PEUGEOT 504 Series 1970 Instruction manual

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ENGINE
CONTENTS
IDENTICATION AND CHARACTERISTICS
ldenttf1cat1on
REMOVAL AND REFITTING
Tools to oe used
Remov<1I ol the engine
Refitting of the engine
Engine tuning
DISMANTLING · REASEMBL Y
Tools
to be usi:d
Dismantling th;; engine
Reassembling
the engine
CYLINDER HEAD
ChecKing me compression
Tools to be used
Removal of the head
Refitting the head
Ret1gt1tcning the head Her 1,000 km (600 milts)
Refitting of thP spark plug tubes
Replac ng a valve
spring (hPad in place)
CYLINDER LINERS
Toois to be u~•~d
F 1tt mg free expanding liners ( XM KF G and K FS crig nes)
Fitting c.omprossed linPrs IXM7· XNl and XN2 eng1rns)
FLYWHEEL
Replacing the llywt eel
Replac.ing tt e
staner r mg geaf
TIMING
Too s to be used
Timing d1agr<.1m
Check ng the timing
Removing the timing dr 1vc
D1srn<1ritling tile cha111tr11s1oner
RPf1ttmg sett mg the 1m my
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Pa ge
01 01 131
02 01 (2)
02 03 <11 to 05 12 1
02 11 and 12
02 51 and 52
..
03 01 c1 1 and 02 <1 1
03 02 121 to 06 121
03 51 131 to 59 111
04 01 111 and 02 111
0411121
04 13 12 1dnd14 121
04 15 (1) to 19
04 21and22
04 51 and 52
05 61to63
06 01
OG02
06 03 to 05
09 01 11 I
09 02 (1)
10 01 14 )
10 02 (1)
10 03 (2)
10 04 c1 1anci 05 12 1
10 05 (2)
10 06 121 and 07
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CARBURETTOR
XM and XM 7 engines
AdJUS 1ng tht:: 1dl111g
Settings of Solex 34 PBICA carbllrettors
Description
Ad1ust1ng the acceleration pump stroke
XN 1 engine
Ad1ust1ng the idling
Settings of Solex cnrburetlors
Descr1pt1on
Cleaning and ad1ustmg
the 32/35SEI EA carburettor
PETROL INJECTION ENGINE
Feed ctrcu1t
Lift pumps
Electrovalve
F1lter1ng
Injection system
tools to be used
Replacing the throttle flap spindle (K F 5 XN 2l
ln1ectors
Delivery valves
Suction valves
ln1cct1on
pump
removal
• rcf11t1ng
· ad1usting • KF 6
• ad1ust1ng KF 5 and XN 2
LUBRICATION
Che .. mg the oil pressure
WATER PUMP
Re111uva1 -rnf1tting
Tools to be used
Dismantling
Reassembly
Che~k1ng the tan engagement
EXHAU ST SYSTEM
Assombly and clearances of the exhaust pipe
• Saloon
Family Saloon Break • Statton Wagon
EN G INE
CO NT ENTS
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Page
1201111
12 02 (1 l
12 03
12 04
1211111and 12111
1213111and14111
1215(1)
12 16 to 19
12 51 and 52
12 53 to 56
12 57
12 58
13 01
13 03 to 13 08
13 09
13 10 and 13 11
13 12
13 15 and 16
1317t l'J
13 21 to 27
13 31 to 16
14 01
15 01 (11
15 03 (2)
15 04 I 1) and 05 I1 I
1506111 008111
15 08 (1 I
16 01
16 02
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ENGINE
IDENTIFICATION
Identification letter
p XM
R
KF6/KF5
T XM ZF
t-- --------~U,_-----------;X~Nl~----------"'.""" }
UA XNl US. 7.6 1comp.
UB XN 7 6 1comp
SERIAL NUMBER (1)
The selial
numb11r stamped on the t .H. eng1r1c
mounting lug is
·preceded and followed by an" X".
• identical to the number stamped on tl e maker's
plate
(a) and on tlie R. H. w1119 V'dlance (b).
WARNING - In the event of replacemen1 of the
cylinde block or the engine, the number as deftned
above, must be stamped on the 1mgine, using 8 mm
letters, in the space provided (1) .
ENGINE NUMBER (2)
The engine numtier stamped on
tl 11' camshaft
tunnel consists of
a prOducuon number (c)
(a letter followed by c ''gur11s).
an identification lern•r (d)
(see table below)
WARNING · In the event of replacement the new
cv nj1 r b " must be stamr · id with the engine
number 111 the space prov1dEd (2) .
Type of engine
(Carburettor 10 CV for SA7 gearbox)
(ln1ection • 10
CV for BA7 gearbox)
!Carburettor 10
CV for ZI=' trilnsm ssron)
lree expamJ1ng liners
1-------------------- ---.
(Carburettor
11 CV for BA7 gea rbox)
(ln1ewon 1 CV for BA7 gearbox
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XN2
XN2
-(ln1ection 11 CV for ZF transmission) compressed liners•
x
XA
XB
y
E
XNl l
XNl US. 7.6 1comp. (Carburettor - 11 CV for ZF transm1ss1011)
XN I 7.6 1comp.
XM7
XM7
7.5 1comp.
8.3 1 comp.
Q. 1--------- .....
(Cnrburetwr · 10 CV for BA7 gearbox) J
(Carburettor· 10 CV "Expar1'')
-----------
• Compren•d llne,. fi"ed , ,,. ... Julv 1970 a nd from se ri al numb er 1 1 78 001.
2 ·7 3 '------------------
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Su persedes page 01 01 (2), class 1. 1
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3 .72
S upers e des p a ge 0 2 0 1 (1) , c lass 1 .
ENGINE
REMOVAL -REINSTALLATION
TOOLS TO
BE USED
8.0102 x
Engine hoisti ng apparatus.
8.0208
D -Hoist beam
E -Front hook
F - Rea r hook
G -Short hook
Key
for the clutch housing securing bolts.
8.0125
Engine or gearbox support bar.
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3-72
Sup e rs e des pa ge 02 03 and 02 04, class 1.
ENGINE
R EMOVAL
-On 504 with automatic transmission, drain the
transmission.
Remove:
-the battery and its tray.
-the bonnet,
-the radiator,
-the ignition coil,
-the starter.
-the windscreen washer bottle.
Disconnect :
-the heater hoses,
-the fuel feed line,
-the carburettor control s.
-the Master-Vac vacuum line,
-the wiring.
- On 504 Petrol Injection
Disconnect ·
-the air ducts,
-the throttle cable.
R
emove:
-the electrovalve (1),
-the alt itude corrector (2).
-On 504 Automatic.
Remove:
-the air filter,
-the bracket (3).
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ENGINE
RE MOV AL
<f'~
Lower the steermg rack housing ) ~
(turn the steering wheel to the left). '\)
- Disengage the exhaust pipe from the manifold.
Remove·
-
the flywheel protector plates,
the clutch housing bolts.-J 0'
4
~-.,
~
Position the hoisting apparatus as shown opposite
(locate the hooks
1n the holes marked "404 ").
- Raise the apparatus unttl 11 is under load.
Remove the four bolts securing the engine
mountings
to the crossmember.
W AR NIN G -Make sure that the front L.H. brake line
is hard up against the crossmember.
- Raise the engine unti I the gearbox abuts on the
tunnel.
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Supersedes page 02 0511), class 1 .
ENGINE
REMOVAL
-Place the gearbox support bar under the gearbox
and bring the centre
bolt into contact with the
housing.
On 504 Automatic :
Remove the 4 bolts securing the convenor to
the flywheel.
-Disengage the convertor.
WARNING · Never remove the engine with the
convertor , make sure
that the convertor remains
attached
to the transmission.
-Separate the engine from the gearbox
without
altering the position of the hoisting apparatus.
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