throttle spindle switch (10),
knock sensor (14).
Uncouple: hoses (6) and (7), Fig. IV (protecting the
alternator from water entry at "a"). Uncouple: Fig. V
Disconnect the engine cooling fan thermal switch. -.
pressure sensor pipe(9),
Remove the engine heat sink. - supplementary air pipe (1 1),
cylinderhead cover pipe (12),
breather pipe (8).
Extract, Fig. III:
- the screws that secure horn (2) support, passing
through the wheelarch, Remove suction pipe (1 3) situated between the f)ow-
meter and the turbocharger or between the flowme-
- the wheelarch lining. ter and the inlet manifold.

r
*
-
11 15 16
- .
,- - k'-
-
2
18 i1
.-f
-
.--
85417
L _i
-- __
_
fl
VI
r

,OVL G AND
1HE LJGNE/GEARBOX
EHTTLG 1 f
Remove: Uncoupe the . lutch cor t.rol, Fg. W

pressure regulator and compressor holder nuts (1) Rernove:
Q_>
(art conditioning option)
adjusting nuts (9),
all the shirns,
and put them in place of the battery. clutch control support screws (10).
`cup
Uncouple the exhaust systern. Uncouple the power take off with double outlet,
Fig. V.
Normally aspirated engine with FFI.:
Fully (nosen screw 11 21, then retighten it by two turns
Rernove the 4 exhaust pipe nuts.
to prevent the speedorneter drive guide frorn being
pushed out.
Turbo with FFI., Fig. II and Hl
Disengage the twin outlet power take off 1111.
Rernove oi( gauge (13).

Rernove:
- screw (2) and shirns (3),
flexible pipe screws (7), Uncouple, Fig. V:
nuts and spacers 14).
- heater hoses (16) and (17),
Release exhaust pipe (8) downwards. fast idle air duct (151,
- petrol supply pipe (18),

Rernove nuts 151 and tiexible pipe 16).
petrol return pipe (14).
Disconnect, Fig. VII:

- connectors (20),
fem'
- sensors (221,
- coils and suppressors (19),
- gear shift link rods (211.
*
851
REMOVING AND REFFTNG
6 1
IHE ENGNEIGEARBOX ASSEMBLY )
Position on Inc engino, Fig. 1:

RH1 IT f INC
sir g 251 7-T.bis

iså
(as shown 00 illustration),
tthing nt the engine crdnkcase water dram plug, fitted with
,--
bracket 6031 -T a
natuially aspiiatcd engine with EFI: brackot to bo fil new sea!: Tightening torque: 3 mdaN.
ted on the exhaust pipe, with one sorew,
turbo with FFI: f it the bracket to the pressure relief Place slirig 2517-T.bis, attachirig bracket 6031-T
valve outlet, and tensioner 4061T; screw the terisioner fully in,
tensioner 4061-T (slack(. Fig. and VI. 1
'rom
Engage the engine/gearbox assembly into its nom
partment, Fig. VI.
-}y
Place sling 2517-T.bis. under tension, tensioner
4061-T being loosened, Fig. II. Loosen tensioner 4061-T, Fig. II.
0
p_>
Ref it: (without tightening)
`°-
R emove:
engine support hracket screw Il),
i-+
screw (1 (from the engine bearer, Fig. III.
torque red screw (71
nut (31 and screws (41 from the gearbox mouriting,
Fig. V (retrieve the shims), gearbox support plate (together with iis shimsl.
screw (21 from the torque rod; slackeri the other

screw, Fig. IV. Tighten:
the engine bearer to 10 mdaN, Fig. III
the torque rod to 9 mdaN, Fig. IV
Slightly raise the power unit assemhly. the gearhox support plate fixings, Fig. V:
screws (41: to 3 mdaN
not (31: to 16.5 mdaN.
Screw terisioner 4061-T fully, Fig. VI and remove
(,A
the engine/gearbox assembly:

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

--h
Before refitting the power unit assembly:

Check the condition of the engine mounting brac-
`+°
kets. Replace them if needed. Locate, Fig. VIII.

the dual outlet power take off (61.
f-+
Adjustment to be tested,
(as per Op.® MA 133.0/11. the ou gauge.

*
15 t
85360
II v
____ -
7
lo
-
( )
7
l)-_\ ---
--
- -- -;_

. Ki REMOVING AND REFITTING MA
100.1/1 9
eka
THE ENGINE/GEARBOX ASSEMBLY
r.
Couple up the exhaust system

Reconnect, Fig. V and V:
connectors (11),
On naturally aspirated engines with EFI, fitted with sensor (12) (with blue ident. mark),
NEW seals: sensor (13) (with no ident. mark),
Tighten the (lange to 1.6 mdaN HT coil (9) cyls 1 and 4 (with yellow ident. mark),
HT cof (10) (with rio mark),
cy)s 2 and 3
On the turbocharged engines with EF/, fitted with the suppressors,
NEW nuts and sea!s: the reversing lamp switch wiring harness,
the throttle spindle switch (141,
Refit: Fig. 1 and II,
knock sensor (181.
- flexible pipe (2) to the pressure release valve outlet,
exhaust pipe 141 to the turbo, screws (3), distance
Recouple, Fig. V and VI:
pieces 151,
the water hoses,
screw 16) and adjusting shims.
air circuit pipes 115), (16), (171, (20) and (211,
There should be a 5 mm clearance at least between petrol circuit pipes (191,
C31
3-1
-
the exhaust pipe and the engine crankcase. gear shift hnk rods,
the accelerator cable.
Tighten, Fig. 1 and II:

Fit:
turbocharger nuts (in the correctsequence), Fig. Il, - the driveshafts,
flexible hose (2) screws (31 and nuts (1) to (See Op. ® MA 372 1/1)
2.5 mdaN, the radiator,
the bonnet,
- screw 161 to 5 mdaN.
- the battery,
- the protection plate located under the spare
Rofit: Fig. III wheel.
the pressure regulator and compressor holder (air

-0:c
conditioning option) together with its shims; tigh- Chock the oil levels. Top up if necessary.
ten nuts 171 to 5 mdaN.
.-.
Vehicies with air-conditioning: F1IIup the cooling circuit (with the heater open) and
carry out the bleeding operation.
'-'
'''
the compressor belt and protection cover, (As per Op E MA 230.0/1).

- the pressure regulator accumulator, fitted with a
NEW sea!,
Bleed the front brakes.
- the HP pump outlet pipe, fitted with a NEW sea!
(Refer to Op. MA 453.0/1).
and its fastenings 181,
the pipe situated between the pressure regulator
--0
-
and the brake accumulator, fitted with NEW seals, Check the gear change.
- the HP pump rubber suction pipe,
the horn. Lower the vehicle to the ground.
*
8531
*
85
122.0/1 ch::
Rotating the crankshaft: Tum:

tha raokshe)t throuqh a camp etc torr, in tf e r ormaf
twa rrrethod. dirc cPor of enqrnc otatron.
1 ) engago the highest geer, ut te the ( anksheft
by mea ns of the road wheel,
ue ti ra sar ew accur og the or crnkshatt prrtey Check:
and torr the crank haft ri the norrnai drrectrorr of cy)rnder No. 1 va)ve clearance
otatiori Uhe cleararrce should be of 0,30 to 0.75 mm.
Remove, Fig. Ad ju st
fl)
_67
sin
the contra) cab)e from the cold start flap (1), the valve clearance:
buse (2), INLET = 0.10 mm
the accelerator control rad and cable, EXHAUST 0.25 mm
cyfinderhead cover (3).
NOTE:
This check can be carried out with a dra) gauge, ss
.2T
Bring:
shown on Fig. IV.
the piston of cylinder No. 4 to TDC
(with the valves in the "rocking" position)
Fit:
Make sure: the cylinderhead cover and rts gasket,

)tighten to OM mdaN).
that mark "a" on the f)ywhee) is facing the zero on
the clutch bet housrng, Fig III.
Recouple:
- the acceferator controf rad and cable,
Set:
the clearance af cy)inder No. 1 inlet valve (4) ta the hases,
150 mm, Fig II. the contra) cable ta the cald start flap.

-
(;'
'T
i
+
i
L)l
7-'
:-
,r
__
p
A:!
-
:
'i
;
85.614
=
25602
035 T
.1
-
-;'
-
____
03
Lr
-
85.615
>

M25/659 MA
VD M251662
RECOMMENDED TOOLS
1682-T Support for the daLgauge osed to check the TDC
2437-T Dia 1 -ndicato r
CHECKING THE
VALVE TIMING
* 8531
®,;
NOTE: Remove Co) 1682T,
Never et1erot to rot te thr renkshaft ht n edo of Check and edjust the vd)ve ocker ole re r cm
the oroehaft puHe c amng nut.
nlet = 0.15 mm
Exhaust = 0.20 mm
Raise the vehicie front ond
Ref it:
Shift in the highest. geer. Move the crankshaft using
the RH. med whenL the cylinderhead sover
the inlet pipes,
Remove, Hg.
"fl
1:
the spark p(ugs Wghtening torque: 2.5 mdaN),
rn)et pipes (1),
the cyhnderhead cover, Lower the vehic)e to the ground
the sparking p)ugs
Bring cy)inder No. 4 piston to TDC

(with the va/yes in the 'rocking" position)
cup
Place too) 1 682-T fitted with indicator in

e--
a dra)
cy(inder No. 1, Hg. II.
Firid the TDC.
Adjust cylirrder No. 1 irriet valve (2) ckarance to

1.10 mm, Hg. Il.
Rotate the crankshaft through a complete tum in the

norma) direction of engine rotation.
Record the c(earance of cy)inder No. 1 irr)et valve.

the figure should be comprised betweer
0.05 and 0.25 mm

t.: ..I
-
.

M25/660 MA
1 22O/3 1
M25/648
CHECKING THE
VALVE TIMING
*
8531
MA
L
122OI3 CHECKNG THE VALVE T 1
Hacn iho venicrr RH sids on stands Check, Flg. fl and Fig. ffi,
Disconnest the hattery negativc CaRle. that mark A is opposite screw (2),
`f'
SeIect the (ughest gear. that there are 35 pitches between marks A and B
passing around tensioner roller (1)
'-'
Remove:
the road whee), Refit:
the wheelarch (ming,
the belt protection covers, the filler plug,
the engine ou fil(er plug.
fl-
-
thn timrng hell covurs,
Posflon: the wheelarch (ming,
the valves of cyhnder No. 1 in the ''rockrng'' position the wheel.
(look inte the cii filler neck), Reconnect the battery negative cable.
the f(ywheel, with marks - a(igned, Fig. 1.

MA
122M13

8h3
*
8531
{°e
MA
1221/1
REMO VAL REF fl TING

Jack up tbc ot P H 4 t( cWcH
NOTE:
TaKc off 1 road whflH
Crankshaft otation, two possble mct( ods
Remove Hg. :
a) ngage the hglres1 gear and torn tho crank

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

tF
shaft by means of the road whoel or the w( co] bob
f!exble hose (2), b) Hotate the crankshaft in the normal direotinn
accoler ator onir 0 rod and cable of engine rotacon usrng the crankshaft pulley fixing
i(-1
ss rew fitted with a distance pioce

cylinderhead cover (3).
Loosen, Fig II, Position:
0
valve rocker adjustrnont scrows (4) so as to reduce the pistons at mid point of their str oke
thc strosses n the camshatt. (with the crankshaft key placed horizoritally).
Fit: Hg, ffi, Adjust the valve clcarance

too! 6012-T, once the ergino tlywheel protechve
plate has been removed Inlet = 0.10 mm
Exhaust -
0.25 mm
Remove, Fig. IV:
the RH wheelarch rubber sea)rng strip,
the alternator beR and hoosing,
crankshaft pulley (5),
137
timing belt casing (6),

too) 6012-T, Fig. Il!.
Slacken, Fig. IV,

the two screws (7) and (8) securing the automatic
tensioner by a halt torn,
Compress the tensioner spring arrd rotighten screws
(7) and (8h
R e move:
the timrng helt.

MA
1 1221/1
24.
-
1,1
-;.__- -
'
r
kto
/
yta
85.61
*
85 1
7
1 f
L9j
r :
. .
, 1
1
«
,

REMOVNG/RERTTNG THE TMNG BELT MA
ON THE VEHCLE 1221/1
tag
/
Position, Fig. : Install, Fig. Dl:

crankshaft key honzontally lwtb mark "c" stagge the timing bet casinq,
ed by 5° upwards),
crankshaft pulley (3),
- mark "a" or "d" on camshaft,
tighten screw (4)
mark "b" on the intermedate shaft. to 8 mdaN on engine -829.A5
avi
to 12.5 mdaN on engine -J6T.A5OO
Each uming mark on the helt must line up with the
tooth wheel rnarks. the alternator helt and cover,
the wheelarch rubber sealing strip
Fit the helt (avoid contact with oil or grease).
Remove, Fig. II,
Release, Fig. 1 and III,
tool 6012-T.
tensioner roller screws (11 and (2) (let the spring act)
then tighten the screws.
Fit:
Tum: the cylinder head cover and gasket

)tightening torque: 0.6 mdaN).
the crankshaft 1800 clockwise.
'-'
Do not tum backwards Recouple:

the accelerator control rod,
Release:
- the flexible hose,
- the tensioner roller fixing screws then retighten
starting with the upper screw (1), Fig. and III. 1
the cold start flap control cable.
Tum: Refit:
- the crankshaft a further two turns clockwise. the wheel,

Lower the vehicle to the ground.
Slacken, Fig. 1 and III:
- tensioner roller screws (1) and (2), (let the spring NOTE:
react), Camshaft toothed pulleys of engines 829.A5 and
U-,
'-`
- then retighten starting with screw (1). J6T.A500 are dentical but the fitment is different,
Fig. 1.
Fit: If, after carrying out the belt tensioning operation,

the timing belt is noisy when the engine is hot,
teol 6012-T., Fig. Il. retension the belt with the engine hot.
*
8531
M25/659 MA
1221/2
M25/662
F?EMOVING AND REFITTING

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

* 8531
"r i AND RE
12 J, A CHA!
AH GEAR, O v
REMOVAL REF TT N G
Jack up ln ti n 8 H Hr it tm run )\ Position tt i im ii itt driv gear vtieu'i fP d witt Itu 1
the ouci
1 W1 1 1' ni nj tu iii ,u that (tre ii ivung vde busnig tenu inre (1,
ruarku "a'' and
''b'' r sitrratu,d <dong lIs, i urin e 1
x x', Fig. V.
NOTE,
Fit the tensioner of ilie t:miruq hain
,-o-
Never use the camufiaft lu arriping ut
...
10 1
to otate he ura nkshaft 1
NOTE:
Remove, Fig. and II

BRAMPTON type tensioner, Fig, III
rn(et pipes (fl, Before puttir g it in to pla e, push the prstoni providud
ilie cy(iruder head cover,
with its sprr rug fri (ly home ai rr) torn clockwso Depr ess
pad (51 to release it.
the spar king p(ogs,
(2 conr ectrng turbochar ger to the SEDIS type tensioner, Fig. V
C/)
(la
ga ten ( tt e
flowrn otur
lo nnlock the pad, torn tt ue sr'r ewdr iver p aced at 'c"
Loosen the 8 valve rockers setting screws as mach to the rrght.
as pessrble sa s to reduce the strsses on camstrafts.
Remove, Fig. II: Check, Fig. IV, that

the wheelarch rubber sealing strip, the play between lrmniter pad (7) and the trming
a>;
chain is:
fl.
tirning cover (31.

0.1 to 0.5 mm
Ref ut:
..w
Engage the highest speed. Run the crankshaft by

'J_
means of the wheel hub. the tirning case (tightened to 1 .7 mdaN),
Line up: the wheelarcf rubber sealing strip,
rnarks "a" and "b" up over the centre line x x' pas the RH front whee(.
'-'
sing through the ceritres of the tirnung gears, Fig. IV.

Remove the charn tensioner (61, Fig. IV. Adjust the valve c(earance:
Inlet :0.15 mm
Exhaust : 0.20 mm
NOTE:
Fit:
BRAMPTON type tensioner, Fig. III:
When dismantling, hold the body (4) and pad (5) toge the cylurrder head cover, (tighten the screws to
ther to preverit the par ts from being scatterr,d 0.7 mdaN),
CL'
SEDIS type tensioner, Fig. V: the rnlet manrfo(d,

With a screwdriver p(aced at "c", torn to the (ett to the spark ng phigs,
lock the pad before disrnantlinrg
the ( owrrueter to turbo Sorger gaiter.
Re move:
[ower the veh de to the gnound.
the carnshaft drive gear wheel,
the tirning chain Set the gear shiN ru neutral.

C)
-_;.,_ ,('-
_
-,.
,
1
Lo
(DI
L]
c.J
1
-
L
85.562
>

F
ViH
M25/66O
M25/64 1/31
RECOMMENDED TOOL
6028-T.K fimtng bet tensioner
REMOVING/REFITTING THE TIMING

BEtT, ON THE VEH/CLE
*
8b3
2
RLMOVAL
o k tre Hl nom öa of tre varm Ii Tighten moHr m ots v' 2 o 2 mdaN

(liacorirea tI ittert nogdOve rible,
m. Lm
l0t 32mdaN
ermqagm' tim H1 est gear t( erabk the er gire
o t at am rm
Rernove tool 6028-T.K.
tel
Fitting the injection pump beR:
CAD
Remove:
- the oad wheel, Run the engine hy torn in the direction of rotatmon
1
tho wheela rch ming, until mnarks- - line up, Fig. 1.

the belt protoction coveis. (with ( ylinder No at the inmtra( tmmmng point)
1
Position: Fig. and II1

Setting the pump to the injection point:
the valves of cylinder No in the ''rocking'' posm
1 refer to Op () MA.146 0/1.
tion (look into the engine oml filleil,
the flywheel with marks- aligned, Ht the injection purrip driving helt with the side oppo
:r,
r-,
camshaft geai wheel mark A opposite screw (21 site the roller, tight.
Slacken the roller riut. Lot the roller spring react.

Loosen:
t17
the nuts of the tensioners and compress the spi ing

of each tensioner. Retighten the nuts. Tighten the nut to 2 mdaN.
Rotate the engine by 2 turns in the direction of nor

Re move: mal rotation and check the pump timing.
'CD
injection pump helt,

the timing belt Remove the tools
Start the engine Warm it up until the electric cooling

fans operate.
REFITTING
Retension the bett white the engine is hot, Fig. IV
Fit, Fig. Il:
the timing helt: marks (( and l(
on the helt Ref it:
should face the rnarks A and B on pinions (thero
are 35 pitches hetween A and B, passing around the protection covers,
the tensioner roller (11).
the wheelarch ming,
Loosen the nuts of the tensioner roller. the road wheel
Instalt, Fig. III:

tonI 6028-T.K. on the roller
the tool weight over the mark 2 of the rod, Fig IV.

* 8
8531
@'m
e3°
Re m ove:
2.5 L ENGINE
/ (0(r) t! o ps tro! uijecttori oriqlrio
the inlet nio utoPi
F rorrr engine dl! rnodels Iftho volvo rockers on still riOiSf afton adjustmr erit,
his spi nderheod sover nd iis gosket proceed is follows
Loosen the carnshaft pulley helt.

Adjust the val ciear an es (with engine co/dl
Screw out the three sarnshaft heaning hoosing
attachmerit screws tbc ated behind the camnshafl
Engine net Exhaust ® pub/et)
2 and 22 L Peti. 0. 10 mm 0.25 rom Ho tate the crankshatt so es to tu lIv open the
Fig. 1
exhaust veive of the 41 tu cyliiider.
Retighten the bearing housing screws

2.5 1 Petr. 0.15 mm 0.20 mm
Fig. fl
Tension the helt.
2.5 L Di. 0.30 mm 0.20 mm
Fig. III Adjust the valve clearances.
Possible methods
Valves
1°! fully Adjust
open
3.t4
20! Valves in
the nocking Adjust
position
1
3 fh
3
1 4
2 h4
2
4. 1,
2 dg
dP
4
2 3I
1

12 OI1 3
*
* 8531
* 8531
r
IH
HL
(J 1 H engine rnountnq bracket, Fig, Hl and IV
nrihond 6
(hu power it ri Hy hcriq in it ci the till
fl qire hr: re: ii):) tt ho ode n :ioeit
inufit ho reph d
)
fl ort hini (6 x u huiween tln he ri r d

the cteaihu
RH engine mounting bracket, Fig. and II:
C39
1
Lay d straigh edge on the ou tei (Ontact side of the

Mcosur o the ein rar u c istirig between tho oncju:u
axio at "a" Fig. fl and III. sipport brac het phrti ond tt o ax e c or tar t face at
"a" and "b''
Position the er gine bearei centre screw (3) center line:
Heduc the shire 6 tickries h the c ieuiar
940 ± 1 mm o)uc ± 1 mm.
hon tt e axie contact surtace 1 ighter screvos 6) to 3 mdaN
lLqhten ecrews (1) and (2) to: N it (4) tE) 16.5 mdaN.
3 mdaN
Engine torque stay, Fig. V.
Tqhten screw (3) to
The er igine/qearhox un it heing pos tioned on the RH
10 mdaN ur d LH bearers:
Fi t the torque stay to the engine.
Note the crankcase ower hatt nr orporates

: a stan Sirde spacers on both side ot the torque stay to
dard HFLICOII thread. remove a ny sti oss in the instailation

Pil 1 33O/1
(i (
//
:
Iv
*
M*329/b MA
180M0/1
J6T,
L M829A5
L + 12 mm J 6 T A 500

853]
2 rn
2
L6 madN
3
M25/659-BV ZF
Civ
LN
M 25/659 11/84
M 25/660 11/85
22mmH
\
\ LLIii
J UL1/
.o1
\\\_
2
C$`
M 2! EhY 1

M251659 MA
1 8OOO/2 2
M251660
M 25/659 1/86
M 25/660 1 2/85
1,6mdaN
2fi
1

*
<- MA 1/1
L2 mdaN

*
8531
MA
180M014
[2TJ ±L1
MA 180 1/1
'r2 rn
LI4ii)T I

-
M25/662 MA
1 18O1/1 1
If i_' M 25/648
X77
CARRYING OUT WOEK ON THE

EXHAUST SYSTEM
*
8531
8/11IOON1HXHAUSTSYSUM
två
s®'
1
NSTRUCTONS FOR FTTNG THE FRONT EXHAUST PPE TO

fil M25/662 and M25/648 TYPE ENGINES
it into Ii ont exhaust pipe (1) tt bo il joint (6) pftis S rew in ha) joirO (roiding dnWr boit (10) to 5 mdaN
joint.
fighten o 2.5 mdaN. (7 4 atP chrnent poirits
Do up bali joini supporr piate
Ht thc turbine housing (5) with a sea)

Remove the 5 mm th ck shim
Engage ciarrip (4) on the turbine 4 studs (3
Slide a 5 mm thick shim betwcen the surnp and

LSD
pipe (1) to allow for a clearance
M25/662, type engine: insert a sea) between waste

pipe (2) and the turhocharger.
Ert the 4 spacers and nuts to the turhine fixing studs (3).
Tighten to 2.5 mdaN in the order
tet'
1 2 3 4.
M25/648, type engine: position the clamp and the

a.-3
sea) of waste-pipe 12). Locate the 3 screws and nuts

Tighten to 2.5 mdaN.
r-«
Adjust ball-loint support plate 17) fiited with flexiole

Ing 18) position, and hold it in an intermediate p00
tion by means of 2 screws.
Pile up AP distance pieces of various thiokriesses bet

ween the bali jomnt and ts flexible log heter to 19)).
Insert the bali jomnt boit (10).
Siacken the 2 bali joint support plate screws (7) and

fit the other 2 attachment poirits without tighterimng.

5
!,-
7
10

*
*
8531
MA
220M/2

4E
`'a
':.
9Z981 -
1k"
{+5
]:
LOO9
LZ9g9

/ MA
22OOI2
-\
2219 i
)..
90°C
4,45 :ars

*
MA
220M13
2279 Tj
/ \
5,.
1
OUT 10 6004 T
f2 - 1

1,11r
831
\L,
6004 T [2279f
mot
X11
1..
SPY
1000 2,5 bars mmi

min
/95°C
___ 4,5- 5bars

1
u. 829 A5
23OOO/1 1
c
_ -
ila
3,5 mdaN
III
lbar-2/84
/ 1,1 bar 2/84 -.
*
8331
;Y,
1 MA
23OOO/2
ED - 880/830 C
n o 0 fl 0 r
1
________
1
[j ''
r150C-28%
- 30°C -- 50%
- 23 dm2]
000

H:.r
- M251659
23O O/3 1
- (?
)
92/87°C
* //85) () 55/48°C + 12,3L
@)
- 15°C- 28%
- 30°C -* 50%
_23_dm2J
/_
rtt
Gil + PT (7/85 )
L.

*
1 MA
23OOO/4
i M2Jl
ED - 88/83°C
- 92/87°C
- 15°C--28%
- 30°C -+- 50%
27 dm2
y
L
/3

HIN M25/648
MÅ
230.00/5
13
-3 ®
-
920/870 C
[1 - 3O°C-- 50%
III
Fl
2.5 mdaN _ T.
III
*
23I6 IIU M25/660
(1)
cD 88°/83°C
92°187°C
-7I85 - 55°/48°C
®- 93°/88°C
/// - 30°C - 50%

I±L23111
FILLING AND BLEEDING

THE COOLING SYSTEM
*
8531
ii]]! en r( ntcr a hedtef er tror
Proteci t)c. a)ter natoi
Loosen the blond serews.
Pr epare the mixturv of water and ont ifreeze (the cornponents ond pr oport ons sF ou)d be obser ved)
- Remove the header tanL cap.
Stowly fifi the circuit. When water flows, tighten the bleed scr ews Pop up until over) low rig the header tank
Refit the cap
Run the engine at 2000 rprn approx until the cooting fon(s) hos (have) out in.
NEVER OPEN THE CAP OF THE HEADER TANK WHEN THE ELECTRIC COOLING FAN(S) S (ARE)
OPERATING
Top up the coolant (eve) in the header tarrk.

CAJ

EI: FUEL AND AIR SUPPLY - CARBURATION ENGINE TYPE
OPERATION
No .
DESCRIPTION
-
PERATIONS
_____
(JJ
0
PetroF
2
PetroF
25
Fue
njecton
5
Presuge
25
Petro
Turbo
25
Presflge
Petro
Turbo
5
Diese
Dese
Turbo
25
Limousne
Dese
Turbo
Safad 20
PetwF
+
FamIiaIo
SafarF 25
Fue]
njecUon
Safari 25
Diese
±
Famijiale
Safan 25
Drese
Turbo
Ambuance
UJ >- 829A5
H- Ci)
829 A 5 J6T A 500 25/659 251659 25/662 25/662 25/660 251648 25/648 829 A 5 25/659 251660 251648 or
_________________ ______________________________________________________________________________ tr _Q ________ ________ ________ ________ ________ _________ _________ ________ ________ _________ ________ ________ _________
25/660
MA
140/1
Tools
0 X X X X X X
MA
142.000/1
General information on carburation \ X X X X
MA
142.00/1
WEBER carburettor specification /\ X X X
MA
142.00/2
SOLEX carburettor specification A X X X
MA
142.00/3
WEBER carburettor specification A X
MA
142.00/5
WEBER carburettor specification \ X
MA
142.0/1
WEBER carburettor checks and adjustments
0 X X X
MA
142.0/2
SOLEX carburettor checks and adjustrnents () X X X
MA
142.0/3
WEBER carburettor checks and adjustments 0 X X
MA
143.00/1
AntipoHution systern specification A X
NIA
M2/659 engine fuel-injection systern specification X X X
144.00/1
MA
M25/659 engine fuel-injection systern: checks and adjustrnents (J X X X
1440/1
MA
M25/662 engine fuel-injection systern specification X X
144.00/2
MA
144.0/2
M25/662 engine fuel-injection systern: checks and adjustrnents 0 X X
MA
Specification and particular features of the DIESEL fuel-inj. systern X X X X X X
146.00/1
MA
Fuel-injection systern: checks and adjustrnents X X X X X X
146.0/1
MA
Rernoving/refitting an injection purnp X X X X X X
146.1/1
MA
Specification and particular features of the turbocharger X X
151.00/1
[MA
____________ 0 _____
__________________________
151.00/2
Specification and particular features of the turbocharger .
X X x
MA
171.00/1
Air circuit specification J X X
1
MA 1
173.0/1
Checking the fuel pressure X X
fEl

FUEL AND AIR SUPPLY - CARBURATION ENGINE TYPE
(/J
25 25 Satan 20 Sa/an 25
OPERATIONS 25 25 Sa/an 25 Salan 25
20 22 25 Prestige 25 0m0n Petrol Diese]
_______ _______ Fuel Fetrol Oesel FueI Dresel Ambulance
Petrol Petrol Prestige Petro/ Diesel Dresel ±
OPERATION
DESCRIPTION
-
(1) /njection Turbo
Turbo
Turbo
Turbo Familiale
_____ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______
Injection
Familiale
Turbo
No
>< >- 829A5
829 A 5 J6T A 500 251659 251659 25/662 25/662 25/660 25/648 25/648 829 A 5 25/659 25/660 25/648 or
_______________________________ A 0 ______ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ 25/660
MA
Fuel circuit specitication X X X X
175.00/1
MA
175.00/2
Fuel-injection system specification Q X X X X X
MA
175.00/3
Diesel fuekinjection system specification Q X X X X X X

MA
140/1
2437 T
1
OUT 106030T
:4
LIZ.
:
3089 T OUT 106027T
OUT 20 6028 T
H J
* 8531
142MOOOI1
CARBURATION
GENERAL FEATURES OF THE CARBURAT/ON
*
*
8531
MA
2 GENERAL FEATURES OF THE CARBURATION
t0-
I=-
142.000/1
SOLEX and WEBER carhurettors are fitted with tampeNproof devices for the mixture adjustment screws.
r-+
The SOLEX carburettor is fitted with protective caps for the throttle spindle stopscrew of 2nd choke and butterfly
adustment screw.
If the carburettor is not properly adlusted, the original protective plug (white on WEBEF? carburettors, black on
°'0ö
SOLEX carburettors) will be removed, and after adjustment of the carburettor, will be replaced by a «REPAIR»
o-,
protective plug (black on WEBEF? carburettors, and white on SOLEX carburettors).
The Replacement Parts Department supplies under Reference number 4029-T a kit for removing and refitting the
L-2
protective plugs on SOLEX and WEBER carburettors.
TOOLS INCIUDED IN KIT 4029-T, Fiq. et II:

,j]
A. Gun.
B. Too) for loading the gun.
C. Too) for extracting the plug (a) protecting the sunken mixture adjustment screw (SOLEX).
0
D. Tool for extracting the plug (a) protecting the sunken mixture adjustment screw (WEBER).
E. Tool for fitting plug (a) and cap (b) (SOLEX and WEBER).
F. Too) for breaking the head of cap (b) of the sunken mixture screw with collar (SOLEX).
G. Tool for extracting cap (b) (SOLEX).
H. Tool for fitting cap (c) protecting the stop-screw for the throttle spindle (SOLEX).
This kit also contains a set of plugs for SOLEX carburettors:
a) Protective plug for mixture adjustment screw.
b) Protective cap for mixture adjustment screw with collar.
c) Protective cap for throttle spindle stop-screw.
The Replacement Parts Department supplies caps in packets of 10, under the following reference numbers
`-°
°-'
- Protective plug for sunken mixture adjustment screw

SOLEX carburettor ................................................ No. 75 489 718 (white)
C75
WEBER carburettor ............................................... No. 5489 716 (black)
- Protective cap for mixture adjustment screw with collar

SOLEX carburettor ................................................ No. 5 501 075 U (white)
- Protective cap for throttle spindle stop-screw and butterfly opening adjusting screw
SOLEX carburettor ................................................ No. 5 507 643 (white)
UTILISATION
1. REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MIXTURE ADJUSTMENT SCREW ON A
SOLEX CARBURETTOR.
REMOVAL. Fig. III, IV et V:

1. Load gun A on too) B.
0
2. Pierce plug (a}r

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

VIN
L LIOOOt'
Al
*
c 1
MA 1
142OOO/1
kizii
c H
76.1188
Iv
, a D
v vi

MA
GENERAL FEATURES OF THE CARBURATION
142.000/1
FITTING. Fig. 1 and II:
5. Fit the tampec-proof protective plug (a):

- !oad gun A.
screw too! E onto gun A.
- position plug (a) in its housing on the carburettors.
°`°
- actuate the gun unti! the p!ug is proper!y !ocated.
-°O
II. REMOVING AND FITTING THE PROTECTIVE CAP FOR THROTTLE SPINDLE STOP-SCREW OF 2nd CHOKE
'f1
(cap c), ON A SOLEX CARBURETTOR.
This operation is to be carried out only in the case of check and adjustment on
p_.
a a carburettor test bench
0
(L'POLLU 2000 type).
REMOVING AND FITTING THE PROTECTIVE CAP FOR OPENING ADJUSTING SCREW OF BUTTERFLY
O'{
UNDER OPERATION OF COLD START DEVICE.
REMOVAL. Fig. III:

1. Remove cap (c) using f!at-nose p!iers.
2. Adjust the butterf!y opening:

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

3. Fit cap (c):
bad gun A,
o-D
-
- screw too! H onto the gun,
- f it cap (c) onto the throttbe spindbe stop-screw,
- p!ace the tool and gun assemb!y against the cap (c) and actuate the gun.
III. REMOVING AND FITTING A PROTECTIVE PLUG FOR SUNKEN MIXTURE ADJUSTMENT SCREW ON A
WEBER CARBURETTOR.
REMOVAL. Fig. V:
1. Load gun A on too! B.
2. Pierce piug (a):

- position and ho!d too! D against gun A,
m:3
- position the gun and too! assembby against p!ug (a), making sure that the nozz!e of the gun is proper!y
5cö
C-0
öms:
centred against the p!ug, and that the assembby is a!igned as preciseby as possib!e in the axis of the plug.
M--
- actuate the gun, and screw the too! into the plug !L.H. thread!.
(L]
(1)
- remove the gun, beaving too! D on the carburettor.
3. Remove p!ug (a), Fig. VI:

- !oad gun A,
- screw too! D into the back of gun A.
- actuate the gun to remove the p!ug.
4. Adjust the !eve! of po!Iution.
*
8531
MA
6
CAJ
142.000/1 GENERAL FEATURES OF THE CARBURATION
HITING. Fig. 1:
5. Fit the tamper-proof protective plug (a):

bad gun A,
- screw tool E onto gun A,
c.,
position plug (a) in its housing on the carburettor (make sure it is fitted the right way round Fig. II),
CO-
- actuate the gun untib the plug is properly located.
EXHAUST EMISSION CONTROL
ln order to comply with current regulations, the checking and adjustment of the exhaust emission from vehicles
`°?
with a petrol engine must, without fail, be performed after the following operations:
ENGINE REPLACEMENT.
Il=
1.
II. CARBURETTOR REPLACEMENT.
III. WORK ON THE CARBURETTOR.

Ffeplacement of parts of the carburettor.
Carburettor adjustment.
Work on the carburettor controls.
IV. WORK ON THE INLET MANIFOLD.

Replacement or removal of:
`-°
u._
the inlet manifold,

the air filter,
- crankcase gas recirculation system.
V. WORK ON THE ENGINE.

m
Rocker adjustment.
the cylinder head,
v-<
the camshaft,
the rockers,
- the valves,
- the liners and pistons.
VI. WORK ON THE IGNITION.

Replacement or reconditioning of the distributor (wholly or partialby).
:3o.
Adjustment or replacement of the sparking plugs.

Adjustment of the ignition timing.
VII. WORK ON EXHAUST SYSTEM.

- the exhaust manifold,
the silencer or any part of the exhaust.
VIII. WORK ON THE EMISSION CONTROL SYSTEM.

When the vehicle is fitted with a specific equipment (e.g. on vehicles of SVt/EDEN, AUSTRALIA or JA PAN type).

MA
142000/1

* 8531
CARBURATON 14/1
CAF?BURETTQF? SPECIFICA TION

* 8531
2 1 4O/1 CARI3URETTOR SPECIFICATION
Engine type 829A5
MAKE : WEBER
Type: 34 DMTR 46/250 88-50
LSD
Ref. W
34 DMTR 46/250 W 89-50 fast idie device
Choke fiap in primary barrel

(die cut off solenoid
Dual choke carburettor of the compound type
Fuel return pipe to tank locatod on the carburettor top cover
ist choke
-_i
DESCRIPTION 2nd choke
Venturi 23 Ref. No. 26 Ref. No.

C'`)
Main jet 112 Rot. No. 120 (under Ref, No .
Air componsator jet 240 Ref. No. 230 Rot. No.

I1_
'i1
Emulsion tube F45 Ref. No. F25

tfn
(under Ref. No .
Idling jet 47 Rot. No. ® 50 Ref. No.

Idling air correction jet
tid
125 70
Accolerator pump jet 40 Ref. No.
Enrichment device jet (petrol) 130

R ef . N o.
-_,
Enrichment device jet (air) 110

Twin fuei float weight 13 ± 0.5 g
BaH type needie va)ve 1 .75 Ref. No.
Positive opening of 1 . 35 + 0.05
mm
ist choke butterfiy 0
Opening of the strangler fiap
3 75 ± 0 25 m m
with 400 mm Mg (530 mb(
. .
er'
(die shut off soienoid Ref . No.

Air reguiating screw Ref No..
Mixture control scrow Ref No.

.
Throttie opening device Ref No..
Adjustments carried out on «L'POLLU » test bench:

m
OPENING OF THE THROTTLE BUTTERFLY INITIAL SETTING OF IDLING SPEED
ist choke ist choke Positive opening

W mixture screw c(osed 2nd choko w mixture screw open 2nd choke ist choke
N 210 K 230 N 265 K 230 Y 280

INI
INI
MA
^'3
142.00/1
.I
6 %01
o
9
®O®
Qo

8531
*
8531
2 CARBURETTOR SPECIFICATION
i'1
1
Engine type 829.A5
MAKE SOLEX
Type : 34 CICF Act. CIT 214 and 214-1
Choke flap in primary harre(

Dua( choke carburettor of the compound type
0
Fue( return pipe to tank (ocated on the carburettor top cover
DESCAIPTION ist choke 2nd choke
Venturi 23 Act. No . 26 Act. No.

Main jet 127.5 (under Fet. No, 115 (under Ref. No.
Air compensator jet 205 Act. No . 140 Ref. No.
Emu(sion tube VA (under Ref. No, ZA (under Ref. No.
Idling jet 55 Het. No .
Idhng air correction jet Act. No .
By-pass jet 60 Act. No.

By-pass air jet 90 Ref. No.
Acce(erator pump injector 60 Ref. No .
Econostat jet
'-'
- Petro( 145 Ref. No.

Air jet .
80 Act. No.
Polyamide fue( float
-+,
Act. No. 12 ± 2 g
BaR type need(e va(ve Het. No. 1
. 8
Positive opening of
ist choke butterf(y 1 .25 ± 0.05 mm
'"'
Opening of the strangler flap

with 400 mm Mg (530 mb) 4 4 + . mm
Mixture control screw Het. No.
d(e out off solenoid Act. No.
Adjustments carried out on «L'POLLU» test bench:
OPENING OF THE THAOTTLE BUTTEAFLY lNITAL SETTING OF IDLING SPEED
ist choke ist choke Positive opening

W mixture screw c(osed 2nd choke w mixture screw open 2nd choke ist choke
N 195 K 205 N 240 . K 205

*
8531
CARBURATION 142OOI3
CARBURETTOF? SPECIF/CA TION
*
8531
MA
2 142M013 CARBURETTOR SPECIFICATION
(1I
Engine type J6T.A500
MAKE : WEBER
Type: 34 DMTR 110/100 Ref. W 145-50
Choke fiap in primary barrei

die out off soienoid
Duai choke compound carburettor
Fuel return pipe to tank iocated on the carburettor top cover
Throttie closing dashpot
Anti-potution device
--30Il0I85 30/10/85-
D ESC R PT1ON
1
ist choke 2nd choke ist choke 2nd choke
Venturi 24 Ref. No. 26 Ref. No. 24 Ref. No. 26 Ref. No.

Main jet 115 ® @)
paj
Ref. No. 97 under fel. No. 115 Ref. No. 117 (under fel. No.
Air compensator jet 210 Ref. No. 130 Ref. No. 240 Ref. No. 130 Ref. No.
Emuision tube F63 Ref. No. F25 (under fel. No. F63 Ref. No. F25 (under fel, No. j)
ldhng jet 52 Ref. No. ® 50 Ref. No. 50 Ref. No. 50 Ref. No.
dhng air correction jet 170 70 170 70
Bali type needie valve 1.75 Ref. No. 1.75 Ref. No.
Float setting
'-'
7 ± 0.25 mm
FCO
7 ± 0.25 mm
Petrol enrichment jet 1 30 (under fel. No. 1 130 (under fel. No.
Air enrichment jet 115 (under fel. No. 115 (under Rel. No.
®
ro.
Accelerator pump jet 50 Ref. No. 50 Ref. No.

_________________
Air regulating screw Ref. No. Ref. No.
Mixture controi screw Ref. No. Ref. No.
die shut off solenoid Ref. No. Ref. No. (j __________________
Throttle opening device Ref. No. Ref. No.
Positive opening full choke 1 .20 ± 0.05 mm 1.20 ± 0.05 mm
0penngofthestrangrfiap
4.25 ± 0.25 mm 4.25 ± 0.25 mm
Adjustments carried out on «L'POLLU» test bench:
Positive ist choke 2nd choke ist choke

Cumulation
opening W mixture screw c(osed W mixture screw open
X 110 N 200 K 245 N 255 N 310

INI
INI
MA
142.00/3 3
M20

* 8531
CARBURATION 14I5
CA/7BURETTOR SPECIFICA TION
*
*
8531
2 CARBURETTOR SPECIFICATION
Engine type J6R A 500
MAKE : WEBER
Type 34 DMTR 120/100 Ref. W 149-50

Choke flap in primary barrel
Idle out off solenoid
Dual choke compound carburettor
Fuel return pipe to tank located on the carburettor top cover
Throttle closing dashpot
Anti-poliution device
DESCRIPTION ist choke 2nd choke
Venturi 24 Het. No. 26 Ref. No.

;l-
Main jet 110 Ref. No. 125 Under Ref. No.

Air compensator jet 180 Ref. No. 240 Ref. No.
Emulsion tube F45 Het. No. F25 Under Ref. No.
ldhng jet 52 Het. No. 50 Ref. No.
Idling air correction jet 55 70
tfn
Bali type needie valve 1 . 75 Ref. No.

Float setting 7 mm ± 0.25
Petrol enrichment jet ii 5 Under Ref. No.
Air enrichment jet ii 5 Under Ref, No.
Accelerator pump jet 50 Ref. No.
Air regulating screw Ref. No.
Mixture control screw Het. No.
Idie shut off solenoid Ref. No.
--i
Throttle opening device Ref. No.

Positive opening full choke .20 mm ± 0.5
+
Opening of the strangler fiap

4 mm ± 0 25
with 400 m Mg (530 mb)
Mechanical opening 8 ± 0.5 mm
specifications: MA 142.00/3 p.3

Refer to: checks and adjustments: MA 142.0/3
anti-pollution devices: MA 143.0/1
+-'

+1 JHL __ MA
142.0/1
WEBER
34 DMTR
46/250 W 88-50

* 8531
MA
2 142.0/1 i r)°( 829 A5
.rom
F..
Jr= 1,35
« 85.584 fiii

=* 1
'!tJf
___
829 A5 1
MA
142 .Oii 3
85,583
o
252o
Co2 > 9
0
A
'
,i
'
:- _
+=g 5O(
85.621
*
8531
E.
f 1
..
-
1:
81.522
H 7164485
fri
r
- 6990058 1
81.12731
REP214
J=o
m
REP 2141
* 8531
INI
MA
2 142.0/2 I
r)(L, ______
829 A5
- -
H-'-'- 1 _.
_
rw& ,
-------
Afs
J=o--- ____ - -
-- -- -
-
-'-.
:' ii:.
'lo' 1
-
29j j [39
J = 4,4 ± 0,5
II
49

u+I '-(L,
_______ _____
829 A5
142.0/2
l,o
Eli
0 - t
*ij !F
____
LJ .-- 1 __ ___ __
_____
J = 1,25 ± 0,5
1
-
EIll1
r
8L638
1!
_____
-..
(
-
1
1
81,524
II
Co
>1
< 2,5
1 1
IS)
Co2 > 9 750
*
8531
INI
MA
142.0/3
WEBER
4
34 DMTH
110/100 W145-50 -
'r-
/
:;
______
f -FE m_. '

85.591
*
8531
MA
2 142.0/3
1
HL, __
'Ln _____
J6TA500
,F^
mom,
_;y
III
.''..-,,.
ryt

MA
U::
HL 'L,-II J6T A 500 142.0/3 3
> 0,8
Co < 1,5
Co2 > 9 ____
800±
0
0
50

* 8531
MA ____
4 u=t4'»
1 42M13 1J)-°-(L
tII1I
1
J6 TA 500
.15ft-
It
k..
-
[85.634 ...
42

* 8531
c3,

ANTI-POLLUTION ioii
SPECIFICA TION AND PAR TICULAR

FEATURES OF THE ANT/-POLLUTION SYSTEM
*
*
8531
*
8531
ELECTRONIC FUEL INJECTION
"LE Jetronic"
System
*
8531
MA "LE JETRONIC" ELECTRONIC FUEL
2 14400/1 INJECTION SYSTEM
M251659
"LE Jetronic" system
The "LEJetronic" isa fuel injection system which injects intermittently petrol, at low pressure, into the inletrnanifold.
CL)
The main characteristic of the device is to meter directly the air drawn in by the engine, which is the only reference
for the fuel quantity to be injected. The fuel metering is carried out by electromagnetically triggered injectors. These
are under a constant fuel pressure.
The quantity of fuel injected depends on how long the injectors remain open. The duration of opening is optimally
determined for each engine operating phase by an electronic control unit, from data supplied by various electric
sensors.
The "LE Jetronic" device is composed of:
No. COMPONENTS MADE BY
z
REFERENCE
l42 Electronic Control Unit IEC,U.l BOSCH 0280 000 300

192 Throttle spindle switch « 0280 120 301
280 Supplementary air control « 0280 140 1 72
302 Flow meter » 0280 202 021

345 Electrovalve » 0280 141 011
576 Injector » 0280 150 254
683 Electrical fuel pump » 0580 464 008
731 Relay » 0280 230 009
841 Water temperature sensor » 0280 130 026
F Fuel filter » 0450 905 002
R Fuel pressure regulator » 0280 160 216

*
co
LO
(V)
8531
MA
2 1
& g= 3 i4/i & '

Ih11tiIIflI
/VV
144O/1
M251659 M25/659
(731j
3'
Bc
-* 2
[
Mr
r{i
N
___ Ic
FBt
EJ
Gr
A
731
M N
1r1HFDFCi1 + (731 -* 6-* : 12V
F.J FVe EVe EJ
50
r irn xirn
Bl FBI
-JI
EJ
EJ
6 -+3 12V
ff
FN FBI
FBI
St
Bl Sr
Bl
EJ
I
IM IM IM IM
I
IC
___
1 TB
L 12
Ic Bl
576MN Bl +
Ut
x2
31 32 33 34 -
-- R
IC IC IM IM IM IM
__ AAAAAAAA
Mr
liii
Gr
1
EVe EVe EVe

D-- 1
v
m-D -+ 9V
z-M-D
EJFGr9 8
-*
Bc 3021'
r
i,
EVe EVe
Mv N
EJ
Bl Jr Gr R
Fte
Bl
J
Bc
14-83
L:i -* 9V
t>7
5 :
683 '8 l'C

1
I'C
5
--_________
EVe EJ J J EVe EMr
j rfi
S 4-9-13
LE2 Jetronc 1
'tifl162
1
-*13
1
EVe F.Mr EVe EMr
9V
1
F.N
---
R J I
AL
tiiJ J 142
4 :
3tFIVe
2
9 -*13 : 9V
IC IC L-1JI1 IC
10 ----.--J 9
192
41 280
38 26 3O2
L IM--- IM-
Mr
FJ
114.83

1
MA
& 1 c1ItflI M 25/659
144.0/1
639
1' 1 -* ut
142
5 -*9: 20°C-* 3OOO
L[%
302 9 - 8 : 20°C 200 J
LI1
-* -* 20°C 100
0
8 7 :
----- 302
L5-12 1
'cii1Ji1I 576J
1421
-* ut
(14,
5 -3 12 : 4 -* 5
citflIf-*
576 1 - 2#16
[ 239
ut
192
1142] (14,
-+ 2 -* 9 : 0
2 -+ 9 :
*
8531
MA
& I c:lluiI1JIf3
M251659
9-*3 :
9 -* 3 o-
um4DI 192 ut
IlJr
0 X2
0 192
0
192
9-*2 =O
iii 1
0 x2
5 -9 3 #
L H
D

& 1 ctfflf M251659
1
MA
44M11
-o
Ut
142
IlJr
0°C:50OO
5 -* 10 20°C: 2500
80°C: 300
L28OJ [1(731] -* Ut
5-9-13
Ut
[142]
9 -3 5 # 50
9 -3 13 # 50
*
8531
MA
144.0/1 &
M25/659
775
min
775
min
-
C)
r___ LP
mr
97
L1 1EH 2 bars
Ut
: 2,5 bars

MA
& 1 144.0/1 8
M 25/659
0
e
+ 50
1000
min
.'-
sr.
1
- 1
0,5 -+ 1,3% Co
> 10% Co2
*
-'i
LAi
+ 50
700
min
*
8531
(2 ELECTRONIC FUEL INJECTION 14OI2
"LE Jetronic"
System
*
*
8531
MA "LE JETRONIC" ELECTRONIC FUEL
2 144.00/2 INJECTION SYSTEM
M251662
"LE Jetronic" system
The "LE Jetronic" is a fuel injection system which injects intermittently petrol, at low pressure, into the inlet manifold.
The main characteristic of the device is to meter directly the air drawn in by the engine, which is the only reference
for the fuel quantity to be injected. The fuel metering is carried out by electro-magnetically triggered injectors. These
are under a constant fuel pressure.
The quantity of fuel injected depends on how long the injectors remain open. The duration of opening is optimally
determined for each engine operating phase by an electronic control unit, from data supplied by various electric
sensors.
The "LE Jetronic" device is composed of:
No. COMPONENTS MADE BY REFERENCE
142 Electronic Control Unit (ECU.) BOSCH 0280 000 224

192 Throttle spindle switch 0280 120 313
280 Supplementary air control <
0280 140 178
302 Flow meter '> 0280 202 061
345 Electrovalve ' 0280 141 011
575 Cold start injector 0280 170 409
576 Injector '> 0280 150 200
683 Electrical fuel pump '> 0580 464 008
731 Relay 0280 230 009
841 Coolant temperature sensor 0280 130 026
870 Slow thermal switch 0280 130 214
F Fuel filter >
0450 905 002
R Pressure regulator 0280 160 216

8531
c)
*
14O/2 3
:IIIII:
841
c)
302
() 0
Ni -
--1
142
0
1-i 345
870
-r(
576
iH Y
280
1 4
T fl
- /
575
5L5
»LIIIILITiI
1 14.64
PDF
* compression, OCR, web-optimization with CVISION's PdfCompressor 8531
INI
3Ji4I2 & a=
iiii9 M25/662 E1
+ _____
- 30
2
-* 12 V
-IC----I1-N
734 -
I1>
v BI-N
--* 3 12V
iL
EK ti 3
BIBI
v
-*2 12V
» 4r\
1
L
4 1
IM IMIMIMIMIM R
1-2-5
4 37 38 40 41 48
C576CCfl 8 5 -* 12V
46 15 33 32 14 34 683
10-16-17-29
r-3
IM IM IC IM IM IM IM IM
1 1 1 1
-3 10 -* 12V
4 46 15 33 32 14 34
- 142 29 -* :
IC IC IC IC IC C
L
870 m4
10 -* 16 12 V
-*17
-i>
lE LE2 Jetronic 10
J 1
6 7 9183 2 M VV-Mv
AEI \141
1I
N-31
-3I
-*
13
IM
c ic c c ic ic c c
Z2Z2
4x-rfiflhflIf' 1
2 -* 12V
L14-84
84127672B jB_J
B
2x Ut
-M 302
-3
- Ic lu
Z ml
114.84

4-*
4-10-16-17-29 9V
29-*
142
10 -* 5
1O-*16 : 9V
10 -+ 17
L6-7-9-27 1
3O2 Ut
1142 OJr
1
27 -* 9 2O°C#28OO
7 10oo"
7 -* 9 2O°C#50O
6 -*27 2O°C#2OO
*
8531
576
111
14
1O-*15 45
32
33
Q192
2-3-18
142
EiII* 2 -* 18 o
2 - 18 00
3 - 18 00

MA
.
& ::4*» 1 1TIIEiIJITIf3 144.0/2
M 25/662
3 -3 18 :
O192 0 -4 ijt
IlJr
flx2
192
2 18 O
0x2
(3iJ --3 Ut
"Jr
1
8 -+ 3#1(2
*
8531
14I2 & I t1If M25/662
ciio
870
Ut
> 30°C
12 0 :
< 20°C
2 30
-3 Ut
lur
-3 1-32 : 4,2 20°C
LJ (-T-- i'<
-3

0°C: 5000
1 20°C: 2500
80°C: 300 I2
L280 JI73iJ Ut
I14
34
142j -+ Ut
"Jr
8 -*34 50
V14.35a
0
8531
14/2 & J ctffl3
80°C
fl
800
I+=o min
800
min
-
1 il
(___ AP
:ter
'nr
4O73T)
LRJ- 2 bars
2,5 bar

& D=4I 14I2
IIII M251662
III
60
>.
_ c50
14.64b
______________ __
0,8 -3 1,2% Co
> 10% Co2
*
8531
*
c},
8531
M25/660
M25/648 M25/669 (2/87)
(J1
-2187 *2/87
DPC MAS 200 88443 A 360 A
D:-
ROTO-DIESEL DPA MA 300 DPC MA 260 8443 A 1114 R0T0DlESEL DPC MAS 100
or 8361 B
ROTO-DIESEL F SL AC ROTO-DIESEL F SL AC
CAV 7111/796 CAV 7111/796
ROTO-DIESEL RKB 45 SD 5422 ROTO DIESEL RKB 45 SD 5422
ROTO-DIESEL RDNOSDC 6577B R0T0DIESEL RDNOSDC 6751 ROTO-DIESEL RDNOSDC 6850 C
BERU 0100 221 106 BERU 0100 221 106
BOSCH 0 250 200 059 BOSCH 0 250 200 059
ROTO-DIESEL R53 56 501 B +® ROTO-DIESEL R 5356502 R 53 56 503 C
Orange paint White paint Blue paint
M 25/660 M 25/648 M 25/669
By timing marks on cylinder block and flywheel
STATIC SETTlNG2/87 4.32 ± 0.05 mm 3.24 ± 0.05 mm 3.58 ± 0.05 mm

BTDC BTDC BTDC
or 22°
or
2/87-- 4.71 19°
DYNAMIC Engine hot at a speed of 800 ± 25 rpm

TIMING 10.30' ± 1° 9° ± 1°
IDLING SPEED 800 ± 25 rpm
DPA 800 ± 25 rpm

ANTI-STALL 800 ± 50 rpm
DEC 800 ± 50 rpm
MAXIMUM
NO LOAD 4625 ± 125 rpm 4550 ± 200 rpm 4400 ± 125 rpm
SPEED

INI
M 25/660 MA
1 46M0/1 3
M25/648
/
- - -
r)S '
j _'\
i 't sfr
f!!:
[3I' r 82.iil
M25/648
1ii r
_
11i»jjiT
1 mdaN
k1
2,5 mdaN
/1
paj
__ rti
112
bars
M25/660 122
bars
127
bars
M25/648 137 bars
C31

* 8531
FUEL SUPPLY MA
EL
146.0/1
CARBURATION
RECOMMENDED TOOLS
2437-T. DiaLgauge.
3089-T.F. Dial-gauge.
3089-T.H. Feeler.
4026-T-bis. Injector test bench.
4059-T. Right angled lever for dial-gauge.
5008-T.C. DiaLgauge mounting fixing screw.
6027-T. Set of 3 tools.
6030-T. Dial-gauge mounting.
CHECKING AND ADJUSTING

THE FUEL INJECTION SYSTEM

* 8531
MA
2 CHECKING AND ADJUSTING THE INJECTION SYSTEM
Pst
111
146.0/1
c
ADJUSTING THE INJECTOR SETTING PRESSURE
(:i
1.
Test fluid: Keep the equipment dean.

The parts should be lubricated before assembly.
Deodorized petroleum or Kerdanne or Dilutine.
Viscosity. to 2.5 centistoks at 20°C.
1
- ln the injector-carrier body (3), place:
Density: 0.770 to 0.810 at 20°C.
- injector (41 and its nut 15),
Tighten to 6.5 mdaN
Q_)
Precautions to be taken: - push-rod (6),
As the flash point of paraffin is low, it is essen - spring (71,
tial to ensure that at safety precautions are taken
before the test. adjustment screw (2).
Keep your hands away from the spray (use a - Adjust the pressure:
transparent protective screen).
n-+
The penetrating strength of these sprays is such

M 25/660 M 25/648 M 25/669
that they could create serious injuries and cause
arm.
blood poisoning. +5
Pressure 112 bars 127 bars
setting 0 0
RDNOSD RDNOSD RDNOSD

Checking the setting pressure: Inlector
6577 B 6751 68-50 C
Actuate the pump lever slowly; record the pressure
value measured by the manometer on opening the Injector RKB45SD RKB45SD RKB45SD
injector Icalibration pressure). Write the value down. carrier 5422 5422 5422
The pressure setting is carried out using screw 121. Paint

orange white blue
Fig. 1. mark
Injector setting pressure adjustment screw (21 - Fit seal (8) and cap nut (1).
is to be screwed in or out on the test bench Tighten to 2 mdaN
4026-T. bis only. The fuel pump lever must be
operated continually to keep the needle and its Checking the spray:
seat lubricated and cleaned.
If the pump lever isactuated with a brisk sharp action,
the injector should produce a very fine and homoge-
n-.
neous spray.
fl.
Checking the needle seat for leaks:
DISMANTLING Test should be carried out with the injector in a verti-

cal position.
'",
To open an injector-carrier, place it in a vice equip- Wipe the end of the injector until dry.
ped with lead vice grips. By actuating the pump lever, maintain a pressure
10 bars below the setting pressure.
The injector should not drip within 30 seconds,
Never tighten an injector-carrier alone in vice. Moistening should not be regarded as reason for
fp'
a
.a:
rejection.

*
*
8531
CHECKING AND ADJUSTING MA
THE NJECTION SYSTEM 146.0/1
II. - INSPECTION AND TIMING OF THE "ROTO-DIESEL" INJECTION PUMP
Raise the LH side of the vehicle and support it on Timing the injection pump:
stands.
- set the engine to the initial timing point, Fig. 1
Disconnect the battery negative lead.

the crankshaft by 1/4 tum in the opposite direc-
0.5
- tum
Engage the 5th gear. Rotate the engine by turning the tion to normal direction of rotation, then tum back
,-«
in the direction of rotation to bring marks (--) and
-C>
wheel.
l--) opposite.
Set the No. 1 cylinder to the initial timing point, Adjusting tho pump tim/og, Fig. III:
Fig.I. Slacken off the injector pipe connections and the 4
(look into the oil filter orifice). attachment points.
place cylinder No. 1 valves in the rocking position; Bring the pump to the injection point with the feeler
_5-
-
tum the crankshaft by one tum in the normal direc- at the base of V-shaped groove Itiming point).
tion of engine rotation.
C/)
Set the "0"
mark on the dial opposite the needle on
- align marks on the flywheel and on the crankcase the dial-gauge. Orientate the pump casing towards the
engine.
tum the crankshaft back through a quarter of a torn Slowly tum back to the injection point Ineedle facing
the "0" mark on the dial), by moving the pump
-..
casing away from the engine (in the opposite direc-
Remove either the plug (with a 32 mm ring spanner) tion to engine rotat/on).
or the inspection plate depending on the type of the
pump.
Tighten the pump fixing nuts to 2.4 mdaN. During
this operation, the needle should not move.
+'_-
Refit, Fig II or III, according to pump:

the feeler, Check the pump timing
+"'
- the support for the dial-gauge. Remove the timing tools.

- the dial-gauge equipped with ts right-angled lever.
Refit the plug, (tighten to 2 mdaN), or the inspec-
tion plate.
Finding the pump internal timing point:
,-t
(/)
Seal the injection pump plug.

- tum the crankshaft in the direction of rotation until
the large pointer on the dial indicator starts moving
in the opposite direction. Tighten the injector pipe connections to 2 mdaN.
- set "0" mark on the dial-gauge in line with the large Reconnect the battery negative cable
pointer.
Switch on the ignition (electricai STOP solenoid cxci-
tationl and prime the tuel circuit using the manual
pump 15) located on the filter.
0
Checking the injection pump timing:

E
t.1_
- rotate the crankshaft by a quarter tum in the oppo- Fully depress the accelerator pedal to facilitate the
site direction to its direction of rotation. engine bleeding and start.
tum back in the normal direction of rotation until the

"0" mark on the dial-gauge has been reached.
in that position, marks (--l and (--( should be in line, Note: the initial timing point corresponds to:
Fig. 1. 3.24 ± 0.05 mm BTDC: M 25/648
000
C'')
4.32 ± 0.05 mm BTDC: M 25/660 DPA pump

L31
If not, re-check the timing. 4.71 ± 0.05 mm BTDC: M 25/660 DPC pump

8531
MA CHECKING AND ADJUSTING
6 146.0/1 THE INJECTION SYSTEM
III. - ADJUSTING THE ROTO-DIESEL INJECTION PUMP CONTROLS
m
25/648, Fig.
L!')
DPC type pump from engine M 1
DPA type pump from engine M 25/660, Fig. II
E
ENGINE COLD
Checking the fast-idle control Set the engine speed to:
Ensure that lever (7) is against ts stop, by pushing 800 ± 50 rpm (DPC pump)
it in the direction of arrow l--). 800 ± 25 rpm (DPA pump)
0
-f-)
E
If not, adjust tension of cable by means of cable end
v:3
by turning stop screw (5).

clamp (6). Complete tightening of cable using sheath
tensioner (4) Remove the 3 mm dia, rod and the shim.
Adjust the idling speed to:

800 ± 25 rpm
ENGINE WARM
1 by turning stop screw (8).
Checking the fast-idle control Checking the engine deceleration:
Make sure that the cable is slack. Accelerate the engine to 3.000 rpm, then release the
accelerator lever sharply.
If not, check the operation of the thermal sensor (10)
- if the deceleration is too fast (engine often stalling),
+-'
loca ted on the water out/et duct: the cable must ope-
unscrew stop-screw (5) by 1/4 tum,
rate over a range of 6 mm between its "ENGINE
COLD" and "ENGINE WARM" positions. if the deceleration is too slow (poor engine braking),
screw up stop-screw (5) by 1/4 tum.
Adjusting the accelerator control ln both cases, checK the idling speed and adjust if
necessary.
Engine stopped:
Fully depress the accelerator pedal. If the malfunction continues to exist, carry out the
Check that lever (1) is against stop (2). adjustments again.
If not, move (3) of acce/era tor cable.

pm
Make sure that, at idle, lever (1) is against stop (5). Check the efficiency of the mechanically operated
STOP control (9).
Adjusting the anti-stalling device

t!1
Engine running:
lnsert a 1.5 mm thick shim (DPC pump, Fig. Il
2 mm thick shim (DPA pump, Fig. II)
between lever (1) and stop-screw (5) at "b". Note: The setting figures are identical if the vehicle
Place a 3 mm dia. rod through the hole in lever (7) is equipped with air-conditioning and the adjustments
at "a" by pushing STOP lever (9) outwards. are to be effected with the air-conditioning off.
(/)
+-+

*
-* 8531
INI
FUEL SUPPLY MA
146.1/1
CARBURATION
0
RECOMMENDED TOOLS
2437-T. : DiaL-gauge
3089-T.F. Dial-gauge.
3089-T.H. : Feeler.
4059-T. : Right-angled lever for dial-gauge
5008-T.C : DiaL-gauge mounting fixing screw.
6027-T. : Set of 3 tools to check the timing.
6028-T. : Driving pinion extractor.
6030-T. : Dial-gauge mounting.
REMOVING AND h'EF/TTING DP.A. AND D.P.C.

ROTO DIESEL INJECTION PUMPS
8531
J
REMOVING/REFITTING D.P.A. AND DPC.
CAJ
MA
2 146.1/1 ROTO DESEL INJECTON PUMPS , .
1
REMO VAL
Raise the RH. side of the vehicie and support it on

MANDATORY: TO AVOID THE PUMP BEING
stands. DAMAGED NTERNALLY WHEN REMOVING
THE DRIVING PINION, PULLER REF. H AND ITS
Disconnect the negative !ead from the battery. NUT J FROM TOOL BOX 6028.T MUST BE
USED.
Engage the highest gear. Using the road wheel,
+-'
tum
the engine.
Set No. cylinder to the initial timing point, Fig. Fit the nut and clamp of tool 6028.T, Fig. II.
+..
1 1.
(look into the oj! filler hole) Slacken the nut of too! 6028.T until the injection
pump drive shaft starts moving.
- Bring cylinder No. 1 valves into the rocking position
by rotating the engine one tum clockwise. Disconnect the e(ectrical STOP solenoid.
- Marks-and--should be aligned. Uncouple:

- the accelerator cable,
`-'
Remove: - the fast idling cable,
- the fuel supp(y pipe,
- the road wheel,
- the fuel return pipe.
»
the whee(arch (ming,
- the be(t upper protection cover.
DPC injection pump, Fig. III:
Loosen: Disconnect from the overfuelling circuit:

- the injection pump driving pinion nut, - the diese( fuel return pipe (2!,
the helt tensioner nut, the air pipe (1).
compress the spring of the tensioner.
`D-
Re move: Push the diese! fuel filter to one side.
- the pinion nut,

-°-
- the injection pump driving helt. Remove:

- the spring,
- the injectors sets of feed pipes,
- the pump fixing nuts (3) Fig. IV.
by means of a 13 mm A/F open spanner
and a 6 mm hexagon Al/en key.

INI
MA
1461I1 3
-
..
-
-
-
/ -
/ iL:]
r- -l
; 4r
/
1r 1
Nid
114.40
III
(Q
6028 T
114.44 114.42
It Iv
* 8531
2
REMOVING/REFITTING D.P.A. AND D.P.C. MA
1
146.1/1 5
ROTO DIESEL INJECTION PUMPS
REFITTING
Prepare Remove the tools
- the pump (see Op. MA 146.0/1).
Refit:
either the p)ug ttighten to 2 mdaN),
ter
Fit
- the pump with the mounting studs in the middle of - or the inspection plate.
the slots,
Seal the injection pump plug.
,-t
the pump fixing nuts but do not tighten home.
II)
Refit:
Assembie, Fig. the belt upper protection cover,
."C-
-
E
1:
the injection pump driving pinion (1); hand tighten - the wheetarch lining,
nut (2),
,-r
- the accelerator return spring,

the pump drive belt with the side opposed to the - the injector set of feed pipes.
tension roller being without slack (take care not to
,..,
..'
rotate the pump).
fl.
Recouple:
avi
Unscrew, Fig.
°_)
1:
- the fast idle cable,
tensioner nut (3); et the tensioner bad the belt - the accelerator cable,
without assistance.
ute.
- the fuel pipe,
- the return pipe,

Retighten, Fig. 1:
- tensioner nut (3) to 2 mdaN, D.P.C. pump, Fig. III.

2
- pinion nut (2) to 5 mdaN. Connect to the overfuelling circuit,

- the diesel fuel return pipe (6),
avi
Carry out the pump timing: - the air pipe (5).

._.
Tum the pump towards the engine to find the point Put the fuel filter back into place.
of injection, (needle facing the "0" mark on the dial).
Reconnect:
- the electric STOP solenoid,
Screw up, Fig. II, to 2.4 mdaN,
- the negative cable to the battery.
- the pump fixing screws (4); when tightening, the dial
°_'
gauge needle should not move.

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

Adjust the injection pump controls and idling speed
(refer to MA 146.0/1). as explained in Op. ® MA 146.0/1.
8531
MA
151.00/1
GarrettTAO3 M 25/662
T3--M25/666
__
TAO3
T3
:4l0mbar
MAXI
:440 mbar
flui _ 6-'I
5000 tr/mn
_ P71
OOOH
_
MAXI (1
1
)7i10000C
_ \
/L\
1
0,025 _. 0,100 mm [_0,7

_. 2,1 bar 0,080 _- 0,165 mm

8531
MA ___
151 .00/2
j
fEI:j1 EI
Garrett TAO3 -* M 25/648

T025 M 25/669

CARBURATION 17/1
SPECIFICA TION AND PARTICULAR FEATURES

OF THE AIR SUPPL Y SYSTEM
*
8531
MA SPECIFICATION AND SPECIAL FEATURES
2 171 OO/1 OF THE AIR SUPPLY SYSTEM
829A5 and J6T.A500 are fitted with device regulating the temperature of intake air.
(J1
m
Engines types a
This device has been designed for maintaining a minimum temperature of the air drawn into the carburettor
ill
It consists of a thermal sensor and a vacuum capsule operating a flap.
Thermal source
The thermal sensor is located in the pipe connecting the air filter to the inlet manifold ol the carburettor.
0
This bimetal type thermostat, is subjected to the inlet air temperature.

CD-
It controls the opening of valves allowing passage for a depression towards the capsule.
This depression is picked up by a union having a calibrated orifice, fitted to the pipe connecting the ou breather
to the intake manifold of the carburettor, and by a Tshaped union situated near the carburettor base plate, 50
+-.
as to have an action over the engine bad.
+-'
The thermal sensor allows the depression to circulate when the temperature is bebow 1 5°C and stops it when the
temperature exceeds 25°C.
Vacuum capsule.
The capsule, bocated in the inlet of the air filter, is subjected to the depression. When energised, it operates a flap
which lets the heated air coming from a tapping bocated on the exhaust shiebd enter. At rest, the flap lets intake
air coming from behind the grill enter.

MA
CARBURATION 173.0/1
CHECKING THE PETROL SUPPL Y

8531
2 1 7I1 CHECKING THE PETROL SUPPLY
829.A5-J6TA5OO
1
Pump AC DELCO TYPE: PB3
CHECKING THE PETROL PRESSURE WITH APPARATUS 4005-T:
Oms
- Position apparatus 4005-T.

Disconnect the carburettor fuei return pipe; fit p)ug (2).
,-,
- Unscrew tap ED by one tum approx.

- Start the engine.
a) Check the petrol pressure at zero delivery:

,,,
screw up the tap; the pressure shou(d not show reading of more than 325 m.bar for the stabilised
pli
- FuHy a
pressure.
b) Check the tightness of the pump delivery valve:

Stop the engine: there should not be a sudden drop in pressure.
c) Check the tightness of the carburettor needle valve:

- Unscrew tap ; start the engine, leave it running for a few minutes.
- Stop the engine: there should not be a sudden drop in pressure.

- Remove apparatus 4005-T and f it the fue( suppy pipe and the fuet return pipe to the carburettor.
(after plug (2) has been removed).
0
'2n
CHECKING THE PUMP FOR LEAKS:
Close the pump detivery tube. B)ow compressed air under 800 m.bar pressure into the suction pipe. Immerse the
pump in a container filled with c)ean White Spirit: no eak should be detected.

*
8531
* 8531
8531
ISNI
2
MA _____ M25/660
17500/3 _______
M25/648
99
\//
CO
LO
Cs,1
LJ
t
(0
co

8531
210.0/2
X X X X X X El. the Checking
MA
adjustments and checks ignition: Transistorised 210.0/1

X X X X
MA
X X 0 ) (7/86 Turbo litres 2,500

sensor single with El. the of features Special
210.00/4b
MA
-.--7/86) (7/85 Turbo Iitres 2.500
X X 0 I.E.I. the of features Special
210.00/4a
MA
X X 0 (-'--7/85) Turbo litres 2.500

tEL the of features Special
210.00/4
MA
X X X 0 (7/86-.--) 2500
sensor single with El. the of features Special
210.00/3b
-
MA
7/86) (7/85 2500
X X X 0 [EJ. the of features Special
210.00/3a
MA
-7/85) (7/83 2500 0.00/3 21
x x x 0 [El. the of features Special MA
(-'--7/83) 2400 210.00/2

o
-
EL the of features Special MA
210.00/1
X X X X A specification ignition Transistorised
MA
210.000/2
X X X X X A ignition electronic integrated the on information General
MA
210000/l
x X X X ignition transistorised the on information General
MA
________ ________ . ________ _________ ________ ________ ________ ________ ________ ________ _ _Q _____________________________________________________________________________ _________________
25/660 A
or 25/648 25/660 25/659 5 A 829 25/648 25/648 251660 25/662 25/662 251659 251659 500 A J6T 5 A 829 (.1)
>-
-w
829A5 :
><
.
No
-J DESCRIPTION
Familiale Familiale Turbo Turbo -
OPERATION
(1)
Turbo Injection Turbo Injection
+ + Diesel Diesel Petrol Prestige Petrol Petrol ______ _______
Ambulance Diesel Petrol Diesel Petro
Diese Petrol Limousine 25 Prestige 25 22 20
Safari 25 Satari 25
.
25 25 OPERATION
Safari 25 Safari 20 25 25
TYPE ENGINE IGNITION

EI::
1 CONCERNED VEHICLE CHAPTER: THE IN APPEARING OPERATIONS OF LIST
IGNITION SYSTEM 21OO/1
GENERAL INFORMA TION

ON THE TRANSIS TOR/SED /GN/T/ON
*
*
8531
(a7
MA GENERAL FEATURES
2 210.000/1 OF THE TRANSISTORISED IGNITION SYSTEM
TRANSISTORISED IGNITION
PRINCIPLE OF OPERATION
The plug spark is triggered by distributor (1) which comprises a coil located inside the field of a magnetic circuit
,-.
permanent magnet. The magnetic circuit has four fixed branches and four movable branches driven by the distribu-
tor shaft.
When the movable branches, in their rotation, come opposite the fixed ones, a variation of the magnetic field is
brought and current is induced into the sensor winding.
This current, in tum, triggers electronic module (2) which builds up the current in ignition coil (3) primary winding
5-°
and then cuts it off, thus creating a high tension current in the coil secondary winding and triggering a spark from
the plug selected by the distributor rotor arm.
IGNITION DISTRIBUTOR (1)

The advance curves are specific for each engine type
N: Distributor rpm Dl, m.bars
in
D = Vacuum
A: Distributor degrees D2, in mm.hg.
C3'
.._
avi
Pick-up coil resistance: 1100 ± 10% (990 to 1210 Q).

Setting the distributor static timing on the engine is impossible owing to design.
a variation of the magnetic field which will send a signal to the
CD.
A revolution of the distributor is requirod to create

avi
mädule. Consequently, when fitting a distributor, place it in mid-slot; start the engine and adjust the distributor
-O_
by means of a timing light or a diagnosis console.

The duration and amplitude of the signal depend on the speed, therefore the DWELL ratio is not significant.
_9)
The air gap between the branches is non-adjustable and it cannot be measured.
ELECTRONIC MODULE (2)

lntended to operate with the magnetically-triggered distributor.
Do not carry out a check with an ohmmeter since the results would not be significant.
Do not operate the module without cooling (aluminium plate heat sink and heat conductor grease).
The operation of the ignition system is possible with the engine stopped: - connect an earthed sparking plug to
0-_
the coil HT lead; short "+ 12 volts" pulses on module red lead (path 5) (with all leads connected, cap lifted) will
paj
generate a spark from the plug: simulatiori of a signal from the distributor pick up).
Do not operate the module and coil without a plug and HT lead. (It could result in the module being destroyed).
IGNITION COIL (3)

The coil must not be kept alive under 12 volts without ts module (overheating).
`y-
O.-
The coil current flow is generated by the module which then reduces it, prior to cutting it off when the engine
ignition timing occurs.
°_'
Only use a rev. coun ter with a HT induction clip.

210 oI1
ki$i::
r-!1 ___ _
-oooQ-- 3
L
1
5, __
L21.31
CX 20 829 A5
d eqr s aUu rn ur
de r s allu m eur
__
121lOal
:
0 500 700 10C
tfl 1 500
F
20 00 25
ffft
b
fl
L2 1.ll aJ 1 00
O
200 3 00
4 LUJ 6
400
Orn
4 50 mm Hg
bar
CX 22 J6T A500
DO ,7
1000 1500 2000 25 00 3000
__________ _________ _ 100 200 30 0 400 50 0 ji

75 150 22 5 300 37 5 02
_[ 1.2 6
1 12 1,27
*
8531
21:OI1 1
784 829A5 6/84 -+ 7/85 829A5 7/85 - 829A5 7/85 -* J6TA500
(y7
DUCELLIER: 525 368 DUCELLIER: 525 541
R303 C022
D59 D017
AC 42 LTS
f!?
BOSCH H7 DC CHAMPION 5 281 YC CHAMPION S279 YC
CHAMPION BN9Y EYQUEM 755 LJS
EYQUEM 755 LJS EYQUEM C72 LJS
(S1
lid
BOSCH: 227 190 111

BOSCH: 0227 100 111 DUCELLIER: 521 013
DUCELLIER: 520 007 MARELLI: 6 F $ 750 92 AE
SOLEX: 18 10001
BOSCH : 0221 122 317 BOSCH : D 221 100 352

C71
1
1_3_42
- 1 2
0
DUCELLIER BOSCH DUCELIJER BOSCH
J
J
0,8 ± 5% 0,82 ± 10% 60O0 ± 5% 8250 ± 10%
________
1
c
1 - 1,3 mdaN 8301-T
M 14 x 1,25 16 mm 0,6 - 0,7 mm : +
4 ___________
tI i :I 8302-T
&
EIEII 829 A5 J6T A 500
(fl
480 mm 615
E
1 270mm 310
2 300mm 350(
3 425mm 825
1T 4 500mm 900

8531
IGNITION SYSTEM 21OOOI2
GENERAL INFORMA TION

ON THE INTEGRA TED ELECTRONIC IGNITION
* compression, OCR, web-optimization with CVISION's PdfCompressor

PDF 8531
MA GENERAL INFORMATION ON THE GENERAL INFORMATION ON THE MA
2 210.000/2 3
INTEGRATED ELECTRONIC IGNITION INTEGRATED ELECTRONIC IGNITION 210.000/2
E
LIST OF COMPONENTS
OPERATING PRINCIPLE OF THE I.E.I
45 Battery 229 Anti-theft/ignition switch on 4 cylinder CX
c1"
: :
46 : Instrument panel 279 : Heating control Iighting

The ignition should produce a spark, at the exact moment, in a determined cylinder. This is done by several units:
51 : Ignition coil, 1 & 4 280 Supplementary air control
52 Ignition coil, 2 & 3 285 Interference supression capacitor
Cl)
: :
A datum sensor (1) : It consists of a coil around a magnetic core, which gonerates a current when the
0 0
0
59 : Knock sensor control unit 300 Starter motor stud (3) fixed on the flywhee!, is passing, (which causes a variation of the magnetic field).
90 Door lock control unit 302 : Flowmeter
114 Sparking plugs 576 Injectors A flywheel pick up sensor (2) : Identical to the previous one, but situated in line with the f(ywheel ring, this
Cl)
: :
sensor records the passing of the teeth; since 1987 Mode! Year (7/86), sensor (1) has been deleted, and repla-
Cl)
C
683 Fuel pump
0)
131 Datum sensor :
ced by the dua! function pick up sensor (21, one of the teeth of the starter ring being now shorter than the others.
132 : Flywheel pick up sensor 731 : Tachometer injection relay
This sing)e sensor informs the E.C.U. of the engine speed and of the position of the crankshaft/con rod/piston
Cl)
1 36 Vacuum sensor (Turbo) - Pressure sensor 784 : Injector resistances assembly. This allows the E.C.U. to determine the right instant when the current must be cut off in one of
+-'
Cl)
137 Anti-knock sensor 795 Lighting rheostat the two coils.
Cl)
: :
141 I.E.I. control unit 841 Water temperature sensor (injection)
Cl)
: :
Two coils (5) are
-Ci
in tum control)ed by the E.C.U. The current cut off in the primary winding generates a high
142 FueI injection control unit
tension current at the secondary winding terminals. Each terminal is connected to a spark plug (4) which pro-
-c6
v_,
1 92 : Throttle spindle switch
duces a spark in a cylinder. One cylinder is at the end of its exhaust phase; the spark, lost in the cylinder which
in'
is at the end of its compression phase, ignites the air/fue( mixture and operates the engine. The E.C.U. also
C/l
Cl)
receives information about the state of engine bad from an inlet manifold vacuum sensor.
Finally, on a turbochargod engine, an anti-knock sensor (6) can detect the area of frequencies generated by
`-°
Cl)
LIST OF HARNESSES the pinging and send it to the Electronic Control Unit.
,-r
Thus, from the information it receives spoed, depression and knock, the E.C.U. computes the optimum igni-
.-t
Cl)
:
AV : Front (--7/85) FP : Pump feed wire R : Roar tion advance.

The electronic control unit supplies the instruments on the instrument panel with information on speed
C/)
B : Junction box IC Injection chassis SV : (5) Speed control

(rev. counter), turbo pressure and knock.
CD Vacuum sensor IM Injoction engine TB (TI Instrument panel
(I,
: :
lead end MP: Pump earth wire Z : (Z1 and Z2) El
G Front left 0 : On-board computer

H : Interior
PDF* compression, OCR, web-optimization

* with CVISION's PdfCompressor 8531
8531
II
21O/1 1
- 784 829A5 6/84 - 7/85 829A5 7/85 - 829A5 - J6TA500
pip
7/85
R303 C022
D59 D017
AC 42 LTS
BOSCH H7 DC CHAMPION S 281 YC CHAMPION S279 YC
CHAMPION BN9Y EYQUEM 755 LJS
4 _____________
IIS
EYQUEM 755
_______
IIS
EYQUEM C72
BOSCH: 227 190111

BOSCH: 0227 100111 DUCELLIER: 521 013
DUCELLIER: 520 007 MARELLI: 6 F $ 750 92 AE
SOLEX: 1810001
0
4 BOSCH: 0221 122 317
DUCELLIER: 5200 15
BOSCH: D 221 100 352
DUCELLIER: 520 015
1_3.42
DUCELLIER BOSCH DUCELLIER BOSCH
0,8 fl ± 5 %
_
0,82 fl ± 10 % 6000 fl ± 5 % 8250 fl ± 10 %
LO
____
III
1 -' _____
1,3mdaN 8301-T
M 14 x 1,25 16 mm 0,6-' 0,7 mm +
4 ____ ______ 8302-T
mm & fl
________ 829 AS J6T A 500
480 mm 615 fl
E
1
270mm 310fl
2 300mm 350fl
3 425mm 825t)
17 4 500mm 900fl

8531
* 8531
MA
210.00/2
//
T11IIEiNL ______ CX 2400 &E]
136
r21
0
-FVe 11
-@
114
______
0 142
_____cF.J-
lic
j285
j
1 iEi-285
F.Ve F.V
TB"
U'1
____
1/II ________
731
:N//////// //////
51 & 52 Deico Remy 3 474220
131 & 132 Thomson 20 165 521
136 : Ducellier 16 038 177
141 Thomson 20 165 562 LAS LD3
AC 42 FS
114 Champion L87Y 0 M14x 1,25 >0,6 0,7 mm < Q 2 2,5mdaN

E
Eyquem 705 S
E
500 mm 2300 3 825 mm 4150

E
1 : :
2 700 mm 3450 4 4550

E

MA
210.00/2 3
+ __________
R
(_)
EJ 229
Mr Et3r
R _____________________________________________
'i42
-t1
FJ EVe
N 285 285
R L.Troaj 4, r, EVe
r c ic ____________
300$ ,j7
86
- 88c 88y
____ jIII 52
Bl 114
731'tt r::i ____ *
EMr EJ
32r(1 (1]131
(A:
frrh
1Ve 1Mr
R R
EVe EMr
C
EJ
1
fJ
Bc EVe Bl Bc Bc Mr
EJ[
R
2J14jJ
FJ Mv
1<
R
141
F-Ve EVe
8c t1J
FVe FVe FVe 4j
Bl Bl
683
--- i.
f-'
TB
142 I(
.Tronic
$46
136 L
1 ml
*
8531
MA
210.00/3
//1//7 CX IE-A.E.I. 251

136
141 _-i r-
FJ-Sc 1 __________________________________
FJ- 2
I
FVeMv 3
FVeGr 4
F.Mr- 5
EMr-J 6 ________________________
FJ-.-Bt 9 0
FVeMr 10
-F.Ve-Fjv 11
-EVe- 12
-F.Ve-i 13
14
15
__________
________________________________________
Bc
Il?
231.5 67091O1i1213141
EVe BcB1N j
IVe
131
FMr
683
FVe_. R
tc
ii
52
285
-: 285
1
B10460J
EVe
s.v
46
;;;
EJ // /
51 & 52 : Deico Remy 3 474 220

131 & 132 : Thomson (EA) 20 165 653
136 : Ducellier 527 005 A
141 : Thomson EA 20 165 646 LA8 LD4
114
Champion L82Y Ø M14x 1,25 >0,8 - 0,9mm < () 1,5a - 2mdaN
Eyquem 755 SX
500 mm 2300 3 825 mm 4150
700 mm 3450 2 4 : 4550

MA
210.00/3
+ __________ CX-IEA.E.I 2,5t
Bc R
Mr F.Gr
AV EJ
N
i-' Gr
___ +
FJ
trNH FVe
285 285
____
1
R
EVe
Ic
1C511
30041F.Bl FV N Mv 1 1
-
52
{r
-o0
\'
1144
*zt5F
EJ F.8I SV
N
ni
--N
Ic Ic Ic 132 i1131r!
Ic Mv EVe EMr
LjJ
Ic EJ
1i, EVe :j
EVe EMr
FJ FVe
EVe E 1 EVe EMr Bc
KAEl I
142 LQJL4JLJ -141
R Mr Gr Mv J Bl
EVe
0-<-w-
EVe
51-132
EVe EVe
/-L
G1_
Bl
Mr Gr Mv
J
-J
683( i 1
sv AV
136 TB
*46
ml
*
8531
210 W3a
-
(1)
MRG
7 136
114
132
)
<i3
21-46
285,
3N
1fI!I1t5
51
u-m
u-m
141
9G
1<3
11 Mv--V-.
Il -Vt--
13 JV-
C')
51 & 52 : Deico Remy 3 474 220

131 & 132 Thomson (EA) 20 165 653
136 Duceflier 527 005 A
141 : Thomson EA 20 165 970 D LA8 LD4
114
Champion L82Y Ø M14x 1,25 > 0,8- 0,9mm < () 1,5a - 2mdaN
Eyquem 755 SX
1 500 mm 2300 2 3 : 825 mm 4150

+ 10
mm & ± 10% 2 : 700 mm 3450 4 : 900 mm 4550 t

MA 2
21 O.00/3a
t2
¶
229-/--- -E T
Mv
:in: 14
r 4B1
F1
iu:is il5
G 1
L
4B4
-
G
V Lv
VMv 71
T T
2 1
IC IC
-Bl-
15
Til
1 Vir2
Ni
KiTH 1
___ Bl
1jf ______ 1j
ml,
114
IC IC IC r--
132 131
UNJ kBT2BdhM2M1
z+4
NGN
z z z 2 Z Z Z Z
VIMv VI VN IBI Vii ii VI I
FP 141
ÌN
B NiO N3
VM V1o VR v
z z 2
683 ayupIM lo IR
CD CD CD +
0ri2 T0r3

* 8531
MA
21 O.0013b
-
-4--.- 683
192 136
3N N 841JJ ___
142
_____ z.I.
m8 ___
-'InrjJ3 2 80 -5i--.-- 0
f
'r'
114 576
9J
i= CL
E85
132
II II]L'1III
14-77
\AEI
_____ 141 '4.
::'
'_^
45\\
ml
C}'
51 & 52 Deico Remy 3 474 220

C31
132 Thomson (EA) 20 165 653

136 Duceflier 527 005 A
141 : Thomson EA 85 102 F LA8 LD4
114
Champion L82 Y Ø M14 x 1,25 > 0,8 - 0,9 mm< () 1,5 - 2 mdaN
Eyquem 755 SX
.`J
Bougicord 403 1 : 500 mm 2300 (2 3 : 825 mm 4150 (2
mm 2 700 mm 3450 (2 4 900 mm 4550 (2

E
: :

MA
210.00/3b 2
- 229 229
F7
2U4
4 i
F2 F3
JR
Mv 45
VI I9TI
t-Ic-J
490
1S
131
Ic
Mv
N
N
>'N lm' mim
-'l
300
_________ - IC
BBS
V Mv
352
-Bl- 14 IIl1lI N
Bl
V11
J V
0 ?N1 3142 285 7 OM?

1413114132 14j33 Nj34
31423141
IM IM IM IM ViS Z
31 32 33 _134 34
5 5 5 1J 52 (1
192
576 TBI 3N3 6 6
5 5 23
ti5 -Bl- 77TVTf/7,'? B
Ni P42 143 B{4 504 EI Bl

IC IC 1 : IM IM IM IM
IC IC IC IC H H ilN3F1
- v
-N<
2)1 2)2
IB
>fl
14 Bl IR IS M
142 141
IIN
31\
zzzz
' TT
'7'
BNI
IC I C
IC
IBI
zz
V Mv7lcViS 4 7 MvVR VS M
I M
I
R
l SR 514 SR ii1o
IM
I
i?
DB? DB? DM4 DB
13j 6
E J
r',,
14-
41
83
26 1
MP 1:
IC
4M3
- IM
DM1
1 1 1 1 1 1
1 1
2 3 4 5 6 1 8 9 10 Il 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 21 28 29 3Q 31 32 33 34
*
8531
MA
IIII
1
21 0.00/4
_<I
-31
683
u-t
r-m
-31
_-_
Ì-
21.49
46
/11
51 & 52 : De(co Remy 3 474 220

,a'
59 Meco E 002 B90 131

E--
131 & 132 EA Thomson 20 165 653

136 Generai Motors 16 038 177
137 Meco E 001 T90 272
C) 2 - 2,5 mdaN
141 (EA) Thomson 20 165 865 - B - LA 11 - LD6
Champion L82
114 Ø M14x 1,25 >0,8-0,9mm< Q
C31
Eyquem 755 X
Bougicord 403 1 500 mm 2300 3 825mm4150

'.s
:
`r'
2 : 700 mm 3450 4 900 mm 4550

MA
210.00/4 2
''^
I"
I\Tfl tL9I
---
6
r
21-31
*1
!--
diil42
KE] 1
2 Z2 Z2
JJtJ
^-N
!'1
Ic Ic Ic
1
132 131
i..
ml

1 MA
210.00/4a
©
136
hrr
,;,
.-I
51 & 52 Delco fRemy 3 474 220

131 & 132 EA (Thomson) 20 165 653
136 General Motors 16 038 177
2-2,5mdaN
Cup
137 Meico 001 T90 272

E
C)
141 EA (Thomson) 20 165 951 - C - LA11 - LD6
Champion L82
114
Eyquem 755 X
0 M14x 1,25 >0,8-0,9mm< Q 1,5-2mdaN
Bougicord 403 1 : 500 mm 2300 ( 3 825 mm 4150

+ 10
ni-
mm & ) ± 10% 2 700 mm 3450 4 : 900 mm 4550

MA
21 OOO/4a 2
IV 2
4M4
229 T
4B4
III
IC
III 5 III 5
3B12 3B11
N M T Mv
-- --1
___ 87
Il
1
1
TD
66
`-1
I>N
ric
V V B VIBt
FP IC T
il vi v
-j V Bl
IC
T T B
8
Bl
i4
Ii 52
iij4.
683
N
J Bl
___ -
fl
MP 132 2
13 1
Ii B
IBI
ni '0
L21-36
(T
lz z z z z z z z z z z -J
7-_T>
Mv MI V
AEI
¶
MB 141
z z Z
* IG
R
CD CD CD
ø-IC
1
jR
[J [JJ
1 IM
30r1
iG
0r2 30r3
137 fl
LJ H 136
ml 'w J

8531
MA
21 O.0014b
--- 683
192
841f
'1`
lE 142
3N i' IM
___ 136
__
f'1
m8
280
114
fI 576 6J
132
660
784
14-i3
_____ 141
_____________
45
1ESI1!jG
\\
51 & 52 : Deico Remy 3 474 220

132 EA (Thomson) 20 165 653
136 : Generat Motor 16 038 177
137 : Metco E 001 T90 272 () 2 - 2,5 mdaN

141 : EA (Thomson> 85 095 - H - EC 002 ED 003
Champion L82
114 0 Q
z
M14 x 1,25 > 0,8 0,9 mm <

A
1,5 2 mdaN
E
Eyquem 755 X
Bougicord 500 mm 2300 3 825 mm 4150

E
1 : :
O_0
mm 2 700 mm 3450 4 900 mm 4550

E
: :
4

2
_0w
OY 21112
'.312 4M1
229
Lat
1124 111 m 42114
III'
±Jl
JR V F2F3
4s
OMR 6J2
195
V
6 V1 6 6
4146l_
liv 11111
731 E 92 /_
T
I9V7l
i1ITOJ V
___--
M
46
4 v
- ________
___________
j
- --
1
___________
300
___
_4_ - J 6 5 B
3V2
-
TTB
HI
20 21
rsri
'-I
285
<I-
Ic Ic Ic Ic 0 TT
5 565
-
V120V121 V122V123
11h1
1E3EI1 z
WI31 17132 12133 17134
IM IM IM IM
4
''5
f311I
*
LIi_j:51
1
f-
--N
31 32 33 134 4 1
j 1
192 V6
O0 7J61
114
3113 (3
G
S76 3 ajJa - J 8
1 1 lai
137 5M3 5M4
-GG - i[_1
ISO
Bl
- LTICTT
'1:H-i-I
8 .1
___ 1
IC 1111 1112 1113 1114
IC IC IC 1 1
2 2
IMIMIM IM
L L...
3q--
6356.16 IC IC ic H Il itL N2
VRVlG
31r
VIM17I8 1 vi
V9V1 M25V2 V IM
z
'8
z z
LVN
2 Z Z
MII Z 2 2 2
VB1
v'_
7112 11 111 11 15
___________
142
______________ [ _______
24 ______ Bl_rN1l1r12'81r151r1c1r1n81 f17fl 111 85 ______
_615
zzzIl-4II
E 1
18J12J 11 B2 63 67 614 LJLi2i LJiiiiLNlIEN2J 141

V8 V7 7
IIHft-'-
zzzzzz
17 5 J ¶3 VJiO
»
IN-Q
Ic
BL
zz frI
VJicVi MVVRVGI8 v j
M21
8 7 V V
511 56 N10
IM FP 1
1 32l l
10 L____J
6
1
841
80j$L_ 5N 6
1738
36LT1
MP
-_LIM
____
i
37i5
IC
m1
___________ -
..o
1
1 1 1 1 1 1 i 1 1 1 1 1 i i 1 1 1 1
2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 32 33 34 35
21
30 31

* 8531
IGNITION SYSTEM 21/1
CHECKING THE TRANS/STOH/SED IGN/TION
* 8531
2 21'/1 CHECKNG THE TRANSISTORISED IGNITION
CAJ
ELECTRO-MAGNETICALLY TRIGGERED TRANSISTORISED IGNITION
PRELIMINARY CHECKS:
nspect:
the connection of the different leads (in particu(ar to coi): a bad connection can cause a high vo)tage drop preven
(1)
ting the current from passing into the coi) primary winding (15 A approx),
fl-
Q-'
___
- condition of the (eads (circuits broken, short-circuits across screening, etc.),

:
- condition of the sparking p)ugs (deposits, cracks due to overtightening),
+-.
condition of the distributor cap (wear, cracks) and the rotor arm (loose).
Disconnect the interference suppression capacitor and the diagnosis harness, from the circuit.
Carry out a «spark test» with the starter motor and one p(ug earthed.
IMPORTANT: The module may be destroyed if one of the secondary wires is too far from the earth.
L.,
1
CHECKING THE COIL (3) (ignition module and supply to coli disconnected):
MEASUREMENT OF Ohmmeter placed between channels No. Reading (in 9)
DUCELLIER 0.76 to 0.84

Primary winding resistance 1 and 4 BOSCH 0.74 to 0.90
DUCELLIER 5700 to 6300

Secondary coi) resistance 1 or 4 and HT coil contact BOSCH 7425 9075
Insu)ation 1 or 4 and earth
Checking the caj) power supply using a (amp or a voitmeter:

Switch on the ignition: there should be a 12V current between the "BAT" termina) of the coi) and the earth.
- Switch off ignition.
CHECKING THE IGNITION MODULE (2):

The modu(e is designed to function with the ignition distributor and the coi).
- Do not operate the module without coo)ing (a)uminium p)ate heat sink) or venti)ation. fl
c0'
- Do not check the module with an ohmmeter since the resu(ts wiU be non-significant.
Checking the modu)e power supp)y using a )amp or a vo(tmeter:

_>.
- Disconnect the modu)e cannector

X._
- Switch on the ignitian: there shou)d be a 12 V current between the channe) 4 of the cannector and the earth.
- Switch off ignition.
The (ow va)tage ignition circuit being connected (in working order), disconnect the coi) - distributor HT lead on
the distributor side and connect it up to an earthed plug: by sending short pulses ) + 12 V) to channe) 5 (red wire)
from the module, sparks should occur at the p)ug )simu)ation of distributor spark current).
CHECKING THE IGNITION DISTRIBUTOR (1):

:.4
Test the impu)se generator with the module connector disconnected.
MEASUREMENT OF: Ohmmeter placed between channels No. Readings (in 9)

E
Resistance 5 and 6 950 to 1250 approx.
Earth
Insu)ation
2
5 and 2
and engine earth
then 5 and 3
0
fl
210.011
0>
-
-
1
8-
QO (-3
in
G
-M
-R- Ic
1
Öi
$1
- 2-J
LJTI t,
5,4

8531
01
6 21/1
E I::
CX2O 829A5
d egr s aflu me ur
15°
II: de res ciflu m eur
bar
L L
1( UrneUrL 0 1 00 20 0 3 00 400 4 50 mm F1(
:::
:
E
0 500 700 1O X 1 500 2D 00 25XJ 3000
L21.lOaI L21.1 1a
CX22 J6TA500
" A
CO?? 150 ---- - - - --
D017
::
00!
30
N
'
j
100
75
4 200
150
-
LI
300
225
I
400
300
I I I I
! I I
ii
I
500
375
i
Dl
02
12126 J
121,27 1

CHECKING THE TRANSISTORISED IGNITION 21/1
fri
0
'r?
CHECKING THE DISTRIBUTOR ON TEST BENCH, Fig. 1
To check the magnetic distributor on the bench, a transistorised module in good condition is essential. Use the
uti
°'l
vehicie module and eads if the bench is not equipped. The ignition coil is not required.
CAD
C.)
CHECKING THE CENTRIFUGAL SPARK ADVANCE

Fit the distributor onto the bench:
.-«
Connect module (3) and distributor (1) to the harness (2).

Connect wiring harness plugs (2) to test bench:
To check the distributor: Fig. II and III.

F--
Compare the distributor centrifugal spark advance curve with the theoretical curve:
- If the curve plotted does not correspond to the theoretical curve, modify the spring tension by bending the spring
E
hooking point support plate.
In order to do this, remove the cap and alter the spring tension by bending the attaching bracket, Fig. III and IV.
(D : release the spring, T : tighten the springl
Curve measured Spring concerned Bending direction
5 T
II 5 D
III 4 released T
IV 4 not in use D
CHECKING THE VACUUM SPARK ADVANCE

m
Compare the distributor vacuum spark advance curve with the theoretical curve.
E
fl..
NOTE: The vacuum spark advance dovice is not adjustable: If the curve measured is out of tolerance, change the
capsule.
ADJUSTMENT ON THE VEHICIE
Distributor timing:
- Fit the distributor, positioning it approximately midway between the s)otted holes.
paj
- Start the engine.

- The vacuum capsule being disconnected, use a strobe lamp to set the distributor timing to:
CX2O CX22
Advance (degrees
ic 10°
before TDC)
Engine rpm 750 800
- Reconnect the vacuum capsule.
*
8531
CHECKING THE INTEGRATED ELECTRONIC MA
210.0/2
E IGNITION (LE.I.)
TEST PROCEDURE USING CONVENTIONAL EQUIPMENT
on the CX 2500 vehicie with M 25/659 type engine
Checking the voltage in the secondary winding of each coil
öos
Operating procedure: Disconnect one sparking plug and bring the end of the released wire cm approx.
Boö
(å)
1
from the crankcase. (Repeat the operation for each set of cylinders).
Operate the starter motor:
if a spark occurs The incident is not to be attributed to the LE.).

Check the injection system, the valve timing, the rockers etc.
,'C.,
- examine the engine sparking p)ugs.
- inspect the circuit between the lE.). control unit white terminal 1 and the fuel
injection control unit terminal 1 5 for continuity: read 0 ), the connectors from
...
the control units being disconnected.
if no spark occurs The incident is due to the ignition system-a--carry on to next tests.
Working on the primary winding of each coil

Opera ting procedure: Connect a 1 2V warning lamp of the Wedge base type between the negative and
the positive terminals of the coil (Le. between terminals 1 and 3, connectors con-
nected to coil).
{ Operate the starter motor:
if no regular breaks occur incident in the coil primary winding

0
or
incident in the ECU. contro) circuit.
if regular breaks occur incident in the secondary winding

vnit
The following checks are to be carried out with lE.), and fuel njection control units connectors disconnected.
Checking the coil primary windings:

Operating procedure: Measure the resistance between terminals 1 and 9 of the lE.). control unit black
connector: Read 2.5 - .
Warning: the ignition shou(d be switched off.

If the reading is incorrect, investigate for a failure in this circuit.
Checking the E.C.U. pick up sensors:

Operating procedure: Measure the resistance between terminals 5 and 12 then 6 and 13 of the LE.).
,_,
control unit black connector: Read 50 ft
Checking the feed for the E.C.U. and earth connection, with ignition switched on.
Operating procedure: Measure the voltage between terminals 10 (white connector) and 2 (black con-
m(Döc
®{ nector) of the lE.). computer: Read the battery voltage.

The same check should be carried out between terminals 2 (earth) and 11 of the black connector:
ignition switched on, starter motor operated, read the voltage.
Check that the distance between the datum sensor and the ftywheel ring is 1 mm ± 0.5.
Incident on the ignition circuit secondary winding: make sure that the resistance of each coil
winding is: 3500/4000 ].
*
8531
MA CHECKING THE I.E.I.
2 210.0/2
TEST PROCEDURE USING CONVENTIONAL EQUIPMENT
on the CX 2500 Turbo vehicie with M 25/662 type engine
Checking the voltage in the secondary winding of each coil

.-h
Operating procedurer Disconnect one sparking plug and bring the end of the released wire 1 cm approx.
GGR
from the crankcase. (Repeat the operation for each set of cylinders).
Operate the starter motor,
if a spark occurs The incident is not to be attributed to the [El.

Check the injection system, the valve timing, the rockers etc.
- examine the engine sparking plugs.
inspect the circuit between the LE.). control unit white terminal 1 and the fuel
injection control unit terminal 1 5 for continuity: read 0 , the connectors from
the control units being disconnected.
.-'
if no spark occurs The incident is due to the ignition system---carry on to next tests.
,..
Working on the primary winding of each co))
avi
Operating procedurer Connect a 1 2V warning lamp of the Wedge base type between the negative and
the positive terminals of the co)) (Le. between terminals 1 and 3, connectors con-
''J
nected to coil(.
{ Operate the starter motor,
if no regular breaks occur incident in the co)! primary winding

or
incident in the ECU. contro! circuit.
if regular breaks occur incident in the secondary winding
The following checks are to be carried out with El, and fuel injection control units connectors disconnected.
Checking the coil primary windings:

Operating procedurer Measure the resistance between terminals 1 and 9 of the lE.!. control unit black
connector: Read 2.5 - .
Warning: the ignition shou!d be switched off.

If the reading is incorrect, investigate for a failure in this circuit.
Checking the E.C.U. pick up sensors:

+e+
(El.
v,'
Operating procedurer Measure the resistance between terminals 5 and 12 then 6 and 13 of the
control unit black connector: Read 50 -
Checking the feed for the E.C.U. and earth connection, with ignition switched on.
}U,
Opera ting procedurer Measure the vo(tage between terminals 1 0 (white connector) and 2 (black con-
nector) of the (El. computer: Read the battery voltage.
c-5
The same check should be carried out between terminals 2 (earth) and 11 of the black connector:
ignition switched on, starter motor operated, read the voltage.
Check that the distance between the datum sensor and the flywheel ring is mm ± 0.5.
typ
v0,
ncident on the ignition circuit secondary winding: make sure that the resistance of each coil
winding is: 350014000ft
*
g531
*
8531
MA
210.0/2
VION
C
COURONN YL 1<
D1CONEC
23
CONNEC
"Cdl?t NJ
N

MA
LO
CHECKING THE IGNITION SYSTEM 210.012
USING CHECKING EQUIPMENT OUT 106 029T
The instrument can be utilised on CX 2400 LE. with naturafy aspirated engine and CX 2500 LE. TURBO. Howe
ver, on CX 2400 LE. having an integrated electronic ignition system with a single connector E.C.U., it is neces-
sary to proceed as foltows:
connect the El. control unit to the black connector of OUT 105 029.T
- set the switch of the apparatus to the '1 connector" position
- El, with 1 or 2 sensors can be checked with this device.
a) Testing the ignition coil primary winding:

^.;
- ding.warning
The lamps, blink rythmically with the impulses transmitted to their primary win-
one at each coil,
Steady blinks indicate that there enough current the secondary winding.
to generate spark in
`c°
is a
- switch situated under warning lamps makes

The the it possible for the primary windings of both coils to
interference coming from the circuit when
,+-
insulated,
be by pushing, in the'out circuit' position,
of any HT
åar
the frequency of illumination for sensor warning lamps is checked.
If the warning lamps blinking is correct, the failure may be caused by:
- the ignition informtion to the fuel injection control unit, (paragraph c),
- the secondary winding (coil wires, coils),
- any other item required for a correct operation of the engine such as injection, valve gear, rockers etc.)
- If the warning lamps blinking is not correct, examine the control unit warning lamps, (paragraph b),
b) Testing the sensors:
- the warning lamp

The connected with the "datum" sensor blinks rythmically with the impulses transmitted
one blink per engine revolution, (2 sensors fitted).
peg, i.e.
by
- warning lampteeth.
The connected with the "flywheel pick up" rythmically with the impulses sent
sensor, blinks
`N°
the flywheel
by
The frequency of the flashes is such as they can hardly be seen.
avi
o',
Apparently, the lamp stays on, (1 or 2 sensors fitted).
On the CX 2400 lE, and 2500 lE. with norrnally aspirated engine, the vacuum pressure warning lamp lights
02)
up momentarily after a sharp acceleration: this warning lamp is no longer usable on the CX 2500 lE. with
fl.
ner
turbocharger.
c) Tests related with the l.E.I. control unit:
ECU. functions:
- The counter warning lamp blinks rythmically with the impulses transmitted to the counter.
rev. rev.
- The inlection warning lamp blinks rythmically with the impulses sent to the fuel injection control unit.
*
8531
MA CHECKING THE iGNITION ADVANCE
210.0/2 of the l.E.l. system
On CX vehicies fitted with l.E.l.
These vehicles having fixed sensors, are not equipped with TDC sensors
1) Marking the TDC:
Draw mark on the crankcase, in the opening ocated next to the flywheel pick up sensor
Cl)
a
- Remove the ist or 4th cylinder sparking plug

- Finding the T.D.C. with a locating peg: jack up the vehicle on one side and engage a gear.
Rotate the road wheel in one direction.
Mark down the place where locating pm will enter the flywheel.
Draw a temporary line on the flywheel ring. Rotate the lifted road wheel in the opposite direction, with
the pm still engaged. Mark the position of the pm in the flywheel ring. Take an average of these two marks-
'-«
which corresponds to the TDC. Draw a white paint mark on the flywheel ring, opposite the one on the
3:o
crankcase.
- Refit the sparking plug.
2) Testing the development of the speedometer advance curve:

- Connect a phase shifting strobe lamp
Set the strobe amp to the 2 cyl. u stroke or 1 cyl. 2 stroke position.
- Disconnect the pipe of the bad correction depression operated capsule from the mot manifold. Blank
,.-
off the orifice.

- Run the engine and check the advance curve development.
3) Testing the operation of the air-operated capsule on normally aspirated engines:

t/)
Blank off the vacuum capsule venting orifice.

:3.,
-
Connect a vacuum pump to the capsule pipe.
,-+
-
- Run the engine to 2.000 rpm; record the advance reading.
,-+
.-.
Create a 400 mbar depression in the vacuum capsule.

The ignition advance increases by about 15° and the engine accelerates to 200 rpm approx.
O..
On turbocharged engines:
,,,t
- Connect a vacuum-pressure pump to the capsule pipe.

'"O
- Rotate the engine to 200 rpm. Read the advance.

Cl)
- Build up a 500 mbar depression in the capsule:

- There will be a 22° increase of the ignition advance, approx. and about a 500 rpm engine acceleration.
0
E
- Build up a 500 mbar pressure in the capsule:

-t7
- There will be a 11 ° decrease of the ignition advance, approx. and about a 500 rpm engine slowing down
Pinking: occurs when the engine speed exceeds 1 .000 rpm. The warning lamp should light up in the
.CA
,,,
following cases:
- anti-knock sensor system broken or short-circuited,
ö°°
- knock sensor broken or short circuited,

- improper earthing provided by the knock sensor.
- Check the operation with the strobe lamp, and a 2.000 rpm engine speed Record the ignition timing.
II,
- Disconnect the knock sensor:

The ignition advance decreases by 10° approx.
Cl)

* 4
20 - - Avance par dpression
150 - -
100 - - cx
2400
3,
5- - -
- -
226 260 283 310 336 386 en'm.6
2 200
cx
2500
il 100
-
47
- _j.. J 00_.
co 0
_____
1000 2000 3000 4000 5000 0 100
75
VIIIIIIIIIIIIIiL
200
150
300 400 500 Dl
225 300 375 02

.-
4I CLUTCH ENGINE TYPE
25 20 Salan 25 Salan
OPERATION 25 25 25 25 5 Sa/ann 25 Salan
20 22 5 Limousine Petrol Diese/
____ ____ Fuel Petrol Prestige Diesel Petno/ Diesel Ambulance
Petrol Petro/
Injecton
Prestnge
Turbo Turbo
DeI Diesel + +
Turbo Injection
SYMBOLS
Turbo
OPERATION _j Turbo Familnale Familia/e
DESORIPTION 0 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______
TEXTS
No
>< 829A5
n- (1)
829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_________________ ______________________________________________________________________________ (3 ________ ________ ________ _________ ________ ________ _________ ________ ________
25/660
MA
boIs 0
0
0
31 2/1 X X X X X X X X X X X X X X
MA
0
0
Specification and particular features of the clutch (3 X X
'''
312.00/1 X X X X X X X X X X X X
MA
0
0
Clutch cable adjustment X X X X X X X X X X X X X X
312.0/1

MA
III 312/1
*
8531
0 e 31/1
- 10/85
3 &4
829.A5
J6T A 500
_ _ __ 215 CP 450
215 mm
829.A5
10/85 - 215 CP 510
J6T A 500
8 21
M25/660 235 DBR 450
M25/648
C31
______________ 235 DBR 525

228,6 mm
M25/659
M25/662
c-n
(NO
235 DBR 575

M 25/666
c(0
M25/669
*
8531
2j 31O/1 C)
TT - 6/85
of.
ro,
o0
TT6/85-
o.
//(l 0 / /
,v.

31I1
5,5
*
8531
-

GEARBOX - DRIVE SHAFTS ENGINE TYPE
25 20 Satah 25 Safari
OPERATIONS 25 25 25 25 25 Sa/an 25 Sa/an
20 22 5 Limousine Petrol Diesel
_____ Petrol Prestige
å_>
Fue/ Diesel Petrol Diesel Ambu/ance
Petrol Petrol Presuge Dse/ Dese/ + +
-j
SYMBOLS
Injection Turbo Turbo Turbo /njectlon Turbo
OPERATION Turbo Famdiale Familiale
DESCRIPTION _____ _____ _____ _____ ______ ______ _____ ______ ______ ______ _____ ______ ______ ______ _____ ______
TEXTS
No .
><
829A5
-
tfn
825 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_________________ ______________________________________________________________________________ z c ________ ________ ________ ________ _________ ________ ________ _________ _________
25/660
MA
330/1
Toots 0 X X X X X X X X X X X X X X
MA
330.00/1
Specification and particular features of 4-speed gearboxes 0 X X X
MA
0
Specification and particular features of 5-speed gearboxes (3 X X X X X X X X X X X X X X
330.00/2
MA
0
Specification and particular features of the automatic gearboxes X X X
350.00/3
MA
372.00/1
Specification and particular features of the drive shaft assemblies J X X X X X X X X X X X X X X
MA
Removing and refitting the drive shafts X X X X X X X X X X
,-r
372.1/1 X X X X
MA
372.3/1
Overhauling the drive shafts 0 X X X X X X X X X X X X X X

*
8531
2
MA
3 30/1
LIIID ®
1671 T
13.551

33/1
__
10/85
2,8 mdaN
1,3mdaN
,5mda
14,5 mdaNf
20,5 mdaN
2.3 mdaN
12/85 12/85 - 8.5mdij

TOTAL TRANSMISSION 75 W/80 W
2,8mdaN
`,R
'.
4 mdaN
81.433 J
4mdaN L 0,15L
*
853
-2
MA
1
___
330.00/1
OOSmm 1,71 mm
1,41 mm
003 mm 68 mm
)4)4 0-.-0,05mm
003 mm 1 67 mm
-44-j4 0-øO,O5 mm
0,06 mm 1,82 mm
0,05 mm
_____________ 5,65 mm
_________
1,52 mm
4,25 mm
0,15 mm P 0,10 mm

f3Eii 33OI1
FF' 1
1
- CX2O
x
1
1 i
--i 7/84
E41j
CX25D
KM/h
1 12/38 0,0695 8,21
2 18/33 0,1201 14,19
3 30/34 13/59 0,1944 22,97
4 35/28 0,2754 32,55

C37
R 13/41 0,0698 8,25
j 10/20
CX 20 : MICHELIN 185 HR 14 XVS

CX 25 D : MICHELIN 185 SR 14 XZX
= 1,970métre
*
8531
MA ___
330.00/1
1+'
N°
1
[2GE651
j2GE66
1
1
- CX 20 \
II iL / 7/84 I- 3/86
E71l
I2GE721
1
1
---CX25D /
2GE73 CX 20 RE
3/86
2 GE 63 CX 25 RD
EP __ _____ __
BIÖ
1 12/38 0,0726 8,39
2 18/33 0,1253 14,49
3 30/34 14/61 0,2024 23,44
4 35/28 0,2875 33,21
R 13/41 0,0729 8,42
15/29
U-)
MICHELJN
195/70 R14 MXL
= 1,930 métre

33/1
1+'
1FF
L y

* 8531
*
8531
MA
2 330.00/2 __ i
0:" I-_I._-Ii
mm
,.
-+ 0,02
0,05 mm
-B-
4 0--0,05mm
0---'- 0,05 mm
0,05 mm
OO6mm 1,82mm
0,15 mm
0,10 mm

__ 330I2
522
L
N° - 7/84
1
2 GE 1 0
- CX25D
Km/h
__ __ ___
121:
1
___ 1.
12/38 0,0695
__
8,21
l
2 18/33 0,1201 14,19
3 28/35 13/59 0,1762 20,82

--`
4 33/31 0,2345 27,71
5 45/33 0,3004 35,50
R 13/41 0,0698 8,25
(:
)
10/20
CX 20 : MICHELIN 185 HR 14 XVS

CX 25 D : MICHELIN 185 SR 14 XZX
= 1,970 métre

* 8531
MA 1
__
330.00/2
1)-' E$
I2GE69I
-
i
1 I2GE7O 1
CX2O
II
__________ j 7/84 -,- 3/86
2GE67 1
-
E
1
2GE68j CX 25 D )
II 1
2 GE 70 CX 22 TRS 7/85 I 3/86
Il
/ TRD
m
2 GE 75 CX 25 RD )
3/86-
2GE76 -ø. CX2ORE/TRS
_______ __
KM/h
WiR
12/38 0,0786 8,3
Q0)
2 18/33 0,1253 14,49
3 28/35 14/61 0,1840 21,26
4 33/31 0,2438 28,29
5 45/33 0,3128 36,23

--'
R 13/41 0,0729 8,42
(..' E) 15/29
MICHELIN
195/70 R14 MXL
= 1,930métre

I+Ii 33I2
_______ 1
2 GE 35
CX Limousine TURBO - 7/84
R1R
1
- _____ __
12/38
18/33
0,0822
0,143
Km/h
9,8
--`
2 16,9
29/35 16/61 0,2158 25,7

C37
',1
3
4 33/31 0,2756 35,1
46/31 0,3848 46
f`')
R 13/41 0,0824 9,8
) 10/20
.6 MICHELIN
185/70 SR 14XZX
= 1,97 métre

* 8531
6
MA
330.00/2
1 ht
____
DIESEL TURBO
N°
1
487 CX 25
2 GE 36
4/83 _____________ _____________
______ CX Break 4/83 -* 7/84 7/84
_________ CX Limousine 7/84 - 3/86 CX 25 CX25
CX Break
2 GE 77 CX 25 RD / TRD 3/86 CX Break CX Limousine
Km/h
1 12/38 0,0822 9,49 9,59
2 18/33 0,143 16,40 16,56
3 29/35 16/61 0,2158 24,91 25,16
4 34/30 0,2938 34,07 34,42
5 46/31 0,3848 44,60 45,06
R 13/41 0,0824 9,52 9,62
1 5/29
MICHELIN
190/65 HR 39OTRX
= 1,91 métre
MICHELIN
CX 25
4/83 -7/84 CX BREAK
195/70 HR 14 MXV
_______ _____ = 1,93 métre
CX 25
7/84 CX Limousine
MICHELIN
190/66 HR 390 TRX
= 1,93 métre
7/84 - CX Break

33OI2 7
I-H
2 GE
G31
CX 25 GTI 7/83 ____________ ____________
2 GEj 7/83 - 7/84 7/84 -
7/84 3/86
C37
_______ CX 25 RI
2 GE 79 - CX 25 RI : 3/86 CX 25 GTI
CX 25 GT
CX 25 RI
1 12/38 0,0727 8,6 8,67
2 18/33 0,1265 14,8 14,98
3 28/35 14/59 0,184 21,75 21,98
0,2438 28,95 29,24
OND
4 33/31
45/33 0,3128 37,1 37,46

1\C)
R 13/41 0,0729 8,61 8,71
15/29
6 MICHELIN 6 M ICHELIN
____ 195/70 HR 14 MXV
7=0
190/65 HR 39OTRX
= 1,91 métre = 1,93 métre
7/83 - 7/84 CX 25 GTI 7/84 - CX 25 RI
MCHELIN
190/65 HR 390 TRX
= 1,93 métre
7/84 -* CX 25 GTI
*
8531
8 33,2 E
_
L j 10 X 20
CX 25 Pallas lE
CX 25 Prestige
B CX 25 Break TRI
GE57j -*7/84
:':
15 X 29
XVS TRX
A B
H1R
1
__ ___ _______
12/38 0,0758 9,2 8,9
18/33 0,132 15,9 15,4
L[)
2
3 28/35 15/61 0,192 23,3 22,5
4 33/31 0,2544 30,9 30,
5 45/33 0,3264 39,6 38,4
R 13/41 0,0760 9,2 8,9
6 MICHELIN MICHELI N
185 HR 14XVS 190/65HR39OTRX
pip
= 1,97 métre = 1,97 mé tre

1 MA
330.00/2 9
N°
2 GE 57 1
CX 25 Pallas
12 GE 58!
CX Prestige 7/84 i- 3/86
CAD
L
1
I il CXBreakTRI /
2GE78 CX25GT1 /CXBreakTRI: 3/86 i-- 7/86

2 HEO2 CX 25 GTi/ CX BreakTRt : 7/86--
i:i:'.
1 12/38
D __ __ 0,0758 8,99
2 18/33 0,132
0
15,53
3 28/35 15/61 0,192 22,78
4 33/31 0,2544 30,30
5 45/33 0,3264 38,83
R 13/41 0,0760 9,02
15/29
'0.
MICHELIN MICHELIN
190/65 HR 39OTRX 195/70 HR 14 MXV
= 1,93 métre = 1,93 métre

* 8531
33O/2
N°
2 GE
CX GTI TURBO
________ 9/84 -* 3/86
2 GE 80 CX 25 GTI TURBO 2: 3/86
Km/h
_____ ___
--`
Ff11R
1 12/38 0,0749 8,63
2 18/33 0,1294 14,90
3 29/35 14/59 0,1866 22,64
4 34/30 0,2689 30,98
5 46/31 0,3521 40,55
R 13/41 0,0752 8,66
15/29
MICHELIN
210/55VR 390 TRX
= 1,92 métre

MA
330.00/2
fl ,
4kH
:=1
+1
EK EH1R
F
-
hi. . -
_____
_
-
'__
I;;9i:

* 8531
* 8531-8532
MA
2 35000/1 __
____
ZF 3 HP 22
TOTAL DEXTRON D20-356
13'
i = -i1
6,5L
(__jIc TIj
190 mm
A--B = 0,5 L
L:i. 2,5
20 4 mdaN
____
__ /\ _ _ P
., \, /.
4ft :
- -
,
(-
[O.1332

MA
____ 1 350.00/1
ZF 3 HP 221
______ ____
_______ ___
N°
ffi
A ___
2GZO1 /'rnmJ'-\
1
1
-i ) X 25 Pallas lE
_______ CX 25 Prestige
10 X 20
N° CX 25 Break TRI
-+ 7/84
oro
B ,_
2 GZ 021
[ 1
1 5 X 29
________________________
xvs J
TRX
___ ____ _____ _____ A
Km/h
B
E
Automatic
1x 42
1
2,478 x 29 0,1169 14,5 14
2
1x42
1,478 x 29 13/62 0,1960 24,3 23,5
1 x 42
3 0,2897
1 x 29 35,9 34,8
1 x 42
R 0,1389
2,085 x 29 17,2 16,7
MICHELIN MICHELIN
185HR14XVS
!!)
190165HR390TRX
= 1,97 métre - ,91 métre
*
8531
C31
Km/h
Automatic X ____
1 x 42
1
2,478 x 29 0,1169 14,18
1 x 42
2 13/62 0,1960 23,76
1,478 x 29
1 x 42
3 0,2897 36,16
1 x 29
1 x 42
R 0,1389 16,85
2,085 x 29
( ) 15/29

- 2'
-
MA
350.00/1
ZF3HP22
fil[
9](4
*
8531
37O/1
1
37,5 mdaN
/
H
50gr () (*)
(X)_(X*)
.l3h1
4. V -* 6/84
.1.
829A5 508 mm
C31
t31
516 mm A
4. V 7/84 -
____ 161,Smm 174mm
829 AS 543 mm
C31
551 mm AB
SV
Automatique 527 mm 519 mm ABC
M 25/662 543 mm AB 174 mm
*
8531
37O/1 0/1
____________(y) - (y*)
_____ (X)_(X*)
.
\ 1 J
LIIIIJ/
1 mdaN
/ ::H Gi
N
/
JG1
250 gr
gr
[ Ii
1
375 mdaNj
ill
_
4. V -* 6/84
1
Y x* xx*
829 A5 525,5 mm 538 mm 0
4. V 7/84 -
___ 516 mm 508 mm A
ftI ....I
_____ 829 A5 490,5 mm 503 mm DE
5V
Automatique 516 mm 528,5 mm DEF
M 25/662 503 mm DE 508 mm A

GEARBOX MA
372.1/1
DRIVE-SHAFTS
RECOMMENDED TOOLS
0
Lower arm baH-joint extractor with bosses
(Y)
3312-T
or
6323-T Lower arm baH-joint extractor with or without bosses.

E
6310-T Hub locking tool.

0
6320-T Anti-roU bar (ink rod extractor.
6602-T Set of three stands

- Torque wrench (40 mdaN)
- Socket 35 mm A/F
REMOVING AND REFITTING

THE DR/VE-SHAFTS
*
8531
2 372.1/1 THE DRIVE SHAFT ASSEMBLIES
Support the front of the vehicle on stands 6602-T. Extract the nut of the swivel ower bell pm
Uncouple the swivei lower bali pm with extractor
l-«
Release the pressure in the hydraulic system 3312T or 6323-T (Avoid damaging the bailjoint
protection rubber).
...
Set the height control to the "low" position
Removing the LH drive-shaft assembly:
CO)
Remove: Fig. 1: Push the LH drive shaft (5) aside with a chisel (6),
bearing against the heads of the gearbox flange
avi
the road wheel,
screws, Fig. V.
the pm and nut lock,
- the nut (35 mm AlF). Retain the wheel hub using Important : If a few hammer strokes are not enough
tool 6310-T, Fig. 1. to push aside drive shaft (51, the circlip is probably
blocked inside the sun gear. ln that case, undo
clamp (4) and remove the transmission without its
0
drive-shaft, (retrieve the roller).
_.+
Fig. II, Tum the steering through full lock to the left.
(il, Leave the swivel hanging.
avi
- suspension cylinder swivel bali maintaining pm
anti-roll bar link-rod nut (21. Liberate the LH transmission from the hub and remove
it.
Removing the RH drive-shaft assembly:

Uncouple spherical bali (3) from the anti-roil bar iink-
-12
rod by means of pufler 6320-T, Fig. III: (Screw up Slacken the drive-shaft bearing support nuts
0--o
171,
0
the too! nut to the ball-joint stem and fit the too! "U" Fig. VI.
part and spindle).
Swing through a half tum tie rods so as to release
v--
181,
the bearing outer track.
Withdraw drive shaft 19) from the sun gear. IRemove
Disconnect the brake pad wear warning lamp electri- the shaft, the o'ring seal, bush, and dust seall.
.-+
C/)
cal harness.
Tum the steering to full right lock; leave the swivel
hanging.
Disengage the RH transmission from the wheel hub
Take off the brake disc cooling plate securing screws and remove it.

ini
MA
3721/1
Iv
gir,
r+i
II v
';: 1
6320 T
--.
.1
y..
332
III "II

* 8531
A MA
372.1/1
85.326
Iv'
-1
III v

REMOVING AND REFITTING THE MA
--r
DRIVE SHAFT ASSEMBLIES 372.1/1
((n
REFITTING
Lubricate the wheei hub seai lips. Couple up the lower bail-joint, (Wipe the ba/Ijoint
fixing but do not use solvent).
Fitting the IH drive-shaft assembly:
Tighten to 6 mdaN the (NEW NYLSTOP) out.
lnstafl:
Recouple ink rod (10) with the anti-roli bar. (Wipe

- a NEW circlip (2), the ball-joint fixing, do not use solvent).
(.b
- O'ring sea) (1).
Tighten to 4.7 mdaN the NEW NYLSTOP type nut.
on the shaft, Fig. 1.
Refit the suspension cylinder swivei bali and (14).
.-t
pm
Tum the steenng through full lock to the left.
Insert the shaft splines home in the sun gear. Reconnect the eiectrica) harness to the brake pad
wear warning (amp (11).
Make sure that the circhp is fully entered into its Reinstall the brake disc coohng p)ate (13)
location within the sun gear by pulhng the shaft.
Fit the drive-shaft nut (with faces and threads

Engage the drive-shaft into the wheel hub.
lubricated).
Fitting the RH drive-shaft assembly: Clamp the wheel hub with tool 6310-T.
Tum the steering through full right lock.

Slide the shaft into bearing (3). Tighten to: 37.5 mdaN.
Install:
Replace:
- nut (ock (12),
the dust cover (5)
- the pm,
- ring (4),
the road wheel.
.-J
-
- o'ring seal (3).
on the drive shaft, Fig. fl Lower the vehicle to the ground.
Slight(y grease the bearing outer ring (7) before ente-

ring it into bearing (8), Fig. III.
Introduce the drive-shaft into the hub.

vy-
Swivel tie rods (6) by a half tum so that they can grip
:3C
the bearing outer ring.
Tighten nuts (9) to 1 mdaN.
*
8531
E1II
l3i
___
MA
1671 T
1
4083 T

* 8531
MA
21 372311
1
4.
-
1-
-
- -
Yrs
4083 T 1671 T
85ii \L!J fti

:
\(/
85.499 85.O

ini
MA
372.3/1
85.515
/
1L
13.831
- - _

*
41 MA
3 72.3/1
I t
k' ,r '
C
/
[
14261 85.513
J
II
III
Iv
SOURCE AND RESERVE OF PRESSURE ENGINE TYPE
25 20 Safari 25 Sa/an
Nöd
25 25 25 25 25 Satari 25 Safari
OPERATIONS 20 22 25 Limousine Petro/ Diesel
_______ Petrol Petro/ Prestige Diese/ Petrol Diese/ Ambulance
Petrol Petro/ Prestige Diese/ Diesel + +
(.1) Injection Turbo Turbo Turbo Injection Turbo
SYMBOLS
-.--J Turbo Familiale Familia/e
OPERATION
DESCRIPTION (1) a
TEXTS
No .
>< 829A5
° 829 A 5 J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
25/660
_________________ ______________________________________________________________________________ ______ ________ _________ ________ _________ ________ ________ _________ ________ ________ _________ ________ ________ _________
MA
390/1
Tools 0 X X X X X X X X X X X X X X
MA
A
x
Working on the hydraulic system-Precautions to be taken on refitting X X X X X X X X X X X X X X
390.000/1
MA Specification and particular features of the source and reserve of

390.00/1 pressure A X X X X X X X .
X X X X X X X
PDF compression, OCR, web-optimization with CVISION's PdfCompressor 8531-8532
C`7
*
8531-8532
C/3
c
SOURCE AND RESERVE MA
390.000/1
V'^
OF PRESSURE
WORKING ON THE HYDRAULIC SYSTEM

FITTING PRECAUT/ONS

* 8531-8532
MA REPAIR OF THE HYDRAULIC SYSTEM
2 390 . 000/1 FITTING PRECAUTIONS
PRECAUTIONS TO BE TAKEN WHEN WORKING ON

THE HYDRAULIC UNITS OR THE SYSTEM
The correct functioning of the entire system presupposes perfect clean/iness of the fluid and the hydraulic
3.0
units. Stringent precautions must therefore be taken when work/og on the hydrauiic system and dur/og the
stora ge of the fluid and components.
1. HYDRAULIC FLUID:
Minera! hydrau!ic fiuid (LHM) is the only suitable type and must be used to the exclusion ot all others in the hydrau-
lic system of the car.
This LHM fluid is green in co/our and similar to engine oil.
-E-
E5.
The use of any other wou/d ruin the rubber rings and seals in the system.
2. RUBBER UNITS AND PARTS:
Suitable components are identified by their green co/our and may only be replaced by genuine repiacement
components painted or marked in green.
All rubber components (seals, hoses, diaphragm, etc.. .1 are of a speciai quai/ty for use with LHM fluid and are
identified by their white or green colour.
CAJ
3. STORAGE:
Components must be stored, fu/i of f/uid and bianked off. Like the piping, they must be protected against shock
.`'
0-ö
and the ingress of dust.

Rubber tubing and joints must be stored away from dust, air, light and heat.
LHM hydraulic fluid must be stored in its original containers carefuily sealed. We advise the use of one litre (for
--'
'O_
topping upl or five litre cans (for refilling) to avoid having to keep opened containers.
4. CHECKS BEFORE CARRYING OUT WORK:
Beforeworking on the hydraulic system in case of faulty operation, ensure the following:
a) That the con trois or the mechanica/ /inkages of the units or the group of hydrau/ic units invoived are
not stiff in operation
fl'
Cl)
b) and that the HP circuit is under pressure, as follows:

c-)
With the engine at idling speed:

- Unscrew the pressure-release screw on the pressure regulator by one tum to one tum and a halt: a sound
of leakage should be heard from the regulator.
- Retighten the release screw: cut-out must occur which results in a reduction in the running noise emitted
by the H.P. pump.
If not, check in the following sequence:
te-Q
- that there is sufficient fluid in the reservoir,

- that the reservoir filter is dean and in good condition,
-0D
- that the H.P. pump is primed and there is no air leak on the suction side of the pump,
- that the release screw of the pressure regulator is correctly tightened,
that sealing bali (21 is in position, (see Fig. and fl, page 5).

REPAIR OF THE HYDRAULIC SYSTEM MA
390.000/1
Eø FITTING PRECAUTIONS
5. PRECAUTIONS TO BE TAKEN BEFORE WORKING ON THE HYDRAULIC SYSTEM:
al Carrefu/ly dean the aera of work, the unions and the unit to be removed.
+--'
- Disconnect the lead from the negative terminal of the battery.
- Only use petrol or lead-free petrol cleaning.
b) Release the pressure in the circuits:

- Place the vehicle in the «low» position.
Slacken the pressure regulator release screw (by one to one ture and a haif, do not remove the screw:
0
tum
(10
the sealing bali (2), see Fig. and Ii page 5, could get lost,
0)=
1
Wait until the front of the car has reached the low position.
.in
-
0
6. PRECAUTIONS TO BE TAKEN DURING REMOVAL.
al Blank off the metal pipes with plugs, and rubber tubes with round pins of the correct diameter.
bl Blank off the openings of components with plugs of the correct diameter.
NOTE: Plugs and pins must be carefully cleaned betore insertion.
7. CHECK OR TEST OF HYDRAULIC UNITS:
use 4034-T test bench equipped and designed for use with LHM fluid.
_o.
ca.
-
- This bench ispainted green and its accessories are marked in green.
- Never use the bench with another fluid or for testing components operating with another fluid (units of a «D»
car using LHS 2 for instance).
NOTE: The ((Le Bozec» pump used on test benches for checking DESEL injectors can be resorted to for testing
components operating with LHM mineral fluid provided that the bench is cleaned first.
8. PRECAUTIONS TO BE TAKEN DURING REFITTING.
a) Cleaning:
steel pipes must be blown through with compressed air,
- rubber tubes and seals must be washed in petrol or lead-free petrol and then dried with compressed air,
- hydraulic units must also be cleaned with petrol or lead-free petrol and blown through with compressed air.
NOTE: Renew all joints and seals during refitting.
bl Lubrication:
- Follow the indications as stated in the operations in the Manual.
- Joints and internal parts must be lightly oiled before fitting (use mineral fluid LHM only).
- If parts in contact with hydraulic units have to be greased, use a mineral grease only las employed for cardan
shafts or bearings).
*
8531-8532
7C0
REPAIR OF THE STEM
39OM1tOOI1
cl Fitting:
Only use joints of quality compatible with LHM minera! fluid.
E
a
To connect a union, proceed as follows: Fig. III
Position sleeve-seak a » Iightly coated with LHM fluid; this sleeve must not reach the extremity of pipe «b».
Centre the pipe in the housing by lining it up with the axis of the hole, avoiding aU stress. (Ensure that the
end «b» of the pipe enters into the smal! bore «c»).
Start screwing in the union-nut by hand, slacken the unit fixings, if necessary, to make this operation easier.
Tighten nut moderately: excessive force could cause a leak because of the deformation of the pipe.
vi,
Tightening torques:
3.5 mm dia. pipe
0.8 to 0.9 m.daN
2
LO
4.5 dia. pipe

6.0 mm dia. pipe 0.9 to 1.1 m.daN
The design of the various seals ensures that their sealing action increases with fluid pressure. In the case of a
leak, check the tightening torque of the union-nut. If the leak does not stop, replace the sleeve-seal.
To connect a rubber tube, a rubber ring of suitable diameter has to be positioned between the tube and the hose clip.
9. CHECKS ON COMPLETITION OF WORK.
On completion of work on hydraulic units or the system itself, check the following:
al The union for leaks.
bl The clearance between the pipes: pipes must not touch one another or any component, nor may any other
unit., whether fixed or movable, exert any stress on them.
+`+

ini
MA
390.000/1
*
8531-8532
CO-
SOURCE AND RESERVE
m
MA
390.00/1
OF PRESSURE
SPEC/FICA TION AND PAR TICULAR FEA TURES OF

o
0
m
THE SOURCE AND RESERVE OF PRESSURE

* 85318532
N
MA SPECFICATION AND PARTICULAR FEATURES OF
2
390.00/1 THE SOURCE AND RESERVE OF PRESSURE
Reservoir:
The reservoir is located in the left hand rear section of the engine compartment. ts breather, situated on the friler
cap, is connected to a filter-capsule placed in the LH whee)arch.
Level indicator: Fig. 1
A: maximum mark.
B: minimum mark.
E
Key to reservoir diagram: Fig. 1 and Il
1 - Overflow return from front and rear suspension cylinders.
2 - Overflow return from security valve and front rear height correctors.
3 - Reservoir breather with filter in whee)arch.
4 - Hydraulic control block return pipe (ABS).
5 - Operational and overflow return pipes from compensator-brake contro) va)ve.
6 Operational return pipe from pressure regulator and front and rear height correctors.
Uti
7 - Suction )ine for HP pump.
8 - Baffle def)ector.
9 - Filter for overflow and operationa) return pipes.
10 - Fluid level indicator float.
11 - Filter on HP pump suction line.

* 8531-8532
ini
CHARACTERISTICS AND SPECIAL FEATURES OF 1
MA
THE SOURCE AND RESERVE OF PRESSURE
390.00/1
High pressure pump: Fig. 1
- Five-piston volumetric-type pump.
- The pump rotates at half engine speed.
- Pump delivery per tum (for information) :................................... 4 cm3
- Maximum pressure: Theoretically, there is no limit to the maximum pressure. ln practice, the maximum pressure
is controlled by the pressure regulator. Priming the five-piston HP pump can only be carried out when the pressure-
release screw of the regulator is open.
Pressure regulator with pilot slide-valve: Fig. II
- Cut-out pressure ...................................................... 170 ± 5 bars
....................................................... 145 ± 5 bars

+..
- Cut-in pressure
Thickness of shims tor cut-out adjustment ................................ 0.3 mm

--1
- 11)
- Thickness of shims (2) for cut-in adjustment ................................. 0.3 and 0.7 mm
- One 0.3 mm shim brings about changea ........................

in pressure by approx. 3 bars
- One 0.7 mm shim brings about change ........................

in pressure by approx. 7 bars
E
Main accumulator: Fig.

fl;
II
- Capacity ............................................................ 0.4 Litres
- Calibration pressure ................................................... 62 ± 32 bars
*
8531-8532
C`)
MA SPECFICATION AND PARTICULAR FEATURES OF
6 390.00/1 THE SOURCE AND RESERVE OF PRESSURE
Security valve: Fig. 1
Calibration pressures for slide valve return spring:
- Pressure for isolation (no supply to suspension at A and D) ......................... 110 bars min.
Pressure for supply to suspension (del/very at A and D) ............................ 130 bars min.
E
-
Key to diagram:
A : Feed to front height corrector.
B Feed to steering rac and control unit.
HP. biot
'''
C :
D : Feed to rear height corrector.
E : Leakage return.
(1) Adjusting shims for the calibration of si/de valve return spring.
:
Shim thickness ...................................................... 0.9 mm

(2) : Slide valve.
(3) : Fault detector (mechanically operated through shifting of slide-valve (2) ).
Brake accumulator: Fig. II
Capacity ............................................................... 0.4 litres
Calibration prossure ...................................................... 62 ± 2

bars
F : HP iniet.
G: Centrifugal regulator, security vaive.
H: Bra ko control vaive.

8531-8532
ini
ini
SPECIFICATION AND PARTICULAR FEATURES OF MA
390.00/1 1O 39O/1
E THE SOURCE AND RESERVE OF PRESSURE
E011
7/83
-* 3/85
- KEY TO THE HYDRAULIC CIRCUITS
high pressure
i_,
______
- ______ ______ HP/2 (supply to the steering rack)
pressure sent by the centrifugal regulator
III
- - - - -
- ______ - ______ - pressure to the suspension cylinders
- - - - - hydraulic feed to the brakes
return to the reservoir
ri
________________________ overflow return
venting for the suspension cylinders

(1)
--1 -0' III
III
III
III
---
'_.
1
i
PDF* compression, OCR, web-optimization with CVISION's PdfCompressor 8531-8532

MA MA
12
E011
390.00/1 390.00/1 6
-* 3/85 L@ABs
III
.j.
III
111
III
111
rJ
1TT II..
III
III
III
111
...
[_
__j
...
_J
fl
...
E H
7 L8_J
1 ILi _
L39.lOaJ 139.27

PDF* compression, OCR, web-optimization with CVISION's PdfCompressor
8531-8532
LISTE OF OPERATIONS APPEARING IN THE CHAPTER: VEHICLE CONCERNED
ENGINE TYPE
_G1
FRONT AXLE
25 25 20 Safari .
25 Safari
OPERATIONS 25 25 25 Safan 25 Safari
0 2 25 restige 5 Umousine Petrol Diesel
_____ Petrol DseI PetroP Diesel Ambulance
Petrol Petrol Prestige Petrol Diesel Diesel + +
SYMBOLS
Injecteon Turbo Turbo Injection Turbo
OPERATION Turbo Turbo Familiale Familiale
DESCRIPTION _____ _____ ______ _____ ______ _____ _____ ______ ______ ______ _____ _____ ______ _____ _____ ______
TEXTS
No .
><
'-n
829 AS
° 25/662 25/662 25/660
829 A 5 J6T A 500 25/659 25/659 25/648 25/648 829 AS 25/659 25/660 25/648 or
______ _________________________ A 0 ___ ___ ___ ___ ___ ___ ___ ___ ___ 25/660
MA
410/1
MA
410.00/1
Specification and particular features of the front axle 0 X X X .
X X X X X X X X X X X
MA
Removing/refftting an upper wheel arm X X X X X X X X X X X X X X
412.1/1
MA
Removing/refitting a lower wheel arm X X X X X X X X X X X X X X
41 2.1/2
MA
412.3/1
Reconditioning an upper wheel arm 0 X X X X X X X X X X X X X X
MA
41 2.3/2
Reconditioning a lower wheel arm 0 X X X X X X X X X X X X X X
MA
41 3.1/1
Removing/refitting a swivel A X X X X X X X X X X X X X X
MA
426.1/1
Removing/refitting a front wheel hub A X X X X X X X X X X X X X X
PDF compression, OCR, web-optimization

* with CVISION's PdfCompressor 8531-8532
OUT 50 6602 T
*
85318532
MA
41 0/1
J
OUT 20 6306 T 1
OUT 202063 12 T
OUT 32 6335 T 1
OUT 30 6322 T bis
T 4'
84.330

MA
7 41 0.00/1
P=14mm
+ 13'
B = 0
B 29'
rDL!1
LIL!Lt
- 7/85 7/85 -
*
a b
165 ± 8 mm 215 ± 8 mm 210 ± 8 mm

NIA
LII_IUfJ 41OOO/1
IL
0,5
f1 _
E
*
8531-8532
c!)
FRONT AXLE 41/1
RECOMMENDED TOOLS
6303-T. Upper arm shaft extractor.
6320-T. AntLroII bar link rod extractor.
6602-T. Set of three stands.

AN UPPER WHEEL ARM
*
8531-8532
412.1/1 AN UPPER WHEEL ARM
REMOVAL REFITTING
Raise and support the front of the vehicle on stands The LH whee/ arm is different from the RH one. Boss
6602-T. « a » should be direc ted towards the rear of the
vehicie when the whee/ arm has been fitted.
Depressurize the hydrauhc circuit.

Set the height control ever to the « low » position Reinstall, Fig. V
the arm fitted with its thrust cups (7)
°Y'
Remove, Fig.
L%)
1
(the thinner cup facing rearwards),
- the wheel,
- the adjustment shim (6) found on dismantling, facing
- the suspension cylinder pivot retaining pm (1>, forward.
:-"
the anti-roll bar link rod nut (2).
Engage the spindle ; place a new NYLSTOP out.

Uncouple ball-joint (3) from the anti-rofl bar link rod
using pu)ler 6320-T, Fig. Il. Tighten to 12.5 mdaN
Screw up the too! out in the bal/-joint stem. Fit the
too! cross piece and pio.
Recouple the upper ball-joint.
Tighten the new NYLSTOP nut to 7 mdaN
Extract, Fig. III,
p_)
- the not from upper ball-joint (4).

Reconnect the anti-roll bar link rod (wipe the bal/-joint
fixing but do not use solvent).
Disconnect the upper bafl-joint.
Tighten the new NYLSTOP out to 4.7 mdaN
NOTE:
...
the vehicie is fitted with the ABS, the removal of

-«,
Refit the suspension cylinder pivot and pm.

't''
if
the upper ball-joint nut requires pushing back the
transmission.
Vehicies equipped with the ABS:

Remove:
- the pm, Fit the drive-shaft nut (with the faces and threads
- the nut (ock,
lubrica ted).
- the drive-shaft nut. Tighten to 37.5 mdaN.
Fig. IV Replace:
- nut (5),
- the nut lock,
Fig. V - the pm,
- the spindle with extractor 6303-T. - the road wheel.
Remark: An adjustment shim may be found between

T1.
the arm and the front face of the subframe.

MA
412.1/1
i:
;Sr
V
VI
13.774
IV

* 85318532
LO
MA
FRONT AXLE 412.1/2
TOOLS TO BE USED
1671-T Inertia extractor.
3312-T Lower wheel arm ball-joint extractor

with bosses.
or
6323-T Lower arm ball-joint extractor
with or without bosses.
63O6T Adaptor.
6312-T Expandable element to secure the lower

wheel arm fluid b!ocks.
66O2T Set of three stands.

A LOWER WHEEL ARM

* 8531-8532
412.1/2 A LOWER WHEEL ARM
REMO VAL REFITTING
Support the front of the vehicle on stands 6602-T Note: the RH and LH arms are not alike.
+''
If the wheel arm has been removed following an
Release the pressure in the hydraulic system.
impact, it will be necessary to readjust the caster
Set the height control lever to the « low » position
angle.
Withdraw:
Place the expander of too) 6312-T in the wheel arm,
C01
- the road wheel, with screw A pointing rearwards, Fig V.
- the brake pad wear warning lamp harness holding
clips,
Bring tubes (5) and into contact, Fig. V. ln order
0(0
16)
- the lower ball-joint nut. to do so:
Uncouple the lower ball-joint from the arm using puller Fig. VI:
3312-T or 6323-T, Fig. 1
- Grip the arm in a vice,
- Tighten the expandable element by means of

Take off: spanner B from tool 6312-T.
- the plastic trim cover,
nut (il, Fig. II,
- spindle (2) with the help of inertia extractor
1671-T and adaptor 6306-T, Fig. III.
Mark adjustment shims (3) and (4) location, Fig. IV.
Remove the wheel arm.

MA
412.1/2
Iv
G.
t.i___ -
-
:L.....
.
:
t
1671T
*
8531-8532
AVANT ARRIERE
141.5
13.602

REMOVING AND REFITTING MA
LO
412.1/2 5
A LOWER WHEEL ARM
Refit Fig. 1
the arm together with its adjustment shims

(1) and (2) placed in the position they were
found on dismanting.
Insert spindle (3), Fig. Il.
Loosen expander A with tool 6312-T spanner B.
Drift out the assembly via shaft (3).
Tighten the new NYLSTOP nut (4) to 14.5 mdaN,

Fig VI.
Reconnect the (ower baU-joint to the arm (wipe the

ball-joint fixing bot do not use solvent).
Tighten the new NYLSTOP nut to 6 mdaN.
Reinstall - the brake pad wear warning lamp harness

securing clips,
- the road wheel.
Lower the vehicie to the ground.
*
8531-8532
41/1 1
L1671 T]
OUT 30 6322 T bis OUT 32 6335 T 1
*
8531-8532
2 412.3/1 0
c,9
012mmJ
0 -
1J

* 8531-8532
41/1
85,648

III

* 8531-8532
6 4123/1
85.656 I
85.659 I
—
(/ MA
1 ILJ 412.3/1
IN
-1/87
X = B-A
e = X - 9,34± 0,08 mm
AV AR
1/87-- T.BCX® N°2
85.718
85.651
* 8531-8532
8412 A
r1J
9,34
9.341
10,04
G6
85.653 I

0)
071 412.3/1
-
-;
.-'
p
*
LO
c)
(N
LO
LO
c-)
8531-8532
*
8531-8532
2 4i/2

t MA
412.3/2 3
/ WULkLWÅWÅW -
1
1
85,755
rL
85.750 ,' . .
-p.
--

8532
MA j 4
412.3/2
f
MAXI
1,2 t.
1w1J

FRONT AXLE 41/1
TOOLS TO BE USED
6310-T. Hub locking tool
3312-T. Lower arm balkjoint extractor, with bosses
.n°
or
6323-T. Lower arm ball-joint extractor, with or without bosses
Torque wrench (40 mdaN)
Sleeve 35 mm A/F
REMOVING AND REFITTING A SWIVEL
*
8531-8532
MA REMOVING AND REFITTING A SWIVEL
2 413.1/1
REMOVAL ABS vehicies, Fig. $V
Support the front of the vehicie on stands.

Extract the screw 0) securing the sensor.
II'
(1
Depressurize the hydraulic systems
E
Disconnect the brake pad wear warning lamp
avi
CD>
Remove:
harness.
- the road wheel,
- the pm,
Withdraw:
- the nut ock,
- the brake disc cooling plate,
- the nut (35 mm AlF)
- the harness screw and fixing bracket; release the
Lock the wheel hub with tool. 6310-T, Fig. 1.
harness.
Fig. II: Remove the lower ball-joint nut.
nut 11) and its washer; disengage the ball-joint from

t-'
-
the swivel, Uncouple the swivel lower ball-joint using extractor
III
- lock nut (6>, 3312 T or 6323 T, Fig. V,
- nut 151. (avoid damage to the bal/-joint protection rubber).
Uncouple, Fig. II and III

Pull out the drive-shaft.
cable 12) from the contro) lever,
avi
spring 131,
c-0
-
Take off nut (11) from the upper ball-joint, Fig. VI.
-'^
- cup 141,
- connection 17).
Uncouple the upper ball-joint.
Take off, Fig. ID, nut (8) together with its washer.
Remove the swive).
Liberate f)exible pipe (9) from ts fixing bracket,
Fig. III.

ini
ini
MA
413.1/1 3
L63 1 OT
13751 1'
..,..'..
,
:l:11 L_1. 1
Ik ..:
3312Tou 6323 T]
-
{t.
$S7
1
86752
-
:
7>9
fil
t[1
86.754
v
*
8531-8532
ini
Ii MA
413.1/1
- -. -
-
L
36.754
Iv
,a3

MA
REMOVING AND REFITTING A SWIVEL 4131/1 5
REFITTING Replace, Fig. IV:

- flexible pipe (11) into its fixing bracket,
Wipe the bal/-joint fixings and location, do not use
solvent. - washer (10).
Recouple the upper ball-joint with the swivel. Tighten nut (9) to 2.2 mdaN.
Refit, Fig. 1:
Recouple:
-washer (1), - Fig. IV, connection (1 2) provided with a new sea!.

not (2).
- Fig. V, the steering ball-joint.
Tighten to 7 mdaN (New NYLSTOP nut).

Refit:
-washer (13),
Introduce the drive-shaft end into the wheei hub
(lubricate the hub sea! 1/ps). nut (14) (New NYLSTOP one).
Couple up the lower ba)I-joint. Tighten to 6 mdaN.
Tighten to 6 mdaN the new NYLSTOP nut. Reconnect:

-cup (17),
-spring (16),
Reconnect the brake pad wear warning tamp harness.
-cab(e (15).
Refit, Fig. II and III:

- electrical harness fixing bracket (4),
Adjust the handbrake (as indicated in © 454.0/1).
'LO
- earth ead (5),

Cl)
pli
Put the drive-shaft nut into place.

"-'
- screw (3),
- metal panel (6). (Faces and threads lubricated).
Lock the hub, utilizing too) 6310-T Fig. VI.

ABS vehicles, Fig. III:
Reinstafl sensor (7) (spread MOBIL TEMP No. 1
grease over the ou ts/de of the sensor.

Bleed the front brakes (see @ 453.0/1).
Tighten screw (8) to 1 mdaN.

Fit the wheel.
Lower the vehic(e to the ground.
*
853 1-8532
MA
FRONT AXLE 426.1/1
TOOLS TO BE USED
3312-T. Lower arm baIJjoint extractor, with bosses
or
6323-T. Lower arm ba-joint extractor, with or without bosses
6310-T. Hub locking toot
Torque wrench too! (40 mdaN)
Socket, 35 mm A/F
REMOVING AND REFITTING A FRONT

WHEEL HUB
* 8531-8532
c3,

MA REMOVING AND REFITTING A FRONT
2 426.1/1 WHEEL HUB
REMOVAL REFITTING
c
Support the front of the vehicle on stands. Introduce the wheel hub into the swivel.
--a
Take off the road wheel.

Position the screws previously fitted with /ugged
contact washers, Fig. III. Tighten to 2.7 mdaN.
:3'
Withdraw, Fig. 1
the pm,
Insert the drive-shaft end into the wheel hub (grease
."r
- the nut lock,
the sea! contact face).
- the 35 mm A/F nut.
Couple up the lower bati-joint.

Lock the hub with tool 6310-T.
irr-
Tighten the new NYSL TOP nut to 6 mdaN. (Wipe
Gli
the ball-joint fixing and recess, do not use so/vent).
Remove the brake disc (as stated in chapter @,
op. MA451.1/3).
Refit the brake disc (Refer to MA 451.1/3) fl
Extract the swivel lower ball-joint nut
Relocate, Fig. IV
- the nut, use tool 6310-T to hold the hub in posi-
Uncouple the swivel lower ball-joint, Fig. II, using tion, tighten to 37.5 mdaN,
either puHer 3312-T or puller 6323-T (be careful
the out lock,
not to damage the ball-joint protection rubber).
- the pm.
Liberate the drive-shaft.

Bleed the front brakes
(See MA 453.0/1).
Take out, Fig. III
Reassembie the road wheel.
'-'
the screws,
- the hub. Lower the vehicle to the ground.
.
MA
426.1/1
/.
13.751
Ii'
13.750
-
II

* 8531-8532
-

REAR AXLE ENGINE TYPE
25 25 20 Safari .
25 Safari
PERATIONS 25 25 25 25 Salan 25 Safari
0 2 5 Prestige 5 Limousine Petrol Diesel
75.-2
Petrol Petrol Diesel Petrol Diesel Ambulance
SYMBOLS
UD Injection Turbo Turbo Injection Turbo
PERATION Turbo Turbo Familiale Familiale
DESCRIPTION _____ _____ _____ ______ _____ ______ _____ _____ ______ _____ ______ _____ _____ ______ _____ ______
TEXTS
UD
No.
><
829A5
'-
tfn
829 A 5 J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 A 5 25/659 25/660 25/648 or
0
________________ ________________________________________________________________________ (J _______ ________ ________ ________ ________ ________ ________ ________ ________ ________ ________ ________ ________
25/660
MA
0
0
Specification and particular features of the rear axle X X X X X X X X
(/,
420.00/1 X X X X X X
MA
422.1/1
Removing/refitting a rear axle arm A X X X X X X X X X X X X X X

* with CVISION's PdfCompressor 8531-8532
MA
420.00/1
-3 7/85
1 1
LL
1
7/85 -
=Oä4mm o
B=00_24,
*
8531-8532
42O/1
® -
h rf
======
-,__________
/' .- NJ\NI
____________
\
-
//(///////J///////J/,L'IJJ ///////////J//
/ //////////////////////J/
II -
///////////////
/
-
fl I\[
-
0
In
Iii 1
1--
II 1

*
8531-8532
*
*
8531-8532
MA
2 422.1/1 REMOVING AND REFITTING A REAR AXLE ARM
REMOVAL REFITTING
Raise the rear of the vehicle and support it on stands, Position the axle arm Ithe thinner thrust cup (91
c[>
t/)
wheels free. 9.34 mm thick at «c» facing the interior of the
vehicle, - 1/87), Fig. V).
Remove the road wheel.
Release the pressure in the hydraulic systems.
1/87 -* the thrust cups are identical and the adjust-
ment is effected by means of shims facing the exte-
Remove protection plate (11, Fig. 1. rior of the vehicle.
Vehicie having the A.B.S. fitted, Fig. Il: Return the shaft to its original location.
Withdraw sensor 13) and push aside the meta) panel
and sensor, liberating the electrical harness from the
Place nut (8), new NYSL TOP out, Fig. IV.
retaining clips.
Tighten to 13 mdaN.
Remove suspension cylinder 15), Fig. III.
öö,
Recouple the anti-roll bar, Fig. III. Add the screws (6)
(As explained in MA 433. 1/2). and (7) together with the adjustment shims and
washers found at «a» and «b» on dismantling.
Take off fixing lug 14), Fig. III.

Tighten screws (7) to 6 mdaN and 16) to 10 mdaN.
Uncouple:
- brake hose (2), Fig. 1, Reconnect brake hose (2) Fig. 'f!
61' 1, fitted with a NEW
sleeve sea!. Tighten it.
- the anti-roll bar, Fig. III. ln order to do so, extract
screws 16) and 17) and keep adjustment shims and
washers «a)) and «b».
Refit fixing lug 14), Fig. III.
Take off out 24 mm A/F, Fig. IV.

C13
18)
Locate suspension cy)inder 15), Fig. IV.
(See ®
MA 433. 1/2).
Free the shaft and remove the arm.
+-,
ABS vehicle, Fig. II:

Refit sensor (3), (grease the outside of the sensor with
'"'
MOBIL TEMP No. 1).
Tighten the screw to 1 mdaN.
Reassembie:
- protection p)ate (1), Fig. 1,
- the road whee).

ini
MA
422.1/1
ir
85.603
Iv
3T
2( II
142.5
v
sia
85.61

* 8531-8532
MA
11$11 :IIIIIIIIIIII3 430/1
3505 T
02TJ OUT 20 6320 T
--.---:-
13.811 85.333
*
8531-8532
2
I MA I
430/1
EI
6401 Tj OUT 50 66O!J
F 13.815
1136 FACOM
p
82.827

8531-8532
c)
LÖ
MR 630-58/3lci co
9 ason LO
co
2Q
indication
11
/
H
__________ ______________ Cut out 28 mm from ---- / 100
(initial
45 (60 nitial 34
the centre (me dimension(
____ _____
1
dimension( _________
____________ 76
Longth 15 (portion to be de(eted( (corrected
dimension(
- ______ -
Profile of the reworked part
-
\. Profi(e of the original part
25.5 . j23.5 initia( dimension(

9 as an
indication I.ri -ln )fl
11
100
(irutial
dimension( 34:e
- - Cut Out 28 mm from
the centre e
_________________________
It is forbidden
to weld on this
1
1 ________
Lengh 15 surface
- Tool 6401-1 includes 2 clamp J_Lg. (portion to be deleted(
assembhes Alter (corrected
dimension(
)
ml m2 on 1 clamp assembly
/
m3 on both clamp assemblies Profile of the original part /
1 3 to 450 chamfer
(23.5 initial dimension( to locate the weld

4MA 430/1 IIID
/ 95
III
MR 630-51
0
11-0.5
3-8.2
side
N ure to engrave
50
4 chamfers
4ch. 1,5 to 45
3442
- u.uJ
P25r
Fiat spot
O.3toO.5 mr
200
;
-
_ R25k
4±0.05
0
4 chamfers 1.25 to 45
)
Material
Ref. a laminated A 33-1, dia. 4

Developed iength = 435 approx.
IV /
sheet metai 24 Figure to
Ref. b and c : E
Brown finish
50r
8Q

43/1 1

* 85318533
MA
21 430.00/1 7
11,
1 j
829-A5
23 mm
6
: I::IIIII:I::I:
_____________
J6T A 500
____________ ____________ 35 mm V.V.B
24 mm -+ 7/85
829-A5
25 mm 7/85 -
24 mm 0 1,9
M25/659 24 mm - 7/85 37 mm V.V.BI
25 mm 7/85 -
24mm
ø19
M25/660 24 mm -* 7/85 37 mm V.V.8I
25 mm 7/85
ø19
24mm
__________________ M25/648
M25/669 24 mm - 7/85 37 mm V.V.BI.
25 mm 7/85 -
0 1,65
M25/662
25 mm 37 mm V.V.Br
M25/666

Er -Ii 43/1 3
\rn3LHM\_500 cm3 40 bars
829.A5 0 1,25
M25/660
M 251659
17,5 mm 35 mm Bl.BI.Br
M25/648
M 25/669
J6T.A 500
@125
19,5 mm 35 mm BI.BI.Br
7
/
j
35 bars
829.A5 17,5 mm 0 1,5
M25/659 7/85
42 mm J .J . J .
M25/648
C71
19,5 mm
M25/669
M25/660 7/85
*
LO
8531-8532
LO
II
J3 = J4
-+ 7/85
= J2
Ji
Ji

__
<0
cv)
W5
w g'=r
___
L!
rid
[ifl
__
J
©
©
-
98/L
r_ L!±
___
[
0
__
J
;H\
,©
©
\
/7
W
W
S'C
g'j
=
= zr

*
LO
cr)
LO
c)
8531-8532
ini
6 43OI1 II
13447
st 1150
a
m
165±8mm 215±8mm
UD
00
E
E
cm
r-
M
M
E
E

ini
ini

8531-8532
SUSPENSION 43/1
TOOL TO BE USED
Chain wrench

HYDROPNEUMA TIC SUSPENSION SPHERE
AND CYLINDER

* 8531-8532
MA HYDROPNEUMATIC SUSPENSION SPHERE
2 433.1/1
AND CYLINDER
REMOVAL REFITTING
Unlock the pneumatic unit by 1/4 tum max. with a

chain wrench.
Check that the suspension cylinder dust-guard
-arv
contains LHM fluid. If this is not the case, fil! with
Chock the front of the vehicle.
7 cc. of f)uid.
Remove the road whee),
Depressurise the hydraulic systems.
.,,
tid
(See ® MA 390.000/1). Fit the suspension cylinder and thrust race (4).
Take off suspension cylinder hinge retaining pm
(3), Fig. 1. Recouple feed pipe (5) (equipped with a NEW sleeve
sea!, Fig. II).
Push back the piston rod so as to drive out the fluid

contained in the cy)inder. ReinstaH:
- c)ip (6), Fig. II,
Remove the suspension sphere. the hydropneumatic sphere whose contact face «a»
has been slight/y lubricated, fitted with a NEW sea!.
Uncouple, Fig. 1 and Fig. Il tighten by hand

pipes (1) and (2),
- pipe (5). Couple up, Fig. 1
- overflow return pipe (1),

Remove: - venting pipe (2).
clip (6), Fig. II,
- the suspension cylinder. Insert pm (3), Fig. 1.
Start the engine.

civ
Check the circuit for leaks.
Replace the road wheel.
Lower the vehic)e to the ground.

nav

* 85318532
* 8531-8532
REMOVING AND REFITTING A REAR
2 433.1/2
AND CYLINDER
REMOVAL REFITTING
Jack up the rear of the vehicle. Position the suspension sphere with the contact
surface slightly greased and equipped with a NEW
sea!; hand tighten.
Depressurise the hydraulic circuits.
® MA 390.000/1).
(.0
(See
Extract the suspension cylinder hinge retaining pm (1), Ascertain that the suspension cylinder dust-guard
Fig. 1. contains LHM fluid. If not, fil) with 25 cc of fluid.
Disconnect pipes (2), (3) and (4), Fig. II.

Put the suspension cylinder!pneumatic unit into
Remove clamp (5), Fig. II. place.
Disengage the pneumatic suspension unit/cylinder Reconnect, Fig. II:

assembly.
- feed pipe (4) having a NEW sleeve-sea! fitted,
- overflow return pipe (31,
Grip the suspension cylinder in a vice fitted with soft
jaws, and introduce a 8 mm dia. rod in orifice A to - venting pipe (2).
prevent the cyhnder from rotating.
Tighten the vice MODERATELY.
Install, Fig. 1 and II:
Slacken the pneumatic unit using the chain wrench. -holding pm (1),
- clamp (5) without tightening.
Run the engine.
Set the height adjustment control switch to the «high»

position.
Make sure that the hydropneumatic sphere makes

contact with the axle unit. Tighten clamp (5), Fig. II.
Test the hydraulic system for leaKs.
Refit the wheel.

MA
433.1/2
85,608

* 8531-8532
SUSPENSION
:er
TOOLS TO BE USED
3505-T. BaH-joint extractor
6301-T. Equipment for positioning the haif front axles
6301.T bis. Front axle ocking too
6320-T. Anti-rol bar ink rod extractor
6401-T. Set of 2 clamps for fitting the anti-roll bar bearing

+-,
6602-T. Set of 3 stands
Modification to clamps 6401 T

See drawing MR 630-58131a
® 430/1 page 3
REMOVING AND REFITTJNG

AN ANT/-ROLL BAR
*
8531-8532
435.1/1 A FRONT ANTI-ROLL BAR
REMO VAL LH side
Raise and support the vehicie horizontaHy on stands

6602-T. Remove:
suspension cy)inder retaining pm (12), Fig. V,

Re)ease the pressure in the hydrau)ic circuits. Set the upper wheelarm )ink-rod nut 111), Fig. V.
height contro) switch to the "normal driving position".
C/)
O.. Uncouple the link-rod (13) from the anti-roll bar, using
Remove: too) 6320-T, Fig. VI.
- the road whee)s,
- the wheel arch rubber seals,
- both brake control valve securing screws,
- exhaust shields (2), Fig. 1,
- cover 13), base p)ate (5) from the height corrector RH side
protection casing and the casing (4) itself, Fig. 1.
Withdraw the anti-ro)) bar )ink-rod nut (14), Fig. VIII.
Uncouple and free automatic height contro) clamp
(1), Fig. 1.
Disconnect )ink-rod (1 5) from the anti-rol) bar with
:1!
Remove automatic height control rod (6), Fig. II. too) 3505-T, Fig. VIII.
(Pull out the an tf-roll bar to allow passage for too!

Disconnect the swivel track rods. 3505-T).
Disengage rubber gaiters (7) and plastic trim cover Strip down the anti-rol) bar, on the vehic)e.
c/1
18), Fig. III.
Loosen maintaining ciamp 19), Fig. IV.
Take off the screws (10) fixing the bearings to the

axle unit, Fig. IV.

ini
MA
435.1/1
...
_..
86.817
!.
86.813
v
II
86.826
VII

* 8531-8532
A MA
4351/1
Iv
v
y$.
6301
6 01 T hi
86.846

REMOVING AND REFITTING 1 MA
A FRONT ANTI-ROLL BAR 435.1/1
f
Extracting the anti-roll bar REFITTNG
Reassemble the anti-roll bar on the LH side.

RH side
Add the bearing items, (Fig. V):
'T1
Tum the steering through full lock to the right.
gaiter (41,
1. Lift up steering track rod (11, (Fig. 1).
- retaining clamp (5),
- the two half thrust cups 161,
2. Rotate by a quarter tum toward the upper sec steal thrust washer (7),
tion of the anti-roll bar (2), (Fig. II).
- spring 18),
- steel thrust washer (91,
Push the anti-roll bar to the left, (Fig. II).
,-.
3.
- the two halt ball-joints (101,
- bearing 111),
- ring (131,
LH side
-sheath 112).
Tum the steering through full lock to the left.
Coat all the parts with TOTAL MULTIS grease.

4. Lift up steering track rod 13), (Fig. III).
Put the anti-roll bar into place towards the LH side

a-0
5. Slightly rotate anti-roll bar (2), (Fig. IV). of the vehicle. ^<D
(Reverse the fitting procedure, Fig. IV, III, fl, 1).
`CD
6. Free the anti-roll bar from the LH side of the

vehicie, (Fig. IV). Reassemble the anti-roll bar on the RH side, in the
order indicated below.
Place the halt axles in line, (in the normal driving posi-
tion) using tools 6301 T and 6301 T bis (Fig. VI).
*
8531-8532
6 435.1/1 A FRONT ANTI-ROLL BAR
Wipe the bal/-joint cones, do not use solvent. Tighten the bearing which is touching the axie unit
correctly. Insert shims beween the unit and the
second bearing so as to secure it without exerting
Recouple any stress on the anti-roll bar, (one shim thickness
only - 1 mm).
- the LH ink rod with the upper wheei arm; hand tigh-
ten the nut (new NYLSTOP one),
Tighten, Fig. 1, screws (1) fitted with lugged contact
- the RH (ink rod with the anti-roil bar; hand tighien washers, to 2.7 mdaN.
the nut (new NYLSTOP one).
Tighten the nuts untii springs (5) and (8) turns touch,
Refit bearing fixing screws (1) and nuts (2), Fig. 1 by means of clamps 6401-T.
and II. Check that plate (3) has been fitted the right Siacken the nuts of each tool by 1/2 tum, Fig. III
wa y. and IV.
Equip each bearing with the set of ciamps 6401-T,

-''
Centre the anti-roli bar in the axle unit, Fig. V. The

Fig. III and IV, piacing the modified too! to the LH LH and RH ends of the bar should be the same
side). Compress springs (5) and (8) moderately. (The distance «1)) from the subframe, to within 2 mm.
aim of this operation is to hold both half ball-joints and
thrust cups in position).
Tighten retaining ciamping coliar screws (4) and (9)
to 1.3 mdaN, Fig. III and IV.
Make sure that bearings (6) and (7) are in contact with
the axie unit.
Remove c)amps 6401-T
IMPORTANT : if one bearing does not touch the axie,

proceed as foflows: Ful dust cover (10) with TOTAL MULTIS grease,
-00
in.
Fig. VI.
Return, Fig. VI:

- dust covers (10) and (13),
-ring (11),
- trim cover (12),
to their rest location.

.-r

1!L

* 8531-8532
MA
8 435.1/1

435.1/1 9
A FRONT ANTI-ROLL BAR
[
RH side: Refit, Fig. III
Tighten the anti-roll bar link-rod nut (1) Fig. i, to - the heght corrector protection casing (4),
5 mdaN. - the exhaust shield (5).
Attach the brake control va(ve. Tighten the screws

LH side: to 1.8 mdaN, equipped with contact washers.
Tighten the anti-rol) bar nut (3) Fig. II to 5 mdaN.
Reposition:
Fit the suspension cylinder pivot and pm (2).
- the wheelarch rubber seals,
- the whee)s.
Recouple the steering track rod to the swive),
equipped with washer and nut (now NYLSTOP one).
Tighten to 10 mdaN.
Refit the automatic height contro) to the height cor-

Check the front heights.
rector.
Adjust if necessary.
Reconnect the automatic contro( c(amp with the anti-
roll bar. (See MA ® 430.00/1).
Centre the automatic height contro( sideways in

the height corrector ball-joint to prevent the shde
valve from being stressed.
Tighten the automatic height control clamp to

1.5 mdaN.
Remove tools 6301-T and 6301-T bis.

t`7
*
8531-8532
SUSPENSION 43/2
TOOL TO BE USED
6302-T. Set of 2 chocks for positioning the rear axle.

A REAR ANT/-ROLL BAR

* 8531-8532
MA 1
2 435.1/2 A REAR ANTI-ROLL BAR
(
REMOVAL Position, but do not Ughten:

m
Raise the rear of the vehicie and support it on stands, - both half-bearings (6),
.-r
screw (5),
(31
-
- screw (4).
'1)
Depressurize the hydraulic circuits.

Centre the anti-roll bar in the rear ax(e unit the
Set the height control switch to the «norma) running» clearance at (ca» should be the same on either side
position. (LH and RH), to within mm.1
Available shim thicknesses:

Uncouple the automatic height corrector clamp and 0.5 - 1 - 2 - 3 - 4 mm.
move it clear.
Tighten bo(t (7) fitted with a contact washer, Fig. IV,

Take off, Fig. 1 to 6 mdaN.
- screw (1) and its adjustment washers at «b»,

- screw (3), the two haif-bearings (2) and shims (ca),. If necessary, place shims at «b» with a 0.3 mm
c(earance max.
Free the anti-roll bar from the R.H. side of the vehicle.
Reconnect the automatic height contro( with the anti-

roll bar.
Centre automatic control (9) sideways in the

0
Opp
REFITTING hoight corrector ball-joint, Fig. V, to avoid the

.£g
slide valve being stressed.

Engage the anti-roll bar towards the RH. side of the
car.
Tighten the automatic height control clamp screw to

Utilize tools 6302-T to place the ax(e arms in line, 1.5 mdaN.
(in the «normal driving» position), Fig. Il.
Remove tools 6302-T.
Lower the vehicle to the ground; check the front

,C.
heights.
Readjust if required. (Refer to ® MA 430.00/1).

ini
ini
MA
435.1/2 3
';i
1
[. t-
;..L
... - 1)
kul
Fri
85.602
6302T
-n.
Iv
E :
86.974

*
MA
471.00/1
__________
ED ED ED ED ED ED ED
XVS XVS XVS 390 TRX 390 TRX xZX XZX

1755R14 185SR14
<3'
7C7
:t7
175HR14 185HR14 185HR14 190/6SHR 190165HR
(_)
(_)
9 mdaN 0 5 1/2J14 5 1/2J14
6J14
15OTR 390 5 1/2J14 5
__________
9 mdaN
BAR BAR
A 2 A 2
CX2O
8 2,1 ED 8 2,1 ED
CX 20 TRE
C 2,6 ED 130 km/h maxi C 2,6 ED
A 2 A 2,2
CX 25 Pallas lE B 2,1 B 1,4
C 2,6 130 km/h maxi 2,6

E
C ED
A 2,2
CX25GTI 8 1,4
C 2,6 130 km/h maxi

E
ED
A 2,2 A 2,2 ED
CX 25 Prestige 8 2,2 B 1,4
C 2,6 130 km/h maxi C 2,6 ED

E
ED
A 2,2 A 2,2
CX25D
988
8 2,1 B 2,1
CX 25 D Paflas
C 2,6 130 km/h maxi C 2,6
E
ED
A 2,4 A 2,4 ED
CX25RD 8 2 B 2
C 2,6 130 km/h maxi C 2,6 ED

E
ED
A 2,4
CX25TRD 8 2 ED
C 2,6 130 km/h maxi

E
ED
A 2,2 ED A 2,4 ED
CX Limousine 8 2,1 B 2
C 130 km/h maxi C 2,6 ED

E
Turbo 2,6 ED

8531-8532
JMA
L 471.00/1
ED ED ED ED ED ED
6Q)
MXL MXL MXV MXV 390 TRX 390 TRX
rr
185/70R14 195/70R14 195/70R14 195/70R14 190/65 HR 210/55VR
(_)
______ [jJ
51/2J14
:L25:: :25::
9 mdaN
(_)
6J14 15OTR 390 15OTR 390
t.[)
9 mdaN
-
AR BAR
A 2,2 A 2,2
0
CX2O
B 1,4 ED B 1,4 ED
CX 20 TRE
A 2,4 A 2,2
CX 25 RI
CX 25 Pallas lE B 2 B 1,4 ED
CX25 Prestige C 2,8 ED 130 km/h maxi C 2,8 ED
A 2,2
CX25GTI B 1,4
C 2,8 ED 130 km/h maxi

E
A 2,4 A 2,2 ED
CX25D B 1,8 (1) B 1,4
C 2,8 130 km/h maxi C

E
ED 2,8 ED
A 2,4 A 2,4 ED
CX25RD B 2 B 2 ED

E
A 2,4 A 2,4 ED
CX25TRD B 2 B 2 ED
C 2,8 130 km/h maxi C 2,8 ED

E
ED
A 2,4 ED A 2,5 ED
CX Limousine 6 2 6 2
ED
Turbo
C 2,8 130 km/h maxi C 2,8
E
ED ED
C`)
A 2,3
CX 25 GTI Turbo 6 1,5

tid
ED
C 130 km/h maxi

E
2,8 ED

MA
(II 471.00/1
__________
ED ED ED ED ED ED

185/70R14 195/70R14 195/70R14 195/70R14 190/65 HR 210/55 VA
5 1/2 J14 5 1/2 J14 5 1/2 J14
9 mdaN
FHA 5-45 FHA 5-45 FHA 5-45
(_)
6J14 15OTR 390 15OTR 390
9 mdaN
__ W CX2O RE
A 2,2
(5 W_
A 2,4
8 2,1 ED B 2
CX 22 TAS
2,8
(C)
C ED 130 km/h maxi C 2,8 ED
A 2,4 ED A 2,4
CX25D 8 1,8 ED B 2
C 2,8 (j) 130 km/h maxi C 2,8 ED
CX 25 RI
A 2,4 A 2,4
CX 25 Prestige
B 2 8 2 ED
CX 25 RD _______ _______ _______ _______________ _______ _______ _______
CX 25 Limousine
C 2,8 ED 130 km/h maxi C 2,8 (0
A 2,4 (0 A 2,4 (0
CX 25 TRD
6 2 (0 8 2 (0
CX 25 TAl
A 2,3 (0
CX 25 GTI Turbo
8 1,5 (0
CX 25 Prestige Turbo

8531-8532
4MA 471 OOI1
_
XVS XZS XVS XVS 390 TRX
175 HR 14 185 SR 14 185 HR 14 185 HR 14 190/65 HR
______ [jJj
t77
51/2J14 51/2J14 51/2J14
9 mdaN
6J14 150TR390
9 mdaNJ
_
'd'
2,6 130 km/h maxi
'V'
C C 2,6
A 2,2 A 2,2
CX250 B 2,2 6 2,2
C 2,6 130 km/h maxi C 2,6
A 2,4
CX25TRI 8 1,9 ()
C 2,6 (j) 130 km/h maxi
A 2,4
CX25TRD B 1,9
C 2,6 130 km/h maxi

5
IIII 47OI1
Fri
______
MXL MXL MXV 390 TRX

full
185/70R14 195/70R14 195/70R14 190/65 HR
______ Ililj
51/2J14 51/2J14
(_)
9mdaN
6J14 150TR90
- - ______
C 2,8 130 km/h maxi C 2,8 ED
A 2,4
CX25TRI B 1,9
C 2,8 130 km/h maxi
A 2,5 A 2,6
CX25D 6 2 B 2,3
C 2,8 130 km/h maxi C 2,8 ED
A 2,6
CX25TRD B 2,3
BAR BAR
A 2,5 A 2,6
CX2O
B 2,3 B 2,3
CX25D
C 2,8 ED 130 km/h maxi C 2,8 ()
II
A 2,5 A 2,6
CX 25 TRI
B 2,3 8 2,3
CX 25 TRD _______ _______ _______ _______________ _______ _______ _______

8531-8532
SUSPENSION - WHEELS - TYRES ENGINE TYPE
L1
`r'
(öms
PERATION 5 5 25 Safan 25 Satari
_____
________ _____
0 2 5 Prestige 5
DseJ
Limousine Petro! OJ
(-D
________ Petrol Petrol Petrol Diesel Ambulance
SYMBOLS
Injection Turbo Turbo Injecton Turbo
__ Turbo Turbo
OPERATION Familiale Familiale
DESCRIPTION _____ ______ _____ ______ _____ _____ ______ _____ _____ ______ _____ _____ ______ ______ _____ _ ______
TEXTS
No .
><
829A5
`-O
829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_______________________________ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
0
A Q
0 0
25/660
MA
430/1
MA
0
xx
Specification and particular features of the suspension X X X X X X X X X X X X X X
`-'
430.00/1
MA
Removal/refitting of front suspension cylinder X
.,...
433.1/1
a X X X X X X X X X X X X X
MA
A
0
Removal/refitting of a rear suspension cylinder X X X X X X X X X X X X X X

433.1/2
MA
Removal/refitting of an anti-roII bar X
0
435.1/1 X X X X X X X X X X X X X
MA
0
435.1/2
Removal/refitting of a rear anti-roll bar X X X X X X X X X X X X X X
MA
471.00/1
Special features of the wheels and tyres X X X X X X X X X X X X X X
*
MA
11$11 :IIIIIIIIIIII3 430/1
3505 T
02TJ OUT 20 6320 T
--.---:-
13.811 85.333
*
8531-8532
2
I MA I
430/1
EI
6401 Tj OUT 50 66O!J
F 13.815
1136 FACOM
p
82.827

8531-8532
c)
LÖ
MR 630-58/3lci co
9 ason LO
co
2Q
indication
11
/
H
__________ ______________ Cut out 28 mm from ---- / 100
(initial
45 (60 nitial 34
the centre (me dimension(
____ _____
1
dimension( _________
____________ 76
Longth 15 (portion to be de(eted( (corrected
dimension(
- ______ -
-
\. Profi(e of the original part
25.5 . j23.5 initia( dimension(

9 as an
indication I.ri -ln )fl
11
100
(irutial
dimension( 34:e
- - Cut Out 28 mm from
the centre e
_________________________
It is forbidden
to weld on this
1
1 ________
Lengh 15 surface
- Tool 6401-1 includes 2 clamp J_Lg. (portion to be deleted(
assembhes Alter (corrected
dimension(
)
ml m2 on 1 clamp assembly
/
m3 on both clamp assemblies Profile of the original part /
1 3 to 450 chamfer
(23.5 initial dimension( to locate the weld

4MA 430/1 IIID
/ 95
III
MR 630-51
0
11-0.5
3-8.2
side
N ure to engrave
50
4 chamfers
4ch. 1,5 to 45
3442
- u.uJ
P25r
Fiat spot
O.3toO.5 mr
200
;
-
_ R25k
4±0.05
0
4 chamfers 1.25 to 45
)
Material
Ref. a laminated A 33-1, dia. 4

Developed iength = 435 approx.
IV /
sheet metai 24 Figure to
Ref. b and c : E
Brown finish
50r
8Q

43/1 1

* 85318533
MA
21 430.00/1 7
11,
1 j
829-A5
23 mm
6
: I::IIIII:I::I:
_____________
J6T A 500
____________ ____________ 35 mm V.V.B
24 mm -+ 7/85
829-A5
25 mm 7/85 -
24 mm 0 1,9
M25/659 24 mm - 7/85 37 mm V.V.BI
25 mm 7/85 -
24mm
ø19
M25/660 24 mm -* 7/85 37 mm V.V.8I
25 mm 7/85
ø19
24mm
__________________ M25/648
M25/669 24 mm - 7/85 37 mm V.V.BI.
25 mm 7/85 -
0 1,65
M25/662
25 mm 37 mm V.V.Br
M25/666

Er -Ii 43/1 3
\rn3LHM\_500 cm3 40 bars
829.A5 0 1,25
M25/660
M 251659
17,5 mm 35 mm Bl.BI.Br
M25/648
M 25/669
J6T.A 500
@125
19,5 mm 35 mm BI.BI.Br
7
/
j
35 bars
829.A5 17,5 mm 0 1,5
M25/659 7/85
42 mm J .J . J .
M25/648
C71
19,5 mm
M25/669
M25/660 7/85
*
LO
8531-8532
LO
II
J3 = J4
-+ 7/85
= J2
Ji
Ji

__
<0
cv)
W5
w g'=r
___
L!
rid
[ifl
__
J
©
©
-
98/L
r_ L!±
___
[
0
__
J
;H\
,©
©
\
/7
W
W
S'C
g'j
=
= zr

*
LO
cr)
LO
c)
8531-8532
ini
6 43OI1 II
13447
st 1150
a
m
165±8mm 215±8mm
UD
00
E
E
cm
r-
M
M
E
E

ini
ini

8531-8532
SUSPENSION 43/1
TOOL TO BE USED
Chain wrench

HYDROPNEUMA TIC SUSPENSION SPHERE
AND CYLINDER

* 8531-8532
2 433.1/1
AND CYLINDER
REMOVAL REFITTING
Unlock the pneumatic unit by 1/4 tum max. with a

chain wrench.
Check that the suspension cylinder dust-guard
-arv
contains LHM fluid. If this is not the case, fil! with
Chock the front of the vehicle.
7 cc. of f)uid.
Remove the road whee),
Depressurise the hydraulic systems.
.,,
tid
(See ® MA 390.000/1). Fit the suspension cylinder and thrust race (4).
Take off suspension cylinder hinge retaining pm
(3), Fig. 1. Recouple feed pipe (5) (equipped with a NEW sleeve
sea!, Fig. II).
Push back the piston rod so as to drive out the fluid

contained in the cy)inder. ReinstaH:
- c)ip (6), Fig. II,
Remove the suspension sphere. the hydropneumatic sphere whose contact face «a»
has been slight/y lubricated, fitted with a NEW sea!.
Uncouple, Fig. 1 and Fig. Il tighten by hand

pipes (1) and (2),
- pipe (5). Couple up, Fig. 1
- overflow return pipe (1),

Remove: - venting pipe (2).
clip (6), Fig. II,
- the suspension cylinder. Insert pm (3), Fig. 1.
Start the engine.

civ
Check the circuit for leaks.
Replace the road wheel.
Lower the vehic)e to the ground.

nav

* 85318532
* 8531-8532
REMOVING AND REFITTING A REAR
2 433.1/2
AND CYLINDER
REMOVAL REFITTING
Jack up the rear of the vehicle. Position the suspension sphere with the contact
surface slightly greased and equipped with a NEW
sea!; hand tighten.
Depressurise the hydraulic circuits.
® MA 390.000/1).
(.0
(See
Extract the suspension cylinder hinge retaining pm (1), Ascertain that the suspension cylinder dust-guard
Fig. 1. contains LHM fluid. If not, fil) with 25 cc of fluid.
Disconnect pipes (2), (3) and (4), Fig. II.

Put the suspension cylinder!pneumatic unit into
Remove clamp (5), Fig. II. place.
Disengage the pneumatic suspension unit/cylinder Reconnect, Fig. II:

assembly.
- feed pipe (4) having a NEW sleeve-sea! fitted,
- overflow return pipe (31,
Grip the suspension cylinder in a vice fitted with soft
jaws, and introduce a 8 mm dia. rod in orifice A to - venting pipe (2).
prevent the cyhnder from rotating.
Tighten the vice MODERATELY.
Install, Fig. 1 and II:
Slacken the pneumatic unit using the chain wrench. -holding pm (1),
- clamp (5) without tightening.
Run the engine.
Set the height adjustment control switch to the «high»

position.
Make sure that the hydropneumatic sphere makes

contact with the axle unit. Tighten clamp (5), Fig. II.
Test the hydraulic system for leaKs.
Refit the wheel.

MA
433.1/2
85,608

* 8531-8532
SUSPENSION
:er
TOOLS TO BE USED
3505-T. BaH-joint extractor
6301-T. Equipment for positioning the haif front axles
6301.T bis. Front axle ocking too
6320-T. Anti-rol bar ink rod extractor
6401-T. Set of 2 clamps for fitting the anti-roll bar bearing

+-,
6602-T. Set of 3 stands
Modification to clamps 6401 T

See drawing MR 630-58131a
® 430/1 page 3
REMOVING AND REFITTJNG

AN ANT/-ROLL BAR
*
8531-8532
435.1/1 A FRONT ANTI-ROLL BAR
REMO VAL LH side
Raise and support the vehicie horizontaHy on stands

6602-T. Remove:
suspension cy)inder retaining pm (12), Fig. V,

Re)ease the pressure in the hydrau)ic circuits. Set the upper wheelarm )ink-rod nut 111), Fig. V.
height contro) switch to the "normal driving position".
C/)
O.. Uncouple the link-rod (13) from the anti-roll bar, using
Remove: too) 6320-T, Fig. VI.
- the road whee)s,
- the wheel arch rubber seals,
- both brake control valve securing screws,
- exhaust shields (2), Fig. 1,
- cover 13), base p)ate (5) from the height corrector RH side
protection casing and the casing (4) itself, Fig. 1.
Withdraw the anti-ro)) bar )ink-rod nut (14), Fig. VIII.
Uncouple and free automatic height contro) clamp
(1), Fig. 1.
Disconnect )ink-rod (1 5) from the anti-rol) bar with
:1!
Remove automatic height control rod (6), Fig. II. too) 3505-T, Fig. VIII.
(Pull out the an tf-roll bar to allow passage for too!

Disconnect the swivel track rods. 3505-T).
Disengage rubber gaiters (7) and plastic trim cover Strip down the anti-rol) bar, on the vehic)e.
c/1
18), Fig. III.
Loosen maintaining ciamp 19), Fig. IV.
Take off the screws (10) fixing the bearings to the

axle unit, Fig. IV.

ini
MA
435.1/1
...
_..
86.817
!.
86.813
v
II
86.826
VII

* 8531-8532
A MA
4351/1
Iv
v
y$.
6301
6 01 T hi
86.846

REMOVING AND REFITTING 1 MA
A FRONT ANTI-ROLL BAR 435.1/1
f
Extracting the anti-roll bar REFITTNG
Reassemble the anti-roll bar on the LH side.

RH side
Add the bearing items, (Fig. V):
'T1
Tum the steering through full lock to the right.
gaiter (41,
1. Lift up steering track rod (11, (Fig. 1).
- retaining clamp (5),
- the two half thrust cups 161,
2. Rotate by a quarter tum toward the upper sec steal thrust washer (7),
tion of the anti-roll bar (2), (Fig. II).
- spring 18),
- steel thrust washer (91,
Push the anti-roll bar to the left, (Fig. II).
,-.
3.
- the two halt ball-joints (101,
- bearing 111),
- ring (131,
LH side
-sheath 112).
Tum the steering through full lock to the left.
Coat all the parts with TOTAL MULTIS grease.

4. Lift up steering track rod 13), (Fig. III).
Put the anti-roll bar into place towards the LH side

a-0
5. Slightly rotate anti-roll bar (2), (Fig. IV). of the vehicle. ^<D
(Reverse the fitting procedure, Fig. IV, III, fl, 1).
`CD
6. Free the anti-roll bar from the LH side of the

vehicie, (Fig. IV). Reassemble the anti-roll bar on the RH side, in the
order indicated below.
Place the halt axles in line, (in the normal driving posi-
tion) using tools 6301 T and 6301 T bis (Fig. VI).
*
8531-8532
6 435.1/1 A FRONT ANTI-ROLL BAR
Wipe the bal/-joint cones, do not use solvent. Tighten the bearing which is touching the axie unit
correctly. Insert shims beween the unit and the
second bearing so as to secure it without exerting
Recouple any stress on the anti-roll bar, (one shim thickness
only - 1 mm).
- the LH ink rod with the upper wheei arm; hand tigh-
ten the nut (new NYLSTOP one),
Tighten, Fig. 1, screws (1) fitted with lugged contact
- the RH (ink rod with the anti-roil bar; hand tighien washers, to 2.7 mdaN.
the nut (new NYLSTOP one).
Tighten the nuts untii springs (5) and (8) turns touch,
Refit bearing fixing screws (1) and nuts (2), Fig. 1 by means of clamps 6401-T.
and II. Check that plate (3) has been fitted the right Siacken the nuts of each tool by 1/2 tum, Fig. III
wa y. and IV.
Equip each bearing with the set of ciamps 6401-T,

-''
Centre the anti-roli bar in the axle unit, Fig. V. The

Fig. III and IV, piacing the modified too! to the LH LH and RH ends of the bar should be the same
side). Compress springs (5) and (8) moderately. (The distance «1)) from the subframe, to within 2 mm.
aim of this operation is to hold both half ball-joints and
thrust cups in position).
Tighten retaining ciamping coliar screws (4) and (9)
to 1.3 mdaN, Fig. III and IV.
Make sure that bearings (6) and (7) are in contact with
the axie unit.
Remove c)amps 6401-T
IMPORTANT : if one bearing does not touch the axie,

proceed as foflows: Ful dust cover (10) with TOTAL MULTIS grease,
-00
in.
Fig. VI.
Return, Fig. VI:

- dust covers (10) and (13),
-ring (11),
- trim cover (12),
to their rest location.

.-r

1!L

* 8531-8532
MA
8 435.1/1

435.1/1 9
A FRONT ANTI-ROLL BAR
[
RH side: Refit, Fig. III
Tighten the anti-roll bar link-rod nut (1) Fig. i, to - the heght corrector protection casing (4),
5 mdaN. - the exhaust shield (5).
Attach the brake control va(ve. Tighten the screws

LH side: to 1.8 mdaN, equipped with contact washers.
Tighten the anti-rol) bar nut (3) Fig. II to 5 mdaN.
Reposition:
Fit the suspension cylinder pivot and pm (2).
- the wheelarch rubber seals,
- the whee)s.
Recouple the steering track rod to the swive),
equipped with washer and nut (now NYLSTOP one).
Tighten to 10 mdaN.
Refit the automatic height contro) to the height cor-

Check the front heights.
rector.
Adjust if necessary.
Reconnect the automatic contro( c(amp with the anti-
roll bar. (See MA ® 430.00/1).
Centre the automatic height contro( sideways in

the height corrector ball-joint to prevent the shde
valve from being stressed.
Tighten the automatic height control clamp to

1.5 mdaN.
Remove tools 6301-T and 6301-T bis.

t`7
*
8531-8532
SUSPENSION 43/2
TOOL TO BE USED
6302-T. Set of 2 chocks for positioning the rear axle.

A REAR ANT/-ROLL BAR

* 8531-8532
MA 1
2 435.1/2 A REAR ANTI-ROLL BAR
(
REMOVAL Position, but do not Ughten:

m
Raise the rear of the vehicie and support it on stands, - both half-bearings (6),
.-r
screw (5),
(31
-
- screw (4).
'1)
Depressurize the hydraulic circuits.

Centre the anti-roll bar in the rear ax(e unit the
Set the height control switch to the «norma) running» clearance at (ca» should be the same on either side
position. (LH and RH), to within mm.1
Available shim thicknesses:

Uncouple the automatic height corrector clamp and 0.5 - 1 - 2 - 3 - 4 mm.
move it clear.
Tighten bo(t (7) fitted with a contact washer, Fig. IV,

Take off, Fig. 1 to 6 mdaN.
- screw (1) and its adjustment washers at «b»,

- screw (3), the two haif-bearings (2) and shims (ca),. If necessary, place shims at «b» with a 0.3 mm
c(earance max.
Free the anti-roll bar from the R.H. side of the vehicle.
Reconnect the automatic height contro( with the anti-

roll bar.
Centre automatic control (9) sideways in the

0
Opp
REFITTING hoight corrector ball-joint, Fig. V, to avoid the

.£g
slide valve being stressed.

Engage the anti-roll bar towards the RH. side of the
car.
Tighten the automatic height control clamp screw to

Utilize tools 6302-T to place the ax(e arms in line, 1.5 mdaN.
(in the «normal driving» position), Fig. Il.
Remove tools 6302-T.
Lower the vehicle to the ground; check the front

,C.
heights.
Readjust if required. (Refer to ® MA 430.00/1).

ini
ini
MA
435.1/2 3
';i
1
[. t-
;..L
... - 1)
kul
Fri
85.602
6302T
-n.
Iv
E :
86.974

*
MA
471.00/1
__________
ED ED ED ED ED ED ED
XVS XVS XVS 390 TRX 390 TRX xZX XZX

1755R14 185SR14
<3'
7C7
:t7
175HR14 185HR14 185HR14 190/6SHR 190165HR
(_)
(_)
9 mdaN 0 5 1/2J14 5 1/2J14
6J14
15OTR 390 5 1/2J14 5
__________
9 mdaN
BAR BAR
A 2 A 2
CX2O
8 2,1 ED 8 2,1 ED
CX 20 TRE
A 2 A 2,2
CX 25 Pallas lE B 2,1 B 1,4
C 2,6 130 km/h maxi 2,6

E
C ED
A 2,2
CX25GTI 8 1,4
C 2,6 130 km/h maxi

E
ED
A 2,2 A 2,2 ED
CX 25 Prestige 8 2,2 B 1,4
C 2,6 130 km/h maxi C 2,6 ED

E
ED
A 2,2 A 2,2
CX25D
988
8 2,1 B 2,1
CX 25 D Paflas
C 2,6 130 km/h maxi C 2,6
E
ED
A 2,4 A 2,4 ED
CX25RD 8 2 B 2
C 2,6 130 km/h maxi C 2,6 ED

E
ED
A 2,4
CX25TRD 8 2 ED
C 2,6 130 km/h maxi

E
ED
A 2,2 ED A 2,4 ED
CX Limousine 8 2,1 B 2
C 130 km/h maxi C 2,6 ED

E
Turbo 2,6 ED

8531-8532
JMA
L 471.00/1
ED ED ED ED ED ED
6Q)
rr
185/70R14 195/70R14 195/70R14 195/70R14 190/65 HR 210/55VR
(_)
______ [jJ
51/2J14
:L25:: :25::
9 mdaN
(_)
6J14 15OTR 390 15OTR 390
t.[)
9 mdaN
-
AR BAR
A 2,2 A 2,2
0
CX2O
B 1,4 ED B 1,4 ED
CX 20 TRE
A 2,4 A 2,2
CX 25 RI
CX 25 Pallas lE B 2 B 1,4 ED
CX25 Prestige C 2,8 ED 130 km/h maxi C 2,8 ED
A 2,2
CX25GTI B 1,4

E
A 2,4 A 2,2 ED
CX25D B 1,8 (1) B 1,4
C 2,8 130 km/h maxi C

E
ED 2,8 ED
A 2,4 A 2,4 ED
CX25RD B 2 B 2 ED

E
A 2,4 A 2,4 ED
CX25TRD B 2 B 2 ED
C 2,8 130 km/h maxi C 2,8 ED

E
ED
A 2,4 ED A 2,5 ED
CX Limousine 6 2 6 2
ED
Turbo
C 2,8 130 km/h maxi C 2,8
E
ED ED
C`)
A 2,3
CX 25 GTI Turbo 6 1,5

tid
ED
C 130 km/h maxi

E
2,8 ED

MA
(II 471.00/1
__________
ED ED ED ED ED ED

185/70R14 195/70R14 195/70R14 195/70R14 190/65 HR 210/55 VA
5 1/2 J14 5 1/2 J14 5 1/2 J14
9 mdaN
FHA 5-45 FHA 5-45 FHA 5-45
(_)
6J14 15OTR 390 15OTR 390
9 mdaN
__ W CX2O RE
A 2,2
(5 W_
A 2,4
8 2,1 ED B 2
CX 22 TAS
2,8
(C)
C ED 130 km/h maxi C 2,8 ED
A 2,4 ED A 2,4
CX25D 8 1,8 ED B 2
C 2,8 (j) 130 km/h maxi C 2,8 ED
CX 25 RI
A 2,4 A 2,4
CX 25 Prestige
B 2 8 2 ED
CX 25 RD _______ _______ _______ _______________ _______ _______ _______
CX 25 Limousine
C 2,8 ED 130 km/h maxi C 2,8 (0
A 2,4 (0 A 2,4 (0
CX 25 TRD
6 2 (0 8 2 (0
CX 25 TAl
A 2,3 (0
CX 25 GTI Turbo
8 1,5 (0
CX 25 Prestige Turbo

8531-8532
4MA 471 OOI1
_
XVS XZS XVS XVS 390 TRX
175 HR 14 185 SR 14 185 HR 14 185 HR 14 190/65 HR
______ [jJj
t77
51/2J14 51/2J14 51/2J14
9 mdaN
6J14 150TR390
9 mdaNJ
_
'd'
2,6 130 km/h maxi
'V'
C C 2,6
A 2,2 A 2,2
CX250 B 2,2 6 2,2
C 2,6 130 km/h maxi C 2,6
A 2,4
CX25TRI 8 1,9 ()
C 2,6 (j) 130 km/h maxi
A 2,4
CX25TRD B 1,9
C 2,6 130 km/h maxi

5
IIII 47OI1
Fri
______
MXL MXL MXV 390 TRX

full
185/70R14 195/70R14 195/70R14 190/65 HR
______ Ililj
51/2J14 51/2J14
(_)
9mdaN
6J14 150TR90
- - ______
C 2,8 130 km/h maxi C 2,8 ED
A 2,4
CX25TRI B 1,9
C 2,8 130 km/h maxi
A 2,5 A 2,6
CX25D 6 2 B 2,3
C 2,8 130 km/h maxi C 2,8 ED
A 2,6
CX25TRD B 2,3
BAR BAR
A 2,5 A 2,6
CX2O
B 2,3 B 2,3
CX25D
C 2,8 ED 130 km/h maxi C 2,8 ()
II
A 2,5 A 2,6
CX 25 TRI
B 2,3 8 2,3
CX 25 TRD _______ _______ _______ _______________ _______ _______ _______

8531-8532
ENGINE TYPE
G_1
STEERING
(!J
OPERATIONS 25 25 25 Safan 25 Safari
20 22 25 Prestige 25 Limousine Petrol Diesel
_______ Petrol Petrol Dee Petrol Diesel Ambulance
-
SYMBOLS
Injection Turbo Turbo njection Turbo
OPERATION Turbo Turbo Familele Pamiliale
DESCRIPTION _____ _____ ______ _____ ______ ______ _____ _____ ______ ______ ______ _____ ______ ______ ______ ______
TEXTS
No.
><
829 AS
829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
______ _________________________ 0 ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
0
z\ 25/660
MA
Specification and particular features of the steering system X X X X X X X X X X X X X X
440.00/1
H H H H H H H H H
PDF compression, OCR, web-optimization with CVISION's PdfCompressor * 8531-8532
44OI1
/d/Z \\\
I
1 mdaN
I
7//F \\ Yf//
Y
7/
-
2,75 mdaN /
11°
-
1,4 mdaN
LN I3, 2,75mdaNI
j
lOmdaN
___________
- P=lå4mm A 8
- g+
2,5 '-1'L"-'\-' -"-1'f'- / 13,5
t31
*
C`)
8531-8532
MA
44000/1

*
_J,
iI
41
HTflU'
4
44O/1
85318532
1
LIST OF OPERATIONS APPEARING IN THE CHAPTER: VEHCLE CONCERNED 1
BRAKES ENGINE TYPE [
25 25 20 Salan 25 Salan
OPERATIONS 25 25 25 25 Salan 25 Salan
20 22 25 Prestige 25 limousine Petrol Diesel
_______ _______ Petrol Petrol Diese Petrol Diese! Ambulance
Petro! Petro! Prestige Petro! Diesel Diese! + +
Injection Turbo Turbo
SYMBOLS
Injecbon Turbo
OPERATION __ Turbo Turbo Familiale Familiale
_____ ______ _____ ______ ______ _____ ______ ______ ______ _____ _____ ______ _____ _____ ______ ______
(1)
DESCRIPTION
TEXTS
No.
><
829A5
'- 829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660
/
25/648 or
_________________ ______________________________________________________________________________ ______ ________ _________ ________ 25/660

_________ ________ ________ _________ _________
MA
0
0
boIs X X X X X X X X X X X X X X
450/1
MA
0
Specification and particular features of the braking system (2) X X X X X X X X X X X X X X
450.00/1
MA
451.0/1
Checking the run-out of the front and rear brake discs A X X X X X X X X X X X X X X
MA
451.1/3
Removing/refitting a front disc brake A X X X X X X X X X X X X X X
MA
453.0/1
Bleeding the braking circuit 0 X X X X X X X X X X X X X X
MA
454.0/1
Checking and adjusting the handbrake A X X X X X X X X X X X X X X
MA
456.1/1
Removing/refitting the ABS hydraulic contra! block A X X X X X X X
H H H
*
H H H H H
with CVISION's PdfCompressor
H
8531-8532
MA
450/1
1
5602 T 1
2437 T 1
80. 1854 12.821
OUT 104060T
80. 1855 13.725
In Iv

8531-8532
kii 45OI1
- Ø 260 mm 224 mm
2Omm 7mm
E
E
E
[
Emini l8mm
E 5mm
0,2 mm maxi
E
0,02 mm maxi
E
E
4-*42mm 2-*3Omm
E
E TEXTAR T288 TEXTAR T288 FERODO 2430 T

-
( 2/87)
E 11,5 mm l2mm l3mm
-
Emini 3mm 2mm 2mm
E
E

8531-8532
PAA
2 450.00/1
flE
260 mm 235 mm
3
Ø
0 E 2Omm l8mm
Emini 18 mm 16 mm
0,2 mm maxi
E
E
0,02 mm maxi
E
E
E
4-42mm 2-*4Omm
E
-1 - E TEXTAR T288 TEXTAR T288 FER000 2430 T
. 11,5mm l3mm l2mm

u.'
2mm 2mm
_
Emini 3mm
E
E
E
E

*
8531-8532
MA
4 450.00/1
iI
Till
III
2'
\\\`
r:
1
6,5 mdaN 1
1 1'

*
PDF compression,
8531-8532
OCR, web-optimization with CVISION's PdfCompressor
-
6 45OI1
*1
_w -7
__ IJ
1 + 1
fI 'lp
1
1 1
622bars

*
8531-8532
r
a'
a
0,1 -+ 0,8 mm
ABS

8531-8532
C'7
MA
"
450.00/1

BRAKES 45I1
TOOLS TO BE USED
5602-T. Support for dal gauge.
2437-T. Dial gauge with total recorder needle.
4060-T. T.D.C. dial gauge mounting.
CHECKING THE RUN OUT OF

FRONT AND HEAR BRAKE DISCS
* 8531-8532
2 45/1 FRONT AND REAR BRAKE DCS I1
Jack up the vehicte.
(Fig. 1 and II).

Before carrying out any check, it is IMPERATIVE
to bring the brake disc against the wheel hub.
To obtain this condition, fit and tighten two wheel

screws (1) opposite disc securing screw (3) (whose
tightening has been verified). Connect two 13 mm dia.
spacers (2) to wheel screws (1) to ensure a correct
contact.
Put the supports for universa) dial - gauges 5602-T

and 4060-T into place. Set dial indicator 2437-T,
with pointer as perpendicular as possible to the disc
face.
The run-out reading should not exceed 0.2 mm.

* 85318532
*
85318532
451.1/3 A FRONT BRAKE DISC
REMOVAL REFITTING
Support the front of the vehicie on stands. Make sure that the parking brake internal pad is in situ.
Remove the road wheel. Release pressure in the hydrau-

lic circuits and brake accumulators.
Refit, Fig. III
- brake disc (8),

Disconnect the wear warning wires (1), Fig. 1.
- screw (7), tghten the screw,
- NEW 0-ring seals (9).
Take off, Fig. 1
LSD
- spindle (5), Confirm that the parking brake external pad is in position.
- spring (2).
Recouple the ha)t-caliper.
Push back the brake pistons. Put screws (6) into place, Fig. Il.
Slacken screws (4), Fig. 1.
Fit, Fig. 1
Draw back the parking brake pads using the eccentrics. - brake pads (3),
- spring (2),
Withdraw, Fig. 1 and Il:
- spind)e (5), pushing it to its locking position.
- brake pads (3),
- screws (6).
Reconnect the wear warning wires (1), Fig. 1.
Uncouple the ha)f-caliper from the swivel and tilt it.

Adjust the parking brake.
Remove, Fig' III

(See © MA 454. 1/1)
Bleed the front brakes.

- screw (7),
(Refer to MA 453.0/1)
- disc (8).
Fit the road whee) and lower tho vehic)e to the ground.

* 8531-8532
tbi 45/1
__
II VI
'6H
III
VII
VIII
Iv
*
8531-8532
VI
VII
800tr VIII
'It.:Ii
IV
v
_,m
*
8531-8532
kii
LJ
I JEll
41 LHM

.+N
BRAKES 45I1
TOOL TO BE USED
650 1T Emergency brake eccentrc adjustng spanner.
r
`T'
EMERGENCY
CHECK AND ADJUSTMENT
*
8531-8532
MA EMERGENCY BRAKE
2 454.0/1
X31
CHECK AND ADJUSTMENT
Place the front of the vehic)e on stands. ADJUSTMENT OF THE EMERGENCY

BRAKE OPERATING CABLES:
Remove the front wheels.
Release handbrake ever to maximum extent
r-.
On each biake unit, Fig. IV
Ensure that the sleeve and ts end piece (7) are

ADJUSTMENT OF THE ECCENTRICS correctly positioned.
Remove, Fig. 1
Pull out each threaded end-piece (8) in tum and
- lock nut (2), measure ts protrusion «C)).
- adjustment nut (1) for operating cables.
Difference in Iength of the cable must remain the
o°'
same after adjustment. (This operation ensures that
-#.
5.0
Start the adjustment by the outer eccentric. the brake cable compensatoris in a centra/position).
Slacken, Fig. II
- stop (3) and make sure that levers (5) are on their Screw down cable adjusting nut (1) against lever (5),
stops «a» and «b», Fig. V.
- screws (4).
Tighten lock-nut (2) to 1.5 mdaN.
Tum eccentric (6) with TOOL 6501-T Fig. III, as

shown on the table below, until the pads just
contact the disc at the point of maximum run-out.
0
CHECKING THE EMERGENCY BRAKE
Operate handbrake lever severa) times.

L.H. SWIVEL RH, SWIVEL
Check that the adjustment does not change and that
the locking system opemates satisfactomily.
Outer Inner Inner Outer
eccentric eccentric eccentric eccentric Refit the front wheels.

Direction
up- down- up- down-
of
wards wards wards wards
adjust.
-w.
(Ctockwise, seen from the rear of the swivel)

.-.
Tighten screws (4) to 7.5 mdaN, Fig. Ii.
Apply same procedure to each eccentric of the brake

fl'
unit.
Bring stop screw (3) into contact with the brako unit
(tighten its /ock-nut), Fig. II.

ini
45/1
L-
(L 1
,
1
1
t:: 1
F
- -1-!;--
4
r'
c
yF D
__
86ii -________ 86.666
_ --_____
- Iv
tI.
it.
4
1186.660 86.662
II
v
bfr
-
6501 T
..---4
Il 86.664
*
8531-8532
BRAKES 45I1
REMOVING/REFITTING THE ABS.

HYDRAULIC CON TROL BLOCK
*
8531-8532
MA REMOVING AND REFITTING THE ABS
2 456.1/1
t}'
HYDRAULIC CONTROL BLOCK
f
REMOVAL REFITTING
Set the height control switch to the «low» poSiUOn Place the hydrauUc contro) block onto ts support
avi
bracket, Fig.II.
Depressurize the hydraulic system
Start screwing in by hand connecting nuts (4), (8) and
Dram the brake accumulator.
(10) and feed pipe union nuts (5 and 9) provided with
NEW sleeve seals.
Disconnect the battery.
Tig hten:
Re move:
- the spare wheel,
- the three nuts «a» securing hydraulic control unit
to ts bracket, to 0.8 mdaN,
- ABS control unit protection panel.
'''
the connecting nuts.
Uncouple the assistance cable from the centrifuga)

regulator. Recouple return pipe (6).
Unclip control unit (1), Fig. 1. Reconnect wiring harness 17).
Extract, Fig. 1 Refit, Fig.l

- screws (2), - trim cover (3),
- trim cover (3). - screws (2).
Disconnect Fig. H. e)ectrica) harness (7). Clip the assembly in place on the contro) block.
GG)
(12
Uncouple, Fig. Il Recouple the power cable with the centrifuga)

regulator.
- rear brake outlet pipe 14),
- supply inlet from rear brake control valve (5),
- fuel tank return pipe (6), Bleed the brakes:
- LH front brake out)et pipe (8), Apply the same procedure as for non ABS, vehicles.
- RH front brake outlet pipe (10), (See © MA 453.0/1).
- supply inlet from brake control valve (9).
Slacken the hydraulic control unit fixing nuts «a»,

Lä.
Fig. II.
Remove the block.

* 8531-8532
LIST OF OPERATIONS APPEARING IN THE CHAPTER:
c/)
VEHICLE CONCERNED 1
ELECTRICAL SYSTEM ENGINE TYPE
1
N1!
OPERATiON 20 22
25
25
25 25 Safar 25 Safan
Prestige 25 Lmousine Petro] D ese
_______ Petrol Petrol Petrol D iese l A m bu ance
Petrol Petrol Prestige Petrol Diese/ Diesel + +
l
Injection Turbo
OPERATION _
__ Turbo
Familiale Turbo
In/ection Turbo
Famihale
No DESCRIPTION _____ ______ _____ ______ _____ ______ ______ ______ _____ _____ ______ ______ ______ _____ ______
TEXTS
.
LLJ
°> 829 A J6T A 500 25/659 25/659 25/662 25/662
829A5
5 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_________________________ A Q ___ ___ ___ ___ ___ ___ ___ ___ ___ 25/660
MA
510.000/1
Electrical installation general characteristics
A X X X X X X X X X X X X X X
MA
510.00/1
Juncuonbox ALL MODELS A X X X X X X X X X X X X X X
MA
Instrument panel A
0
51000/2 ALL MODELS X X X X X X X X X X X X X X
MA
510.00/3
Positioning of relays and electronic controllers ALL MODELS 0 X X X X X X X X X X X X X X
t1!
MA
Arrangement of the electrical nstaUation
510.00/10 Q X X X X
MA
510.00/11
Arrangement of the electrical installation 0 X X X X
MA
Arrangement of the electrical installation 0
CAD
510.00/12 X X X X
MA
510 .00/13
Arrangement of the electrical installation
0 X X X
MA
510.00/21
Electrical diagram for sun-roof, optional fitting
0 X X X X X X
MA
Cruise control system
510.00/22 Q X X X X X X
MA
510.00/23
Automatic gearbox 0 X X X
MA
510.00/24
1986 Model Year Club Safari 0 X X X X
MA
510.00/25
Anti-locking brake system
0 X X X X X X X X
MA
510.00/26
Reinforced air-conditioning
0 X X
IVIA
520.1/1
Removing the instrument panel ALL MODELS 0 1
X X X X X X X X X X X X X X

ELECTRICITY 51OO/1 1
ELECTRICAL INSTALLATION GENERAL OUTLINES
PRESENTATION:
--3
The electrical system operations are cornposed of:

A main wiring diagram.
A circuit diagram.
- Lists of parts,
harnesses,
earth connections,
connectors between harnesses.
- A fuse table.
A lamp chart.
- Various circuit and wiring diagrams for special functions or optional equipment.
UTILISATION:
The wiring diagram indicates the location of the components, harnesses, earth connections and connectors
on the vehicle.
The circuit diagram presents the electrical circuits in functional way.

:-:
n°'
The components symbols in the circuit diagram are those shown on the symbol key (see pages 2 and 3).
'fl
- Several symbols can be used for a component and the item can be shown.exploded on different lines
E
according to the functions.

Switches are shown at rest, with vehicle stationary, and the doors closed.
The switches must be moved from right to left.
}U,
-
E
CD-
- The position of relay coil, generally to the left of the contact switch, is not compulsorily so.
+-'
- In cases where the selector switch is complex, the contact movements are shown in the manner to be
considered the most comprehensibie.
C2'
i--
--1
- The e(ectronic control units are not shown in detail.
Parts list: the parts are in the alphabetical order, and numbered.
The number of the item remains the same on all the diagrams provided the function has not changed. The
'L-'
parts list enables any item to be located on the wiring diagram (by means of letters and figuresl, and on the
circuit diagram (with a vertical line No). The identification of the connector and the ref. etter of the harness
attached to the part are also included in the parts list.
List of harnesses: it gives the position of electrical harnesses on the wiring diagram and the location of each
lead of this harness on the circuit diagram (capital letter in the middie of the wire).
+-'
List of earth connections: it indicates the location of the earth connections and the wires or connectors and
CD=
the connecting harnesses lletter «m», followed by a number).
List of harness inter connections : it indicates,
- the reference of the harness concerned,

- the type of end fittings: 1, metal contact or connecting pm,
U, clip or socket,
L-.
- the colour of the wire insulator and the marking or sleeve colour code,
`co
- the junction connector: number of channels, colour and channel involved,

the location of this connector on the wiring diagram,
+L-
-
the location of each channel of the connector on the circuit diagram.
..,
-
0
The harnesses are described in alphabetic order.
* 8531 8532
PDF compression, OCR, web-optimization with CVISION's PdfCompressor -
MA
ELECTRICAL INSTALLATION GENERAL OUTLINES
510000/1
Example:
Con nector
Location
iI
________________ ________________ ________________
No of channe)s Diagram)
1
Type W)re
Colour
______________
1
Marker No
Colour
Chan
Colour
Ler Type
'
3
______________
Circuit
1
Wiring
M V 3 B 1 N V 91
0 1 .. .. 2 .. U M 1
d5
- __________ _______ _______ 3

_______
Between harnesses G (LH front) & M (engine), there is a white 3 channe) connector. On channel the wire 1
is colour brown with a green marker and a fIat pm on the side of LH harness. On the side of engine harness,
it is colour black with a green marker ending in a clip.
_.0
This connector is found on "d5" on the wiring diagram (referred as round 0. This circie can inciude other
con nectors).
The No. 1 channel of the white 3 channol connector is to be found on line "91' of the circuit diagram
(reference 3B1 1
REF. MARKS: severa) ref. types are utilised.
Large capital figures identify the parts.

Large capital letters dentify the harnesses.
Small letters denote the colours according to the code below:
CD'
B: White G: Grey lc: Clear Mv: Mauve Ipurple) Or: Orange Rz: Pink
Bl: Blue J: Yellow M: Brown N: Black R: Red V: Green
(D=
When used on their own, these letters indicate the colour either of a paint mark or of a colour stripe on the wire.
..O
- When a horizonta) bar is over them, the letters identify the colour of the wire insulator.
Used in a box, a (etter denotes the colour of the connector.
+-'
Small figures: indicate the number of channels or the channel No. of a connector. Marking is on the insulator
_c".
O.-
linjection). The channels are numbered 1 to 10 but in fact, 10 is represented as 0.

'-'
Roman figures: are used to number the function diagrams and the columns on the junction box and to locate
the various outlet connections of the latter.
Example:
1795
This connector is the first one of the 2nd column (Il) of the junction box, situated to the right hand side.
-..
It isa brown IM) 10 channe) 0 connectorPi The channel is the 8th way (8) marked on the junction box,
3(M
starting from the RH side. From the channel is a black wire (NI, included in the instrument panel (Bl to junction
7.7
'-'
box harness. The wire has an interna) splice: the grey spliced wire (01 incorporates a black (NI marker on the
O.-
`D<
section entering the channel from 4 way white connector! 4B1 of lighting rheostat (795).
1
KEY TO SYMBOLS
er)
1. Socket connection 9. Manual swich 17. Engine

2. Pm connection 10. Permanent position switch 18. Indicator
3. Connector connection 11. Mechanically-operated switch 19. Resistance
avi
4. Screened conductor 12. Pressure switch 20. Rheostat

5. Fuse 13. Temperature switch 21. Winding (ielay, etc.)
6. Diode (rectifier( 14. Lighting lamp 22. Ground connection
7. Accumulator unit 15. Warning lamp 23. Electronic control unit
8. Capacitor 24. Delay unit
(1)
16. Sound equipment

51OO/1 3
1 17
+
2 10 18
rf_i
3 1
11. 19
HI 12 204
-mor
5 13O 21
6 ___ 14 22
7 15 23
IiI
8
_____ 16 24 [FL
TT 51J
* 8531-8532
LC)
MA
E--
JUNCTION BOX 510.00/1
The junction box is to be found under the dashboard, to the left (right on RHD) of the steering wheel. It combi-
nes most of the e(ectrical functions.
It is presented on page 3, as seen from above, the front of the vehicie being directed to the eft.
COMPONENTS:
- 14 fuses (refer to the table)

- A relay for the electric cooUng fan : Ri
- A relay for the rear window winder motor R2
- A relay for the front window winder motor : R3
A relay for the heated rear screen R4
'.O
- :
- A direction indicator unit : C

- A delay/timer unit for the windscreen wiper
- Connectors
Connectors:
26, all different, can be connected.

,..,
They are different by the number of channeis and their colour, each colour being attributed a specific casing slot.
Cl)
They are grouped by columns 1 to V (from lett to right( and stages 1 to 6 max. (from top to bottom).
All these figures are to be found either side of the conductor on the circuit diagram.
How to read the table (page 2): Example 111 0 M 9

B
Connector situated in the 2nd column (Il), ist stage (1).
It is a brown (M) 10 channe( (0) connector.
The (ead (conductor( is (ocated in the channel 9 of the connector concerned on the circuit diagram.
Function lead supp(ying the c(ock electrically: + permanent after fuse F7.
Wires and stripes (V i) Green wire with a black stripe.
Position (68): number of the vertical line on the circuit diagram where the channel and the connector in
°-'
question are to be found.

The etter positioned below indicates the harness which connects at that place: B (boxl.
Special features:
The two black 2 channel connectors used, cannot be mistaken: they ditfer by a 9 mm clip on the one hand
and a 5 mm fiat pm on the other hand.
tfn
The yeilow 2 channei connector and fuse F14 are used in cold countries only.
8531-8532
MA
2 510.00/1 ELECTRICAL JUNCTION BOX
Colour Colour
ellag.
Function Function
ar k er
Channe
Marker
Stage
oco
eSDL)L) Wire
ro2
Wire
o o = o c
L) CD L)
2 5 M 3 M Earth 106-201 211 Mv + lgnition 40
-M'
1 III 5 3 Bl 1 J
2 V L/H Front Side Lamp 201 2 V Mv + Ignition Switch 38
-1-
--
On Harness G
3 J Main Beam 212 3 V B Tachorneter 66
4 G V Dipped Beam 213 _____________ ________________________
G
-
5 V Bl L/H Direction lndicator 107
co2
III 6 6 B 1 3 Mv + lgnition Switch - Heater 20
______________
+ lgnition Switch Heater
.-.
2 J G - 27
1 3 5 B 1 0 Dipped Beam 214 3
2 J 0 Main Beam 215
H
3 R/H Side Lamp 202
-
V 5 3 R Heater Earth 24
D 4 J M Earth 111-203 216
- 5 V Bl R/H Direction lndicator 112 - 6 3 Bl Heater Earth 31

paj
_______________ ____________________________
______________
IV 1 0 J 1 Bl Main Beam 215
l 4 0 B Heated Rear Screen 162
.°_
1
2 J V Dipped Beam 213
2 Heated Rear Screen 163 3 0 Rear Fog Lamp Switch 208
' Boot Lighting 188
3
4
(3
Side Lamps
0f)
217
4 G N + Direction lndicator Switch 108
L/H Direction Indicator
Ribbon
5 G Bl 109
5 Rear No Plate Lamps 219 B
°°°
6 G M Earth 105
R 6 Stop Lamps 147 7 0 R Side Lamps 211
7 L!H Direction lndicator 109
o>>
8 G B R/H Direction lndicator 110

8 2 R/H Direction Indicator 110 + Direct Lighting
--+
9 N 201
,-.
3
9 Reversing Lamps
0
- Rear Fog Lampa 208 _____________
IV 2 4 M
- 0
1
Bl N + Direct Lighting
_________________________
+ Ignition Switch
Battery -
201
138
1 0 M 1
2 + Ignition Switch
Battery - 27
0 Main Beam 216
-
2 3
3 + - Ignition Switch
Battery 5
-
3
4 + - lgnition Switch
Battery 38
4 ________________________
5 B R Side Lamps 211
B 6 IV 3 1 N
- 1 Heated Rear Screen
-
7 _________________________
M V Hand Brake 90
8 + Ignition Switch 79 IV 4 6 J Windscreen Wiper Fast Speed 133
+'{'
N J R >>>
°-.
--
V
-
N + Direct 68 2 J Mv Windsc. Wiper + lgnit. Switch
Windscreen Washer Pump
138
.>E
0 V Bl Tachometer 65 3 G Mv 138
_______________ ____________________________ 8 4 3 Bl Wi n d screen Wi per Sl ow S pee d 134
Windscreen Wiper Parking
.>c ,>c
II 2 8 B 1 Side Lamp 204 5 G V 136
-- 0 Windscreen Wiper Timer 135
-17)
2 B G Hazard Warning Switch 111 6 3
3 B N + Direct 110 ______________________
<I'
4 L/H Direction Indicator

..- 4J=
B Bl 111 IV 5 7 B 1 0 Mv Windscreen Washer Pump 138

B
-
Mv + Ignition Switch
.°.
5 B 111 2 0 M Earth 6-80 138

6 B J + Direction Indicator Unit 107 3 J G Earth 160
---
7 B R/H Direction Indicator 112 4 M Cooling Fan Relay
8 M Earth 113
o 5 G B Horn 159
6
_______________ __________________________ 6 Bl Cooling Fan 7

Il 3 2 B 1 V Cigar Lighter Lighting 203 7 V 3 + Ignition Cooling Fan Relay 6
H 2
Il 4 3 M J Earth 94
Vi 3 J 1
1
2 B V Horn 159
2 J Earth 93 B 3 M + Horn 159
MB B
_______________
3
-
J Earth 92 ________
V 2 4 Bl 1 Bl
_______________
Rear Window Motor 116
(Il
5 3 B 1 V 3 Rear View Mirror De-Icing 158 2 J V Height Corrector Earth 141

2 V B Heated Rear Screen Switch 162 H 3 N + Direct height Corrector 144
-
3
_______________
H 3
--
V Mv + Ignition Switch
IHeated Rear Screenl 162 _____________ --
4 3 B + lgnition height Corrector
_________________________
139
---
V 3 2 N 1 N + Battery - Junction Box 2
1 2 M 1 J Earth 204 189
G N + Battery - lunction Box 2
H 3 N + Cigar Lighter 90 ______________ __________________________
Windscreen Wiper Fast Speed
<C<
V 4 5 J 1 3 R 133
2 6 M 1 G N + Stop Lamp Switch 147
2 G M Earth 90 2 3 Bl Windscreen Wiper Slow Speed 134
Windscreen Wiper Parking
>c_
3 0 B 136
D 4 3 N + Ignition Windscreen Wiper 137
H 4 V R + Glove Box Lighting 187
_______________
5
6
G
V
Stop Lamp Switch
Hand Brake Switch
__________________________
147
90
V 5 4 3
-
5
1
J
J R
Earth Windscreen Wiper
_________________________
Starter Solenoid
134
5
3 2 N V + Direct Radio 191 2 G Bl Reversing Lampa 33
+
1 R
_______________
H
--
2 1+ Ignition Switchl
__________________________
G 3
--
4
G + Ignition Switch After Fl
+ Ignition Switch Rev Switch
34
33
,-.
G R .
____________________________
III 4 4 B 1 Ignition Switch + C lF3l 138
2 Ignition Switch + lF2l 27 V 6 3 Bl N Rear Window Motor 128
-}-
C R 1
3 Starter Switch H 2 G R + Direct Alter P7 179

Ignition Switch + lgnition 38 3 M + Direct Rear Cigar Ligther 139
-?-
4 C 3

ini
J-j
*
85318532
..i
12) INSTRUMENT PANEL 510.00/2
INSTRUMENT PANEL CONNECTORS
*
8531-8532
Connectors Colour Connectors Colour
Location
- - .2
Marker
Circuit
Circuit
-
co co
Marke
Function Function
Wire
-
Wire
Col.
No.
No.
'ON
o d
0o
. co - co
____ co
o
0 ____________________ ___ ____ 0 _____________________ ____
al
510.00/2
3 B 1 M B Eng. OU Pressure Sensor 91 3 B 1 M Choke 84 0
M G
Eng. OU Sensor
93 8 2 Diesel Pre Heating 0>
0
M Front BuIb Failure
3 B 1 N V Low Fuel Warning Lamp 94

M R 'Stop" Warning 74
2 2 N J F ue l G auge 95
1
______ -
6 B
3
1
-
M
B
J Fuel Transmitter Earth
Instrument Lighting 105

96
9
2
3
4
5
M
V
V
V
V
M
Mv
B
HydrauUc Warning
Eng. OU Low Pressure Warning
Water Low Level Warning
Water Temp. Warning
80
79
77
73
'
L/H Dir. md. Warning 106 6 V + Ignition Switch 80
-}-
2 B Bl N
Battery Charge Warning 89
I'-
3 Seat Belt Warning 7 M Bl
3 4 V Mv + Ignition Switch (After F2( 85 8 M B Eng. OU Temp. Warning 70
5
6
G
N
M
8
Earth
R/H Dir. md. Warning
107 - 211
108 ______ --- - \
9 Water Low Temp. Warning
_______________________________ ______
0 0
0
6 1 N M L/H Rear Door Warning 100
4 B 1 N Mv + Ignition Switch (After F2) 65 2 V Boot Door Warning 102
-
2 M Earth 66 3 V G R/H Rear Door Warning 101
3 Diesel TDC 4 M B L/H Front Door Warning 98
_______
4 V
--
4
1 V B
Tachometer
Turbo Pres. Warnng

65
64 ______ --- - 6
5 N
V
B
R
R/H Front Door Warning
B onnet D oor W arn ng
i
_______________________________ ______
99
97
2 V G Anti-knock Warning 63
3 9 V 1 Yelow Warning
. econoscope
4 2 Red Warning
U-)
3 V M Brake Pad Wear Warning 85
4 - 1
11
4
5
M V Hand Brake Warning
Rear Fog Lamp Wrning
90
2
6
<<<
3 6 V R Side Lamp Warning 211
______ - 4
_______________________________ _____
'
7
8
V
V
Bl
J
Dipped Beam Warning
Main Beam Warning
212
214
_________
7
3 B 1 M R Earth
Test
Warning
Rear BuIb
Failure
Unit
81
82
83
_______
1 2 2 B
-9
1 M
Clogged Filter Warning
__________________________________ _______
ABS Warning 103
2 V Mv + Ignition Switch ABS 103

*

co
LO
co
co
Lo
co
8531-8532
Z`1)
LOCATION OF THE ELECTRONIC CONTROL 1 MA
UNITS AND RELAYS (AI Models) 510.00/3
*
LO
8531 -8532
MA 1 LOCATION OF THE ELECTRONIC CONTROL
51000/3 UNITS AND RELAYS (All Models)
J
POSITIONING OF THE ELECTRONIC CONTROL UNITS AND RELAYS
No. Description Location
(.J
54
IS)
ABS Control Unit G
57 Fuet Caiculator Unit A

60 Air Conditioning Controt Unit A
76 Window Winder Unit F
80 Speed Regutating Unit E
81 Heater Controt Unit A

84 Water Leve! Unit L
87 Water Temperature Unit B
89 Door Locking Warning Linit A
C3)
90 Door Lock Controt Unit A

91 Remote Controt door Lock Unit C
92 Interior Lighting Timer A
93 Buib Failure ndicator Unit (SaIoon) H
93 Buib Faiture Indicator Unit (Safari) J
110 Heater Plug Control Unit K
127 Side lamp Audib(e Warning D
141 Ignition ECU K
142 Injection ECU E
tfn
151 Water temperature Ftasher unit B

658
UTI
Biower Speed Controt Unit E
731 Fuel Injection electronic Relay M

733 Air Cond. Engine Fan Re(ay K
734 Injector retay M
735
111
Main Beam Relay D

739 Height Controt relay B
743 Air Horn Compressor Retay K
avi
745 Blower Motor Fast Speed Retay A

750
t!1
Fog Lamp Retay 8

756 ABS Electro-Valve Relay L
757 ABS Protection Retay L
772 Blower Fan Motor 2nd Speed Retay K
773 Engine Cooting Fan Inverter Retay K
775 Starter Motor Safety Retay (Auto GIBox)
it)
8
Fuel Heater/Starter Motor Retay (with diode(
1,4
778 K
779 Fuet Heater Ou pressure Relay (with diode) K
781 Main fue( Heater Retay K
Al Engine Cooling Fan Retay B
R2 Front Window Winder Relay B
R3 Rear Window Winder Relay B

R4 Heated Rear Screen Retay B
Windscreen Wiper Timer Relay B
C Direction Indicator Unit B

MA 51OOO/3 3 4 MA 510.00/3
/\ r
----
TT
772-rr
773J jj
/ // 778 L8O
/ 779
781 V/
1
.....
i..

510.00/10 1
2'MAI
510.00/10
CX 22 TRS
7/85 -+
PDF
8531-8532
MA 510.00/10 3 4 MA 510.00/10
}F4 -CX 22 TRS 7-85

Ö
229
-CX 22 TRS- 7-85
riv
Fl F2 F5
iG
&lj
84BI
Is
Ri
1Ix5I B
---4_____T
1
______ Mv lMv
___
___ [1
__
__ - ----j-»_________
---
r
1__ 2B 6B
RC 1 _____
13M213M11 rfl 180
® B4ffJ_t
N
RC
vv ::
I__.
570
tt
1 1112
420
-__:-T
SIW
6M3 B2
i_ N GH
SIF
31<
' B B
*' H
_
yR k{B NBt NM
1
1
V4 V
lJ
G J J 1 i
( 1
Zv 1 4
1
{B
r
LMT
T
T1 vv
'
IN N
JV
;254I-(_(j'
--I
F--
640: BLL T T T T T T
'
IN
T T T
Ini
T T
1
jK G-l
3M37 j
P P R L
125M3
uti
r_____
635
rH
c ____
279
ii1rL
CA
L 1
L L L LL L L * 1
w
52J
ffJ
-13
1 7M Q
'j1
'4
271 658 uT rk/1 VB4 vii
11M TTTT
:
45E:
nål
R
31`
1 j B
MO
uR J
H r __ I4
Itu
__
I8L I5
BAM
1
WI
1
1 1B
1GGHHHGHHHHHt
:
B B B
1 1
815811
J li
__ 'l 'BB
1
K:
_
M7P M
- ___ d4!
__ _
1
L J
- ________
__l&2
B B1
VR
1
G1R
dra
G J
1301 Jul
___
____ 3
ner)
N N
1
o==
GLI
M l
...
-'-- o-' - J J J 238 x 114 113
VVS
,
'
1
5M dB7
CPRM RC PC 81
go QPTN
v
1
M M
1
788 Z 3 VBI
___________ M6 IM
N2N7Nf ___ PG R R PCPC
CPCA nu _____
_____
_______
IBh 84 r---I-- I
1
0
8
___ [/
flJ4
L.1
LL]2B2
__:
Ic
853 JJ21 M
T w w
II
Bl B2 1 l T 810 1 1
811
Ii Ii K K ____ _______
582rB3j
bN5N6I2
vVl 239 lo «1iBL
__
I
23 241
MJ LUI
Ti G 0 L JL lo 6 V 521
v FF ZZZ ODD 835 580
331
1931 Ic
-JRJ
2'
I-.
M
Il 27
________
_________ iM
1
________
1
1
'
Il J5B5I5B ?
______
_______ 279 M 480 1
:
481
L1
1
liI31, 06 LV LV
I
_______
13N13N13N1 5 VM
____ 242243F -
22 ___
____ _____ M M 8
11ijM __
__
___
___
1
8237 Vtc
P0 ww
O-n
t
RM cli
lic
1
235 NVN
j
S5
fl
mm-
2M 1
'B 81
L 855
iEi
M
le 1e850 Fl
1
Q
[E} ___
463
____
____ ______
_______
_______
_________
65
G
190
Fl1 8 8
L 4 3 _____
160116611 1
V H H PG B
///////
_____________ ic 3
1181 6 d bd C F F
300 _________ __________ _____ __________ __________ 4304j 431 G V'8 BI 0
.mo
1 EG
Lic 2483
__________
ic
h H rih Fl
H
_
1f_
Fl _
PC 727 _________ _____
,1 ft - 0
X13
IM JC
Mij IL k
I-,
Itu
i-,
81
Ml 83 M IM
B2 7B2
F]
1
.-n
111j6
m7 1 2 11112
11!:_1t_14
m3 m3 m3 ml' ml 1 ILJ Fj, m3
,,,
54j1 112 113 11j2
____________________________ 1
16
1
j
1 1 1 1 1 1 1 4 1 4 1 1
1 1 1 4 1 1 1 1 1 1 1 1 1
1
1 1 1 1 4 1 1 1 1 1 1 1 4 t 1 4 1 1 1 1 1 1 1 1 1 1
1
10 20 30 40 50 60
..n
2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 2 3 4 5 6 7 9 2 3 4 5 6 9 4 4 10
1 11 1 7 8 i 2 3 5 6 7 8 9 1 2 3 4 5 6 7 8 1 2 3 5 6 7 8 9 1 2 3 4 5 6 7 8 9 80 1 2 3 4
PDF compression, OCR, web-optimization with CVISION's PdfCompressor 151.171 1 51.172

(/)
ARRANGEMENT OF THE ELECTRICAL INSTALLATION
510.00/10
C77
1II
LOCATION CONNECTOR HARNESS
REF. DESCRIPTION _________ ___________ Number (or uni t)
C"')
__________________________________________________________ - Circuit Wiring Channel-colour ___________
1 Front cigar hghter & lighting 137-151 5 3B-lV H

5 ignition distributor 30 to 34 3N Z
lN lic
zzz
10 Alternator 51 to 54 h6 + CA & M
25 lN + lN
Ok-I
A & 8 Horn 107 - 108 c7 A
45 Battery 1 b8 lN + lN CP & CN
46 *
6,3
Instrument panel 36 to 73 159 to 162 g6 T
50 ignition coil 30-31 1 N + lic G
75
Ner'
Ignition module 30 to 32 7N 7
81 interior heating control unit 21 to 24 hS 8N K
84 Coolant leve! indicator unit 41 to 43 e4 5B D
89 Door locking ndicator lamp unit 131-132 j5 5N H
90 Door locking control unit 124 to 134 j5 9V H
91 Remote control door locking unit "PLIP' 120 to 122 n5 8N
_.-
P
92 Interior lamp timer 117 to 122 j5 7M H
93 Buib failure detection unit
27,46 to 48, 74-75, 104-165 s8 3B + 68 & 6J L & W
95 Junction/Fuse box * g8 * *
127 Side lamp audible warning 122-123 g6 5N T
130 TDC sensor 28 3M
170 Boot light switch 136 lM
N++N-
s6 E
174 Boot door locking switch 126 2M
,-.
tS C
lN + lV
C,1
180 Reversing lamp switch 27 d6 G
185 Stop lamp switch 104 h6 lN + lM H
190 Hand brake switch 55 k5 2M H
225 Carburettor choke switch 49 10 8
229 Ignition switch 4-30, 44-95 h7 4M + 48 1951
230 LIH Front door switch 119 t9 1 M H
231 R/H Front door switch 120 fl lM H
232 LIH rear door switch 122 I9 1 M H
233 R/H Rear door switch 123 kl lM H
234 Giove box switch 135 f3 1 Ic + 1 Ic H
235 Hydraulic fluid low pressure switch 46 lM
fl.
e6 G
236 Hydrauhc fluid leve! switch 45 e8 Ic + M
-f-
1 1 G
237 Coolant low leve! switch 41-42 e3 3R D
238 R/H Front door lock switch 64 ji 28 H
239 LIH Front door lock switch 63 28 H
241 R/H Rear door lock switch 66 ql 28 PD
242 L/H rear door lock switch 65 q9 28 PG
243 Boot door lock switch 67 c5 2M C
244 Bonnet lock switch 62 aS 2M V
,(D-.
251 Height control switch 96 to 100 j5 2M & 4M H & 1608!

254 Lighting/Direction indicator switch 72 to 75, 57 to 163 g7 58 4M 3M T
255 Windscreen wiper/Washer & Horn switch 90 to 95, 107 g6 48 58 28 T
268 Air recycling switch 15 to 17 hS 4J 0
271 Air distribution switch 12 to 14 h5 4M 0
278 Blower motor speed control 18 to 20 h6 38 0
23 to 25-68 58
S2°
279 Heater control & Lighting h4 K

'lt
300 Starter motor 2 to 4 bS 1 N & 1 R CP

365 Ashtray lighting 152 j6 28 H
370 136 lc
c-'-
Boot lighting s4 1 N & 1 F

375 Glove box lighting 135 f4 IN & lM H
380 Engine compartment lighting 150 c6 lN EC
385 L/H rear number plate lighting 166 t6 lic + lM E
386 R/H rear number plate lighting 167 t4 lIc + M

+
1 E
390 Steering lock lighting 156 g7 lIc + 1 Ic T
+-{-
,?.
420 Carburettor idle cut-out solenoid 25 1 N M

430 LIH front brake caliper 48-49 d9 2N + lN Ulg.)
431 RIH front brake caliper 50-51 dl 2N + lN U!d.l
-f-
440 LIH front side lamp 149 a8 2M G

441 R/H front side lamp 151 a2 2M D
442 LIH rear lamp 165
443 R/H rear lamp 166
60
NOS
445 L/H rear lamp cluster t8 F

446 R/H rear lamp cluster t2 60 F
457 L/H Stop lamp 104
*
Particular Specification
ill

8531-8532
MA ARRANGEMENT OF THE ELECTRICAL INSTALLATION
6 510.00/10
..a
CX 22 TRS 7/85 -
L0CATI0N C0NNECT0R I-RN
Z
S
REF DESCRIPTI0N ________ ________ Number
1
Circuit Wiring ChanneLcolour
458 R/H stop lamp 105

460 L/H rear fog lamp 1 56
461 R/H rear fog lamp 157

462
--I
L/H reversing lamp 27
463 R/H reversing lamp 28
470 Fuse g8
480 L/H front direction indicator 73 a7 30r 0
481 R/H front direction ndcator
h(-
76 a3 30r D
482 L/H rear direction indicator 74
2.2
483 R/H rear direction indicator 75

486 L/H long range lamp connector 159 a7 2B G
487 R/H long range lamp connector 164 a3 28 D
488 L/H headlamp 160-161 a8 31c 0
489 R/H headlamp 162-163 a2 31c D
500 L/H front loudspeaker connectons 139 g9 18 + 1 R H
501 R/H front loudspeaker connections 141 g9 18 + 1 R H
502 L/H rear loudspeaker connections 142 k9 28 RO
503 kl
7?T
R/H rear loudspeaker connections 147 28 PD
506 L!H front tweeter connections 140 h9 28 H
507 R/H front tweeter connections 140 hl 28 H
n30
511 Rear fog lamp switch 156 to g5
01
158 881 8
01C0
paj
3-0
519
=_=
LIH window motor switch on driver's door 85 87 to h9 58 PC

520 R/H window motor switch on driver's door 80 82 to h9 5M PC
521 L/H window motor switch on passenger's door 85 87 to hl
-.j
58 PR
532 Heated rear screen switch
03'
110 to 112 j5 SM P
545
(il
Interior lighting switch j5
Zon
114 to 116 58 P
570 Hazard warning switch 75 to 78 g5 8N B
580 Fuel gauge transmitter 59 to 61 g6 lM lN 1J J
600 Windscreen wiper motor 90 to 94 e4 58
0
D
608 Height control motor 97 to 103 j4 38 H
615 R/H front window motor 30r
0
80-81 g9 LV
616 L/H front window motor 85-86 gl 30R PR
621 Air intake motor 15-16 e3 28 0
622 Air distribution motor 13-14 g4 28 0
625 R/H front door lock motor 125-1 27 j9 2M-3B H
-+^
626 L/H front door lock motor jl 2M-3B

.-.
128 to 131 H
627 R/H rear door lock motor 125 to 127 p9 2M-3B PC
628 L/H rear door lock motor 128 to 131 p1 2M-3B PD
n.-
629 Boot door lock motor 131 tS 28 C

630 Fuel flap lock motor 127 s2 28 X
635 Engine cooling fan motor 11 a6 1 M-l R V
640
7c'
32 to 34 f5 4M
C+')
Clock BA
650 Engine ou pressure switch 44 d3 lM RC
658 Blower fan speed control module 20 f3 V-l Bl 0
fl.
680 Windscreen washer pump el

fl-
95 2N D
690 Central interior Iighting 113 to 115 nS 1N+2xllc+1M P
695 Front interior spot lamp 113 nS lN-lM P
698 Headphone socket 143 to 146 k5 SB H
710 12 V supply soket 89 k5 lN + lM
,-.
H
721 Radio connections (l2V and loudspeakers) 1" +" [SI 1R+4x2B
O__
- &, 139 to 147 kS H

727 Carburettor mixture heating element 7 lIc RM
735 Main beam relay 163-164 q7 5N T
739 Height control relay 98 to 102 f7 SN H
745 Blower motor fast speed relay 18 to 20 g4 5N 0
778 Mixture element temperature relay 5 to 7 SIc
.O.
RC
1-o
779 Mixture element engine running relay 8-9 Sic RC

781 Mixture element engine starting relay 6-7 SN RC
788 Engine cooling fan resistance 11 38 V
795 Lighting rheostat g6
810 L/H direction indicator repeater connections
62 48
11cM + llcV
- 8
,n,.
72
-22
e9 G
m°°
811 R/H direction indicator repeater connections 77 el 11cM + llcV D

831 Interior temperature selection motor 21 to 25 gS 58 K
835 Ou level sensor 67-58 c4 28 M
839 Interior air temperature sensor 24 jS 28 P
850
853
2 stage engine cooiing fan thermal switch
Mixture element tomperature thermal switch
11-12
5
b6
-
1JV
3lc
+
-
1JM
V
RM
855
CDCD0
Max. cooiant temperature thermal switch

935
39 c4
- 18
lN + lN
M
0
-0-
Blower motor 19 dS
945 Heated roar screen 111 r3 to 7 lN + lN F + ML
980 Door locked warning lamp 132 g9 lIc + lic H

MA 510.00/10 7 8 MA 510.00/10
J-B---
''P
.oms
TTN Å
-CX22 TRS- 7-85 ____
L0r
l17
Ò'
Ö
i--
i}.
143J
229
_ _____
lej
Fl
IJ
1-I
"'2
Y 6 m12 1 14 IIU1 111 3 L,J
0J7 .
t4
______ ________ Ni
_____________
- ___
01 GIR
B 735
iN
1L7
v gjp
VR B
.'D
B
z
____________________________
-
LM
____________ _________________________ _____________________________________________ ________ R L
r4TJ
,
H
Z-O
1J
i--d;
1
<I3
31m
-
185 vj 721 721
[3 3] 6J2 I0I ___________ _____
R2I T- M
__ - ¶ BR rjj;:;
__ T
1
T T
T (TO.)
6 M 127 N
___
_____
______ IL
ir1
1
1
1 Fly BMv VVN P T H

NIi
__
3R1
£v1
:F Hj4:
ABS
-H _____
.o!
'N
- __
Radio
di N
[oiJ
v
1
i 1
5 N N B V B V Bl M BIV J V M
o BB J
69 R 1 v 1
R
1<I
Vii
1
V
HH
' 7
N
IL2 H Fl H 721 i
r?I 2
H
r111l {
JL 9VY7
1-
Ism
NVM
RTg1g-
J M3
tVN
1
__
-
. M 231;F
rIl 89 I( G D H
- :
91
uIRJiJGv H: i ___
t11
25SF MI69O
-
L
5B25B35
JM I2 p
__ Rc L ----
IQ,
__
EbG
1It--w_251
T T T T T
_J
HHHHH
1
'
_____
:-
_______________ B
-VBBIE _______
__
1L - Fl 1 1
___________
r-G
,>m
Er H
LBI ;11iJ
MllJl3Bl
V a H ,
1519
TR
'l
G1V
Bi
ii
R
_
B2
e
1
__ M22$J __ TIVMv
__
8 w
____j __ __
B B B
PC PC B
KPLI L365 1
__
j
F
5V
_________ I4J91 VRM VR M
B 'Mv
__________________
_____
________ _____
___
1
________
_________
ini
II?M1J1 P
t!
J
3B1v1
It@
_
M
4V 'B 563
S81
M dE&
'GM it
t21
: 7 'L
83 J
44Jl -V
all
VJG H H H ___________
H H r---- -GR
G T PG pGi
VIJVIG
PD pJ W
R
1
B ri lV1fl1l Mv
E
I
93 4I3
j _ IN
V(N
TN ____
7°C
_7
R R P H V c
8 jRJB( GBJ
L--
__-L-_ _
Bl
___ _
628 v P6 PD
_
!
1 1
N F1O
H L J 6J
Pp PP PP 386
N
12121313
1
I
d8 N EC
___ ___
__
B1 5B2 114
___
l
G
'
1
oas
r ?' w tRL
- Mv
--- 37or;
I-+
E4
B35B -t-:i
III
5
__________ 3
i JJJ 502
é
&R
15
R
ml>
S<1
G
v 6 V MvV Ml Ml
0
0 0 0
;!1
_
,v j [192 N V M
B&
J1
V V B
IM VIM
-W1
___ i- 5O3 m6
Gal
6600'r
f P6 P6 P0 P0 G Ii
L 1
OH w w _______
________
>1 ;oibi
Mv
rrr
°'m
ivi la 'M V M
1
IM B
il'
1
_..
3I3
JRJBI 683 VM VB
/.8
VM
3M1
WF ÉD H I
v Mv E
HHFF H-
_
PP PP B3c -.
H
5WM
EJ :1G
__
__
210
`.0
VÉ
_____
V IRO - ____
_____ P6 P0
fJ
___________ % lI Ii
1F
°O_
Bl
VLJR 231
j X H w
u`3
V'j
232FBl
c!
r'
cal
)N VR
-AV
-:F
23O V lJ MvVMv
02
___
rE4j_rN51 N3
H F Ml 31c 31c 31c c
-6 M
F\L,
1
,!
J441;,
l
28 4O
d Z_=
1 1
i-,
231
Nits
2B2 661
0 N
all
cal
FJ! 2r
L'7
6 _________________________________________
1
42
__________________
782
m3 m3' 78 r
TTT 44 TT
5 2M 888
13ffl162 Gmi/
1 1 1 1 1 1 1 1 1 1 1 1 1
--
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
C)-
1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1
5 6 7 8 9 90 1 2 3 4 5 6 7 8 9 100 1 2 3 4 5 6 7 8 9 110 1 2 3 4 5 6 7 8 120 1 2 3 4 5 6 7 8 9 130 2 4 5 6 140 4 150

1 3 7 c 1 2 3 5 6 7 8 9 1 2 3 4 5 6 7 8 9 160 1 2 3 4 5 6 7
PDF compression, OCR, web-optimization with CVISION's PdfCompressor 151.172

151.173
51O/11 2 51O/11
LOJ
CX 25 GTI
7/85 -*
PDF
8531-8532
MA 51 0.00/11 3 4 MA 510.00/11
L2
785 __
37N
z
42 4
-CX 25 GTI
229 229
ffi 14
111
5
orl9
N
'V'
G
Fl Fl
N
T
Mv
vi
_____ ___ V R
180FM
4v
Ic
4B1
r4 4269
'0:
A b
- VMv 46
R1I 13
?IF
c
-
270 TD
BIE
935
837 ______
-C3
3N LJ L' 839. Ysi __ ------
- - _____
JN VMv
'NN -;1 0 1
M6Jc ___
III
III
Q
III
lM 3V2
N _:1-
-0±i --
-------
iMMiMiMFP ICO
1
745
_; J 11
21c
160k lj[4 R
jNJ4 VBBI 1
v1I
0 0 0 Ic Ic Il 1
CA 6 0 635 J7B31B4l!B6J 9M
IN 576 57 1
1i44i3
Ic dc J,
L=j
`7m
teE
: M'-
4
Q Q a Q Q 0 _______________ v '. i V V 24M 25
lic 12 1 J 8
o--
15
--0
1
1 8!
_______ BN1 8N2 8N1 8N6
[41 12 fisJ 24 25 1
856
ILS
GMv R N
, 8484
fil
lE 142 0 0 Z Z Z Z Z 7 7 Z Z Z Z BABABA
m<'
MB
I3)
B2
SIN
381
te-I
l-.
C1-1
F
- v
LLJ
111
N R 634 D 831 - Ml Mi IC IC IC IC IC IC IC IC N4 N3 Vii Vi Vi
N2 NiO tLJ
Ss:
i 12 V6
41034
ii
0
- 2°
(77
282
----
v
- ___ [ - - -
621 622
2 9 10 7
llJ11
8Vi
- Z Z Z BR
4[2
9l
T7H813M20 463 7 7JM
ii
<In
28o$L
H
61I
41/77/? 850
4j733 JV34V3V2 NI -
Bi28i
.Tmi z/m1
1
n1
j M
TT ________
_______ ____________________________
123456789101234567892012345678930123456789401234567895012345678 234567897012345
PDF compression, OCR, web-optimization with CVISION's PdfCompressor 6O
151.174
MA 510.00/11. 5 6 MA51O.00/11
-CX 25 3TI - 7-85

F5 (9
w-'
n--Gli
L8 8-
om}
T
46 R3 R21
iM
ini
Fl
'1J
-w.
zon
V6 ON
J IMv
281
3R1 255
Bl ABS
ANN
570
.>o
____________
Vi MV8I G NV NU Mi VRlBBt
T8tJ
cal
T V
T T T T T T T T
TM TT TT
PC
'1
254 IM
<in
MM :8 :BL L'J
3v3
L L L 19
3M3
31w T
IMV
Vi iF 1B1BLVMGV
IRIV
[5MJ
520 PC 1
-
VM L L L 8 :1
GBGG HHHGHHHHHG
1
X13
363 1
6 4M
IB
I-,
6 GABS
y
G
k (3 (3
1
BL Mv
L K3H N
++J VR VI i ii
''1
N M
`14
885
-r`
VMv NM G' Ml MMJ1 J J 238 101

?IIPOI)( (ABS)
te-I
R
V
EIJ
'p_
N
- 93
1102
PGI PC PC PP PP PP
M
07w
i lIc 1
hB) b
8) J! IL
___ _=J
1 1
650U H 1
810 W 811
j 521Lj
0<I
7IMVIR Ic 239 241
L ----- IL c
Ici
L
84 V
0 835 580
331
[r:
G fiiIc
l11
2M2
93
_I
1
I-,
JJR J i1V J1R
1Rd?' IM
tio
3<1'_____
M i
cal
mil
S2- LV LV PPPP
\N}
0 0 0 235 ,1
OU 1
PD
1
J ' L )R ) 1
Iv lpflU
}n{
_______
______
Iö3I3Orfl
J j.
---
VN 1
680
31N
2M 2M2 585
L--
-
'81
(>m
M 0i4 1
VIR Vi
l L - J
J[
1 1
Q,1
8 Bl H 5B2
- ____
02
190 rN51rI
F VHHPGI FF
4571 4518
__ J C 8
-VBVBL L
M - E6L I
___
___
31N
L 6 o 0
237 - 43 4 _____ 1 2483 -
Itu
1 6(316(31
___ ±
(3
m1 Fl 0 N
____________
Fl __________________
_________
m6
i G)
___ Fl 0 ________
123
`13
_______
M'BM'BMB avi 5
-(3M
W\3
M1
IM Iv
................ J!II
M JM
m3 m3 m3 mi m3 016 SM1 F
mi m3 m3
________________________ 'i
6789801234567899012345678 olOOi -
23456789110123456789120123456789130123456789140 . 1 1
1

151.175
MA 510.00/11 7 8 MA 510.00/11
-B---j J! JN VN
-CX25 GTI - 7-85 L

254 Mi
1-Z
L+0r
F8
[
- __________
V6
JF7
IN
TIT
1_y
mT3 1115 1U12 1
Jl
GLI
3B3 P2 B3
735
RIN
cal
______ V Mv GR B B
- -H----
III
--------------
Gli
'-'
---
I1
{:l
vi
vi
Wi
H _721 721[ F13 F12 II IF11
vivT
j532J
1
TT
1
2-2-
B
BM P
882
Irc
ii
>I>
[02]
Lfi
-
R R
-'l
Ii
X11
+
dnr
255L
Vi M
89[tK ¶ G
_-
0 41
QI '
LJ' ___ -J L/L\\_LL__
690
Ir- _ -
Lj
¶ :f
=-j
4-:
r
8 IV
J
1
P p p
___j
HHH T _____
-:: _ H El 1
____________
I>_
T A V8 BIVi VB 626 i1i H H
H tc G
M11B21
I`>
L
8 i m31
883
i ____
'II
8L
___ Mv
J
u
1I3
B
--------
KPLIP©I
_______ M2
1-TT b65
_______________
i
T 8 W
1I!
_...
1
vt__ VR M yR 1
)Ø 1
B B
Mv
F
11I5 14 14 1 L8J 91
__ ____ j __ __
tB2 _______ IF
I1>
P P I
JvIi
II 1IK3
18h
IB
i
isö
5
V1iV
482
IR
HH ____
Ti' _______ M TV J
z-2
vii
l;7
11 M 016 OJ 2 J1
I11
IB Mv
p6J P0 W 1
B E4
6 11J T P6 PDJ 4M3
[ ____
G11
VJN
Ic
11>
281 R R 0 Vi 2B 2
}--
83 7 628 P6 P0 fJjFiO
2 63
A 1
Vi JN
B
EC 1 2 1 2 13: 386
82 080
VN Bl
- __________
R
_________
__________ _________
__________ :ii JO
2
W NI
RI 502 R
VM M1
8
IM VIB V1M V 8
VIN1
503
34 OJ m6
P6 P6 P0 P0
2
WW >1 BlM 1 1
VM 501
w
B 6 6 D D
0)7
__ - iI V Mv
SIF
SIS
iI1 0 E
lA H M 5
__ --H JB
V M
WO 019 J1 H--- VB l Vii

P0
l H____
P
--O
O0_
231 x H - w
V
-GJJ VMv
230 232F 1J
H F 17 R -Mi Ml
440
486 487
"71
F
[]
1
441 vii
`_=
945 Fl Fl Fl 488 489
31N
2B2 651 651
?LN
________ -I
E 1
656606
174 c IM
Gli
Ni NI
_
ML
6 ______________________________ 0 651651
L'7
6 0
is 460
Ill
1 F JIM 1 J
721 721 721 1 NI
3M2 5 6M 888
,,,,,,
m3 m6 m3 m7
1i 12
1
-CD
1
12345678915012345678916012345678917012345678 918012345678919012345678920012
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
1 1 1 1 1 1 1 1 1 1 1 1 1
..n
`.'
ARRANGEMENT OF THE ELECTRICAL STALLATION
51OO/1 1
c-n
REP. LOCATION CONNECTOR HARNESS
DESCRIPTION Number
. . . . (or unitl
__________________________________________________________ Circuit Wiring Channel-colour
1 Front cigar iighter and (ighting 172-186 j5 3B-l V H

0
10 Alternator 86 to 89 b6 lic & lN M & CA

44 Digital display 67 to 74 f5 1 5V BA
45 Battery 2 b8 lN & lN CP & CN
46 Instrument panel 63 to 108 g6 * T
51 Ignition coii cyls 1 & 4 57-58 c6 . 3N Z
52 Ignition coil cyls 2 & 3 61 -62 c6 3N Z
57 Fuel metering unit (optionl 47-48 j5 4B 0
60 Air conditioning control unit loptionl
0
12 to 15 h5 7B 0
81 Interior heating control unit
LO
CAD
27 to 30 h5 8N K
84 Coolant level indicator und
-Q7
,..,
76 to 78 e4 5B D
89 Door locking indicator lamp unit 166-167 j5 5N H
90 Door locking control unit 159 to 169 j5 9V H

91 Remote control door locking unit 155 to 157 n5 8N P
92 Interior lighting timer 152 to 156 7M
f,,
iS H
93 Buib failure detection unit
33-109-110, 81 o 83, 139- 191-200 s8 3B 6B 6J L & 2xW

95 Junction/fuse box * * *
g8
0)-03
127 Side lamp audible warning 157-158 g6 5N 1
131 Flywheei datum sensor 60-61 c6 2M Z
132 Flywheel teeth sensor 58-59
0-)
d6 281 Z
136 ignition vacuum sensor 59 to 61 e3 30r CD
140 Mileage sensor (option) 50 e7 2B 0
141 control und
LO
,,-
(El 54 to 65 e8 1 5B-l SN Z
142 Injection electronic control und 39 to 49 g3 25N IC
170 Boot light switch 171 s6 lM + 1 E
174 Boot door locking switch 166 tS 2M C

--+
180 Reversing lamp switch 33 d6 lN-lV 0

185 Stop lamp switch 139 h6 lN-lM H
190 Hand brake switch 90 k5 2M H
192 Thrott(e spindle switch

'-'
45 to 47 b4 3N IC
229 Ignition switch 5-27, 38-130 h7 4M-4B 95
230 LIH front door switch lM
-,t
154 f9 H
231 R/H front door switch 155 fl lM H

232 LIH rear door switch 157 k9 lM H
233 R/H rear door switch 158 kl lM H

234 Glove box switch 170 f3 2x lic H
235 Hydraulic fluid low pressure switch 81 e6 lM G
236 Hydraulic fluid leve) switch 80 lic-lM

(ID
e8 G
237 Coolant low level switch 76-77 e3 3R D

,
*
Particular Specification

8531-8532
MA ARRANGEMENT OF THE ELECTRICAL INSTALLATION
1
510 . 00/11 CX 25 GTI 7/85 -
CONNECTOR
DESCR(PTION
LOCATI0N RSS
__________________________________________________________ Circuit Wiring Channel-colour
238 R/H front door lock switch jl

w`-
99 28 H
239 L/H front door lock switch 98 j8 2B H
241 R/H rear door lock switch 101 ql 2B ED

242 L/H rear door lock switch 100 q9 2B PC
243 Boot door lock switch 102 tS 2M C
244 Bonnet lock switch 97 a5 2M V
251 Height control switch 131-1 35 j5 2M & 4M H & 608
254 Lighting/direction indicator switch
107 to 110- 192 to 198 g7 5B-4M-3M T
255 Windscreen wiper/washer & horn switch
tid
125 to 129-142 g6 2B-4B-58

tfn
T
271 Air distribution switch 19 to 21 h5 4M
278 Blower motor speed control rheostat 23 to 25 h6 2B 0
279 Heater control & ighting 29 to 31-103-104 h4 5B K
280 Supplementary air control (injection) 38 b6 2N IM

285 Ignition suppressors (radiol 2xlN
'-"
59 & 60 b6 Z
295 Air horn compressor 143 c7 1MV-1N A
300 Starter motor 3 to 5 bS lN-lA & lN CP & CA
302 Flowmeter 42 to 44 b2 5N (C
345 Fast idling electrovalve (air con option) 14 d2 2xlV V

370 Boot lighting 171 s4 lN-lic F
375 Glove box (ighting 170 f4 1 N-l M H

380 Engine compartment (ighting 185 c6 1 N EC
385 L/H rear No. piate lighting 211 t6 lM-lIc E
386 R/H rear No. p(ate iighting 212 t4 lM-lIc E
390 Steering (ock lighting 2xllc

c--
191 g7 T
410 Air con compressor clutch 13 c6 lN V
430 L/H front brake caliper 83-84 d9 2N & lN U
431 R/H front brake caliper 85-86 dl 2N & lN U
440 L/H front side (amp 184 a8 2M G
441 R/H front side lamp 186 a2 2M D

442 L/H rear side (amp 200
443 R/H rear side lamp 201
445 L/H rear lamp ciuster t8 6G F
446 R/H rear (amp cluster t2 6G F
457 L/H stop lamp 139

458
tid
R/H stop lamp 140

460 L/H rear fog lamp 191
461 R/H rear fog lamp 192
462 L/H reversing lamp 33

ARRANGEMENT OF THE ELECTRICAL INSTALLATION MA
CX 25 GTI 7/85 51000/11

REF. DESCRIPTION ___________ __________ Number (or unit)
Circuit Wiring Channe)-colour
463 R/H reversing lamp 34

470 *
Fuses g8
480
:.p
L/H front direction indicator 108 a7 30r G
481 R/H front direction indicator 30r
C`')
111 a3 ,
D
482 L/H rear direction indicator 109

483 R/H rear direction indicator 110
486 L/H long range lamp 194 a7 2B 0
487 R/H long range lamp 199 a3 2B D
488 L/H main and dipped beam 195-196 a8 3(c G
489 R/H main and dipped beam 197-198 a2 3lc D
500 L/H front loudspeaker connections 1 74 g9 1 8 & 1\R H
501 R/H front (oudspeaker connections 1 76 g2 1 B & 1 H
502
(31
L/H rear loudspeaker connections 1 77 k9 28 PC

503 R/H rear loudspeaker connections 182 kl 2B PD
506 L/H front tweeter connections 175 h9 2B H
507 R/H front tweeter connections 1 75 hl 28 H
511 Rear fog lamp switch 191 to 193 g5 8 Bl B
519 L/H window motor switch on driver's door 120 to 122 h9 5B PC
520 R/H window motor switch on driver's door 115 to 11 7 )9 5M PC

521 L/H window motor switch on passenger's door 120 to 122 hl 5B PP
532 Heated rear screen switch 145 to 147 j5 5M P
545 lnterior lighting switch j5

.-.
149 to 151 5B P
570 Hazard warning switch 110 to 113 g5 8N 8

576 lnjectors 41 to 44 c3 4x2G IM
580 Fue) gauge transmitter 94 to 96 g6 1 M-l N-l J J
600 Winscreen wiper motor 125 to 129 e4 58 . 0
615 R/H front window motor 116 g9 30r LV

616 L/H front window motor 121 gl 30r PP
621 Air intake motor 17 e3 28 0

622 Air distribution motor 20 g4 28 0
625 R/H front door lock motor 160 to 162 j9 2M-3B H
626 L/H front door lock motor 164 to 166 jl 2M-3B H
627 R/H rear door lock motor 160 to 162 p9 2M-38 PG
628 L/H rear door (ock motor 164 to 166 pi 2M-3B PC


* 8531-8532
C'3
510 W11
LOCATION CONNECTOR HARNESs

DESCR)PTIÖN
_________________________________________________________ Circuit Wiring Channel-colour
630 Fuel flap lock motor 162 s2 2B X

634 R/H engine cooling fan motor 9 a4 lM-lA V
635 L/H engine cooling fan motor 9 a6 1 M-l R V
650 Engine oj) pressure switch 79 d3 1 M M
655 Blower fan speed transistorised module 25-26 0
,-«
f3 1 V-1 Bl
660 On-board computer 50 to 53 g4 .12N 0
680 Windscreen washer pump 130 el 2N D
683 Fuel pump
f2°
45 g4 1 B & 1 FP-MP
690 Central interior lighting 148 to 160 n5 lN, lM & 2 x lic P
695 Front interior spot lamp 148 n5 1 N & lM P
698 Headphone socket 178 to 181 k5 5B H

700 Air con refrigerant pressure switch 13 c7 2x1)c V
710 l2V supply socket 124 k5 lN & lM H
721 Radio connections 112V and )oudspeakers) («+»,- & H.P.)

..a
174 to 182 k5 lA & 4 x 2B H
731 Fuel injection relay 38 to 46 a2 9N lC

733 Engine cooling fan relay lair con) 12 to 14 b8 5N V
735 Main beam relay 198 to 199 g7 5N T
739 Height control re)ay 134 to 137 f7 5N H
743 Air horn compressor relay 142-143 c7 5N A

745 Blower motor fast speed re)ay 24 to 26 g4 5N 0
772 Engine cooling fan fast speed re)ay 10-11 b8 5N V
773 Engine cooling fan inverter relay
t',
7 to 9 f8 5N V
795 Lighting rheostat 97 g6 4B B
810 L/H direction indicator repeater connections 2xllc

'--
107 e9 IV & MI G
811 R/H direction indicator repeater connection 112 el 2xllc IV & MI D
831 )nterior temperature selection motor 27 to 31 g5 5B K
835 Engine oil leve) gauge 92-93

Ni
c4 28 M
837 Air con evaporator temperature sensor 12-13 f5 2N 0
839 Interior air temperature sensor 30 j5 2B P
840 Coolant temperature sensor Ito displayl 73-74 c4 28) M

841 Coolant temperature sensor linjectionl 39 c3 2B IM
850 2 stage engine cooling fan thermal switch 9-10 b8 3lc V
856 Critical oj) temperature therma) switch 70
!-,
c5 1 Bl M
935 Blower motor 25 dS 1 0
945 Heated rear screen 146 r3 2xlN F & ML
980 Door locked warning lamp 167 g9 2xl Ic H

kiiz 51O/12 1
CX 25 GTI Turbo
7/85 -
PDF
8531-8532
MA 510.00/12 3 4 MA 510.00/12
V3 w12
VIN
2
2N
1^1
4
-t 25 GTI Turbo- 7-85
229 229 29
83
2J
1114 4
Bli
________ J Mv
I5 Ui6 ni6 ]F1

111
DM9
(_J
681 6B2
Ri VN
J My JO
rr 1115 6
Gli
H H 38
Mr
\- -i 6
VMv l
j
4B1
il
482
-lIv 1
481
T
0- ______ __ ______________
1
V R
483
180 diri
[11 H
EL -
V M5.)
- -VM STOP
A
269 1
rh
?
74 131 KE
5M55M1
T Y 46
f/ 9I Y
270 G [31 (ABS)
837 B 1
JBi T V- t'J
-
L
Vi 484 482 93 8 9 35 31
Vl3 VBV 8ii ]11 8l V BMR

iN
n'"
-- __________
VMvJIc V
r. Bl N Bl
¶
III
((I
3M2 3M1 7M2 M3 7M6
r° T
37 41 48 T T
38413
838
Ni1f "5
ml>
<I`
P IM IM IM IM IM IM FP IC 0 0 N CN
°r°
P P 1
-J285 285
__
VG VN VjR T 6 6 6
0 VI
37 38 40 41 48
___ MvVlB
loooi Vi
m(1
635 )7851!7B3fl1B4jI786
- 575 516 280 57 V1BMvVINVlR
LQJ j
`ro
271 IC IC IC 6 G 1 L?J
BlM
L - 14
tf
\CP/ R
r1f
1d ilJ
1_ii
58
0
B2 583 581 82
L
riiri
IM
46
IM IM
115 33
IM IM IM
32 '14 34683
0
f
iil
0
__N
VN '
V
TT
fl Jl]
773t1L 6 6 6 M BIV
»
J J B R
CP
E 6 MP
45= HII I51 8N8 8N3 ICICICICICJ IC IC

00
132 31
j j
10o
Y VJB
n fl T rr
38
H RJ
K JK v1 870 - VVlI
1
u .]
-
rm--
J Ic
vv I700 K K K Vc3
lE 142
jj Z Z Z Z Z Z 7 Z Z Z BA BA B A BA BA BA B A BA
31N
________ ______
lzo°
m<)
--3 F.-
B12 h Mli N9 N1 3 N6 N5 N1 2 N i 815 85 89 V8 1 0 V9 Vi S V2 V3 1 4 V13
1" 634
rv 1
831 Ml
t1 KAEl
N10[JJ
141
tJLib.6i
44
31m
IC IC IC IC IC I C I C NI Vii V12 V6 V7
0U34 0
ovlo 1 I 1 1 1
Jf40 8 V MV IG V I i J1 Ii IN lo r B R
1 6G2I11] M I 1 1 1 1
,zzz BE
z1( 31°i
13 27 6 7 8 9
Mj M Ur
621 622 8 SN 5N 5N 5N 5N
7 ZVM lp MjJ VIBIVIBI
8 41 -J 3Ni
666 NIB NR
GO
A10
lag
300
Bl 0 CD CD VBIV8I
1
382 3B3
1 1
J 381 B Jj
lp
1
_________ FTBINBI N1BJ

850 H H 1
MM
IM 302
V 18M 13M 2
137ff MM
te-I
JR I?!
M
[ MIG 8110 616

685
3181
686
1116
192
136
______ 281 281
mi [1 40
71
___________________ 1
1234567891012345 6189201234567893012345678940l2345678950i234567896012 74567897012345

1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1
1 1 1
1
1 1 1 1 1 1 1 1 1
1 1 1 1 '
1
1

MA 510.00/12 5 6 MA 510.00/12
229
- CX 25 GTI Turbo- 7-85
tar
4B1
`'L
F5 F9 F6[ F3
____________________________________ 1
_________ _____________________ __ ____________

____ ____ _______
_____________________ _______
6J2
IMvIB __ ___
IN_____ ______
01I
_________
te-I
8
4BB
8
0
T 185
T1ti
R3 R2
R J J2
46 i
TcJ T tT 1 1
M
I F
Mv
T- Mv
-
P
(TO)
GM
*?
GN
H
1
281
255
r ABS
o
*° ** 570
J i oJ
810
Ism
IN N
`-I
1IH
9J4 9J3 'J2
'."
361 3B T'
Mv MFVRJ -
L
mas
m>>
Bl
NGN
82
l1 F52 3 I3Å
H
-F-
-F-
NÖJ 520 682 6E
TTTTTTT tjiiJI
--1
T T T T
T
TTTTTTTTT"I!'TTTT NB N181
T
4:H( r; H
1
H
_0L4
251
6Bj i I ri
333
Mv Ni R J
8888
1
TJ
31U
<In
(lam
3.n
3r3
MvM
482
8'
++
P-1
VB(
mli
1R VJ
IVMI LLL PC PC PC PC P
!R
'
J V
GBGGGHHHGHHHHHG
min
363 IM1 6
HrLLi -'i
1 1
3v
A2
+
9E
P0 PD
3821
m-o
1 1
j
6 GABSG
<In
r------i
i<H93
..a
B5
ft+++++ 2±+s,
I-+
Inb
5B
civ
6 I RJ]BI
Gli
N111
l8T
8M N
PG
608
JJFL]rL P6 L 6
L--__=_J
o1,
r 718 1
617 618
ism
JN N B1 N GR
650 fJ
362 381 OJ
IMvR
184 II P0' 4 LJL 23 241}j
,Z.
MV
!CD
6 835 580 0
___
I 236 flB2 iJ2M1 JR iN
3N3
383
561562583
2'
1
J R T G B J N
Il HHF
3:Q
842 PP B1S
244 f-o 242
- S
--
Il243 R71° P6 P0
0 0 D
i1I!;l 235 P0 On 0r3
VN 585 80
3R13R3 '5B2
' -j
civ
28 6t5Ö' -
jiN\ilrrL 1
V H H P68 C
U11
WI
civ
615
L
237 - 4304j 31 + ml N2 739 -
H
`_I
c11
1 1 1
:1
678980123456789901234567891001234567891101234567891201234567 89130123456789140123456789150
1 1 1
1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1
PDF
* compression, OCR, web-optimization with CVISION's PdfCompressor 8531-8532
151.169
MA51O.00/12 7 8 MA 510.00/12
-B --
,-z
`-I
254
-CX 25 GTI Turbo- 7-85
<13
F8
1
fli-
=_1
115 V6
383
B- +
-t__
V Mv
-r -------------
12i] H _721 721
2
VfMvI B
JjFl3
F12 F11
T T
532 .L Ti mni 14 14
r
5M1 5fr2 1 1
rn
VNVN P
jJN5 95/8 9 4 9V7 W6 9V5 v[2Vi H NI

90
--
1 1
1 Radio 62 565
o5 IN 8 } i B V BL R BL 1 v M
698
Ic R R
VNVr
H HH HH RB 721
-f____
Tal
Ne
tT'
M VN BL 89K21
H - 16
`J'
v
w
P Rt 1 lB 626 Ii L H H / /
)Jil
v
R4I
EJ 1
I\
VPLIP
L,J
LLJ625Z
VR M_T jF
w
v
."O
91 8
114 1
JVG
934
w'.
16
T P6 .pr;J PC
RR
386
582
j
OJ
j J9 VMvVN 5
W MjI1
iV 1 I1E192
1!
J
ww 31w<]
<13
313
6 M1B V18
4231f
iiL
III
230 o 232F 630

NN
945
=In
629 174 L
L1JMV
.. m6
TIG Bl J
m3 m3 m3 m3
ljL ml m7 m7
123456789160123456789170123456 789180123456789190123456789200123456789210123456789
-,n
1 1 1 1 1 1 i i 1 1 1 1 1 1 1 1 1 1 i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 i i 1 1 1

ARRANGEMENT OF THE ELECTRICAL INSTALLATION MA ARRANGEMENTOFTHEELECTRICALINSTALLATION
II CX 25 GTI Turbo 86 MY 510M0/12 51000/12
UNIT IDENTIFICATION UNIT IDENTIFICATION

LOCATION CONNECTOR HARNESS CONNECTOR
REP. DESCRIPTION LOCATION HARNESS
__________ __________ Number or uni RER DESCRIPT(ON
__________________________________________________________ Circuit Wiring Channel-colour or u
Circuit Wiring Channel-colour
1 Front cigar iighter and hghting 189-203 j5 3B-1V H 229 Ignition Switch 5-27-38-138 h7 4M 4B
3 L/H roar cigar hghter 124 n9 3B PG 230 Door Switch (L/H Front( 171 f9 iM H
4 R/H rear cigar Iighter 132 ni 3B PD
231 Door Switch (R/H Front( fl
(1)
1 72 1 M H
10 Aiternator 86 to 89 b6 lic & iN M & CA
232 Door Switch (L/H Rear( 174 k9 1 M H
44 Digital disp(ay und 67 to 74 f5 1 SV BA
45 233 Door Switch (R/H Roar( 1 75 kl Ni H
t11
1
Battery 2 bB iN CP & CN
46 Instrument panei g6
234 G(ove Box Switch 187 f3 1 lc-i Ic H
2B-3B-3B
63 to 108 235 Hydrauhc Fluid Pressure Switch 0
46 Instrument panel g6 3B-3B-4B 81 e6 M
E
an T
46 Instrument panel g6 6B-4V-6V 236 Hydraulic Fluid Leve( Switch 80 o8 lc-1 M
E
1 G
211 to 214
46 Instrument panel g6 9V-9J 237 Water Level Switch 76-77 o3
E
3R D
47 ABS hydrauhc und * 7 to 9 e6 5B Y 238 R/H Front Door Lock Switch 99 (1 28 H
51 HT coil iCyi 1 and 41 57-58 c6 3N Z 239 L/H Front Door Lock Switch 98 j8 28 H
52 HT coil (Cyi 2 and 31 61-62 c6 3N Z 241 R/H Roar Door Lock Switch gi
101 28 PD
54 ABS control unit * 2 to 12 p6 35N Y 242 L/H Roar Door Lock Switch 100 g9 2B PG
57 Fuei caiculator 47-48 j5 4B 0 243 Boot Door Lock Switch 102 tS 2M C
60 Air conditioning controi unit 12 to 15 h5 78 0
244 Bonnet Lock Switch 97 a5 2M V
76 LIH front window winder unit 113 to 115 j9 9 Bl PC
81 Interior heating controi unit
251 Height Contro( Switch 139 to 143 j5 2M H
27 to 30
(31
h5 8N K
84 Water Jevel indicator unit 251 Height Contro( Switch J5 4M 608
76 to 78 e4 5B D
89 Door iocking indicator lamp unit 183-184 °
(St
5N 254
t!)
H Lighting/Direction lndicators Switch g7 5B-4M-3M T
90 Door (ocking control unit 176 to 186 j5 9V H }
91 Remote controi door locking unit 172 to 174 133 to 138
n5 8N P 255 Windscreen Wiper/Washer and Horn Switch g6 28-48-58 T
92 Interior Iighting timer 169 to 173 j5 }
('')
7M H
93 Buib faiiure unit 268 Air Recycling Switch 16 to 18 h8 4J 0
33-109-110
,-.
s8 3B L
269 Air Conditioning Switch 20 to 23 48 0
.-.
tet'
93 Buib failure unit 81 to 83, 147-208-217 s8 6B-6J W h5
95 Junction box * 270 Maximum Air Conditioning Switch 7 to 19 h5 481 0
g8 B-D-G 1
95 Junction box * 271 Air distribution Switch 0
'--
g8 H-MB-R 19 to 21 h5 4M
95 Junction box *
g8 229 276 Roar \/iew Mirror Switch 152 to 157 h9 38-48 H
127 Side lamp audibie warning 174-175 g6 5N T 278 Blower Motor Speed Control 23 to 25 h6 38 0
131 TDC sensor 60-61 c6 2M Z
132 Flywheel sensor
279 Heater Control and Lighting h4 58 K
58-59 d6 281 Z
136 Vacuum advance warning 59 to 61 30r
C'')
e3 CD 280 Supp(ementary Air Control 44 b6 lN
-(D
Z
137 Anti-knock sensor 57-58 b2 2N Z 285 HT Coil Suppressor 59 b6 1 N Z
140 Distance sensor 50 e7 2B 0 285 HT Coil Suppressor 60 c5 1 N Z
141 Ignition ECU 54 to 65 e8 18B-15N Z
295 Air Horn Compressor
(,J
160 c7 1MV-1M A
142 injection ECU 36 to 48 g3 35N IC
* 5,6 300 Starter Motor 3 to 5 bS 1N-lR CP
146 L/H front whee( sonsor (ABS option) d9 2M Y
147 * 7,8 302 Flowmeter 40 to 44 b2 5N IC
R/H front wheei sensor (ABS option( di 2M Y
148 LIH roar wheel sonsor (ABS option( * 11,12 r8 2M Y
345 Fast (dIe Electro-valvo 14 d2 iv-iv V
149 R/H roar whee( sonsor (ABS option( * 8,9 r2
365 Ashtray Lighting 204 (6 2B H
2M Y
170 Boot light switch 198 s6 1 M E
370 Boot Lighting 188 s4 iN-lic F
174 Boot door locking switch 179 tS 2M C 375 Glove Box Lighting 187 f4 iN-iM H
180 Reversing (amp switch 33 d6 lN-iV G 380 Engine Compartment Lighting 202 c6 iN EC
185 Stop lamp switch 147 h6 lN-lM H 385 L/H Roar No Plate Lighting 218 t6 iM-lic E
190 Hand brake switch 90 k5 2M 386
H R/H Roar No PLato Lighting 219 t4 1Mi(c E
192 Thrott(e spindle switch 45 to 47 b4 3N IC 390 Steering Lock Lighting 208 g7 1 lc-l (c T
410 Air Con Compressor C(utch 13 c6
E
1 N V
430 L/H Front Caliper 83-84 d9 2N-iN U
* 431
Special diagram R/H Front Caliper dl 2N-l N
'Lo
85-86 U
* On RDH vohicle, rovorso tho positions (eft and right

"0n

-1:
UNIT IDENTIFICATION
LOCATION CONNECTOR
51O/12
HARNESS
11
- 510 W12
UNIT IDENTIFICATION
-_i
REP DESCRIPTION
(/%
REP. DESCRIPTION Number (or un t( Circuit or uni
.
Circut Wiring
.
Channe(-co(our
i
Wiring Channe(-co)our
440 L/H Front Side Lamp 201 a8 2M G 626 R/H Front Door (ock Motor 181 to 183 jl 2M-3B H
441 R/H Front Side Lamp 203 a2 2M D 627 L/H Rear Door Lock Motor 177 to 179 p9 2M-3B PC
442 L/H Rear Lamp 217 628 R/H Rear Door Lock Motor 181 to 183 pl 2M-3B PD
443 R/H Rear Lamp 218 629 Boot Door Lock Motor 183 tS 28 C
445 630 Fuel Flap Lock Motor 28
(71
L/H Rear Lamp Cluster t8 6G F 179 s2 X

446 R/H Rear Lamp Cluster t2 G6 F 634 R/H Engine Cooling Fan Motor 9 a4 lM-lR V
447 L/H Front Fog Lamp 206 a8 1 (c-1 M AB 635 L/H Engine Cooling Fan Motor 9 a6 lM-1R V
448 R/H Front Fog Lamp 207 650 Pressure Switch lM
C,)
a2 1 lc-1 M AB Low Engine 0(1 79 d3 M
457 L/H Stop Lamp 147 658 Blower Fan Speed Contra) Module 25-26 lV-1BI 0
`+-
f3
458 R/H Stop Lamp 148 660 0n-Board Computer 50 to 53 g4 l2N 0
460 L/H Rear Fog Lamp 208 680 Windscreen Washer Pump 138 el 2N D
461 R/H Rear Fog Lamp 209 683 Fue( Pump 45 g4 1 8 FP
462 L/H Reversing Lamp 33 690 Centra) Interior Lighting 165 to 167 V-l M
L()
n5 1 P
463 R/H Reversing Lamp 34 693 L/H Rear Interior Lighting (Sun roof option) 166 g7 lN
c--
P
470 Fuses
*
g8 694 R/H Rear Interior Lighting (Sun roof option) g3 lN
c--
168 P
480 L/H Front Direction Indicator 108 a7 30r 695 lN + lM
Cl)
G Front Interior Spot Lamp
it)
. 165 n5 P
481 R/H Font Direction Indicator
o_..
30r
C'`')
111 a3 D 698 Headphone Socket 195 to 198 k5 58
l.0
H
482 L/H Rear Direction Indicator 109 700 lc-l
I,-
Air Con. Pressure Switch 13 c7 1 Ic V
483 R/H Rear Direction Indicator 110 710 12 V Supply socket 123 k5 lN-lM H
486 L/H Long Range Lamp 211 a7 2B G 721 Radio Connections ("+", & LS) "-" 191 to 199 k5 lR-2B-2B-2B-2B
+
H
487 R/H Long Range Lamp 216 a3 2B D 731 Fuel Injection E(ectronic Relay 38 to 46
",t
a2 .. 9N IC
488 L/H Head Lamp 212-213 a8 3(c G
733 Air Con. Engine Fan Relay 12-13 b8 5N V
Cl)
489 R/H Head Lamp 214-215
<Il
a2 3(c D
734 Injector Re(ay 35-36 a2 5N IC
500 L/H Front Loudspeaker 191 g9 18 - 1R H
735 Main Beam Relay 215-216 g7 5N 1
501 R/H Front Loudspeaker 193 g2 1 B - 1 R H
739 Height Control Relay 142 to 145 f7 5N H
502 L/H Rear Loudspeaker 194 k9 2B PG
743 Air Horn Compressor Re(ay 159-1 60 c7 5N A
503 R/H Rear Loudspeaker 199 kl 2B PD
745 B(ower Motor Fast Speed Relay 24 to 26 g4 5N 0
506 L/H Front Tweeter 192 h9 28 H
750 Fog Lamp Re(ay 206 to 208 g8 7G B
507 R/H Front Tweeter 192 hl 2B H
756 ABS E(ectro-Valve Relay (ABS option( 5 to 8 dS 5N Y
Cl)
510 Front Fog Lamp Switch 204 to 206 g5 8 B B
757
,r,
tfn
ABS Protection Re(ay (ABS option( 3 to 5 dS 51c Y
511 Rear Fog Lamp Switch 208 to 210 g5 8Bl B
772 Blower Motor 2nd Speed Re(ay 10-11 b8 5N V
519 Driver's Door Window Winder Switch (R/H Window( 120 to 122 h9 5B PC
520 Driver's Door Window Winder Switch (L/H Window)
773 Engine Cooling Fan Inverter Relay 7 to 9 b8 5N V
11 5 to 118 h9 6B PC
795 Lighting Rheostat 97 g6
Kl-
521 R/H Front Window Winder Switch 48 B
120 to 122 hl 5B PP
522 L/H Rear Window Winder Switch 810 L/H Direction Indicator Repeater (Export) 107 e9 IcV + cM G
-0.
1 1
125 to 127 k5 58 H
523 R/H Rear Window Winder Switch 129 to 131 k5 5M H
811 R/H Direction Indicator Repeater (Export) 112 el 1 lcV + 1 cM D
530 Sun Roof Switch 141 j5 5J P

814 L/H Rear View Mirror 151 to 154 g9 2B-3J H
532 Heated Rear Screen Switch 162 to 164 j5 5M P 815 R/H Rear View Mirror 155 to 157 gl 2B-3J H
545 Interior Lighting Switch 166 to 168 j5 58 P 831 Interior Heating Distribution F)ap Motor 27 to 31 g5 58 K
570 Hazard Warning Switch 109 to 113 g5 8N 8 835 Engine Oi) Leve( Sensor 92-93 c4 28 M
575 Co(d Start Injector 38 b6 2 Bl IM 837 Air con. Evaporator Temp. Sensor 12-13 f5 2N 0
576 Injector 40 to 43 c3 2G IX 4) IM 838 Outside Air Temp. Sensor 71-72 aS 2N 0
580 Fuel Cauge 94 to 96 q6 lM-1N-lJ 839
Cl)
J Interior Air Temp. Sensor 30 j5 28 P

600 Front window wiper 133 to 137 e4 5B D 840 Water Temp. Sensor 73-74 c4 28) M
608 Height control Motor 140 to 146 j4 38 H 841 Water Temp. Sensor (injection( 39 c3 28 (M
610 Sun Roof Motor fl4l pS 38 P
842 Engine 0(1 Pressure Sensor 91 c4 1V M
615 L/H Front Window Motor 116 g9 30r LV
843 Engine Oi( Temp. Sensor 70-71 c5 2N M
616 R/H Front Window Motor 121 gl 30r PP
850 Engine Coo(ing Fan Therma( Switch 9-10 b6 3 Ic V
617 L/H Rear Window Motor 126 n9 30r PG
618 870 Therma) Switch (Co(d Start Injector) 37-38 c3 2M IM
R/H Rear Window Motor 130 nl 30r PD
621 Air (ntake Motor 17 e3 28 0
935 B(ower Motor 25 dS lN-lN 0
622 Air Distribution Motor 20 g4 28 0 945 Heated Rear Screen 163 r7 and r3 1 N and lN F-ML
625 L/H Front Door Lock Motor 177 to 179 j9 2M-3B H
980 Door (ocking warning (arnp 184 g9 1 Ic-l Ic H
PDF* compression, OCR, web-optimization with CVISION's PdfCompressor 8531-8532

MA
510.00/12 1 3
A
U J
V
lN c 1 b7 - ____ _____ ____ -
U IN 1 EC 201 e2
-- c8 Mv Mv
0000
2 B u 1
G 1 G 138
J 0
______ _______ ______ 2 138
T ____
U
j _____
1BI
J
__
____
lBl
v
V
VMV 5B3
4
MVV
v
V
U G 76
85
f8
V 8 R V 77
J
B M
0 1
2
G
M
J
B
211
159
D
- _____ ______
lic
_____
B V 3 V B 159 I
___
M 85
d2
u BB 8 B 211
- ____ _____ ____
U V 1 N 85
torn
5 Bl V 65
M V 6 V M 90
lic
-
V
____ ____
N
N 7
8 MvN
____
N V
-
68
79 - ______
U
U
___ ______
____
lic M
112
112
2
8
U 4B
1
2 0
V
B
M i
102
84 f7
- ______ _______ ______ -
U
U
V
V
1 B
ic V 188
78 f6
c1.
1 1
J 3 207
-
B N
- ___ ___
J
___ U-
m
7
B _ ___ 4 Mv B
1
E M 1 M M F 219 s8
J
J V
1
V
Bl 215
213
- ______ _______ ______
i lMv V V U 219
c--0000.-
2 J
Z-««««««
V
O 3 0 209 v J G 208
0 4
MC)
N N G 108 v 0
0 Bl
io j 5 Bl G 109 v 2 G 33
-,I
u
G M 6 M 0 105 V Bl 3
G R 7 R G 211
Bl V 110
0 V B 4 B V 109
B 8 B 0 110 V R
J N 9 N J 205 F 10 J. 5 0 147 t8
- U
R
J
J N
R
10
1
N
R
Bl
J
- 133
V
V Mv
6 V 219
J Mv 2 Mv 7 Mv V 217
J 138 V
0
--
3 M 138 V N 8 N 0 188
u 6J
--
4
010)A
Bl J 134 J 9 J 163
O V S V G 136 ___ ____ ___
N 10 J 162
____J _____
G
____0
6 J 135
FP 1 J lic J U 45 g2
MvV IC
V
2M12 ____
00o
Or
- d8
M-M
8 B N 73 U
Or R
1
2 R N 74 ____8 _____
V V
ZZZ
M
zzz zzz
Bl B 3 B V 73 1 N
M G 2 92
Bl R 4 8 V 74 G N
U Or V 9 Bl s j v i G 71 f6 V J 3 J N
89
Bl
Bl
V
N
6
7
J
Bl
V
V
72
70
U 8B 5 M N
Bl 8 N 8 6 M d5
-,1-1
G Bl V 71 B N
Mv
-
Bl 9 Bl M 70 N R 7 R N
___ ____ ___ - ___ 8 ___
-
>mm
>mm
v M V V N 91
Z
z
Or N 68 1
1 V Bl 3 B 2 Bl N U 70
N
- -
1
BA U Or j 4 M 2 J M 1 69 f6 V Bl 3 Bl N 71
Or G 3 0 V 69
- Or 4 V 67 V
v 3J 2 N V
1 R V 53
f6
'4p
i N U 52
G 0
____
V
____3 ____V
Le)
G 51
>m2
Bl V 52
30r2
1
U BI J R I O 53 f6
v
»»> >2»»»2>
3 M 50 V R 1 8 97
v 2 N M 103
U V 1 lc V 1 185 U v M 5B 3 M V 1 85
V B 4 B V 64
C M M M U X 102 s2 v j
- ___ ____ ___ 5 J V
- 63
1
I V lM v V U 176
V 0 0 v 1 69
M T
2»»
««K
1 M V 59 Bl 2 Bl M 70
CD
N
3 N 2 R V U Z 61 e3 V J 3 J V 89
3 G V 60 v N 4 N V 68 f7
9M
torn
I V B 5 B V U 73
v
2N12 Mv Mv
N-+
N N 6 V 77
N
u 2 V M
CP
b7 v 7 M V 79
7 lA
01<
8 J U 5 M V 8 V M 80
V R 9 R M 74
11 Bl 2
2 Ic u IC
.--N
2 Bl 3 I M M 921
lI MM
I 1 F
3M
J
I
G 21 0 MI UI 931
BI U Y 11 b7J 1
i l I vI
!
3l B MI I
1
91!
853 18532
-
MA
14 510.00/12
_
- U
M
V
1
lN
IC
______ U
84
d8
±- T
u
$
J Mv 4 B
Ei
2
1 N
N
I1 20
27
M'7
J 3 J
707
Bl R
-
1 Bl
- ___ ___ ___ -

3M V Bl 4
U Bl N 2 N Bl 7 b7
_ V 8 3 8 V 97
U V Ic J 104
V 1 V 103 1
G U V N 3B2 N V Y 59 f8 V 3B1
<c_
95
1
J J N
_ V M 3 J V 78 U V 2 V Nt, l 94
J 1 J 57 M 3 M 96
V Bl 2 Bl V 65
5M3 H 7M1
LO
I V B B V U Z 64 d8 8 B M 98
V J 4 J V 63 V Bl 2 Bl M 99
V Mv 5 Mv V U v M 3 M N 1
100
V 6 4 6 V
T 1 0 1
-u
}
1 Ic 107
e8
V
M
Mv
B
5
6
Mv
B
V
N
102
175
U M lIc 107 ___ ____ ____ -
J il J V I V iV V U 104
u v 3B2 V J 94 k4
- -
1
M 8 31 M 96 V M 3 M 1 B M 185
U J 1 B J 142
U V B 2 Bl M 1 X 176 k4
1
V Mv 3 M 102
U M Bl M 179
1 1
u G N 2 B 1 '' 148
f8
1G 2 M V 148
1
U V V 1 169 G
U M J M 176 g2
«K<
4
N-+
1
P V B 1 115) N 40
U J M J 168 U
M Bl 2 (33) N 41
1 1
v B 3 (32) N
1
42
U V 1 N V 1
- 166
- V
____ ____ ____ -
J 4 (14) N 43
(fl
J V 162
7M1
-
1
2 M2
>
u V N 113) N 39
_____ 167
(37) N 41
LO
Bl 1 J 116
Bl 2 (38) N IM 41 d5
Bl M 2 M J 118 (40) N 42
4 M u i h9 G 3 (41) N
-)->
J Bl 3 Bl J 120
IC M
6)00
U 4 N 39
-
15)
J 4
-
B B J 122
--
(4) N 38
M
-
V 5 N
V B B V 181
4.P
1 V Mv 6 (48) N 44
1
V
V M
G
4B23 G
M
V
u
181 V R 7 )34)N - 44
-
V 183 V 3 V V 47
- _____ ______
1
_____ -
M J 4 J V 184 U V Mv Mv V g3
2 0 47
- ___ ___ ___
1
M 3 M 49
l 2B1 V
M
G V
u
M _
101
3B1
c--
2 V N V N 54
- - __
N
il9 2 V
c7
.-N
N 8 1 B V z
H 2 Bl V PD 120
M
3 B M
1
48
u 4 M 3 N V
u
199
k2 M
____ _____ ____
M J 4 J V 199 1
2B1 V
u 28
2 M 32
--
i
''-N
J N N 132 K Bl 3 M 1 Bl 27
u j lN 131
I
J
N 2
3
N
J
U
_ _ J2
Q 31 h4
_.
V
V G
B
4B23
1 B
G
V
V
177
177
--
L U
N
N
N
3M1
2
8
J
Mv
M
M
M
j
1 T
81
82
83
f7
tet'
3
M MV 179
LV J R 2M1 8 J 115
V J 1 J V 180
I
J 2 V j 1
h9
( 2B1
N-'
V 48
N_'
V
___ __M -
i
2B1 PG 1ÖÖ
V
7C'
TL k8 M 2 _____ 48
_____ 2
J B 1 B V 125
J
i
1OJ
__
J
4M23
1
Bl V 126
u 1 J 2 G 33
N V 194 J 3 Bl V 109
V J 4 J V 194 J 4 B V 109
2M1 J 5 8 G
J N N J 124 R u 6 V
l W s8
2 J
J 7 Mv V 217
U1 J lN 125 J 8i N G 188f
9j
i
1
1 JI h
i2i 1
1 l 1 J I 1
163! 1
>
1
162
j J 10 V J
_Ul___________II____
1 1
1 I
J
M
Bl
4M21
3 f6 Bl J 120 T
u M 98J B M 1 1
1
L 221
1 1
TI
1
J M 1BI N! j 4 B J 99!
510 . 00/12 1 5
CX 25 GTI Turbo 7/85
LIST OF BULBS
Function Quantity Base Voltage Power Type
Main and dipped beams 2 P43 t 38 12 V 60/55 W H4
Complementary main beams 2 PK 22s 12 V 55 W H3
Fog Iamps
C31
2
LSD
X 511 12 V 55 W H2
(/J
Stop and tail amps 2 BA 15d 12 V 21/5 W P25/2
Direction indicators 4
'
Rear fog Iamps 2 BA 15s 12 V 21 W P25/1
Reversing Iights 2
Interior lamp 2
Engine compartment Iighting 1 BA 15s 12 V 10 W R19/10
Side Iamps 2
BA 15s 12 V 5 W R19/5
Number plate lamp 2
Direction indicator repeater (Export) 2 BA 9s 12 V 4 W T8/4
Glove compartment !ighting 1

BA 9s 12 V 2 W 18/2
Ignition key Iighting 1
Front interior spot amp 1
Boot ighting
festoon 35 mm 12 V 5 W Cli
1
Interior heater contro ighting 5

Ashtray Iighting 1 wedge base 0 5 12 V 1.2 W
Cigar ighter ighting 1
Instrument panel warning Iamps 31

Q..
________________ __________
Except: battery charge w. lamp 1 wedge base 0 10 12 V 3 W

knock warning lamp 1 LED
Warning Iamps incorporated in

switches and selector switches 8 wedge base 0 5 12 V 0.36 W

8531-8532
ini
MA 1 ARRANGEMENT OF THE ELECTRICAL INSTALLATION
16 51OOO/12 CX 25 GTI Turbo 7/85 -*
t/)
DESCRIPTION OF HARNESSES
A Horn LV Window Winder Extension

AB Front Fog Lamps M Engine
B Junction Box MB Junction Box Earth
BA Digital Display Unit ML Heated Rear Screen Earth
C Booth Locking MP Fuel Pump Earth
CA Alternator Wire 0 0n-Board Computer
CD Turbo Boost P lnterior Lighting
CN Battery Negative Cable PC Driver's Door
117
CP Battery Positive Cable PD R/H Roar Door

D R/H Front PG L/H Roar Door
E No Plate Lighting PP Passenger's Front Door
EC Under Bonnet Lighting 0 Interior Blower
F Roar Light Cluster Inter-Connection R Roar
FP Fuel Pump Wire T Instrument Panel
G L/H Front U° Front Brake Pad Wear
H Interior V Engine Cooling Fans
IC Injection chassis W Buib Failure Detection
IM Injection Engine X Fuel Filler Flap Locking
J Fuel Gauge Y ABS IBrakes)
K Heating Z El (Ignition)
L Bulb Failure ________ _________________________
DESCRIPTION AND LOCATION OF THE EARTH CONNECTIONS

0
0
2
Wiring Connector
No. Location . Harness
diagram No. of channels Colour
11 AB
1 CN
ml On L/H Front Wheel Arch b8
iiij IC
0
1 - 1 I
Y
z
c7 CN
0
m2 On Gearbox Casing N
E
m3 Along L/H Side of the Steering Colurnn g7

(fl
E
MB
m4 At Roar of Centre Console kb 1 T Y
m5 Behind R/H Rear Light Cluster t2 1 i ML
m6 On Boot Door t5
E
1
___________
m7 Behind L/H Rear Light Cluster t7 1 G F

AB CA - F H - lP - Ii .7 CD E - FP_ 6_IM - L -ML - PC - P
y A.B_ BA_ EC- P -w
tu bl cl die!
PD - - PP - Q _______ D - K - LV- M -0 - R -T - V - X _______ cp
C_IC_J_MB CN
'/I
Li

II
1
Ii
II
111
Il
E--
i 683 III ci
'%\ 386
114
- !iRH
£j!J !
1243
91 1 610
Il 110
E
385
945
Lt2o
.rQi=F
611 242
pi q s

ARRANGEMENT OF THE ELECTRICAL INSTALLATION 510 W12 19
TABLE OF FUSE FUNCTIONS
FUSE
SUPPLY PROTECTED CIRCU!TS
No. Rating Colours
+ From ignition switch Reversing lamps and switch.
°C°
1 1OA Red Channel 4 Engine harness, connector (88 4) (not used).
2 25A White + From ignition switch Heating, ventilation and air conditioning unit,
Accessories Instrument panel:
_._
Channel 2 - Turbocharger, fue! leve!, engine oil pressure and
leve!, Tachometer, gauges.
Warning Iamps for: anti-knock, battery charge,
r-.
paj
--<
ABS, front brake pad wear, engine oj! and water
tomperature, hydraulic f!uid pressure and leve!, water leve),
fuel low leve!, engine ou pressure, parking brake, bulbs failure,
doors, bonnet and boot non-closure.
- Instrument panel and heating contro! lighting ahd rheostat.
- Digita! disp!ay unit and computor keyboard.
- Dimmed !ighting for hazard warning, front and rear fog !amp
switches.
Direction indicators and warning lamps.
3 25A White + From ignition switch Front and rear window winders, height corrector control,
Accessories heatod rear screen relay coi!s.
Windscreen wiper, washer timer and switch.
'.O
O_"
Channel 1
Stop !amps.
Sun roof motor (option).
Rear view mirror motors and switch.
4 30A Green + Direct Engine cooling fans !except R/H in fast speed!.
5 1OA Red + Direct Hazard warning !amps and switch,
6 30A Green + Direct Roar window winder motors.
7 30A Green + Direct Interior lamps and timor.

Glove box and boot Iighting.
Height contro! motor.
Digita! disp!ay unit and computer keyboard (dock function!.
r,:
Radio.
Centralised door !ocking, contro) units, warning !amps and motors.
mom=
8 25A White + Direct Horn switch and relay coi!.

Roar screen heater.
Roar view mirror heaters.
9 30A Green + Direct Front window winder motors.
10 SA Brown Side !amps Roar fog !amps.
11 SA Brown Side !amps Roar number p!ate Iighting.
12 SA Brown Side )amps L/H and R/H roar !amps.
13 SA Brown Side lamps L/H and R/H side Iamps.

--._
Lighting: under bonnot, ashtray, cigar-!ighter, key,

>-.
side-!amps warning, digital unit and key-board dimmod !ighting.

Interior !ighting timer.
+-'
Switches and relay coil for front and roar fog !amps.
14 Not used.
*
8531-8532
o00
MA
510.00/13 2 510/13
CX 25 TRD Turbo
7/85 -
C31
PDF
85318532
MA 51000/13 3 4 MA 51000/13
CX25 TRO Turbo 7-85--.-

I 229 V229
-CX 25 TRD Turbo 7-85
1F2
II
N
AGG
L;1
__
VN
382 - 4M
- _____ ___________
NM N
rji VIMv
r
T 8N3 8N
- 1801o
(ANSI
Rh
L
____ ____ ________ B
1
"11
6
340 86 II
_--
G
iI N
i
h 570
- V15
jN
1111H
6
___
fRFMRR
`Ì
31w
L B B
0J4
N
6
r
2 6
TTTTTTT TTTTTTTTTTTTT T
,4_
635
w 7
k 9tL4%
_________
MJ3M443
44
bli
CA [?
524
t11
j
GLLLBI 4II TTTT
l-,
vJ77
sel
-4i
1 1 1
r
V1MI_1
MIV
___j
G G B
GGGHHHGHHHHHG 1
--_ =__
_ N N
LJ T [B13B2I3B1I 1
-
K
pil
>r`-
(4SJ 6 J I 1
R
6
3B2 OP11ON 1
N
N6&IR Vj
N M
-U'
J J J 1 X(ABS1
650I
i-1
238I01
1.3
0_1
L CAC M M V
vI
ffi12 PD
? Y
m7
I
_PG M3 G PC PC
F!_:
X31
J- ---1-
L_1Q;
r - L
BI- I
[/] 1
II
ii
1
685 1
V71
I(I
1 1 1 1
G B G ci BABABAS4l_____ T 810 WW 811

_31
1 1
6 1
i 1< 1< K 1< K 1 '

1
__ tMI
____
1
IBbB2I583I
0
239F 24
I
__
____
VIB
______
IB
O--
[ 1 1
ci )
I 1 1
____
______
2fr11 1 1 1
l 1
1
Hc 1931
GT &M
L - L
________
__________
15&41585158h 1583 582
_______________
8
__
MIB1
______
13M213M11
1 IBt
1
1
_____
Or1JrlI
______
MJ
NJ
1
0 6 0
1
M
279 1M li
4Q:______
___ 481 JIR
LV LV
2420j2430'
1
244
---
v 1
____________
M
F pMHIo0 878 ww
1 '
rrLi.
AIK
- _
1
Bl
P0 __
300 ___ 16V6 ------------- 1 B3R1R3 235 N 211
4l
L jN
001
121fu1
1
3111
036 166216621 831__ 8 Bl
J(\
NR
- LJ
850 N
1° VHHPG
-
483 237 C F F
bnd
j ____
63 J
__ ______ 0
31N
430 V1Bl
[7,
- 431 ci
'33 6GlIt
____
B
___
______
?I
______ 1 482483
EG
jc
1
______ H 1-1 _0_J H ___________ 1

i m6
115 ci
-
155
BM Bl JI i
1BI M
IM
itu
R 3M1
/ ___
83Jö42
_____
i 6
_____
IIk1öJ61
1
rov
ren
i7 m mi m' m n3 m3 OJS 5111 F
ml m2 5 b m1 m wj6 Mj6 M12 J
1j3 8j2
1
mi'
111L11I41114
123456769101234567892012345676930123456789401234567895012345578 960123456789701 23456789801

1 I 1 1 1 I I 1 1 1 1 1 1 1 l I 1 I I 1 1 1 1 I 1 1 1 1 I I 1 l l l 1 I 1 I I 1 1 1 1 1 1
vem,
2
L 51,177 151.178
CX 25 DTR Turbo 7/85 510.00/13
LOCATION CONNECT0R HARNESS

REF DESCRIPTION
Circuit Wiring ChanneLcolour (or unit)
__________
Cigar lighter and iighting 37-1 52 j5
tfn
1 1 3B-1 V H
10 A(ternator (including regulatori 51 to 54 b6 1 Ic + 1 N M - CA
44 Digital dispiay unit (dock and coolant thermomoter) 36 to 40 f5 1 5V BA
45 Battory 2 b8 lN + lN CP - CN
46 Instrument panol 8-31 to 73, 159 to 162 g6 1
LO
81 interior heating contro( unit 25 to 28
W-`01
h5
LO
8N K
84 Coolant (ovel indicator und 41 to 43 e4 58
C..,
O`-
89 131-132
M---w
Door locking indicator lamp unit j5 5N H
90 j5
00-
NN.--
Door (ocking control und 124 to 134 9V H
91 Remoto control door locking unit «PLIP» 120 to 122 n5
'-c
8N P
92 Interior iighting timer 11 7 to 122 j5 7M H
93 46 to 48, 74-75, 104, 156-165 LWW
tfn
Buib failure detection unit s8 38 68 6J
95 Junction / Fuse box g8
110 5N lN 1R
CD-
Preheater unit 6 to 8 e8 M
(1)
115 Preheater piugs 3 to 6 c3 4 x 1N 0 + EV
127 Side lamp audibie warning 122-123 g6
C!)
5N 1
130 33-34
.01
TDC sensor d6 3M G
170 Boot light switch 136 s6 1 M'-,i E
174 Boot door locking switch 131 ts 2M C
180 Reversing lamp switch 15 d6 lN-iV G
185 Stop lamp switch 104 h6 lN-lM H
190 Hand brako switch 55 k5 2M H
229 lgnition switch 5-8, 25-95 h7 4M-4B 95
(.Si
230 L/H front door switch 119 f9 lM H
00000
231 R/H front door switch 120 fl lM H

232 L/H roar door switch 122 k9 lM H
233 R/H roar door switch 123 kl lM
2,4
H
234 Glovo box switch 135 f3 lic + lIc H
235 Hydraulic fluid low pressure switch 46 lM
U70)
e6 G
236 Hydrauiic fluid lovol switch 45 e8 lic + lM G
237 Coolant low (evol switch 41-42 o3 38 D
238 R/H front door lock switch 64 (1 28 H
239 L/H front door lock switch 63 j8 28 H
241 R/H rear door lock switch 66 ql 28 PD
242 LIH roar door lock switch 65 q9 28 PG
243 Boot door lock switch 67 c5
NO)
2207
2M C
244 Bonnet lock switch 62 a5 2M V
251 Height control switch 96 to 100 j5 2M & 4M H & (608)
254 Lighting/Direction indicator switch 72 to 75, 1 57 to 163 g7 58 4M 3M 1
255 Winscreen wipor/washor and horn switch 90 to 95, 107 g6 48 58 28 1
268 Air rocycling switch 19 - 20 h5 4J 0
271 Air distribution switch 16 - 17 h5 4M 0
278 Blower motor speed controi 0
N!"
22 to 24 h6 38
279 Heator controi and lighting 27 to 29-69 h4 58 K
295 Air horn comprossor 108 c7 lMv-1M A
300 Starter motor 3 to 5 bS 1 N - 18 CP
340 Euel pump stop soionoid c3 lN
-C}
7 M
370 Boot lighting 136 s4 lN - lIc E
375 Glove box iighting 135 f4 lN iM H
_'Q
-
380 Engine compartmont hghting 150 c6 lN EC
385 lM +
(0W
L/H roar No plate iighting 166 t6 1 Ic E

386 R/H roar No piate (ighting 167 t4 1 M + 1 ic E
390 Steoring (ock (ighting 1 56 g7 lic+ lic 1
-I-
430 LIH front brako calipor 48-49 d9 2N + lN U(gi

431 R/H front brake catper 50-51 dl 2N + lN Uidi
-f-
°_°13
440 L/H front side lamp 149 a8 2M G

441 R/H front side (amp 151 a2 2M D
442 L/H rear iamp 165
443 R/H roar lamp 166
445 L/H roar iamp ciuster t8 6G E
446 R/H roar iamp clustor t2 6G E
457
77`77[
L/H stop iamp 104

458
ööm
R/H stop (amp 105

460 L/H rear fog iamp 156
461 R/H roar fog iamp 157
*
Particular specification
*
8531-8532
I--
MA
6 510 . 00/13 CX 25 DTR Turbo 7/85 -*

REF. DESCR(PT(ON
Circuit Wiring Channel-colour (or unitl
______ ________________________________________________________
462 L/H reversing lamp 15
463 RIH reversing lamp 16
470 Fuses
* g8
480 L/H front direction indicator 73 a7 3.Or 0
481 R/H front direction indicator 76 a3 3.Or D
482 L/H rear direction ndicator 74
483
C31
R/H rear direction indicator 75
486 L/H long range lamp 159 a7 2B G
487 R/H long range lamp 164 a3 2B D
488 L/H headlamp 160-161 a8 3(c G
489 RIH headlamp 162-163 a2 31c D
500 L/H front loudspeaker connections 139 g9 1 B + 1 R H
501 R/H front loudspeaker connections 141 g2 1 B + 1 R H
502 L/H rear loudspeaker connections 142 k9 2B PG
503 kl
t11
R/H rear loudspeaker connections 147 2B PD

506 L/H front tweeter connections 140 h9 28 H
507 R/H front tweeter connections hl
tet
140 2B
LO
511 Rear fog lamp switch 156 to 158 g5 8Bl B
519 L/H window motor switch on driver's door
(77
(31
85 to 87 h9 58
.-.
PC
520 R/H window motor switch on driver's door 80 to 82 h9 5M PC
521 LIH window motor switch on passenger's door 85 to 87 hl 58 PP
532
f--
Heated rear screen switch 110 to 112 j5 5M P
545
<77
Interior lighting switch 114 to 116 j5 58 P

570 Hazard warning switch 75 to 78 g5 8N B
580 Fuel gauge transmitter 59 to 61 g6 lM lN 1 J J
600 Windscreen wiper motor 90 to 94 e4 5B D
615 R/H front window motor 80-81 g9 30r LV
616 L/H front window motor 85-86 gl 30r PP
621 Air intake motor 15-16 e3 28 Q
622 Air distributor motor 13-14 g4 2B 0
625 R/H front door lock motor 125 to 127 j9 2M-3B H
626 L/H front door lock motor 128 to 131 jl 2M-3B H
627 R/H rear door lock motor 125 to 127 p9 2M-3B H
628 L/H rear door lock motor 129 to 131 p1 2M-3B P0
630 Fuel flap lock motor 127 s2 2B X
634 R/H engine cooling fan motor 11 a4 1 M-l R V
635 L/H engine cooling fan motor 12 a6 1 M-1 R V
650 Engine ou pressure switch 44 d3 lM RC
654 Turbo pressure switch 31 3M 0
658 0
'O0
Blower fan speed control module 23 24 f3 V-1 Bl

E
- 1
680 Windscreen washer pump 95 el 2N D

690 Central interior lighting 113 to 115 n5 1V+ lM P
695 Front interior lighting 113 n5 1 N-1 M P
698
<}t
Headphone socket 143 to 146 k5 SB H

710 12 V supply socket 89 k5 lN + lM H
721 Radio connections (12 V and loudspeakersl (+, -' LSI 139 to 147 k5 1R+4x2B H
735 Main beam relay 163-1 64 g7 5N T
739
2-5
Height control relay

C71
98 to 102 f7 SN H
743 Air horn compressor relay 107-108 c7 5N A
745 Blower motor fast speed relay 22 to 24 g4 5N 0
772
C71
Engine cooling fan fast speed relay 13-14 b8 5N V

773 Engine cooling fan inverter relay 10 to 12 b8 5N V
795 Lighting rheostat g6 48
'-'
62 8
810
f30
L/H direction indicator repeater connections 72 e9 l(cV + 11cM G

811 R/H direction indicator repeater connections 77 el 11cM + lIcV D
831 Interior temperature selection motor 25 to 29 g5 58
C71
K
836 Engine oil Ievel sensor 57-58 c4 28 M
839 Interior air temperature sensor 27 to 29 j5 26 P
840 Coolant temperature sensor 39-40 c4 2 Bl M
850
.,-
2 stage engine cooling fan thermal switch 11 to 13 b8 3 Ic V

856 Critical oil temperature switch 35 c5 181 M
0
0
935 Blower motor 23 d5 lN + lN 0

945 Heated rear screen 111 r3 to 7 lN + lN F + ML
980 Door locked warning lamp 132 g9 lIc + lIc H

MA 51 0.00/13 7 8 MA 51 0.00/13
0
8
- CX 25 TRO Turbo - 7-85 8-- 4. Q11 254- Ml
-1T1
2 M3
F8 G GjP jv I
F7
T T T T
fl15 V6 ff12 1J4 ff)1 mi
__
111
__
6
1
185F ________ ____
_______R2I l3
_____ T- ____
rii: 12gii -
GM
- _
jj (T.O)
_B
'lrii
V
TVN VN D
25
TT T (ABS)
I1
T
H
bl j -
J-'
695
Ill
P
Ej
--E-.
JRGJ
B 82 Bl 58
M 381 83 6115 Vi M B(89JK
Ill
(3V l3I2 n_-=

JH J6
T T T T T EG [(3 2B1
2111
H H VI
Li
86ML w
nr T0H
B(VL H H
4 017
cal
ö1>
6866 6' R
1
INB VPLIP
14 L
LLJ 112
J625 2112
Li
383
VMv
w
F
B,J 91
VR MJ VR 11
!
0'`
w+2z - -
X13
BIE
JIM
GLI
bIN
4 *
GIR
_l
v5
484h82
82
'93
3Ì
V
`-1
(?i
]1JMt
GLI
r;LFH*93 PD 1 IV1 111 Mv
rP0J -
t: r° r-'---- -
bil
_
5J3Si4J :
__L?.::_:i- P ?6 tLi
V N V N j; N
D /?J
IIF
2
:1-'-':
H
J1R Mv
------------ t:jl(3
_ J625
1
'
E!I 3836 28
IN
P0 Ffl
608 B1S 13)3
.-.
L11
SIF
F EC 12
M
82 82
1 1
W 1
' L
H I!1 _ 52
_____
'rrrr
,öl
58358
: 370r1!;J
MM
5
ri 1 W
(l7
502
dal
Ml 82381 R
' D 0 D D M
jo) Tvi IB I8
____
IM IM
66007
R
P6 503 m6
521L _____ P0
iViR
OH WW _______
________
___________
F
8 11
pD
34 w
6 0)7
Mv
TM
j7[ ii
313
SIF
481 48
MG
112
0H V Mv
allt
1
JN 1
PPPP
ljio
H H H F F
- Ii
__ 1J9 IM H
J1(80 MM P0
X31
N
30r -l 1
1
1
1M1 E
4 H w
i
G11
Ill
H 8 82 R Ii Mv V Mv
02
Ni 230IoF232F
O--
N5 N3 2111
170
440
486 487
0 3M2 441 Ti661
H VJVJ T488
E!I
313
2 52
82 82661661
M[GI
__JL ________ ________ _ --'- -H - '
_________________
-
1
Mv
(3 _
- IJ, (3 0 661 661 (3
Bl LE
Fl 16 F 111 JMI 1
m3 m3 5)5 782 4B(2 78 721 721 7211 0 M 1 M
all
2M1 3M2 5
V4 2 5
11 808 0)6 Mi 84 G
m
m6 1
m3 12 13ff202 1
(2 13 m7'
34567899012345678910012345678
1 1 1 1 1 1 1 1 1 1 1 1 1 1
2345678912012345678913012345678 91401234567891501234567891601234567
1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
C71
1 1 1 1 1 1 1 1 1
1 1 1
1 1
1 1 1 1 1 1
1 1 1
91101
i++
PDF compression, OCR, web-optimization with CVISION's PdfCompressor JL5iI] 8531-8532

151.179
51O/21
*5+ " ''
('l
C rh
F3 F7
Hl
-1
712 5 V6
383 R
NI>
2M2
- -
%1O
690
Isc
5r11 532 5M2
1
,&'i,
gö
1' [i L J
[
ri
1
694
____
____
p ) J)
ii
L /1liii
'h'/
___
'# liii
CRT
M
313
M3 SM 91
-JVJN
- Vi M -V 8
3B3 381
- p SBfl 545 583
-
3Ì
fl fl
L
610
5B2 SBl
rL
M1 7M2 17Mi1 /
L7MJ
92 7M4 1
fl
O--
231
230
3--0
LiM3
139
160
i
141
i 1 1 1 1 1 1 Ii 1
yrt
142 143 162 163 164 165 166 167 168 169 170 171 172
L84.16
* 8531-8532
MA
510.00/22
1
Lit _ ___
IS1 2
229
jal
ni
ffl2
ri
185
Io
H
6M5
11t2 21
14 M
_
15
Vi s
250
-----------1 jB -
7-<
El141 * 266
> ________
A!
_
______
93
z
V
341 II
M
_____ 2R1
57M2
-w-
3I"
,,,
--L
w r
1
JN T s
1
s s
830
140
458 457
+,m
- rLlJ
Lf
il F
h-K
V'Mv
BO
lN31
V
rBNT]
N
jN21 fN
m2
L353a

ini
INI
r'Z
___ MA
II* tr- ZF 3 HP 22
N
I:I1
LV2
1
4B4
m4 LT4
25t
+
f3 G
1' 8
T
.T7
N B
N
8
III
-- 414 218 ___

Ep
j 9
NA2I Fl
N1 41c1 6N5' 5M2
N N N
VJN
N
VIBGN N N
_
BLR
9V3 9V1 9V 9V6 9V7 9V8 9V2
8 N A 2
H
II
L-35-2
jG il rn
..n
6v+
9V9
VJ5
cp
L 35.2
*
8531
MA
iI
11112
Fl
254
f
11114
IIS F2 Fi
-
IIS
T 383
651 44
T
-H
2M2
EZB 721
8 v
P
w HP - HO 8
- 5M2
VM
483r/ liJL3 fI3J 8816
Giv
18
ieoI.o "i
v_{
RO
L1J
TM4 6
II
5
rsf 8B11
--0
-r-
jii500! cI 502. -T-
RO
8JJ __
_____
o
46
1
185I0 888
ILL
-'z
N
H C 1 o 1111 112
[O6I H
IrHJ
Fil
F12 FlO
2Bl 1
6M5 4J2 f
IM IIIS
kil
i LO LO EO
1112110
1141414 11414 1411114
- - -
.mo
__
L1J 2 82 O86 088
693 694 L
TT
31!
: LHPJ 3 RO RO 1
MvVM
1
T R R R R R R
loö
V
3V2 7M5 OJS 33j 353
öl>
j37j OJS 0J2 Ou 0J3 OJ1 OJS
M V V8
5,
R,js R 9
721 (1 L L L W W W W W W
fHPJI 1 Mv 81 1
W
086 083 681

-
MN -MN w
, VJ VjMv
W
481
RO
Ris
,ò
OJS M
LP21
VML M -- Mr1F 88BIN
956981
2 6J66J36J1
Mv 6
.-,
958
-ROJ -, 1
1
W W W W W RO
-Iii
loö
V'R 61 V'MV JMY

J
L"11 [6J 5
TJ 0 i3 O J1
Vs s v
1
'
j
4
MlIc
m5 L1 H
E!1 766 h
:L7
L ERV 08108
J R
itu
CH
8141 LH
7.7
RO RO RO RO 8 8
VM 507
1
281
VsVo v V BIV J
94 M
l+243 RO RO RO RO RO
Mv
ER ER ER%
L?82JV9V-
I8 385 386
'°m
-0 '
3--
V s 1
V 1
V 81 V
1
-
J
482 0181 Ic 61s sol
601T rp [h
rLT
=________
H
791
L51-184
17 ]21 606 446 ME

CH RO
BLI
M 1 91 MJ
o3
66j6 t o 5
1 1 1
1 1 1 1 1
1 1
2 3 4 5 6 7 8 10
9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
L 51.184
*
8531-8532
(J1
510.00124
51. 83
OL
9 EU
N6IQ
°- - - -
1££
h
II
___
N
14
w
zos
-if,
14
El
r
IH
oig_
=
r-,
ro
gE
w
1
E6
_
11
r
I-. I-,
1
`-I
ro
iV/ /
ill=
(1 -.
go
AE
+
-

ini
1
0 0
229
481 484
1114 11114
F3 F2
1112 1115 nT
6M1
ri
G
H
ZON
281 3B2
185
T Y
B27
Y
/',/ 282
T
9J6
oi
46
/
VIN 1N
5N1 5N5 756
STOP
650
31N
NIjJ VJ8( MIBI VIN MIN V8 MIB

Y Y Y Y Y 'i' Y 'i'
r:::i II
L---
!:I1ILi [ i1iiI]
146 147 149 148
1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8 9 10 11 12
L45,30
*
8531-8532
MA
_0>
1
51OOO/26 _____
> >
>:
ViII '
F4
,R1ÖI
M
u l
tM 837 0
1
0
3 !2
0 iS T
761 762
-
Bl R 6011<
742
±
H
0 V 8( 6I vi 1 i
LQJ -
461 262
839 1
0
0 CR CR 6 K
; )
*H
Rv
700 G 0 Q QQ
:::Y
v0 27
- 2B
N747JN
v v v v 4-v-1 M
J
irliNVrIiv 0 Q a
ffi
z''
L
41 335
634
L__J
Bl 11 L 0 i
CR
6
I1 1<
lai
362 363 4B2
- -
H CR KR 659 KKK
cZ
Bl 831
1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
[51.181

*
8531-8532
SUSPENSION - WHEELS - TYRES ENGINE TYPE
L1
`r'
(öms
PERATION 5 5 25 Safan 25 Satari
_____
________ _____
0 2 5 Prestige 5
DseJ
Limousine Petro! OJ
(-D
________ Petrol Petrol Petrol Diesel Ambulance
SYMBOLS
Injection Turbo Turbo Injecton Turbo
__ Turbo Turbo
OPERATION Familiale Familiale
DESCRIPTION _____ ______ _____ ______ _____ _____ ______ _____ _____ ______ _____ _____ ______ ______ _____ _ ______
TEXTS
No .
><
829A5
`-O
829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
_______________________________ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
0
A Q
0 0
25/660
MA
430/1
MA
0
xx
Specification and particular features of the suspension X X X X X X X X X X X X X X
`-'
430.00/1
MA
Removal/refitting of front suspension cylinder X
.,...
433.1/1
a X X X X X X X X X X X X X
MA
A
0
Removal/refitting of a rear suspension cylinder X X X X X X X X X X X X X X

433.1/2
MA
Removal/refitting of an anti-roII bar X
0
435.1/1 X X X X X X X X X X X X X
MA
0
435.1/2
Removal/refitting of a rear anti-roll bar X X X X X X X X X X X X X X
MA
471.00/1
Special features of the wheels and tyres X X X X X X X X X X X X X X
*
LIST OF OPERATIONS APPEARING IN THE CHAPTER: VEHICIE CONCERNED
HEATING, VENTILATION AND AIR CONDITIONING ENGINE TYPE
25 25 20 Sa/an 25 Salan
--I
OPERATIONS 25 25 25 25 Salan 25 Salan
20 22 25 Prestige 25 Limousine Petro/ Desel
_______ _______ Petrol Petrol Petro/ Diese/ Ambu/anc e
Petrol Petrol Prestige Petro/ Diesel Diesel + +
f--
co ftrbo
SYMBOLS
Injecton Injection Turbo
OPERATION _j Turbo FamihaleTurbo Fam4a/e
DESCRIPTION co _____ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ _____
______ ______ ______ ______
TEXTS
N o. co
<
29A5
F-
`-°
GLO
829 AS J6T A 500 25/659 25/659 25/662 25/662 25/660 25/648 25/648 829 AS 25/659 25/660 25/648 or
______ __________________________ A 0 ___ ___ ___ ___ ___ ___ ___ ___ 25/660
PAA
Removing and refitting a heating unit - 7/85 X X X X X X X X X X X X
641.1/1
MA
641.1/2
Removing and refitting the heating unit 7/85 - X X X X X X X X X X X X X X

HEATING - VENTILATION
I) AIR CONDITIONING
MA
641.1/1
REMOV/NG AND REFITTING A HEA TING UNIT

-+ 7/85

8531 8532
REMOVING AND REFFITTING A HEATING UNIT
0
MA
2 641.1/1 -+ 7/85
LSD
REMOVAL
1. Disconnect the negative lead from the battery.

2. Empty the refrigerant from the air-conditioning system (refer to the relevant operation).
3. Remove the passenger seat.
paj
4. lake off the anti-theft lock cowling (1).

the cubby hole (2)
,>-
5. Removing
3
Uncouple speedometer cable 119). Örn

Q--
Disengage hydraulic fluid reservoir (20), but extract the 2 nuts (21).
Withdraw the 3 screws located inside the vehicle.
Remove the cubby hole, then disconnect:
0a>
the electrical ou gauge,

- the dock,
- the electronic control unit for injection.
6. Removing the glove box (6):

Take off:
0--:C"
the 5 screws situated inside the vehicle (avoid slackening the 2 lock screws),
Q>)
washer bottle).
Remove the glove compartment then disconnect:
- the glove box lighting,
Ca.
- the 2 nuts positioned on the bulkhead, engine side (under the screen wiper motor and behind the screen
7,"
- the cruise control unit.
7. Removing the rear part of the console:

osv
Disconnect the handbrake switch.

Withdraw the handbrake lever gaiter.
8. Removing the front part of the console:
,..
lake off:
- radio support bracket (3),
- air intake housing 14),
- oddment tray (8),
- the 2 air vents (7),
Disconnect:
window motor switches (10),
- cigar lighter (9),
map reading lamp (5),
- the centralised door lock control unit,
....-,
- the door locking timer unit,

Remove the air conditioning control switch (11) fixing nut.
a._
n"3
(Disconnect the white connector).

Remove the console.
9. Removing the heater unit:

E
Uncouple the 2 pipes (23) from the air conditioning system lpaying attention to the 2 seals).
Disconnect the 2 water pipes (121 and blank them off.
lake off:
- the 2 heating control bracket fixing screws,
- the rear seat air duct (16),
.-r .-r
- the 2 air pipes (18),

- the earth connection securing screws,
the 4 heating unit screws (14),
- the 3 wind sleeve fastenings (241,
.-+
(2 nuts (13) under the instrument panel and 1 bolt on the engine side).
"-'
Disconnect, at the point of attachment to engine:

,-e
the feed wire and the earth lead (22) from the heater unit assemb)y,
-4.
- the motor from the air recycling flap (2 channel white connector situated under the water header tank).
Disconnect, from the interior:
- the motor from the temperature regulation flap,
- the feed wire from the temperature regulation device (1 channel mauve connector)
1:!
- the potentiometer from the control lever,

- the supply wire from the heater control (ighting,
- the temperature regulation control unit (17).
Remove the heater unit fitted with its controlling units (Push aside wind sleeve (24)).
Retrieve the de-frosting gaiter situated at 115).
(7l

0 MA
641.1/1
III
/
f#;1III
/1r'j, ..1 \') 2*i
H
13.174 83.122 L - _____
*
8531-8532
A MA
641.1/1
1
,
2)

REMOVING AND REFITTING A HEATING UNIT 1
MA
7/85 6411/1
X71
REFITTING:
1 Refitting the heater unit:

- Engage the unit in its ocation,
C31
- relocate the de-frosting gaiter (15),

- secure the unit with the 4 screws (14)),
"C*
-attach the wind sleeve (24) (2 nuts (13) under the instrument panel and 1 bott on the engine side).
Reconnect, at the point of attachment to engine:
- the feed wire and the earth lead (22) to the heater unit assembly (2 one channel mauve connectors),
- the motor to the recycling flap (2 channel white connector under the water header tank).
Reconnect, inside the vehicle:
- the temperature regulation control unit (17) (8 channel black connectorl,
---
- the supply wire to the heater control lighting 11 channel red connector),
.-r
m_o
C/)
2)-2
- the potentiometer to the control lever 13 channel white connector),
.-+
- the feed wire to the temperature regulation device (1 channel mauve connector),
S17
v(0
- the motor to the temperature regu)ation flap (5 channel white connector),
(CD
- earth terminal clamps

Reposition:
the 2 air pipes 118),
- the rear seat air duct (16),
- the 2 control brackot fixing screws.
Reconnect:
the 2 water pipes (12),
- the 2 pipes (23) to the air conditioning system, fitted with the 2 seals.
2. Refitting the front part of the console:

'y:
Introduce the front part of the console in it location, white positioning the harness and connecting up:
S?5
- the centralised door lock control unit, (9 channel black connector),

'-'
O-0
_Q0
- the door locking timor unit,

- cigar-lighter (9) (3 channel white connector),
- the cigar lighter lighting,
the map reading lamp (5),
- the window motor switches (10).
,...F
Refit the air conditioning bott (11) (Reconnect the white connector).
(i)
Secure the console.

Put into place:
6N0
- the 2 air vents 17),

t'6
- cubby hole (8),

- air intake housing (4),
- radio support bracket (3).
3. Locate the rear part of the console, and reconnect the handbrake switch.
Replace the handbrake lever gaiter.
4. Refitting the glove compartment (6).
+,,
Fit the glove box, connecting the cruise control unit and lighting.
Screw up:
=S3
- the 2 nuts on the bulkhead, engine side,

,--r
- the 5 screws, inside the vehicle,
Refitting the cubby hote (2):

7>O
Place the cubby hole, reconnecting:

the electrical oil gauge,
.-.
the dock,
.-r
- the fuel injection ECU.

Reposition:
- the 2 nuts 1211, engine side,
- the 3 screws, inside the vehicle.
Secure the hydraulic fluid reservoir, then recouple the speedometer cable (19).
6. Fit the steering lock cowling (1).
7. Refill the air conditioning circuit with refrigerant (see the appropriate operation).
a.+
8. Attach the passenger seat.

9. Reconnect the battery.
a..
*
8531-8532
HEATING - VENTILATION
641.1/2
AIR-CONDITIONING
/'1
REMOVING AND REFITTING A HEA TER UNIT

7/85 -+

8531-8532
MA REMOVING AND REFITTING THE HEATER UNIT
2 641.1/2 7/85 -
REMO VAL
Disconnect the negative battery lead.
>-.
1
2. Empty the refrigerant from the air-conditioning system (see corresponding operation).
3. Remove from the interior:

--. air-conditioning
,
The centre (11),

conso(e sides (5) and
C/)
the control bracket (disconnect the contro(s(,

-- the centre of thepart conso(e (3),
(4)
-- the
the
part of the
rear
the glove box (6),
injection
fue( bracket (7),
conso(e (2),
ECU
the steering wheel,
tho steering (ower panel, (10),
,-+
-- switch
the
the
panelfixing(9),
-- storage
the
the
3
L/H
e)ectrica)
boxes (1),
dashboard fixing screw (8),
unit support (19),
- pane)
fl.
the rear seat duct (20).
4. Remove, from the engine compartment:

-
The water header tank fixing (13) to move it clear,
C,__-
the ducting (12),

-
the securing (2 nuts and 1 bolt) for the air intake tDwer (14),
the 2 dashboard securing nuts (15) on the buikhead.
5. Disconnect, engine compartment:

-- The yel(ow connector to the air-conditioning compressor c)utch,
'"''
veö
the 2 channe) connector to the air intake motor flap (under header tank),
- the 2 air-conditioning hoses (17) (be carefu) of the seals).
6. ln the engine compartment, clamp the 2 pipes (16) to avoid losing the engine coo(ant.
7. Disconnect, inside the vehicie:

-- the
paj
The blower motor speed control module (under the of the dashboard), R/H side
arm
connectors between the ventilation-air con and the interior harnesses,

,-:
4 channe) white connector

situated at (22)
channel clear connector '
>
- the connector between

mag
ò°
the heating and interior lighting harnesses,

avi
channe) white connector situated above the unit

f-:
- the pipes (18).(supply, interior temperature sensor), air

(1)
>-p
8. Remove, the 4 fixing screws (23) from the unit.
9. Remove the unit:

-- lift thethe intake tower (14) some 30 to 40 mm to the right (lift
Push air it to disengage the 2 studs),
dashboard,
-- disengage the heater ducts the upper part of the unit), (on
.,L
remove the unit from inside the vehicle,

- recuperate the situated gaiter at (21(from the defrosting dram.
0
NOTE: The units shown on the photographs opposite belong to L.H.D, vehicies, however, the remova//fitting
operations for units be/onging to R.H.D. models are the same as on a L.H.D. version.

y.,
* 8531-8532
iij L

REMOVING AND REFITTING A HEATER UNIT 1
MA
7/85 - 641.1/2
FITTING
1. Refitting the unit:

- Engagethe unit (ocation, position the harnesses,
in its
the defrosting
(ocate gaiter (4),
-- connect the 2 pipes (1),
dram
the upper part of the unit,

the heater ducts
- engage
secure the unit with the 4 screws
on
(6).
2. Connect, inside the vehicie:

- The connector between the heating and interior (ighting harnesses,
(1)
2 channel white connector situated above the unit.
- The connectors between the ventUation-air con. and interior harnesses
,-.
4 channel white connector

situated at (5)
1 channe) c(ear connector
- The b)ower motor speed contro( modu)e (urider the R/H side of the dashboard).
3. Connect, engine compartment:

-
The yel)ow connector to the air conditioning compressor c)utch,
-
the 2 channe) white connector to the air intake motor flap (under header tank).
4. Locate, and fix dashboard on the buikhead, engine side (2 nuts at (10)).
5. Refit, the three storage boxes (13).
6. Secure, engine compartment:

-- intake tower (9),
The air
the ducting (7),
- the water header tank.
7. Refit, inside the vehic)e:
- The rear seat air duct (3),
--
ner,
the electrical unit support panel (2),

the L/H dashboard fixing screw (20),
..J
-the rear (14) and centre (15) part of the console.
8. Connect the contro)s of bracket (16) and refit it.
9. Refit, inside the vehicie:
-- the fuel injection(18), bracket (19),

The g(ove box
ECU
- the switch (21),
0
pane)
-- the steering
the steering whee(,
(22),
whee( (ower pane(
- the conso)e side (17) and (23).

pane)s
10. (n the engine compartment, reconnect the two pipes (12) for the air conditioning (2 sea(s).
11. Remove the clamps from the two pipes (11).
12. Refilt the air conditioning system (see corresponding operation).

r-.
13. Reconnect the battery.
14. Top-up the coo)ant system.

i-+
*
8531-8532
LIST OF OPERATIONS
4 I
Operation
DESCRIPTION
n umber
MA 800-000 Overhauling the bodyshell

Components sold by the Replacement Parts Department
Il Electrically zinc-coated or galvanized items
III Checking a damaged vehicle
MA 800-00 Preparation of the bodyshell
MA 800-01 Fitting and checking a bodyshell, stripped, on a CELETTE jig
MA 800-02 Exchanging the ongerons, with the mechanical components in situ (using CELETTE jig)
avi
MA 800-10 bodyshell, stripped, on
(fl'
Fitting and checking a a CAROLINER jig
MA 800-1 1 Fitting and checking a Satary bodyshell, stripped, on a CARO)JNER jig
MA 800-12 Checks on a CAROLINER jig, with the mechanical components in situ
MA 800-13 Checking on CAROLINER jig, a Safary bodyshell with the mech. components in situ
MA 801-1 Replacing a front unit, complete

MA 801-2 Replacing the body fixed components
MA 802-1 Replacing a front wing

MA 802-2 Replacing a front wheelarch, complete
MA 824-1 Replacing a rear wing
MA 824-2 Replacing a rear wing, partly
MA 841-2 Removing/refitting a side door

E
MA 841-3 side door, completely

'06
Dismantling and rebuilding a

(fl
MA 851-1 front bumper

..-
Replacing a
MA 851-2 bonnet
t7.
Replacing a
MA 851-3 Opening a bonnet when the catch release fails to operate
MA 853-1 Replacing a rear bumper
MA 853-2 Bonding the rear quarter glasses
MA 856-1 Replacing a dashboard

8531
BODYSHELL 8OOO
OVERHAULING THE BODYSHELL

8531
2 OVERHAULING THE BODYSHELL
8OOO
1. PARTS OBTAINABLE FROM THE REPLACEMENT PARTS DEPARTMENT.
REF. No. DESCRIPTION OPERATION No.
1 Windscreen frame MA 812.1

2 Roat panel MA 825.1
MA 825.1
t31
3 Rear screen pillar
MA 825.1
C31
4 Roat panet with sunroof
5 Rear sheif MA 831.6
6 Seat backrest upper spacer MA 831.5
7 Sheet metal under backrest MA 831.5
Seat backrest lower spacer MA 831.5
Ö..
G31
9 Sun-roof rear crossmember MA 825.1
825.1
t77
10 Crossmember angte sheet MA
``n"
825.1
t77
Ill
Roat crossmember MA
0
11
MA 825.1
ISA
1 2 Interior lamp bracket
13 Windscreen frame pillar MA 812.2
14 Windscreen opening reinforcement MA 812.3
15 Buikhead with windscreen opening cros'smember MA 812.2
16 Louvre sheift MA 812.2
17 Corner plate MA 812.3
18 Header tank bracket MA 802.3
1 9 Stay support bracket MA 802.3
20 Air fitter special support (82 MY.> MA 802.3
21 Closing panel assembly MA 802.3
22 Upper ctosing pane> MA 802.3
23 Side ctosing panel MA 802.3
24 Body fixed component MA 801.2
25 Trim panel upper crossmember MA 801.2
26 Upper anti-recycling baffie MA 801.2
MA 801.2
C.7
27 Gritte fixing bracket

Bonnet ock support bracket MA 801.2
C1]
28
,-,
29 Lower crossmember inner panel MA 801.2

30 Trim panel lower crossmember MA 801.3
31 Anti-recycling side baffte MA 801.2
32 Upper ctosing panet MA 801.1
Lower sheet metal MA 801.1
CO)
33
34 Front wheelarch MA 802.4
35 Front wheelarch, front section MA 802.4
36 Front wheelarch assembly MA 802.3
37 Unit, comptete MA 801.1
38 Front box crossmember MA 801.1
39 Lower scuttle MA 801.1
40 Fuel tank bracket MA 801.1
Steering mounting bracket MA 801.1
.fl
41
42 Centre box crossmember
`°3
43 Centre box reinforcing plate

44 Rear ftoor panel assembly MA 831.1

_
___
C)
0 0- 08
0
2
4p
1
39
60
62
QOo
7
5
45
If-.
I.
1.80.74
4L'08'1
*
LO
C)
8531
<0 0
0800-000 14;
0
0- 09
0
`.U
r®
/
gLS
6C
_
SE:
Dog
OD
K1.80.74
08'1
8OOO
II4 OVERHAULING THE BODYSHELL
1. PARTS OBTAINABLE FROM THE REPLACEMENT PARTS DEPARTMENT
REF. No. DESCRIPTION No. OPERATION
45 Rear crossmember closing piate MA 831.3

Vit'
46 Floor panel rear crossmember MA 831.3

47 Floor panel sidemember MA 831.4
48 Side buffer bridging bracket MA 831.4
0
MA 824.4
.tom
49 Wheeiarch tensioner
50 Roof side member inner panel MA 821.1
51 Crossmember under box MA 831.1
52 Rear ciosing piate MA 824.4
MA 824.4
7z-
53 Rear bench seat mounting bracket

54 Front ciosing piate MA 821.1
MA 821.5
E5'
55 interior reinforcing piate

LO
Front door piflar upper angie sheet MA 821.2

LO
56
57 Front door piliar reinforcemen MA 821.2
,-.
LO
Front wing MA 802.1

,-.
58
59 Front door piUar lower angie sheet MA 821.2
60 Side panel front section MA 821.2
61 Front door piiiar hinge support MA 821.2
62 Side panei MA 821.1
63 Centre door piiiar lower reinforcement MA 821 .3
64 Centre door pillar ming MA 821.3
65 Centre door piliar distance piece MA 821.3
LO
66 Centre door piliar upper reinforcement MA 821.3

67 Rear door piiiar ming MA 821.4
68 Rear door piiiar striking piate reinforcement MA 821.4
O..
69 Roof side upper siM MA 821.1

70 inner rear screen piflar MA 821.4
71 Lamp ciuster panel dri raii MA 824.5
72 Rear wheeiarch MA 824.4
73 Rear wing ciosing piate MA 824.1
74 Rear fender MA 824.1
75 Rear section of the side panel MA 821.4
76 Centre door piiiar hinge support MA 821.3
'L7
77 Centre section of side panei MA 821.3

a-)
*
8531
MA 1
6 800-000 BODYSHELL REPAIRING
II. ELECTRICALLY ZINC-PLATED COMPONENTS
N
The shaded parts represented on the opposite drawing are electricaHy zincpIated to protect the bodyshell from
corrosion
The choice of these parts is function of the vulnerability of certain areas and may bé modified.
fl'
The parts sold by the Replacement Parts Department have undergone the same treatment but the cataphoresis
f=+
coat covering the whole frame prevents the repairer from seeing it.
REPAIRS
When carrying out a repair operation, it is necessary to destroy the coat of cataphoresis on both faces of the
steel p)ates, on the welded areas, athough it damages the zinc coating.
To avoid any risk of corrosion due to this repair operation(especiaIIy on tho weded areas), some precautions
should be taken:
- Avoid grinding the welded areas of the new parts, since sanding discs damage the coat of zinc. It is better
°c'
to use a torch for heating the part slight)y, and to brush it using a wire brush.
After having separated the welding seams, only grind the areas where the welding is too thick.
(CD
PROTECTION BEFORE WELDING
order to avoid any risk of corrosion, it is necessary to apply

In coat of conductive primer on the inner face
c°°
a
of aH steel plates to be welded (zinc-plated or not).
REMARK: The conductive primers are zinc paints allowing the flow of electric current to pass without preven-
ting the welding to be carried out. However, it is necessary to increase the current intensity slightly.
The primers which can be welded are sold by the suppliers of paint (BERGER, CORONA) and products for the
automotive industry:
m
Examples of recommended products:

Primer before welding SWP Welding paste
Supplier: FRANCE ARC
civ
Supplier: KENT INDUSTRIES

rom
Unit 4, Daux Road 47, avenue A. Briand

Bi Ii ngs h u rt 92120 MONTROUGE
West Sussex RH 14 95J Tél. (1) 46.55.47.22
(England)
REMARK: This product enables the spot-welding to
+-Q)
Phone: 403-81.36.71
be carried out, beginning in an angle, without pre-
viously scouring the cataphoretic priming.

MA
800-000
6 -o
5U
000 '1
1/
*
8531
MA
800-000
iI4:
//\\\\\ A
u 1

RECONDITONING THE BODYSHELL 800-000 9
III - CHECKING A VEHICLE WITH ACCIDENT DAMAGE
When inspecting a damaged vehicie, the foUowing checks must be carried out in the order indicated betow:
Visual inspection: nspect for creases, distorsion or cracks.

Check of the axle geometry: Operation to be effected using optical alignment devices, without removing the
mechanical components.
ro=
Check of the dimensions of the subframe: On a jig, with the vehicie compIete
- VISUAL INSPECTION
Distorsions on:
Fixed body components at c) (upper crossmember) and d) (lower crossmenber).
Wings and wheelarches at (b) (front portion of the whee/arch) and (e) (wing distension)
°c'
Side panels and roof at (f) (upper part of the side panel), windscreen frame (lower section), roof panel (at the
centre pi/far and windscreen upright /eve/s).
Wheelarches (a) (rear section, around attachment to ax/es).
CONCIUSION
If the visual inspection shows CLEARLY:
uti
- distorsions at Id), only:

replace the lower crossmember,
- distorsions at (b), (cl and Id) only:
depending on the damages, either replace the parts concerned or change aU the body fixed components
avi
+ the front section of the wheel arch involved.

distorsions at la), le) and (f)
check the bodyshell on the test bench.
fl,
REMARK: Since distorsions affect simultaneously both the axles (or /ongerons) and the bodyshell, the wheel
alignment MUST be checked, when in doubt.
II - CHECKING THE GEOMETRY OF THE FRONT AND REAR AXLES

Consult the Repair Manual, Mechanical Components volume MAN 008181 or 308181
E
Operation MA 410-0 for the condition of the front axle.
Operation MA 420-0 for the condition of the rear axle.
III - CHECKING THE SUBFRAME ON A JIG (without removal of the mechanica( components from the vehicie)
Consult the following operations, MA 800-2 and MA 800-3 (CELETTE Equipment)
<<<
.-.
MA 800-5 (CAROLINEREquIpment)
MA 800-7 (DATALINER Equipment).
*
8531
MA 1
_______ 800-00
. ) / /
180.90
*
8531
,
_,rJ'•
F
-
,
Iii
--
—
4—
.
—
--; .
-
:::::ii:
:..
— [I
—
----
_.
—
—.
-,
.
---
— —w-- _
i4FJj
I
-
—
&

*
8531
MA
800-00 = Al
86.131

*
*
*
8531
114 CELETTE
309.010
____ L L
---:;;- BI,n
ITN
HI J -
180.87
955.909 955.900
1 1
--9I1978 1
TT80 . 13 1TT80 . 121
5.900 1
9/1978 -*
+ ..
TT8O . 121 TT8O .14

J

8531
ci
- 2
__________
_____
CELETTE
211.010]
O5
4 1
J
1 80.16a
. :::
:
TT8O.14j
L . . :
TT8O.14!

114 CELETTE
82
309.516 1
c.
.. .
-
: . !.
: . :
.
.
.:
.
1 80.llb
L955.9o9
t77
955.900 -* 9/1978
+_+[
1 1
I80 13l
_
ORO
fU8O . 12 Ju80 . 14
_ 955.900
:
::
.._
9/1978 -+
JTT8O . 12J 178014
*
8531
_ MA
Q17
-ID
800-10
CAROLINER
*
8531
8O ____ CAROLINER
G 0:17,5 00:22
- °° N G0:25,5 0 bou17,5x 25,5
1 2 3 4 5
Itt
6 7 8
it it
9
[,1
1J_
F F G c 0 0 F F F
1
G
125,5 122,5 141 G
88 43 51,5 71 1045
100
0
143,5 o
96
245
- --(__;- __ -r __
410
-- 1 ___
_____
;
:'
1
H
--4
__
L..
il
410
21
__ ____ 4J-' -: ::-'u.--± H

245
-
[- LL ___
___ _______
769 405 185
- 479 -
903 1130 810
-,N
2525(Bertine)
2775( Prestige)
U'1
180.92 1

MA
'-','_
_____ 3
II4 _______ CAROLINER 1 800-10
_
180.94
___________________________________ 180.94
______________ _____
___________________ 1 80.94
________
__ ou
/
_H
1 80.94 k , C
- _____ _____
1 80.94 0
_
180.94
ii
[Pi i.- __
J
_____________
_____ _________________
el
ll
_
___
180.94 (Fl iiiEE1 ____________
_________________
0
180.94 / ________
*
8531
C37
*
8531
2
_____ CAROLINER 1I4
=175
G:255 Dou175x255
tom,
OQ
1 2 34 5 6 7 8 9
r'1
f.t
F F 6 C D D F F F
1 f 1 1 1 1
tal
125,5 122,5 88 43 2O5 1O 975
D 0
145 96
245
O55
410, 410
521
-
521
1Z5
0$5
LZS
:-' L_-
I-;
____ -
1
----------
iT - - - -
-
_ -
r°-
769 405 __ 15 0 179
903 1130 792
2775
1 8088 1

____ MA
3
1I4 CAROLINER 800-11
-Iii -
1
___________ 1
180.941 180.94
1
_JT
..
180.941\ it1T
,
0
c 2'
JTt
1 80.94 0 L8
LK7ky/)//ri
fl\\ -
180.91
_______
180.91
1:.
*
8531
*
8531
1
CAROLINER
IT: *i -N
i:
\\
---
--'
0
1 2 3 4 5 6 7 8 9 10 11 12
37,5 (2,) (24) (4) 43

(7) (si,s) 30,5 (58) 46 04,5)
1 T Pre
1 1 1
965
___
'TE
645
432
B65
30
Ttii 410
341
4410
__ ___ __
432
440
410
410
645
5'7
447
341
692
Z69
383
- 2330(BerLine)
2470 (Prestige)
200
310
769 405 ___

®et
1130 420,5
1320 750
(Ber(ine)
°'"'
2585
2835 (Prestige)
®M217 L12O
ZM216 L48O
11O
®Jc7J LIJø19Ifif
L 80.93 1

ini
MA
iI4 ______ CAROLINER 8OO12 3
NNk
ji-i ¶\ 0
9
/
-a_JM216
480 -
L 80.96 \ fl\ L 80.96 \\ E 180.96 N

-
0
E4'
o__
g
L1
Eli \
180.96r / 180.96 1
180.96J
gir,
1/
AO N==
1 80.96
-
180.96
0
:1
M225, 120 -
180.96 180.96!
*
8531
ini
MA
800-13
:.i
CAROLJNER
' _
åLLIT L
85.302
*
8531
2
--
12
83
. D
3)5
216
00
r'1
CAROLINER
_tiI_
/
114
-'E1
35 62,5
(J 65 I3
63 46
945
-
645
598
OSS
B65
44d
410
411
432
L17
440
-527
OSS
,I ___
_u___t
55
-
___
_______
- 2470
LL
- ___
^l'
769 405 ___ 210 420,5

et®
1130 732
1320
2835
D M217
® M216
ø19 rnpratif
L80.95

MA
800-13 3
114 CAROLINER
(.i
Nk
\
_____
NI 211
480 -
L80.96 \ L80.96\ ________

tIJ 1
f-I_
0
0 0 0
cp
_*
1
_
________
80.96
r
LIJ
180.96 C
_
_______
L 80.96
017
-- 1
\'
180.96
______________________ kL 180.961 k
_____________________________
BREAK
'180.96
____________________________
BREAK
7
180.96
_ __
I7
M225
96
__
1
120
______
\\ - _
_____
____
BREAK
*
8531
* 8531
MA
801-1
r7. T
L 80.91

* 8531
4MA 801-1 _
________
i:j /
4r
/ 1 '% ___
-=------
_,uu
86.1731

ini fl
1
LI
1l
.
\/7'
r 1LI
4

* 8531
61 MA
8011
__
______
Al E
0/0
MA 800.00
0
1
__ cl
MA 800.00
00

_
-
=' -i
,.
1 06'08
Ls
*
81A2
-'a
2
1 8O97

MA
3
1I4

* 8531
MA
801-2
114
--
- 3=
86.236

* 8531
MA
6 801-2
i1I4

*
8531
2 8A
Fog
LJ
180.97

* 8531
8021
86.124 I

*
*
8531
I MA I
6 8021
iI4
//
85.i

_--
L 80,90
'
! W
86.23 3
* 8531
MA
802-2
k14
Fot
vänt

*
8531
vw
98
Ø 9 WW

*
8531
6
MA
802-2
?c9 @ t

* 8531
MA
8241
21 V114

MA
824-1
114
86.297
________ JJ
13.176

*
8531
MA
6 824-1
i14

'"A
824-2
180.89
t
81.1157

*
LC)
c)
8531
MA
824.2
f 114
/3
lp
*
8531
ini
MA
4 8242
1
ere
-
--
'\ \ _____
\\
yrt
,t,
':1
jj
86.381
7 --:'.
1V/
1T)
d. t r
2
//
/
/
kV /:: j/
F T)
JT!1
81.1183 1
81.1167

MA
824-2
__
81.1185
-
* 8531
MA
6 824-2
iI

_
_____
MA
841-2
8-1303
c- -
*
8531
MA 841.3

* 8531
MA
841-2

MA
5
iiI$,4
in 1
85.35
'
MA 841 .3
*
8531
* 8531
MA
841-3
r.
..-'
_--
J
ORO
85.365

MA
841-3
--;
:'1i.
\ W/
86.1Ö 86.1006
*
8531
r-1
861OO1

-'a
*
8531
MA
841-3
iI$
---.
-
-:4'-
)
85.365
86.1018

1
L 80.97
*
8531
r)I
L
MA 1
e::
851-1
iI$
Jtp
J
art
317: ____ 85.319

8A
mar-
:'
________________________________
4 :: 1
enl
z-,
25.:°
85.318
-____________________
- _______ - .-
_
- -
-
pil
JL*
______ .-
-"
1
-.
85317
- -__ ____ ____

* 8531
_____ _
_____
MA
851-2
* 8531
8512

*
8531
MA
____ 8513
[R. 63O-84IJ
* 8531
MA I
2 8513
iie

_ MA
8531
__ II

8531
1
85.3fl
85.376
85.30i1

Civ
m
REAR QUARTER PANELS 83"2
REPLACING A HEAR QUARTER PANEL

8531
MA 1
2 853-2
REPLACING A REAR QUARTER PANEL
TOOLS: Fig. 1
1. Tool for cutting the sticking beads using a piano wire: Reference 7503-T.
2. Gun for extruding the adhesive sealant.
3. Set of suction pads
4. Tool for removing the adhesive bead left after the withdrawal of the rear quarter glass: MR 630-84/43,
Ini
f'°
or cant chisel sharpened as shown on the drawing of Fig. 1, opposite.
II)
PRODUCTS: Fig. II
Reference
'GURlI"
Sticking kit 9867
it)
--1
ZC 511 U
Cartridge of adhesive sealant 867 447
-11
ZC 9 U
"BOSTIK"
Sticking kit ZCP 830-002
Q-.
Cartridge of adhesive sealant ZCP 830-003

0
PROTECTIO N
Goggles should be worn when cutting the adhesive sealant (in the case of the glass breaking>
CAUTION: The use of other bonding products than the ones recommended is strictly forbidden.
To retain the rigidity of the glass and the surrounding area, the quality of tho sticking is of prime importance.

MA
853-2
TT.96-5
83.68
*
8531
MA
41 8532

II 'AIfiPOURTOII 6Ri II
BX. 96-7 TT. 96.1 TT. 96.11

1
A B
801595 185.14
Vi
* 8531
)
FJVII 81
_____ __ 1
________ i_
__ 7_
180,971
*
8531
MA I
2 856-1

* 8531
4 I MA I
856-1
J
iI$

* 8531
ini
6 MA
8561
J IiI$,

* 8531
8
MA
856-1
ij
Aj.
.
4'a
'1

ini
MA
856-1
85.303

* 8531
MA
MR TOOLS
MANUFACTURING DRA WINGS FOR THE

-,Z
MR TOOLS APPEA RING IN THE CHAPTER

L

8531
MANUFACTURING DRAWINGS FOR THE MR TOOLS
2 MA
APPEARING IN THE CHAPTER
TOOLS TO BE MADE UP
MR. 630.84/23 a: Too! for removing the plastic clips (page 3)

Developed length: 197 mm
<CD
Material: A 33-1 Width: 20 mm Thickness: 3 mm.

E
- -
MR. 630.84/46: Too! for unlocking the bonnet (in case the (ock does not operate correct!y) (page 4).
Deve!oped !ength: 540 mm appro. 0
Material: 5 mm dia. drawn steel bar (CC 35).

MR.630-84/23 a MA 3
MR 630-84/23a
R5()
155
R315
18
50
O3 O,5
65 -
100
20 _
- 24,5
*
8531
c,)
4 MA MR 630.84/46
a°)
IÄrIf ni Ii,
I1I.< OiU.ö(+/4-b

Citroen CX Manual Series 2 PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Citroen CX Manual Series 2 PDF

Caricato da

Copyright:

Formati disponibili

REPAIR MANUAL MAN 058531

CUSTOMER SER VICES SEPTEMBER 1988

Automobiles Citroén. SA. au cap/tal de 800.000.000 F

It is divided into 15 chapters separated by vinyl tab inserts numbered to

Generat Rear axle

Engine Suspension - wheels - tyres

Fuel systemCarburettor Steering

Ignition system Braking system

Clutch Electrical equipment and radio

Gearbox-Drive shafts tij : Heater, ventilation and air-conditioning

Source and reserve of pressure Bodywork

Each chapter includes:

The operation references are made up as follow:

al vehicte code letters: MA

- the figures 0 indicate checks and adjustments

- the figures 2 indicate dismantling and re-assembly

dl figure /1,.../2.../.. standing for a variant,

e) letter: a, b. standing for an evolution.

the various operations are presented:

Parts Department to FRANCE and EXPORT networks.

The tools referenced MR must be made up by the repairer himselt.

O981 mdaN = 1mkg lformer measuring unit).

UPDATING THE MANUAL WITH ADDITIVES:

they are issued.

2 spots . 8531 additive no. 2, etc.

Example : 1 spot 8531 additive no. 1

For all technical information, please apply to:

CENTRE TECHNIQUE CITROÉN

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

Protection of the electrical units A X X X X X X X X X X X X X X

Products to be used on the bodywork A x X X X X X X x x x x x x x

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

Pallas D Pallas D AD Turbo Limousine

______ M25/660 M25/660 M2/648 M25/648

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

420 kg 435 kg 460 kg

685 kg 700 kg 725 kg

755 kg 755 kg 790 kg

3190 kg 3205 kg 3220 kg

3190kg 3205 kg 3220 kg

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

829 AS M 25/659 M 25/660 M 25/648

530 kg 520 kg 510 kg 530 kg

695 kg 730 kg 750 kg 750 kg

1065kg 1160kg 1175kg 1175kg

3380 kg 3465 kg 3490 kg 3500 kg

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

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

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

PROTECTION OF THE ELECTPICAL UNITS

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

is no short circuit (bright sparks or arcs).

d ( When recharging the battery, disconnect the two clamps first.

bl Take the added accessories and the functions into consideration.

Ensure that the regulator is correctly earthed.

Starting the engine:

b Do not operate the module if ts radiator is not connected to the earth.

c Fit the radio suppressor capacitors recommended by the factory.

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

- Gelified iquid designed for stripping DECAPLOC

- Carburettor cleaning product.

- Sealant for joint contact surfaces, screws and nuts.

- Hydrocarbon resistant product LOWAC E 2 S.E.B.I.S.

(TEROSON) _ ________