CITROËN ID 19 Operating instructions

METHOD OF USING THE REPAIR MANUAL
This Manual includes all the main service operations. Primarily it is intended for left-hand drive cars but the application to right-hand drive cars should
present no difficulties as any differences are obvious.
CLASSIFICATION
We have shown at the beginning of this manual a classification of the main units of the car.
The three figured number in front of each unit corresponds to the operation number relating to this particular unit
METHOD OF NUMBERING
The number is composed of :
a) The indication of the type of vehicle : ID
b) A number of three figures indicating the unit or part of the unit (this number is shown in the general classification).
c) A code number, indicating the type of work, dealt with in the operation. These figures are separated from the number by
a hyphen.
Use of the code :
The figure 0 indicates the adjustments.
The figures 1, 4. 7 indicate the replacement of units (removal and refitting).
The figures 2, 5, 8 indicate the stripping down and assembling.
The figures 3, 6, 9 indicate the overhauling (reconditioning).
EXAMPLES :
Operation No. ID 334-0 : Adjustment of the gear selector control.
Operation No. ID 372-1 : Replacement of a driveshaft or a pivot.
Operation No. ID 100-2 : Stripping and assembling an engine-gearbox assembly.
Operation No. ID 442-3 : Overhauling a steering assembly.
Operation No. ID 453-4 : Replacement of a pedal gear.
PARTICULAR POINTS
At the beginning of each operation the particular points are given (tightening torsions, adjustment dimensions, special assembly precautions, etc.). The
number of the line of the particular points corresponds with the number of the paragraph in the operation.
ILLUSTRATIONS
At the top left-hand corner of each illustration is shown the number of the operation concerned with this particular illustration (this information
is not given on the illustrations for the tools).

TOOLS
The special tools used for repairing the ID 19 are indicated as follows :
1. By a number, suffixed by the letter T. These tools are sold by Établissements FENWICK, 15, rue Fénelon, Paris (10e). They
should not be ordered direct but orders should be passed through the usual channels as for normal spare parts requirements.
2. By a number prefixed by the letters MR which are not supplied by us. The necessary information and dimensions for making
them are shown in this manual.
TECHNICAL INFORMATION
Any enquiries should be addressed to: SERVICE DEPARTMENT, CITROEN CARS UMITED, SLOUGH, BUCKS., ENGLAND.
WORK ON THE HYDRAULIC UNITS
When carrying out work on the hydraulic units, precautions must be taken to ensure conditions of the strictest cleanliness (see Op. ID 00).
WORK ON THE BODY, AND UNDERBODY REPAIR
To preserve the vehicle's roadholding and braking qualities. it is essential to locate correctly components to which mechanical parts are fitted.
This can only be achieved by using a surface plate No. 2600-T, designed by our REPAIR METHODS Department, and sold by FENWICK.
The "ID - DS 19 Bodywork Repair Manual" lists all spares sold by our SPARE PARTS Department.
NOTE.
There are in the trade surface plates which are cheaper and which can be used for repairing cars of different makes. We do not advise the use of these
surface plates as they are not sufficiently sturdy and lack the accuracy required for repairing our vehicles.
In fact, it must be remembered that mechanical components are fitted directly onto Citroen bodies and that the vehicle’s qualities (roadholding,
braking. tyre wear) depend essentially on the position of these components.

GENERAL CLASSIFICATION
The number in front of each unit corresponds to the operation number relating to this particular unit.
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Feed system:
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Carburettor and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Petrol pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Petrol tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Ignition system:
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Cooling system:
Water pump. pulleys, belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Radiator and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Gearbox lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

PRESSURE RESERVE
High pressure pump, pressure regulator accumulator, piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Distribution block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Manual height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Steering relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Hydraulic control (master cylinder, pedal gear, piping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Mechanical control (hand brake handle. cables) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
Dynamo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
HEATING – DEMISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 5
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
GENERAL . . . . . . . . . . . . . ID 00 Work on the hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 21
ENGINE . . . . . . . . . . . . . . . ID 100-1 Replacement of the engine-gearbox . . . . . . . . . . . . . . . . . . . . . . . 1 24
Adjustment of the rear flexible brackets . . . . . . . . . . . . . . . . . . . . 27 26
Adjustment of the front crossmember bracket . . . . . . . . . . . . . . . 29 27
ID 100-2 Stripping and assembling an engine-gearbox assembly. Stripping
and assembling for replacement of the engine . . . . . . . . . . . . 1 32
Stripping and assembling for replacement of the gearbox . . . . . . 23 34
ID 100-3 Overhauling an engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 36
Grinding the valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 40
Assembling the oil pump. Adjusting the pressure . . . . . . . . . . . . 24 41
Replacement of a starter gear ring. Grinding the flywheel . . . . . . 25 41
Preparation of parts for the crankshaft line . . . . . . . . . . . . . . . . . . 27 41
Fitting the cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 44
Fitting the oil seal half shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 46
Adjusting the end float of the crankshaft . . . . . . . . . . . . . . . . . . . 36 47
Fitting the timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 47
Fitting the oil pump on the engine . . . . . . . . . . . . . . . . . . . . . . . . 38 47
Crankcase . . . . . . . . . . . . . . ID 111-1 Work on the crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replacement of the Bump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 50
Replace of the sealing half-shells . . . . . . . . . . . . . . . . . . . . . . . . . 9 51
ID 112-0 Adjustment of the valve rocker clearances . . . . . . . . . . . . . . . . . . 1 55
Cylinder head . . . . . . . . . . . ID 112-1 Replacement of a cylinder head or a cylinder head gasket . . . . . . 1 56
Tightening the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 57
ID 112-3 Overhauling a cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 59
Replacement of valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 60
Grinding the valve seatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 60
Calibration of the valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 61
ID 112-4 Work on the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Replacement of an inlet rockershaft assembly . . . . . . . . . . . . . . . 1 64
Replacement of an exhaust rockershaft assembly . . . . . . . . . . . . . 15 65
Replacement of an inlet valve sealing ring . . . . . . . . . . . . . . . . . . 26 67
Replacement of a valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 68
Cleaning a cylinder head cover filter . . . . . . . . . . . . . . . . . . . . . . 46 69
Timing gear . . . . . . . . . . . . . ID 120-1 Work on the timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacement of a timing chain or timing gears . . . . . . . . . . . . . . . 1 71
Fitting the timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 71
Replacement of a camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 72
Replacement of a rocker tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 75

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 6
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
Engine suspension . . . . . . . ID 133-0 Adjustment of the engine suspension (on the car) . . . . . . . . . . . . . 1 76
ID 133-1 Work on the engine suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Replacement of an upper front crossmember . . . . . . . . . . . . . . . . 1 78
Replacement of a front support arm . . . . . . . . . . . . . . . . . . . . . . . . 16 79
Replacement of a rear flexible mounting . . . . . . . . . . . . . . . . . . . . 22 80
Repairing a flexible engine mounting . . . . . . . . . . . . . . . . . . . . . . 44 82
Pre-adjustment of the rear flexible engine mounting . . . . . . . . . . 46 82
Replacement of a rear arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 83
Replacement of a rear bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 84
Feed system :
Manifolds . . . . . . . . . . . . . ID 141-1 Replacement of an inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1 85
Carburettor . . . . . . . . . . . . . ID 142-1 Replacement of a Solex 34 PBIC carburettor . . . . . . . . . . . . . . . . 1 86
Adjustment of the slow running . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 86
ID 142-3 Overhauling a Solex 34 PBIC carburettor . . . . . . . . . . . . . . . . . . . 1 87
Controls . . . . . . . . . . . . . . ID 142-4 Work on the carburettor controls . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Replacement of an accelerator control cable . . . . . . . . . . . . . . . . . 1 89
Replacement of an accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . 12 90
Replacement of a choke control . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 90
Air filter . . . . . . . . . . . . . . ID 171-1 Replacement of an air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 92
ID 171-3 Overhauling an air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Overhauling a Vokes air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 93
Overhauling a Miofilter air filter . . . . . . . . . . . . . . . . . . . . . . . . . . 4 93
Petrol pump . . . . . . . . . . . . ID 173-1 Replacement of a petrol pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 95
ID 173-3 Overhauling a Guiot pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 96
Piping . . . . . . . . . . . . . . . . ID 174-1 Replacement of a petrol feed pipe (tank to pump) . . . . . . . . . . . . 1 98
ID 174-3 Repair of a petrol feed pipe (or a flexible suspension return pipe) 1 100
Petrol tank . . . . . . . . . . . . . ID 175-1 Work on the petrol tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacement of a petrol tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 101
Replacement of a filler pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 103
Replacement of an air pipe and an air vent pipe . . . . . . . . . . . . . . 28 103
Replacement of a petrol gauge tank unit . . . . . . . . . . . . . . . . . . . . 42 105

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 7
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
Exhaust . . . . . . . . . . . . . . . ID 180-1 Work on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Replacement of an exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 1 106
Replacement of an expansion chamber or a front exhaust pipe 16 107
Replacement of an exhaust silencer . . . . . . . . . . . . . . . . . . . . . . . 1 108 &
Replacement of the exhaust outlet pipes . . . . . . . . . . . . . . . . . . . 15 109
Ignition system . . . . . . . . . ID 211-0 Adjustments on the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Adjustments of ignition advance . . . . . . . . . . . . . . . . . . . . . . . . 1 111
Bench test of a distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 111
ID 211-1 Replacement of a distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 113
ID 211-3 Work on the distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Reconditioning an SEV distributor . . . . . . . . . . . . . . . . . . . . . . . 1 114
Reconditioning a Ducellier distributor . . . . . . . . . . . . . . . . . . . . 25 116
ID 211-4 Replacement of an advance control . . . . . . . . . . . . . . . . . . . . . . 1 118
Oil system . . . . . . . . . . . . . ID 220-0 Checking the oil pressure (on the car) . . . . . . . . . . . . . . . . . . . . 1 119
ID 220-1 Work on the oil circulating system
Replacement of an oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 120
Cooling system . . . . . . . . . ID 231-0 Alignment of pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 122
ID 231-1 Replacement of a water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 124
ID 231-3 Overhauling a water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 125
ID 231-4 Work on the pulleys and belts . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Replacement of a water pump and dynamo belt . . . . . . . . . . . . . 1 127
Replacement of a water pump and dynamo pulley . . . . . . . . . . . 7 127
Replacement of a driving shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 16 128
Replacement of a water pump pulley . . . . . . . . . . . . . . . . . . . . . 28 129
ID 232-1 Work on the radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Replacement of a radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 130
Replacement of a thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 131
Checking a thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 131
ID 241-1 Work on the radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Replacement of a fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 132
Replacement of a fan cowling . . . . . . . . . . . . . . . . . . . . . . . . . . 3 132

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 8
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
CLUTCH . . . . . . . . . . . . . ID 312-1 Replacement of a clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 133
ID 312-3 Overhauling a clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 134
Calibrating the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 135
Refacing the clutch driving plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 134
Adjusting the mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 135
ID 314-0 Adjustment of the clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Adjusting the height of the pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 136
Adjusting the clutch cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 136
Adjusting the clutch clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 136
ID 314-1 Work on the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacement of a clutch fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 137
Replacement of a clutch thrust bearing . . . . . . . . . . . . . . . . . . . . . . 9 137
Replacement of a thrust bearing hub . . . . . . . . . . . . . . . . . . . . . . . . 13 137
Replacement of a sealing ring (Cyclam) . . . . . . . . . . . . . . . . . . . . . 28 139
ID 314-4 Replacement of a clutch control . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 140
GEARBOX . . . . . . . . . . . . ID 330-1 Replacement of a gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 141
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 145
ID 330-2 Preparing a gearbox for stripping down . . . . . . . . . . . . . . . . . . . . . 1 146
ID 330-3 Overhauling a gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 147
Preparing the differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 154
Preparing the mainshaft (adjustment of the 2nd and 3rd speed
synchro and the lateral clearance of the bearings) . . . . . . . . . 27 155
Adjustment of the reverse gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 158
Adjustment of the bevel pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 159
Measuring the clearance between the teeth . . . . . . . . . . . . . . . . . . . 38 f) 162
Adjusting the engagement of the gears (3rd and 4th) . . . . . . . . . . . 41 163
ID 330-4 Replacement of a differential shaft, brake disc or differential
shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 164
Gearbox cover . . . . . . . . . . ID 331-1 Replacement of a gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 167
ID 331-3 Overhauling a gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 170
Adjustment of the clearance of the levers controlling the selector shafts 6 170
Calibration of the locking leverspring . . . . . . . . . . . . . . . . . . . . . . . 10 171
Adjusting the engagement of the gears (1st, and 2nd and reverse) 12 171

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 9
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
Replacement of a clutch fork (see Op. ID 314-1) . . . . . . . . . . . . . . 1 137
Replacement of a clutch bearing (see Op. ID 314-1) . . . . . . . . . . . . 9 137
Replacement of a thrust bearing hub and a sealing ring (Cyclam)
(see Op. ID 314-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 137
Replacement of an upper front crossmember (see Op. ID 133-1) . . . 1 78
Replacement of a pulley or a driving shaft (see Op. ID 231-4) . . . . . 7-16 127-128
Gearbox selector control . . ID 334-0 Adjustment of the gear selector control . . . . . . . . . . . . . . . . . . . . . . 1 173
Adjustment of the control tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 173
Adjustment of the ball controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 173
Adjustment of the change speed selector control rod . . . . . . . . . . . . 3 173
Adjustment of the selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 173
ID 334-1 Work on the gear selector control . . . . . . . . . . . . . . . . . . . . . . . . . . 1 174
Replacement of a ball control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 174
Replacement of the balls of the selector bell-crank lever . . . . . . . . 22 176
Replacement of a selector support . . . . . . . . . . . . . . . . . . . . . . . . . . 34 177
TRANSMISSION . . . . . . . ID 372-1 Work on the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Replacement of a driveshaft or a pivot . . . . . . . . . . . . . . . . . . . . . . 1 179
Replacement of a rubber dust cover gearbox end . . . . . . . . 15 180
pivot end . . . . . . . . . . . 19 181
PRESSURE RESERVE . . ID 391-0 Checking and adjusting the pressure reserve units . . . . . . . . . . . . . .. 182
Checking the valve of the suspension pump for leakage . . . . . . . . . 1 182
Pressure control valve bench test . . . . . . . . . . . . . . . . . . . . . . . . . . 4 183
Checking the initial pressure of an accumulator or a suspension sphere 9 184
Checking the pressure control valve (on the car) . . . . . . . . . . . . . . . 13 185
Adjustment of the position of the high pressure pump . . . . . . . . . . 18 186
Suspension pump . . . . . . . ID 391-1 Replacement of a suspension pump . . . . . . . . . . . . . . . . . . . . . . . . . 1 188
ID 391-3 Overhauling a suspension pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 189
Grinding the valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 189
Pressure regulato . . . . . . . ID 391-4 Work on a pressure regulator and accumulator . . . . . . . . . . . . . . . . 194
Replacement of a pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . 1 194
Replacement of an accumulator or a gasket between the accumulator
and pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 195

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 10
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
ID 391-6 Overhauling a pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . 196
Pressure control valve bench test (see Op. ID 391-0) . . . . . . . . . . 4 183
Checking the initial pressure of an accumulator (see Op ID 391-0) 9 184
Checking the pressure control valve on the car (see Op ID 391-0) 13 185
Piping . . . . . . . . . . . . . . . . . ID 391-7 Work on the suspension piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Replacement Of tile overflow return pipes of the height corrector 1 199
Repair of a flexible return pipe (see Op. ID 174-3).
Distribution Block . . . . . . . . ID 393-0 Checking a distribution block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Checking the setting of the suspension non-return valves . . . . . . 1 201
Checking the seating of the valves . . . . . . . . . . . . . . . . . . . . . . . . 4 201
ID 393-1 Replacement of a pressure distribution block . . . . . . . . . . . . . . . . 1 202
ID 393-3 Overhauling a pressure distribution Mock . . . . . . . . . . . . . . . . . . 1 203
FRONT AXLE . . . . . . . . . . ID 410-1 Replacement of a front half axle . . . . . . . . . . . . . . . . . . . . . . . . . . 1 204
Positioning the half axle on the sidemember . . . . . . . . . . . . . . . . . 12 205
Pre-adjustment of the heights . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 206
Adjustment of the heights (see Op. ID 433-0) . . . . . . . . . . . . . . . 1 233
Adjustment of the track and steering lock (see Op. ID 440-0) . . . . 7-10 261
ID 410-3 Overhauling a front half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 207
Adjustment of the castor angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 f) 211
Pivot . . . . . . . . . . . . . . . . . . ID 413-0 Adjustments to the pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Adjustments of the upper pivot ball joint . . . . . . . . . . . . . . . . . . . 1 212
Adjustments of a pivot-steering lever . . . . . . . . . . . . . . . . . . . . . . 5 212
ID 413-1 Work on the pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Replacement of a pivot seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 214
Replacement of a pivot steering lever . . . . . . . . . . . . . . . . . . . . . . 5 215
Replacement of an upper pivot ball joint . . . . . . . . . . . . . . . . . . . 16 216
Replacement of a lower pivot ball joint . . . . . . . . . . . . . . . . . . . . 28 217
Replacement of a wheel locking cone . . . . . . . . . . . . . . . . . . . . . . 34 218
Replacement of a wheel positioning dowel . . . . . . . . . . . . . . . . . . 38 218
Replacement of a pivot (see Op. ID 372-1) . . . . . . . . . . . . . . . . . . 1 179
Replacement of an anti-roll bar (see Op. ID 433-4) . . . . . . . . . . . 1 246
REAR AXLE . . . . . . . . . . . ID 420-1 Replacement of a rear half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 219
ID 420-3 Overhauling a rear half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 223

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 11
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
ID 420-4 Work on the rear half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Replacement of a wheel stub axle or wheel stub axle bearings 1 228
Replacement of a bearing seal or a bearing bush . . . . . . . . . . . . . . . 9 230
Replacement of a wheel locking cone . . . . . . . . . . . . . . . . . . . . . . . 18 231
Replacement of an anti-roll bar (see Op. ID 434-4) . . . . . . . . . . . . 1 254
SUSPENSION . . . . . . . . . ID 433-0 Adjustments on the suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Pre-adjustment of the front heights . . . . . . . . . . . . . . . . . . . . . . . . . 1 232
Pre-adjustment of the rear heights . . . . . . . . . . . . . . . . . . . . . . . . . . 5 233
Adjustment of the front heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 233
Adjustment of the rear heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 234
Adjustment of the front anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . 16 235
Adjustment of the lateral position of the anti-roll bar . . . . . . . . . . . 16 235
Adjustment of the anti-roll bar bearings . . . . . . . . . . . . . . . . . . . . . 17 235
Adjustment of the anti-roll bar side clearance . . . . . . . . . . . . . . . . 18 236
Checking the suspension cylinder for leakage . . . . . . . . . . . . . . . . . 20 236
Checking the initial pressure of an accumulator (see Op. ID 391-0).
Front suspension . . . . . . . . ID 433-1 Work on the front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Replacement of a suspension sphere or a damper . . . . . . . . . . . . . . 1 237
Replacement of a height corrector . . . . . . . . . . . . . . . . . . . . . . . . . . 7 238
Replacement of a suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . 18 239
Replacement of a dust cover or a suspension cylinder rod . . . . . . . . 35 240
Checking the initial pressure of an accumulator (see Op. ID 391-0) 9 184
Suspension units . . . . . . . . ID 433-3 Work on the suspension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Overhauling a front damper valve . . . . . . . . . . . . . . . . . . . . . . . . . . 1 242
Overhauling a rear damper valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 243
Overhauling a suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 7 243
Overhauling a height corrector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 245
Front anti-roll bars . . . . . . ID 433-4 Work on the front anti-roll bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Replacement of an anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 246
Replacement of the anti-roll bar bearings . . . . . . . . . . . . . . . . . . . . 17 247
Rear suspension . . . . . . . . ID 434-1 Work on the rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Replacement of a height corrector . . . . . . . . . . . . . . . . . . . . . . . . . . 1 249
Replacement of a suspension cylinder . . . . . . . . . . . . . . . . . . . . . . . 11 250
Replacement of a dust cover or a rear suspension cylinder piston rod 26 252
Replacement of a suspension sphere or a damper (see Op. ID 433-1) 1 237
Checking the initial pressure of an accumulator (see Op. ID 391-0) 9 184

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 12
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
Rear anti-roll bars . . . . . . ID 434-4 Work on the anti-roll bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Replacement of an anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 254
Replacement of a corrector control rod . . . . . . . . . . . . . . . . . . . . . . 7 254
Piping . . . . . . . . . . . . . . . Replacement of the overflow return pipes of the height corrector
(see Op.ID 391-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 199
Repair of the flexible suspension return pipe (see Op.ID 174-3) 1 100
Height control . . . . . . . . . ID 437-0 Adjustment of a manual height control . . . . . . . . . . . . . . . . . . . . . . 1 256
Adjustment of the heights (see Op.ID 433-0) . . . . . . . . . . . . . . . . . 10 233
ID 437-1 Replacement of a manual height control . . . . . . . . . . . . . . . . . . . . . 1 257
STEERING . . . . . . . . . . . ID 440-0 Adjustments on the steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Adjustment of the lateral position of the steering assembly . . . . . . 1 260
Adjustment of the alignment of the steering . . . . . . . . . . . . . . . . . . 5 260
Adjustment of the track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 261
Adjustment 0£ the steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 261
ID 441-1 Replacement of a steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 262
Replacement of a selector support (see Op.ID 334-1) . . . . . . . . . . . 34 177
ID 442-1 Replacement of a steering assembly . . . . . . . . . . . . . . . . . . . . . . . . 1 263
ID 442-3 Overhauling a steering assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 265
Steering relays . . . . . . . . ID 443-1 Work on the steering relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Replacement of a steering relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 269
Replacement of a lower relay lever (on the car) . . . . . . . . . . . . . . . . 19 271
ID 443-3 Overhauling a steering relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 273
BRAKES . . . . . . . . . . . . ID 451-0 Adjustment of the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Adjustment of a brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 275
Centralising the rear brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 276
Checking the faces of the front brake disc (see Op.ID 330-3) . . . . . 25 b) 154
Adjustment of the mechanical brake cables (See Op.ID 454-0) . . . . 3 302

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 13
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No. No. No.
ID 451-1 Work on the front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Replacement of the front brake shoes . . . . . . . . . . . . . . . . . . . . . . 1 277
Replacement of a brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 279
Replacement of a brake disc (see Op.ID 330-4) . . . . . . . . . . . . . . 1 164
ID 451-3 Overhauling a brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 281
ID 451-4 Work on the rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Replacement of a rear brake drum . . . . . . . . . . . . . . . . . . . . . . . . . 1 286
Replacement of a rear brake shoe . . . . . . . . . . . . . . . . . . . . . . . . . 8 287
Replacement of a rear brake backplate . . . . . . . . . . . . . . . . . . . . . 18 288
Replacement of a rear brake cylinder . . . . . . . . . . . . . . . . . . . . . . 20 288
ID 453-0 Adjustments of the Hydraulic Brake Control
Bleeding the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 291
Adjusting the height of the brake pedal . . . . . . . . . . . . . . . . . . . . . 8-9 292
ID 453-1 Work on the Hydraulic Brake Control
Replacement of a master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 1 293
Replacement of a pedal gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 295
ID 453-3 Work on the Hydraulic Brake Control
Overhauling a master cylinder
On cars produced since February 1958 . . . . . . . . . . . . . . . . . . . . . . 1 296
On cars produced before February 1958 . . . . . . . . . . . . . . . . . . . . 12 297
Overhauling a pedal gear
ID 453-4 Replacement of an articulating rear brake pipe . . . . . . . . . . . . . . . 1 300
Mechanical brake control . . ID 454-0 Adjustment of the mechanical brake control . . . . . . . . . . . . . . . . . 1 302
Adjustment of the brake handle lock . . . . . . . . . . . . . . . . . . . . . . . 1 302
Adjustment of the control cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 302
Adjustment of the connecting cable . . . . . . . . . . . . . . . . . . . . . . . 4 302
ID 454-1 Work on the mechanical brake control . . . . . . . . . . . . . . . . . . . . . 303
Replacement of a handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . 1 295
Replacement of a handbrake release trigger . . . . . . . . . . . . . . . . . 24 297
Replacement of a locking ratchet . . . . . . . . . . . . . . . . . . . . . . . . . . 33 298
Replacement of a control cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 306
Replacement of a connecting cable . . . . . . . . . . . . . . . . . . . . . . . . 51 307
ID 454-3 Overhauling a handbrake control . . . . . . . . . . . . . . . . . . . . . . . . . . 1 308
ELECTRICAL . . . . . . . . . . ID 510-1 Arrangement of the electrical installation . . . . . . . . . . . . . . . . . . . 1 309
Table of lamps fitted on the car

INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL 14
COMPONENT OPERATION DESCRIPTION PARAGRAPH PAGE
No No. No.
Dynamo . . . . . . . . . . . . . . . ID 532-I Replacement of a dynamo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 314
ID 532-3 Overhauling a dynamo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Overhauling a Ducellier 7158-A dynamo . . . . . . . . . . . . . . . . . . 1 315
Overhauling a Paris-Rhône G11. R91 dynamo . . . . . . . . . . . . . . 25 318
Starter motor . . . . . . . . . . . . ID 533-1 Replacement of a starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . 1 321
ID 533-3 Overhauling a starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Overhauling a Ducellier 6003-A starter motor . . . . . . . . . . . . . . 1 322
Overhauling a Paris-Rhône D11. B42 . . . . . . . . . . . . . . . . . . . . . 25 325
HEATING AND DEMISTING ID 642-1 Replacement of a heating and demisting radiator . . . . . . . . . . . . 1 329

INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL 15
No. OF SERVICE REFERENCE OF
ILLUSTRATION DESCRIPTION METHODS No. TOOL ON SALE REMARKS IMPORTANCE
NOTE :
The numbers appearing in the column headed "IMPORTANCE"
have the following significance :-
1. Indispensable in all workshops.
2. Indispensable in order to save time.
3. Indispensable in order to recover parts.
4. Of slight use
5. For use on actual vehicle.
6. Only for very large workshops.
ENGINE
16 Retaining clip for bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-4158 1
111 Jacking bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2505-T 2
42 Chain sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1697-T 6
19 Stand and truck for engine-gearbox assembly . . . . . . . . . . . . . . 2497-T 6
21 to 24 Adjusting fixture for engine supports . . . . . . . . . . . . . . . . . . . . . 1698-T 2
25 Spanner for adjustment of rear engine supports . . . . . . . . . . . . 1699-r 1
25 Spanner for adjustment of rear engine supports . . . . . . . . . . . . 1700-T 1
25 Spanner for adjustment of rear engine supports . . . . . . . . . . . . . 1982-T 1
61 Spanner for hydraulic pipe union (9 mm opening) . . . . . . . . . . 2219-T see pressure
reserve
61 Spanner for hydraulic pipe union (15 mm opening) . . . . . . . . . 2220-T see pressure
reserve
61 Spanner for hydraulic pipe union (10 mm opening) . . . . . . . . . 2221-T see pressure
reserve
87 Strap wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2223-T see pressure
reserve
91 Spring compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991-T see steering
91 Spanner for screw of steering collar . . . . . . . . . . . . . . . . . . . . . 1994-T see steering
54 Spanner for clutch housing screws (two flats) . . . . . . . . . . . . . . 1677-T 1
61 Spanner for clutch housing screws (hexagon) . . . . . . . . . . . . . . 2431-T 1
16 Spanner for carburettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1645-T 1
16 Spanner for sparking plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1603-T 1
15 Spanner for crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1667-T 3
15 Spanner for camshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1731-T 3
15 Fixture for retaining timing wheels . . . . . . . . . . . . . . . . . . . . . . 1680-T 2

INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL 16
No. OF SERVICE REFERENCE OF
ILLUSTRATION DESCRIPTION METHODS No. TOOL ON SALE REMARKS IMPORTANCE
16 Socket for connecting rod screws . . . . . . . . . . . . . . . . . . . . . . . 1624-T 1
5 Valve spring compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1614-T 1
5 Fixture for removing and refitting valves . . . . . . . . . . . . . . . . . 1616-T 1
64 Extractor for oil pump pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 1964-T 1
4 Grinding wheel for inlet valve seat (120°single cone) . . . . . . 1662-T 1
4 Grinding wheel for top clearance (15O°biconical) . . . . . . . . . 1630-T 1
4 Grinding wheel for lower clearance (9O°biconical) . . . . . . . . 1630-T 1
4 Grinding wheel for exhaust valve seat (90°biconical) . . . . . . . 1627-T 1
4 Grinding wheel for top clearance (150°biconical) . . . . . . . . . . 1627-T 1
4 Grinding wheel for lower clearance (60°single cone) . . . . . . . 1633-T 1
4 Valve grinding tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1615-T 1
6 Fixture for calibrating springs . . . . . . . . . . . . . . . . . . . . . . . . . 2420-T 3
11 Fixture for the adjustment of the oil pump . . . . . . . . . . . . . . . . MR-1811 1
7 Torsion spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2471-T 1
Dial gauge for measuring bores . . . . . . . . . . . . . . . . . . . . . . . . 2440-T 1
16 Spanner for plugs closing crankshaft oil-ways . . . . . . . . . . . . . MR-3462-70 4
12 Punched plate for fitting cylinder barrel joints . . . . . . . . . . . . . MR-4134 4
40 Mandrel for centring clutch disc . . . . . . . . . . . . . . . . . . . . . . . . 1712-T 2
13 Piston ring guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1656-T 1
18 Stand for engine resting on cylinder head . . . . . . . . . . . . . . . . MR-3053-160 4
18 Stand for engine resting on crankcase . . . . . . . . . . . . . . . . . . . MR-3053-170 4
9 Fixture for replacement of valve guides . . . . . . . . . . . . . . . . . . 1644-T 3
9 Reamer for valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1642-T 3
17 Extractor for dust cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1608-T 2
58 Fixture for alignment of pulleys . . . . . . . . . . . . . . . . . . . . . . . . 1685-T 1
37 Stand for water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3676-l80 4
37 Spanner for water pump bearing nut . . . . . . . . . . . . . . . . . . . . . 1646-T 2
37 Extractor for water pump bush . . . . . . . . . . . . . . . . . . . . . . . . . 2291-T 3
37 Bush and mandrel for fitting water pump bush . . . . . . . . . . . . MR-3676-270 3
55 Spanner for nut of water pump driving pulley shaft . . . . . . . . . 1640-T 2
17 Extractor for driving pulley shaft . . . . . . . . . . . . . . . . . . . . . . . MR-3404-20 2
20 Fixture for adjustment of the position of the High Pressure Pump. . 1693-T 1
CLUTCH
40 Mandrel for centring clutch disc . . . . . . . . . . . . . . . . . . . . . . . . 1712-T 2
6 Fixture for calibrating springs . . . . . . . . . . . . . . . . . . . . . . . . . . 2420-T 3
39 Fixture for clutch adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1701-T 6
39 Finger disc and clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1704-T 1
40 simplified fixture for clutch adjustment . . . . . . . . . . . . . . . . . . MR-3457-100 1

INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL 17
No. OF SERVICE REFERENCE OF
ILLUSTRATION DESCRIPTION METHODS No. TOOL ON SALE REMARKS IMPORTANCE
GEARBOX
42 Stand for supporting engine on the car and removing gearbox 1797-T 2
42 Support fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1799-T 2
54 Spanner for clutch housing screws (two flats) . . . . . . . . . . . . . 1677-T 1
61 Spanner for clutch housing screws (hexagon) . . . . . . . . . . . . . 2431-T I
55 Spanner for nut of water pump driving pulley shaft . . . . . . . . . 1640-T 2
101 Lever for disengagement of front brake shoes . . . . . . . . . . . . . 2127-T 1
101 Fork for disengagement of brake catch . . . . . . . . . . . . . . . . . . 2128-T 1
101 Spanner for adjustment of front brakes . . . . . . . . . . . . . . . . . . 2129-T 1
53 Stand for gearbox for use on a bench . . . . . . . . . . . . . . . . . . . . MR-3053-130 2
54 Spanner for bevel pinion nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 1734-T 2
57 Extractor body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750-T 1
52 Collet ring and thrust block for differential bearing extractor 1753-T 1
52 Pad for differential shaft bearing extractor . . . . . . . . . . . . . . . . 1742-T 1
57 Split collar and pressure pad for bevel pinion front bearing extractor 1738-T 2
55 Spanner for nut of differential bearing (on shaft) . . . . . . . . . . . 1770-T 1
55 Spanner for nut of differential bearing (in housing) . . . . . . . . . 1771-T 1
57 Spring compressor for locking lever spring . . . . . . . . . . . . . . . 1792-T 2
57 Spanner for spindle caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3691-80 3
-58 Fixture for alignment of pulleys . . . . . . . . . . . . . . . . . . . . . . . . 1683-T 1
56 Mandrel for positioning fork control balls . . . . . . . . . . . . . . . . 1793-T 2
6 Fixture for calibrating springs . . . . . . . . . . . . . . . . . . . . . . . . . 2420-T see engine
52 Mandrel for fitting differential bearings . . . . . . . . . . . . . . . . . . 1768-T 3
55 Mandrel for fitting the oil seal on the differential shaft . . . . . . 1767-T 1
55 Mandrel and bush for fitting the seal in the outside of the
differential bearing housing . . . . . . . . . . . . . . . . . . . . . . . 1772-T 3
13 Straight edge for dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3377 1
54 Mandrel for mainshaft hearing . . . . . . . . . . . . . . . . . . . . . . . . . MR-3045 3
54 Mandrel for assembly of bevel pinion . . . . . . . . . . . . . . . . . . . MR-3676-30 3
50 Fixture for adjusting crown wheel and bevel pinion . . . . . . . . . 2044-T 1
51 Fixture for adjustment of differential bearings . . . . . . . . . . . . . 1766-T 1
51 Dial gauge extension (differential bearing adjustment) . . . . . . 2438-T 1
50 Support for dial gauge (adjustment of tooth clearance) . . . . . . 2039-T 1
50 Dial gauge extension (adjustment of tooth clearance) . . . . . . . 2439-T 1
61 Spanner for ball joint cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3691-60 2
61 Press for fitting selector ball joints . . . . . . . . . . . . . . . . . . . . . . 2427-T 1
PRESSURE RESERVE UNITS
125 Hydraulic test bench 2290-T 1
61 Spanner for hydraulic pipe union (9 mm opening) . . . . . . . . . . 2219-T 1
61 Spanner for hydraulic pipe union (10 mm opening) . . . . . . . . . 2221-T 1

INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL 18
No. OF SERVICE REFERENCE OF
ILLUSTRATION DESCRIPTION METHODS No. TOOL ON SALE REMARKS IMPORTANCE
61 Spanner for hydraulic pipe union (13 mm opening) . . . . . . . . . 2222-T 1
61 Spanner for hydraulic pipe union (15 mm opening) . . . . . . . . . 2220-T 1
87 Strap wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2223-T 1
89 Cone for fitting ring seal on high pressure pump cylinder . . . . 2227-T 1
88 Wooden jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3407-30 1
Spring balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2472-T 1
87 Spanner and spindle for removing pressure regulator cap . . . . 2224-T 1
89 Mandrel for fitting the pressure regulator ring seal . . . . . . . . . 2226-T I
13 Straight edge for dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3377 see engine
51 Extension for dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2438-T see gearbox
89 Mandrel for fitting ring seal on bleed screw . . . . . . . . . . . . . . . 2225-T 1
TRANSMISSION - FRONT AXLE
64 Extractor for steering rod ball pin . . . . . . . . . . . . . . . . . . . . . . . 1964-T 1
64 Pressure pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1968-T 1
113 Gauge for pre-adjustment of the heights . . . . . . . . . . . . . . . . . 2307-T 1
65 Vice support for half axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3053-120 2
64 Extractor for axle arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1864-T 1
64 Spanner for anti-roll bar ball joint . . . . . . . . . . . . . . . . . . . . . . MR-3691-40 3
66 Vice support for pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1922-T 1
66 Spanner for nut between hub and shaft . . . . . . . . . . . . . . . . . . . 1920-T 1
63 Extractor for lower cup of upper pivot ball joint . . . . . . . . . . . . 1856-T 1
63 Fixture for fitting the lower cup of the upper pivot ball joint . . 1857-7 1
67 Mandrel for fitting the sealing joints . . . . . . . . . . . . . . . . . . . . MR-3676-140 3
67 Mandrel for fitting the sealing joints . . . . . . . . . . . . . . . . . . . . MR-3676-150 3
69 Bush for adjustment of castor angle . . . . . . . . . . . . . . . . . . . . . 1865-T 1
69 Bush for adjustment of castor angle . . . . . . . . . . . . . . . . . . . . . 1866-T 1
69 Fixture for adjustment of castor angle . . . . . . . . . . . . . . . . . . . . 2321-T 1
13 Straight edge for dial gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3377 see engine
64 Tool for adjustment of levers or pivots . . . . . . . . . . . . . . . . . . 1867-T 1
7 Torsion spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2471-T see engine 1
REAR AXLE
73 Vice support for axle arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MR-3053-90 2
74 Extractor for stub axle hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2018-T 2
54 Spanner for brake backplate screws . . . . . . . . . . . . . . . . . . . . . 1677-T see engine
75 Extractor for hub bearing (outer cup) . . . . . . . . . . . . . . . . . . . . 2019-T 1