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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w
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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ENGINE
RE INSTALLATION 0
~~11
-Aeinstallation
procedure.
is a reversal of the removal
-Particular points .
engage one of the gears (BA 71 .
·couple the engine to the gearbox by lurning the
flywheel to line the two components up exactly.
On 504 Automatic.
-
Secure the convertor housing to the cyhnder block.
Bring one of the openings in the flywheel to the
bottom.
Rotate the convertor (using a screwdriver engaged
in the cooling fins) to line up one of the threaded
holes with the coupling plate on the flywheel.
-Tighten the bolts to 2. 25 m.kg (16 ft.lbs).
- When fitting the radiator, respect the dimension
(a) : 15 to 20 mm.
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ENGINE
REINSTALLATION
Before starting the engine
check the oil level and top up 1f necessary,
slacken off the banio (1).
• with the engine being driven by the starter. the
011 should flow freely.
On 504 Automatic.
-Refill the transmission with the correct fluid.
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ENGINE
TUNING
In addition to checking and adjusting the ignition system, an engine tune-up may include the following
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Q.
operations
-Compression check (page 0401 l
-Valve clearance setting (page
0422)
- Oil pressure check (page 1401)
-Cleaning the carburettor, fuel pump and air filter (page 1211)
-Checking
the cooling fan air gap I0.35 mm - 0.014")
- Adjusting the engine id ling (page 1201 or 121 1)
2 .7 3 ..._ _______________ _
SPARK PLUGS
- Carburettor engi nes :
For { XM XM7
XM and XN1 U.S.
·Marchal 35 HS
-AC 44 XL
·Champion N9Y
For XN1
· Marchal 35 HS
-AC 44 XL
·Champion N7Y
Electrode gap : 0.6 mm (0 . 024 ")
- Inject i on engin es
- For XM KR>
·Marchal GT 34 HO
· Champion N6Y
Electrod e gap : 0.5 mm (0. 020 ")
-For XM KF5 XN2
-Marchal GT 34 HD
·AC 42 XL
Champion N6Y
Electrode gap : 0.6 mm (0 .0.24 ")
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""'
VACUIJM ADVANCE
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VACUUM ADVANCE
M 48
ENTRIFUGAL ADVANCE
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VACUUM ADVANCE
M 53
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500 1000 1250 1~00
ENGINE
TUNING
CHECKING THE DISTRIBUTOR
Dwell angle: 57° ±2°
(Dwell
percentage : 63 % ± 3 %)
which corresponds to a points gap of approximately
0.40 mm (0. 016") except in the case of S.E.V.
Marchal "cassette" points
se ts where t he gap is
approximately 0.30 mm (0.012").
NB -On Ducellier distributors, check t he dwell angle :
1 - vacuum unit disconnected (atmospheric pressure)
2 -vacuum
unit submitted to a depression of 300
mm Hg.
The dwell an gle must be the same in both cases .
If it varies, wrrect by rotating t he cam (1).
Advance curves :
504 with carb urettor engine
M
48 curve
504
with injection engine
· M 53 curve
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ENGINE
TU NI NG
CENTRIFUGAL ADVANCE
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CENTRIFUGAL ADVANCE
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Advance curves :
The distributors
fitted to 504 U.S. models have
novacuum advance correction.
504 US "69 Standards"
- M. 48 curve
504 US "70 and 71 Standards"
M 69 curve
'104 US "72 and 73 Standards"
M 74 curve
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BEFORE
ENGINE
TUNING
SETTING THE TIMING PLATE
WARNING · Make sure that rhe timing >llate has
not m >1c.J
It 1n doubt. check the setting and ,1d1ust as follows.
-Position No. 4 piston at T.D.C.
Move the
timing plate to line the 'O' up with the
mark on the crankshaft pulley.
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ENGINE
TUNING
STATIC IGNITION TIMING
IGNITION 1 IMING WITH A STROBOSCOPE
Dwell angle correct
Timing plate set
Set the distributor approximately
Find T.D.C.
(1) · w11h 8 mm diameter rod
(2) · pulley mark lrnt!d
up with the "O" on the
plate.
Position the distributor as shown
(3) • carburettor engine
(4) • in1ecuon engine
Connect up the low tension wire
·Switch on the ignition
- Rotate the distributor
clockwise to fully close the µ01ms
-anticloc ~wise until the points begin to open
(spark v1s1ble between them).
·Lightly clamp the distributor.
Fit the distributor <.ap and connect up thP plug
leads.
Disconnect the vacuum line from the unit 5
(where fitted) and seal
off the nozzle
Connect
J strob 1 cope lamp with the sensor clamp on
the coil HT lead.
J 1ev-c..1untcr.
Start up tlrn engine.
The engine speed must not exceed 850 r p. m.
during
the setting.
-
Turn the dephaser needle to "O"
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ENGINE
TUNING
Point the strobos ope at the liming
plate, holcJmg
t per J t:nd1culnr to the plate.
Rotate the distributor until the :
· reference mark on the pulley is in line with the
correct reference (X) on the timing plate.
(X) 0° 101 G04 u::, 71 Standards"
(
)(Nl • XN2 (11 CV) eng nes
(X) =5° B.T.D.C. on 504 US "70. 72. 73 St an-
dards"
(X) -
10
0 B l DC jXM7 (IOCV) engines
· • • · on }b04 US "G~ Standards''
· or • on engines with no timing plate :
until the mark on the flywheel 1s apparent in
the 8 mm hole in the clutch housing.
r1qhllln t he di,,trtbtJlO I Cl amp
the l'ngine spL>cd
the clepr.aser (on zero)
the lining up of thP. timing marks.
Reconncet the vacuum hne (where vacuum unit
IS fitted).
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XI
ENGINE
TUNING
IGNITION TIM ING WITH A TEST LAMP
Dwell angle correct
Timing plate set
1 · Engines fitted with a timing plate
Rotate the crankshaft clockwise unt il the mark
on the pulley is in line with the graduation on the
timing plate (X).
(X)
(X)
(X)
0° for b04 US "71 Standards"
50
BT DC { for XN 1 XN2 (11 CV) engmes
· • • · for 504
US "70 72 73 Stan-
rl<1rds"
100
BT DC {for XM/ (10 CV) .engines
• · · · 1or 504 US "G9 St,mdards"
2 · Engines with no timing plate
Rot ate the crankshaft clockwise until the 8 mm
rod e ng• s m the flywheel.
Pos1tton the d1smbutor as shown oopos1te
Conm~ct ·
the low tension wire
·a test lamp (5W bulb)
Switch on
the 1gn1t1011
Rotate the distributor
·clockwise
ant1clockw1se until
the light comes on , while
holding the rotor arm "fully retarded "
Tighten the distributor clamp
Check, by turning the crankshaft clockwise :
the light must come on
1 ·when the pulley reference is in line with the
gradua11on (X) on the timing plate
2 when the 8 mm rod engages Ill the flywheel
Remove the rod and the test lamp
Fit tt e distributor cap and onnel t u1 tl e HT
leads
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