CITROEN DS 19 Repair Manual

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Table of Contents

Summary of Contents for CITROEN DS 19

Page 3: General Classification
METHOD OF USING THE REPAIR MANUAL This manual includes all main service operations. Primarily it is intended for left-hand drive cars, but the application to right-hand 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.
Page 4 I L L U S T R A T I O N S A t t h e t o p l e f t - h a n d c o r n e r o f e a c h i l l u s t r a t i o n i s s h o w n t h e n u m b e r o f t h e o p e r a t i o n c o n c e r n e d w i t h t h i s p a r t i c u l a r i l l u s t r a t i o n ( t h i s i n f o r m a t i o n i s n o t g i v e n o n t h e i l l u s t r a t i o n f o r t h e t o o l s ) .
Page 5: Table Of Contents
GENERAL CLASSIFICATION The number in front of each unit corresponds to the operation number relating to this particular unit. ENGINE ................Crankcase .
Page 6 SOURCE AND RESERVE OF PRESSURE: High pressure pump pressure regulator accumulator piping ....... Break accumulators .
Page 7: Engine
INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Work on the hydraulics – Precautions GENERAL ..DS 00 ........Revolutions counters and pressure gauges .
Page 8: Timing Gear
INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION OPERATION PARA. PARA. PAGE PAGE COMPONENT COMPONENT DESCRIPTION DESCRIPTION Cylinder head (cont’d) DS 112-3 Overhauling a cylinder head ..........Replacement of a valve guide .
Page 9: Air Filter
INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Carburettor (cont’d) DS 142-3 Work on the carburettor. Overhauling a Weber Z4—30 DCLC or 24-30 DCZCI carburettor ....Overhauling a Zenith 24-30 EEAC carburettor .
Page 10 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Exhaust ..DS 180-1 Work on the exhaust system. Replacement of an exhaust manifold or an exhaust manifold shield ....Replacement of an expansion chamber .
Page 11 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Pulleys and belts . . DS 231-4 Work on the pulleys and belts Replacement of the water pump belts ........Replacement of the high pressure pump belts .
Page 12 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Controls (cont’d. ) . . Replacement of a clutch thrust race ........Replacement of a clutch thrust race hub .
Page 13 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Gearbox cover . . . DS 331-1 Replacement of a gearbox cover ......... . DS 331-3 Overhauling a gearbox cover .
Page 14 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Pipe assemblies . . DS 334-7 Work on the pipe assemblies. Replacement of a front pipe assembly on the gearbox cover ....Replacement of a rear pipe assembly on the gearbox cover .
Page 15 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION High pressure pump DS 391-1 Work on the high pressure pump. Replacement of the high pressure pump belts ....... Replacement of a high pressure pump or a pipe between the pump and pressure regulator (cars produced before October 1958) .
Page 16 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION FRONT AXLE . . . DS 410-1 Adjustments on the front axle. Adjustment of the camber ..........Checking the castor angle .
Page 17 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION SUSPENSION ..DS 433-0 Adjustments on the suspension. Pre-adjustment of the heights ......... . . Adjustment of the heights .
Page 18 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Piping ... DS 434-7 Work on the suspension piping. Replacement of a front corrector feed pipe assembly .
Page 19 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Steering relays ..DS 443-1 Work on the steering relays. Replacement of a steering relay ........Adjusting the angular position of the relays .
Page 20 INDEX OF OPERATIONS SHOWN IN THE REPAIR MANUAL OPERATION PARA. PAGE COMPONENT DESCRIPTION Hydraulic brake control (cont’d) . . . DS 453-3 Overhauling a hydraulic brake control ........Piping .
Page 21 INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL No. of Service Reference of DESCRIPTION Remarks Importance Illustration Methods No. Tool on sale NOTE: Numbers in the column "IMPORTANCE" have the following significance: 1. Indispensable in all workshops. 4. Of small use. 2.
Page 22 I N D E X O F S P E C I A L T O O L S S H O W N I N T H E M A N U A L No. of Service Reference of Remarks DESCRIPTION Importance Illustration...
Page 23 I N D E X O F S P E C I A L T O O L S S H O W N I N T H E M A N U A L No. of Service Reference of Remarks DESCRIPTION Importance Illustration...
Page 24 INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL No. of Service Reference of DESCRIPTION Remarks Importance Illustration Methods No. Tool on sale Spring compressors for gearbox cover ......1798-T Mandrel for fitting the seals of the cylinders controlling the gears .
Page 25 I N D E X O F S P E C I A L T O O L S S H O W N I N T H E M A N U A L No. of Service Reference of DESCRIPTION Remarks Importance...
Page 26 INDEX OF SPECIAL TOOLS SHOWN IN THE MANUAL No. of Service Reference of DESCRIPTION Remarks Importance Illustration Methods No. Tool on sale Spanner for anti-roll bar ball joint cap ......MR-3691-40 Vice support for pivot .
Page 27 I N D E X O F S P E C I A L T O O L S S H O W N I N T H E M A N U A L No. of Service Reference of DESCRIPTION Remarks Importance...
Page 28 I N D E X O F S P E C I A L T O O L S S H O W N I N T H E M A N U A L No. of Service Reference of DESCRIPTION Remarks Importance...
Page 29 DS 19 OPERATION No. DS 00 : Work on the hydraulic system. Op. DS 00 TOOLS IMPORTANT REMARK If any irregularity of working occurs make certain that the hydraulic system is under pressure before doing anything else. To do this :-...
Page 30 DS 19 OPERATION No. DS 00 : Work on the hydraulic system. Op. DS 00 TOOLS For correct functioning of all the hydraulic system, it is essential that the fluid and the units of the hydraulic system should be perfectly clean. The strictest precautions must be observed during work on the car and for storage of the fluid and spare parts.
Page 31 DS 19 OPERATION No. DS 00 : Work on the hydraulic system. Op. DS 00 TOOLS 2. For the pipe assemblies, protect the union flanges with cellulose tape. Protect plastic pipes in the same manner. 3. For the rubber pipes, use cylindrical pegs :- 8 mm dia.
Page 32 DS 19 OPERATION No. DS 00 : Work on the hydraulic system. Op. DS 00 TOOLS On the clutch cylinder : 1 plug ....... D 391-63.
Page 33 DS 19 OPERATION No. DS 00 : Revolution counters and pressure gauges.. Op. DS 00 TOOLS REVOLUTION COUNTERS Certain adjustments and checking cannot be carried out effectively without the use of a revolution counter. In order that these adjustments and checks shall be accurate, it is necessary to use an instrument which is sufficiently accurate for this work.
Page 34 DS 19 OPERATION No. DS 00 : Work on the hydraulic system. Op. DS 00 TOOLS b) Checking of the revolution counter. This instrument permits the checking of the electric revolution counter. It permits of checking engine revolutions at 600 r.p.m. i.e. :300 r.p.m. high pressure pump, 1,200 engine r.p.m. i.e. : 600 r.p.m. high pressure pump and all the multiples of 300 r.p.m.
Page 35 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 PARTICULAR POINTS Removal. Release the pressure in the hydraulic system and drain the fluid reservoir. Drain the radiator and cylinder block. Mark the position of the steering pinion in relation to the steering column and mark the position of the steering in its bearings, before removal.
Page 36 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 TOOLS STRIPPING DOWN Hold the bonnet open (retaining bar MR-4158, see Pl. 16, fig. 1) and put the front of the car on stands (jacking bracket 2505-T, see Pl.
Page 37 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 TOOLS Disconnect the feed pipe assembly (5) from the steering. Remove the sealing plate. Seal the pipe assembly with a plate .............
Page 38 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 TOOLS Remove the fixing screws from the crossmembers on the sidemembers. Do not mislay them or the adjusting shims which will be found between the end of the crossmember and the sidemember...
Page 39 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 TOOLS To adjust the front crossmember bracket : Fit the front crossmember to the hull. Fit the shims found when dismantling between the crossmember and the sidemembers.
Page 40 DS 19 OPERATION No. DS 100-1 : Replacement of an engine gearbox assembly. Op. DS 100-1 TOOLS Connect the feed pipe to the petrol pump. Connect the five-pipe assembly to the gearbox. Insert the seal plates. Tighten the screws (spring washers)
Page 41 DS 19 OPERATION No. DS 100-1 : Replacement of an engine-gearbox assembly.. Op. DS 100-1 TOOLS Fit the coil and bracket assembly. Connect the leads to the contact breaker, the yellow terminal to the lower contact breaker (rear terminal) and the red terminal to the top contact breaker (front terminal). Connect...
Page 42 DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine TOOLS STRIPPING AND ASSEMBLING (for replacement of the engine). Stripping. Place the engine gearbox assembly on the stand Z497-T (see Pl. 19) Stand 2497-T Disengage the high pressure pump feed pipe from its attachment plate on the water tube.
Page 43 DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine TOOLS Assembly. To fit the contact breaker. Put the metal fixing plate on the flat lever. Position the driving dog of the contact breaker so that it corresponds to the oil pump driveshaft. Fit the contact breaker.
Page 44 DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine TOOLS Fit the fixing plates for the exhaust manifold shield, the smaller at the rear. Tighten the nuts (spring washer) 12 mm box spanner Fit the low pressure pump feed pipe, (spanner 2220-T, see Pl.
Page 45 DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine TOOLS c) Disconnect the feed pipes from the brake units and disconnect the accelerated idling pipe from the Spanner 2219-T or left-hand brake unit (spanner 2219-T or 2221-T, see Pl.
Page 46 DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine TOOLS Fit the clutch cylinder, connect the control rod to the fork and fit the belts on the high pressure pump. Fit the feed pipe and connect to the clutch cylinder (spanner 2219-T or 2221-T, see Pl.
Page 47 DS 19 OPERATION No. DS 100-3 : Overhauling an engine. Op. DS 100-3 PARTICULAR POINTS Dismantling. When removing the assembly of the crankshaft, connecting rods and pistons, make sure that the order and direction of assembly of the central bearing is marked. If the crankshaft and bearings are to be re-used make a reference mark so that they are not reversed on assembly.
Page 48 DS 19 OPERATION No. DS 100-3 : Overhauling an engine Op. DS 100-3 Crankshaft endfloat = 0.03 to 0.09 mm adjusted by means of a shim placed between the end cheek of the bearing and the washer on the timing pinion.
Page 49 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS To remove the tappets: Hold the cylinder barrels in position by means of two washers inserted between the barrels 1-2 and 3-4 and Washers: secure by screws ...............
Page 50 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS To remove the pistons from the connecting rods : a) Remove the gudgeon pin circlips from the groove in the piston. b) Heat the pistons to a temperature of 60°C. approximately by immersion in an oil bath or by heating in an oven.
Page 51 DS 19 OPERATION No. DS 100-3 : Overhauling an engine Clean the parts. Do not wash the crankshaft bearing in order to avoid removing the grease. TOOLS The bearing should be packed with new grease. With a spray gun paint the inside of the crankcase. Use a paint resisting the action of hot oil (paint such as AC.8, sold by CLEMENT and RIVIERE or MOUQUET).
Page 52 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS e) Clean the cylinder head with great care so as to eliminate all traces of emery in the valve chambers or gas passages This operation should always be carried out with very great care. The powdered emery (even in very small quantities), entering the engine, will cause rapid wear.
Page 53 DS 19 OPERATION No. DS 100-3 : Overhauling an engine. TOOLS c) Fit the support tube (24). Fit the fixed pinion (22) on the shaft (key and split cotters (23) in position). Insert the shaft (21) in the body of the pump. Fit the support tube locking screw.
Page 54 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS To prepare the parts for the crankshaft (see Pl. 13) In general proceed by renewing the parts. Nevertheless some repairs are possible. a) Crankcase : If the bearing caps have been filed by unskilled repairers, it is not possible to fit the standard crankshaft –...
Page 55 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS c) Connecting rods : 1. The connecting rod bearings can be changed. 2. On engines produced before June 1957, it is necessary to replace the four connecting rods at the same time (thickness in the centre of the body 19 mm).
Page 56 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS To fit the connecting rods on the crankshaft : Oil the bearing faces with an oil-can (SAE 20 engine oil), do not use a brush as this is liable to cause the introduction of dirt of brush hairs.
Page 57 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS d) To prepare the inlet rocker assembly: 1. Dismantle the assembly. 2. Drive out the plugs from the rockershaft by means of a pin punch, passing through the holes for the fixing screws.
Page 58 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS h) Fit the short cylinder head fixing screws. Screw up without tightening. i) Tighten the screws in the order indicated (see Pl. 7), first tightening 21.75 ft/lbs (3 m.kg), second tightening 43.5 ft/lbs (6 m.kg).
Page 59 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS i) Smear the assembly faces of the two half shells with Festinol around the fixing screw holes. Offer up the bearing caps together with their bearings. Put the sump gaskets in position, the end under the front and rear bearing caps.
Page 60 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS d) Fit the chain and pinion assembly, making sure that the keys are properly located on the camshaft and crankshaft. Tighten the camshaft nut to 108 ft/lbs (15 m.kg) (spanner 1731-T.
Page 61 DS 19 OPERATION No. DS 100-3 : Overhauling an engine TOOLS Turn the engine over. Support it on a stand (stand MR-3053-160. See Pl. 18, fig. 2) ..... .
Page 62 DS 19 OPERATION No. DS 111-1 : Work on the crankcase PARTICULAR POINTS Replacement of the sump. Remove the engine-gearbox assembly and leave suspended from a pulley block for this operation (see Op. DS 100-1). Before assembly, cut the old joint close to the bearing caps using a sharp blade. Smear the bearing surface, on the crankcase, with very thin Hermetic (slightly dilute with alcohol if necessary).
Page 63 DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 TOOLS REPLACEMENT OF THE SUMP Removal. Remove the engine-gearbox assembly (see Op. DS 100-1). Leave the engine-gearbox assembly suspended from a pulley block. Drain the engine oil...
Page 64 DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 TOOLS Remove the flexible pipe and water pipe assembly, left-hand. Remove the rubber and bakelite caps from the sparking plug tubes. Remove the sparking plugs (spanner 1603-T, see Pl.
Page 65 DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 TOOLS To remove the sealing shells (see Pl. 14): a) Remove the assembly screws (1l} from the sealing shells (13 and 14) ....... .
Page 66 DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 TOOLS Offer up the bearing caps fitted with their bearings (according to the reference marks made when dismantling). Put the joints in position under the front and rear bearing caps and level with the face of the joint with the half shells and timing cover;...
Page 67 DS 19 OPERATION No. DS 111-1 : Work on the crankcase. Op. DS 111-1 TOOLS Fit the cylinder head cover, sticking the gasket only on the cover with Hermetic. Check that the gasket and the bearing face on the cylinder head cover are properly clean. Tighten the fixing nuts (leather and plain washers).
Page 68 DS 19 OPERATION No. DS 111-4 : Work on the oil circulation. Op. DS 111-4 PARTICULAR POINTS Checking the oil pressure (on the car). Start the engine and leave it running in order to bring the oil temperature to 600 C.
Page 69 DS 19 OPERATION No. DS 111-1 : Work on the oil circulation. Op. DS 111-1 TOOLS Start the engine and let it run at 4000 r.p.m.: read the pressure which should be between 54 and 58.5 p.s.i. (3.8 and 4.1 kg/cm ).
Page 70 DS 19 OPERATION No. DS 112-0 : Adjusting the valve rocker clearances. Op. DS 112-0 PARTICULAR POINTS Valve clearance = 0.008 in (0.20 mm) for the inlet and 0.010 in (0.25 mm) for the exhaust. Adjust the valves of one cylinder with the piston at top dead centre, end of compression, the valves of the corresponding cylinder are then at...
Page 71 DS 19 OPERATION No. DS 112-1 : Replacement of a cylinder head or a cylinder head gasket. Op. DS 112-1 PARTICULAR POINTS Removal. Disengage the push-rods by lifting the inlet rockershaft slightly. Remove the cylinder head fitted with the inlet rockershaft.
Page 72 DS 19 OPERATION No. DS 112-1 : Replacement of a cylinder head or a cylinder head gasket. Op. DS 112-1 TOOLS Disconnect the rubber heater tube from the inlet manifold and the rubber feed pipe from the water pump. On the low pressure system : Disconnect the feed pipe union from the low pressure pump, (lower union).
Page 73 DS 19 OPERATION No. DS 112-1 : Replacement of a cylinder head or a cylinder head gasket.. Op. DS 112-1 ASSEMBLY TOOLS Assemble the cylinder head Refit the rear plate and exhaust manifold shield (plain and spring washers) ......
Page 74 DS 19 OPERATION No. DS 112-1 : Replacement of a cylinder head or a cylinder head gasket.. Op. DS 112-1 TOOLS To fit the carburettor (see Op. DS 142-1). Refit the accelerated idling pipe to the hot spot cover plate (spring washers) ..... .
Page 75 DS 19 OPERATION No. DS 112-3 : Overhauling a cylinder head. Op. DS 112-3 PARTICULAR POINTS Dismantling. Since the cylinder head is made of aluminium, one cannot replace he sparking plug tubes or the valve seats without he use of special tools.
Page 76 DS 19 OPERATION No. DS 112-3 : Overhauling a cylinder head. Op. DS 112-3 TOOLS NOTE – Since the cylinder head is made of aluminium, one cannot replace the sparking plug tubes or the valve seats without the use of special tools. Avoid removing the studs. It is however possible to replace a stripped or damaged thread by a “HELI-COIL”...
Page 77 DS 19 OPERATION No. DS 112-3 : Overhauling a cylinder head. Op. DS 112-3 TOOLS Exhaust valve seating: For the seating .....
Page 78 DS 19 OPERATION No. DS 112-3 : Overhauling a cylinder head. Op. DS 112-3 TOOLS b) To assemble the inlet rockershaft assembly (see Pl. 3) : Oil the inlet rockershaft (40) and with the lubrication holes facing downwards (on valve side), commence fitting at the front : 1 long screw (5) together with the shaft fixing cap (33).
Page 79 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 PARTICULAR POINTS Replacement of an inlet rocker assembly. Removal. Drain the radiator and the cylinder block. It is necessary to remove the last exhaust rockershaft, in order to allow the removal of the last fixing screw of the inlet rockershaft and the...
Page 80 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 Replacement of a valve spring. This operation is only an emergency repair. If the engine has been running for some time, the valve will have to be refaced.
Page 81 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Assembly (see Pl. 1). To assemble the rockershaft (see Pl. 3) : Fit the plugs to the shaft (40) and tin solder. Place in position on the shaft (previously oiled, and with the lubrication holes facing downwards, valve side, (see fig.
Page 82 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Fit the cups (3) and the sealing joints (4) on the sparking plug tubes (see Pl. 1). Fit the cylinder head cover, secure the gasket with Hermetic to the cylinder head cover only. Check that the gasket and the bearing face on the cylinder head cover are properly clean.
Page 83 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Assembly (see Pl. 1 and3). To assemble the rockershaft assembly : a) Before assembly, smear the expanding washer seating face with Hermetic. b) To fit the rockershaft assembly : 1st and 3rd cylinders : place on the shaft, starting from the front, a spring (37), the rocker (38) and a washer (29).
Page 84 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Drain the radiator and cylinder block. Save the water which contains anti-freeze. Unscrew the cylinder head fixing screws. Unscrew the inlet rockershaft fixing screws. Raise the rockershaft and disengage the push-rod of the valve in question.
Page 85 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Fit the air filter and tube assembly. Tighten the fixing nuts (spring washers). Tighten the clips fixing the piping on to the carburettor ..............
Page 86 DS 19 OPERATION No. DS 112-4 : Work on the cylinder head. Op. DS 112-4 TOOLS Adjust the valve rocker clearance (see Op. DS 112-0). Refit the cylinder head cover and the air filter (see paragraphs 23 to 25, this operation).
Page 87 DS 19 OPERATION No. DS 120-1 : Work on the timing gear.. Op. DS 120-1 PARTICULAR POINTS Replacement of a timing chain or timing pinions. On assembly align the reference marks (punch marks). A straight line passing through the centre-line of the pinions.
Page 88 DS 19 OPERATION No. DS 120-1 : Work on the timing gear. Op. DS 120-1 TOOLS b) Turn back the lockwashers and unscrew the pinion fixing nuts (spanner 1731-T for the camshaft nut, see Pl. 15, fig. 3 and spanner 1667-T for the crankshaft nut, see Pl. 15, fig. 1) .
Page 89 DS 19 OPERATION No. DS 120-1 : Work on the timing gear. Op. DS 120-1 TOOLS Place the engine-gearbox assembly on a stand (stand 2497-T, see Pl. 19) ....... . .
Page 90 DS 19 OPERATION No. DS 120-1 : Work on the timing gear. Op. DS 120-1 TOOLS Fit the water pump and dynamo driving belt. Tension the belt, tighten the screw fixing the dynamo and the nut fixing the tie-rod on the dynamo (Op. DS 231-0) 14 mm spanner...
Page 91 DS 19 OPERATION No. DS 120-1 : Work on the timing gear. Op. DS 120-1 TOOLS Fit the flange coupling the exhaust downpipe to the pipe ..........
Page 92 DS 19 OPERATION No. DS 133-0 : Adjustment of the rear engine mountings (on the car). Op. DS 133-0 TOOLS ADJUSTMENT (see Pl. 24). IMPORTANT NOTE – This operation should not be carried out on cars produced after July 1959.
Page 93 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 PARTICULAR POINTS Replacement of a front upper crossmember. Assembly. Between the sidemembers and the crossmembers insert the number of shims required to give a difference in the measurement between the brake disc and the sidemembers, on the left-hand side which should be greater by 70 ±...
Page 94 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 Assembly. Lower the engine then displace the support and flexible mounting, in order to centralise the parts in relation to the support arm on the engine.
Page 95 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS Assembly. Slightly raise the engine-gearbox assembly and offer up the upper crossmember. Place the upper flexible half collars and caps in position. Insert and tighten the screws securing the crossmember on the support arms, inserting locking tabs and tuning down on the screws .
Page 96 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS Unscrew the retaining screw (50) from the locknut (51) of the differential bearing (52) on the differential shaft and remove the nut (51) (spanner 1770-T, see Pl. 63, fig. 4) ......... . .
Page 97 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS Assembly (see Pl. 24). Offer up the flexible mounting on the support plate (4), fitted with the distance piece (14) and the steel cup (15).
Page 98 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS Refitting. Fit the arm on the flexible mounting previously adjusted (see paragraph 50) and tighten the upper nut on the arm (shakeproof washer) ...............
Page 99 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS PRE-ADJUSTMENT OF THE REAR FLEXIBLE ENGINE MOUNTING (cars produced since July 1959) Bring the upper face of the lower nut tightening the arm, to a distance of 98 mm from the bearing face of the flexible mounting on the steel support on the body .
Page 100 DS 19 OPERATION No. DS 133-1 : Work on the engine mountings. Op. DS 133-1 TOOLS REPLACEMENT OF A REAR FLEXIBLE MOUNTING SUPPORT (cars produced before July 1959) Removal (see Pl. 24). Remove the spindle of the flexible mounting (see paragraphs 23 to 28, this operation).
Page 101 DS 19 OPERATION No. DS 141-1 : Replacement of an inlet manifold (cars delivered before July 1959). Op. DS 141-1 PARTICULAR POINTS Removal. It is necessary to drain the water from the radiator and cylinder block. It is often necessary to remove the two rear studs in order to remove the manifold.
Page 102 DS 19 OPERATION No. DS 141-1 : Replacement of an inlet manifold (cars delivered before July 1959). Op. DS 141-1 TOOLS Disengage the accelerator control on the scuttle and turn towards the left. Remove the oil dipstick. Remove the inlet manifold. It is often necessary to remove the two rear studs in order to disengage the manifold . .
Page 103 DS 19 OPERATION No. DS 142-0 : Adjustment of the slow running. Op. DS 142-0 PARTICULAR POINTS The adjustment should be carried out with the engine hot, choke closed, ignition control in the mid-way position. The use of a revolution counter is indispensable. In practice, this adjustment should be carried out after the adjustment of the clutch drag (see Op.
Page 104 DS 19 OPERATION No. DS 142-0 : Adjustment of the slow running. Op. DS 142-0 TOOLS Set the screw (2) to give the minimum opening of the secondary throttle which will allow the engine to idle evenly. Turn the volume screw (3) to increase the richness of the mixture to give the highest speed at the throttle opening already determined.
Page 105 DS 19 OPERATION No. DS 142-1 : Replacement of a carburettor. Op. DS 142-1 TOOLS REMOVAL. Disconnect the petrol feed pipe from the carburettor. Loosen the clip fixing the tube between the carburettor and the air filter and remove the tube.
Page 106 DS 19 OPERATION No. DS 142-3 : Work on the carburettor. Op. DS 142-3 PARTICULAR POINTS Adjust the closing of the throttle valve of the 1st body on the Zenith 24/30 EEAC carburettor: unscrew the stop screw until the throttle valve is totally closed, bring the screw into contact with the stop then screw up three quarters of a turn exactly and lock the locknut.
Page 107 DS 19 OPERATION No. DS 142-3 : Work on the carburettor. Op. DS 142-3 TOOLS Clean the parts in petrol and blow out the passages in the carburettor and the different jets carefully with compressed air. NOTE – Never use metallic wire to unblock the jets, the holes in these are machined with great precision and such an action may modify their output.
Page 108 DS 19 OPERATION No. DS 142-3 : Work on the carburettor. Op. DS 142-3 TOOLS Put the pump jet (41) in position (position marked with a dowel). Fit the joint (40) between the jet and the carburettor body. Put the delivery valve (39) in position, fitting the joint (40) between the pump jet (41) and the head of the valve.
Page 109 DS 19 OPERATION No. DS 142-3 : Work on the carburettor. Op. DS 142-3 TOOLS Remove the plug (22). Remove the filter (21). Remove the plugs (23 and 24) as well as the plug (25). Remove the pump inlet valve (26).
Page 110 DS 19 OPERATION No. DS 142-3 : Work on the carburettor. Op. DS 142-3 TOOLS To prepare the cover (1) : a) Fit on the rod (9) of the piston (7) the steel washer (14) and the rubber washer (13).
Page 111 DS 19 OPERATION No. DS 142-4 : Work on the carburettor controls. Op. DS 142-4 PARTICULAR POINTS Replacement of a control rod. Removal. Withdraw the rod from underneath the car. Assembly. Cars produced before March 1956. In the case of replacement of the outside rod, press down the accelerator slightly in order to obtain an engine speed of between 950 and 1,000 r.p.m.
Page 112 DS 19 OPERATION No. DS 142-4 : Work on the carburettor controls. Op. DS 142-4 TOOLS REPLACEMENT OF AN ACCELERATOR PEDAL Removal. Place the car on a lift or over a pit. Unscrew the nut from the screw fixing the lever on the pedal spindle.
Page 113 DS 19 OPERATION No. DS 142-4 : Work on the carburettor controls. Op. DS 142-4 TOOLS REPLACEMENT OF A CONTROL RELAY Removal (see Pl. 46). Disconnect the accelerator control return spring (22) and the spring (1) of the clutch re-engagement control from the control relay.
Page 114 DS 19 OPERATION No. DS 142-4 : Work on the carburettor controls. Op. DS 142-4 TOOLS Removal (cars produced since January 1959). NOTE – On these cars, it is possible to replace the accelerated idling control without replacing the pipe.
Page 115 DS 19 OPERATION No. DS 142-4 : Work on the carburettor controls. Op. DS 142-4 TOOLS REPLACEMENT OF THE ACCELERATED IDLING CONTROL SEALS ( cars pr oduced bef or e M ar ch 1959) . Dismantling. Remove the coils and bracket assembly ............
Page 116 DS 19 OPERATION No. DS 142-6 : Overhauling an accelerated idling control assembly (cars produced since January 1959). TOOLS DISMANTLING (see Pl. 28, fig. 1 and 2). Remove the support (14) of the spring (13) from the body of the control assembly.
Page 117 DS 19 OPERATION No. DS 171-1 : Replacement of an air filter-silencer. Op. DS 171-1 TOOLS REMOVAL Loosen the fixing clip on the air filter-silencer of the tube between the air-filter-silencer and the carburettor. Disconnect the tube from the air filter-silencer.
Page 118 DS 19 OPERATION No. DS 171-3 : Work on the air filter-silencer. Op. DS 171-3 TOOLS OVERHAULING A VOKES AIR FILTER-SILENCER Dismantling (see Pl. 28 fig. 4) NOTE– It is important to clean the air-filter-silencer every 3700 miles ( 6000 km) (the car running on normal roads).
Page 119 DS 19 OPERATION No. DS 171-3 : Work on the air filter-silencer. Op. DS 171-3 TOOLS Assembly. Make sure that the felt joint (8) for the rear cover is stuck in position. If not, restick (EC 847 paste, see paragraph 3, this operation). Engage the rear cover and tube assembly (6) in the body of the air filter-silencer (7).
Page 120 DS 19 OPERATION No. DS 173-1 : Work on the air filter-silencer. Op. DS 173-1 TOOLS REMOVAL Disconnect the inlet and outlet pipes from the pump. Remove the nuts from the pump fixing studs ........... . .
Page 121 DS 19 OPERATION No. DS 173-3 : Overhauling a petrol pump. Op. DS 173-3 PARTICULAR POINTS Overhauling a GUIOT pump. The seats of the inlet and outlet valves are set in the cover of the pump. In case of poor functioning of the valves it will be necessary to replace the pump.
Page 122 DS 19 OPERATION No. DS 173-3 : Overhauling a petrol pump. Op. DS 173-3 TOOLS Make sure that the screw holes in the diaphragm correspond with the threaded holes in the pump body, tighten the nut (9). Connect the upper part of the pump (4) to the body (5). The diaphragms should be fitted dry without any hermetic or similar product.
Page 123 DS 19 OPERATION No. DS 174-1 : Replacement a petrol feed pipe. Op. DS 174-1 PARTICULAR POINTS In order to avoid leakage from the rear rubber pipe, fit two Ligarex clips as indicated in Pl. 29 fig. 3. Tighten the clips moderately in order to avoid deformation of the nylon pipe.
Page 124 DS 19 OPERATION No. DS 173-3 : Replacement a petrol feed pipe. Op. DS 174-1 TOOLS Insert the rear end of the feed pipe in the petrol tank and couple the rear end of the rubber pipe in the union of the tank.
Page 125 DS 19 OPERATION No. 174-3 Repair of a flexible feed pipe or a suspension return pipe. Op. DS 174-3 TOOLS NOTE - This repair can be carried out by fitting a sleeve on the pipe system (petrol feed or suspension return) or by replacing one of the unions (return).
Page 126 DS 19 OPERATION No. DS DS 175-1: Work on the petrol tank. Op. DS 175-1 PARTICULAR POINTS Replacement of a petrol tank. in order to avoid leakage from the rubber pipe between the feed pipe to the pump and the petrol tank, fit two Ligarex clips as indicated in Pl.
Page 127 DS 19 OPERATION No. DS 175-1 Work on the petrol tank. Op. DS 175-1 TOOLS Refitting. To assemble the tank a) Place the petrol gauge tank unit in position, inserting a rubber joint. Tighten the fixing screws (fibre washers under the heads).
Page 128 DS 19 OPERATION No. DS 175-1 Work on the petrol tank. Op. DS 175-1 TOOLS REPLACEMENT OF A FILLER PIPE Removal. Remove the right-hand rear wing and the side protection panel. Glean the working area carefully ...
Page 129 DS 19 OPERATION No. DS 175-1 Work on the petrol tank. Op. DS 175-1 TOOLS Remove the right-hand rear wing and the side protection panel. Clean the working area carefully ... .
Page 130 DS 19 OPERATION No. DS 175-1 Work on the petrol tank. Op. DS 175-1 TOOLS REPLACEMENT OF A PETROL GAUGE TANK UNIT Removal. Lift and remove the rear squab. Remove the rear seat. Remove the petrol tank cover plate .............
Page 131 DS 19 DS 180-1 Work on the exhaust system. Op. DS 180-1 TOOLS REPLACEMENT OF AN EXHAUST MANIFOLD Removal. Release the pressure in suspension system. Unscrew the bleed screw of the pressure control valve and place the manual height control lever in the low position.
Page 132 DS 19 DS 180-1 Work on the exhaust system. Op. DS 180-1 TOOLS REPLACEMENT OF AN EXPANSION CHAMBER Removal. Remove the nuts of the collar fixing the expansion chamber on its support and remove the collar ... .
Page 133 DS 19 DS 180-1 Work on the exhaust system. Op. DS 180-1 TOOLS REPLACEMENT OF THE EXHAUST OUTLET PIPES Removal. Put the car on stands or on a lift (jacking bracket 2505-T, see Pl. 168) ....... . .
Page 134 DS 19 OPERATION No. DS 211-0 Ignition adjustments. Op. DS 211-0 PARTICULAR POINTS Adjustment of ignition advance. In order to carry out this operation it is necessary to set the ignition control in the midway position. After adjustment, do not forget to remove the rod from the flywheel.
Page 135 DS 19 OPERATION No. DS 211-0 : Ignition adjustments. Op. DS 211-0 TOOLS Untighten the screw fixing the distributor. Find the point at which the contact breaker points open, at this exact moment the lamp should light. Tighten the fixing screw .
Page 136 DS 19 OPERATION No. DS 211-0 : Ignition adjustments. Op. DS 211-0 TOOLS Final adjustment having been obtained, make sure that the average of the two gaps is equal to 0.4 mm. Examples : 0.35 and 0.45 mm. 0.30 and 0.50 mm.
Page 137 DS 19 OPERATION No. DS 211-0 : Ignition adjustments. Op. DS 211-0 TOOLS CLEANING THE SPARKING PLUGS IMPORTANT NOTE - Incomplete cleaning of the plugs after sand blasting can cause rapid engine wear. It is necessary to eliminate all traces of sand after this operation.
Page 138 DS 19 OPERATION No. DS 211-1 Work on the contact breaker. Op. DS 211-1 PARTICULAR POINTS Replacement of a contact breaker (with two breakers). Removal. Drain the radiator and remove the inlet manifold (it may be necessary to remove the two upper rear studs).
Page 139 DS 19 OPERATION No. DS 211-1 Work on the contact breaker. Op. DS 211-1 TOOLS Disconnect the accelerator control from the butterfly control ........
Page 140 DS 19 OPERATION No. DS 211-1 Work on the contact breaker. Op. DS 211-1 TOOLS c) Set the manual ignition control in the midway position. (To do this, it is necessary to count the number of clicks). d) Connect the negative terminal on the battery.
Page 141 DS 19 OPERATION No. DS 211-1 Work on the contact breaker. Op. DS 211-1 TOOLS REPLACEMENT OF A CONTACT BREAKER (with one breaker). If any difficulty is experienced, proceed as indicated in ID 19 Repair Manual, operation ID 211-1. REPLACEMENT OF A VARIABLE IGNITION CONTROL.
Page 142 DS 19 OPERATION No. DS 211 - 3 Overhauling a contact breaker. Op. DS 211-3 TOOLS OVERHAULING A CONTACT BREAKER (with two breakers). Dismantling (see Pl. 31). Remove the cover. Remove the upper condenser (I) and the lower condenser (2) with their bracket.
Page 143 DS 19 OPERATION No. DS 211-3 Overhauling a contact breaker. Op. DS 211-3 TOOLS Put the fixed contact carriers (10) and (11) in position. Insert a plain washer and a spring washer under the heads of the screws and tighten provisionally.
Page 144 Connect the positive terminal of the coil to the positive terminal of a 6 volt battery and the negative terminal to a DS 19 contact breaker (contact gaps set to 0. 4 mm) fitted with condensers in good condition. Connect 1. The secondary outlet “a” to the insulated terminal of the first spark gap (A) which is set during the test.
Page 145 DS 19 OPERATION No. DS 212-0 Checking an ignition coil. Op. DS 212-0 TOOLS b) Secondary outlet No. 2. Reverse the secondary wires to the spark gaps. Put the two-way switch (C) in position to supply the contact breaker (towards the top). There should be practically no misfires in the sparks with the spark gap set at 8 mm.
Page 146 DS 19 OPERATION No. DS 2131-0 Adjustments of pulleys and belts. Op. DS 231-0 PARTICULAR POINTS Adjust the tension of the belts (see Pl. 35). The leverage for tensioning the high pressure pump belt is 24 ft./lb. (3m. kg.) and the dynamo belt 29 ft./lb. (4m. kg.).
Page 147 DS 19 OPERATION No. DS 231-0 : Adjustments of pulleys and belts. Op. DS 231-0 TOOLS Remove the pulley being adjusted. Remove the adjusting washer, measure its thickness and select a washer of suitable thickness from among those sold by our Spare Parts Department.
Page 148 DS 19 OPERATION No. DS 231-1: Replacement of a water pump and low pressure pump. Op. DS 231-1 PARTICULAR POINTS Since October 1957, the pumps are fitted with a new impeller (marked with No. DS 231-7 on the outer face). These pumps should befitted with a new type cover, which has a groove provided for securing the water outlet hose.
Page 149 DS 19 OPERATION No. DS 231-1: Replacement of a water pump and low pressure pump. Op. DS 231-1 TOOLS ASSEMBLY (see Pl. 37). To position the pulley on the new pump a) Place the old pump on a surface plate and measure the distance “d” between the bearing face “a” on the cover and the boss face “b”...
Page 150 DS 19 OPERATION No. DS 231-3 : Overhauling a water pump and low pressure pump.. Op. DS 231-3 TOOLS PARTICULAR POINTS Dismantling. In order to make sure of perfect sealing after a complete pump overhaul, it is necessary to lap the thrust washers and the thrust face of the joint.
Page 151 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Remove the pump from the stand. Remove the spindle and impellor assembly (17) from the water pump body. Remove the thrust washer (18), the ring seal (19) and the cup (20) from the pump body. Remove the spring (21), the cyclam joint (22) and the spindle thrust washer (23).
Page 152 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Assembly (see Pl. 37). To prepare the pump body a) If the body of the water pump has no groove at ‘e’ (see fig. 5), cut one with a chisel.
Page 153 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Fit an abrasive paper washer on the lapping spindle (choose the grain number according to the condition of the surface).
Page 154 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Fit the paper joint with the narrow part to the side nearest the inlet union (union is located near the drain pipes (24) and (25)).
Page 155 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Remove the bearing (extractor 1684-T, see Pl. 41, fig. 3). Remove the steel cup (7), the half retaining rings (8) and the spring (9) .
Page 156 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS Put in position the key (16), the pinion (15) and the wheel (14) previously smeared with hydraulic fluid. Offer up the low pressure pump body (10), turn the assembly over in order to bring the overflow pipes (24) and (25) one opposite the other, with the clearance holes lining up with the tapped holes in the water pump body.
Page 157 DS 19 OPERATION No. DS 231-3 : Overhauling of a water pump and low pressure pump. Op. DS 231-3 TOOLS CHECKING THE BUSH FOR LEAKS (see Pl. 40, fig. 1). To carry out this test, it is necessary to obtain a supply of compressed air at a pressure of 14 p.s.i.. (1 kg/cm Use an acetylene cylinder connected on a compressed air pipe.
Page 158 DS 19 OPERATION No. DS 231-4 : Work on the pulleys and belts. Op. DS 231-4 PARTICULAR POINTS Replacement of the water pump belts. The belts are sold as a paired set of two by our Spare Parts Department. It is necessary to replace the two belts even if one is in good condition.
Page 159 DS 19 OPERATION No. DS 231-4 : Work on the pulleys and belts. Op. DS 231-4 TOOLS REPLACEMENT OF THE WATER PUMP BELTS Removal. Loosen the screws fixing the dynamo and tie-rod. Move the dynamo as far as possible towards the engine.
Page 160 DS 19 OPERATION No. DS 231-4 : Work on the pulleys and belts. Op. DS 231-4 TOOLS Assembly (see Pl. 45). Put the belt or belts on the driving pulley, then on the high pressure pump pulley. Pass the belts between the clutch fork and the clutch housing.
Page 161 DS 19 OPERATION No. DS 231-4 : Work on the pulleys and belts. Op. DS 231-4 TOOLS REPLACEMENT OF A DRIVESHAFT Removal (see Pl. 58). Remove the battery, the battery tray, the spare wheel and the left-hand front wing ..... . .
Page 162 DS 19 OPERATION No. DS 232-1 : Work on the radiator and fan. Op. DS 232-1 PARTICULAR POINTS Replacement of a fan. Refitting. Tighten the fan fixing screw to 72 ft/lb (1 m.kg). Do not exceed this tightening torsion. Replacement of a radiator.
Page 163 DS 19 OPERATION No. DS 232-1 Work on the radiator and fan. Op. DS 232-1 TOOLS Remove the fan (see paragraphs 1 and 2, this operation). Remove the fan cowl fixing screws and remove it ..........
Page 164 DS 19 OPERATION No. DS 232-1 Work on the radiator and fan. Op. DS 232-1 TOOLS To fit the radiator a) Put the radiator in position, connect the rubber connections and fit the distance pieces in position on the radiator fixing plates (the longest distance piece on the right-hand side).
Page 165 DS 19 OPERATION No. DS 232-1 Work on the radiator and fan. Op. DS 232-1 TOOLS CHECKING A THERMOSTAT Immerse the thermostat in hot water. When the water reaches a temperature between 72 and 76 C, the valve should commence to open.
Page 166 DS 19 OPERATION No. DS 312-1 Replacement of a clutch. Op. DS 312-1 TOOLS REMOVAL Remove the gearbox (see Op. DS 330-1). Disconnect the clutch from the engine flywheel and remove .........
Page 167 DS 19 OPERATION No. US 312-3 :, Overhauling a clutch assembly. Op. DS 312-3 PARTICULAR POINTS Dismantling. Mark the position of the clutch driving plate on the toggle carrier plate. Assembly. Compensate for the loss of thickness of the clutch driving plate, after rectification, by fitting steel washers under the spring equal in thickness to the amount removed from the driving plate (original thickness 13.0 —...
Page 168 DS 19 OPERATION No. US 312-3 :, Overhauling a clutch assembly. Op. DS 312-3 TOOLS NOTE - Each rectification of the clutch driving plate surface causes loss of pressure on the clutch disc. To compensate for this loss of pressure, fit steel washers to the springs, equal in thickness to the amount removed from the clutch driving plate.
Page 169 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 PARTICULAR POINTS Checking the clutch cylinder for leakage (test bench 2290-T). The clutch cylinder should be free from leakage under a pressure of 1,070 p.s.i. (75 kg/cm Checking the clutch (test bench 2290-T).
Page 170 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 Adjust the clutch clearance. Pre-adjustment. This adjustment should be carried out with the engine stopped, and the hydraulic system under pressure. Move the clutch fork towards the rear, have the starting handle turned by an assistant.
Page 171 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 TOOLS CHECKING A CLUTCH CYLINDER FOR LEAKAGE (see Pl. 49). In order to carry out this operation, prepare a long pipe by connecting the pipes (A) and (B) (see Pl. 173) and prepare the test bench as indicated on Pl.
Page 172 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 TOOLS NOTE - If this pressure is greater than 425 p. 6.1. (30 kg/cm ), it is probably caused by piston seizure (in this case, it is necessary to replace the piston and cylinder assembly) or a mechanical cause Thrust race slides badly.
Page 173 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 TOOLS Start the engine and note the pressure gauge (M1) : the needle should drop to a pressure of 420 p.s.i. (29 kg/cm minimum.
Page 174 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 TOOLS Adjustment of the clutch drag (see Pl. 45). Accelerate very slowly. The clutch drag should occur between 700 and 750 r.p.m. If not, proceed as follows a) Stop the engine.
Page 175 DS 19 OPERATION No. DS 314-0 : Checking and adjustments on the clutch control. Op. DS 314-0 TOOLS Accelerator control with 1 rod (see Pl. 46, fig. 2). Stop the engine, press the accelerator pedal right down. The hook of the spring should be fitted without strain or without clearance on the pin (6) with the pin resting at the lower part of the slot “a”.
Page 176 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 PARTICULAR POINTS Replacement of a clutch cylinder. When assembling, pass the control rod through the belts. Adjust the tension of the belts to 21 ft/lb (3 m.kg) (see Op. DS 231-0 and Pl. 35).
Page 177 DS 19 OPERATION No. DS 314-1 : Work on the clutch controls. Op. DS 314-1 Assembly. When mounting the casings, fit the differential bearing distance pieces and adjusting shims in their respective positions, marked when dismantling. If the parts are not marked it is necessary to adjust the differential bearings (see Op. DS 330-3).
Page 178 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS Connect the pressure feed pipe to the clutch cylinder (spanner 2219-T or 2221-T, see Pl. 72, fig. 4). The pipe must be fitted without any strain, set it if necessary.
Page 179 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS REPLACEMENT OF A CLUTCH ENGAGEMENT CONTROL Removal (see Pl. 46, fig. 2). Release the pressure. Remove the coils and bracket assembly ............
Page 180 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS REPLACEMENT OF A CLUTCH FORK Removal (see Pl. 58). Remove the gearbox (see Op. DS 330-1). Unscrew the nuts (2) and (3) and disengage the rod (4) from the fork (see Pl. 45, fig. 1).
Page 181 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS REPLACEMENT OF A CLUTCH THRUST RACE HUB Removal (see Pl. 58). Remove the gearbox (see Op. DS 330-1). Remove the clutch thrust retaining spring (73). Remove the thrust race.
Page 182 DS 19 OPERATION No. DS 314-1: Work on the clutch controls. Op. DS 314-1 TOOLS To connect the clutch housing to the gearbox housing : a) Place the differential and crown wheel assembly, complete with bearings in the clutch housing.
Page 183 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS Fit the differential shaft, bearing and brake disc assemblies (see paragraph 61,. this operation). Fit the brake unit and rear support assemblies ........... .
Page 184 DS 19 OPERATION No. DS 314-1 Work on the clutch controls. Op. DS 314-1 TOOLS Connect the flanges to the hydraulic gear selector and to the clutch engagement control. Insert the seal plates (renew the ring seals). Fit the nuts without tightening (spring washers). Connect the pipes to the pressure distributor and the clutch cylinder.
Page 185 DS 19 OPERATION No. DS 314-3 : Work on the clutch control units. Op. DS 314-3 TOOLS OVERHAULING A CLUTCH SYSTEM See Op. DS 314-1, paragraphs 15 and onwards. CHECKING FOR LEAKAGE (see Pl. 49). In order to carry out this operation, the test bench should be prepared as indicated on Pl. 171. Connect the clutch cylinder to the pump orifice “a”, using the pipe (H).
Page 186 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 PARTICULAR POINTS Replacement of a gearbox. Removal. Release the pressure and bleed the front brakes. Mark the position of the steering wheel in relation to the pinion and the position of the steering in its bearings, before removal.
Page 187 DS 19 OPERATION No. DS 330-1 Work on the gearbox. Op. DS 330-1 TOOLS REPLACEMENT OF A GEARBOX Removal. Hold the bonnet open (stop MR-4158, see Pl. 16, fig. 1). Drain the water cooling system (save this water which contains anti-freeze).
Page 188 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 TOOLS Disconnect the steering levers from the relay. Hold the steering column (setting gauge 1993-T, see Pl. 125). Disconnect the steering feed pipe assembly (5), from the pinion housing. Remove the bearing caps and remove the steering.
Page 189 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS330-1 TOOLS Put the support fixture 1779-T on the gearbox (see Pl. 51). Hold the gearbox with a lifting tackle in order to avoid damage to the shaft or clutch plate when disconnecting the gearbox from the engine .
Page 190 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 TOOLS To adjust the height of the brake units (see Pl. 141), work on the length of the adjusting rods (113) (see Pl. 50) so that the linings stand slightly proud of the disc at the front by approximately 1 mm (see fig. 1).
Page 191 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 TOOLS To fit the radiator a) Place the rubber blocks in the cups on the crossmember. b) Offer up the radiator and put the distance pieces in position on the plates on the radiator, the longer on the right-hand side.
Page 192 DS 19 OPERATION No. DS 330-1 Work on the gearbox. Op. DS 330-1 TOOLS Adjust the clutch clearance (see Op. DS 314-0, paragraphs 20 to 23). NOTE - It is sometimes necessary to make this adjustment again after a few dozen miles .
Page 193 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 TOOLS To remove the 1st speed selector lever a) Unscrew the lever spindle (23) until the lever is free from its trunnion, the fork being in contact with the 1st speed pinion on the bevel pinion shaft.
Page 194 DS 19 OPERATION No. DS 330-1 : Work on the gearbox. Op. DS 330-1 TOOLS Fit the connecting pipe between the pump and the pressure regulator (spanner 2220-T and 2280-T, see Pl. 72, fig. 4 and 5) ................
Page 195 DS 19 OPERATION No. DS 330-2 Preparing the gearbox for stripping down. Op. DS 330-2 TOOLS STRIPPING To remove the front crossmember bracket. a) Remove the lower nuts from the tie-rod front brackets of the brake units ......
Page 196 DS 19 OPERATION No. DS 330-2 : Preparing the gearbox for stripping down. Op. DS 330-2 TOOLS Fit the brake unit and rear support assemblies. Tighten the screws fixing the supports ....
Page 197 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 PARTICULAR POINTS Dismantling. After having disconnected the clutch housing from the gearbox casing, remove the outer differential bearing races sideways, the centre of the differential is not on the line of the joint between the clutch bellhousing and the gearbox casing.
Page 198 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 To prepare the mainshaft. Note the descriptions given in the text. There are different types of assemblies. (a) Clearance of the third-speed pinion locking segments 0.02 to 0.06 mm.
Page 199 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 3303 To fit the rear pipe assembly. The tightening flange of the control cylinders being placed on the 4th speed cylinder, the clearance between the flange and the other cylinders (fitted with their retaining plates for cars produced before March 1957) should be between 0 and 03 mm.
Page 200 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 3303 TOOLS Remove the circlip (16) retaining the rear mainshaft bearing (17) (use circlip pliers). Remove the distance piece (18), the bearing (17) and the 1st speed pinion (19) ..........
Page 201 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS To strip the intermediate train (see Pl. 53, fig. 2). Disconnect the 2nd speed intermediate pinion (44), the 3rd and 4th speed intermediate pinion (45). Take out the driving pins (46).
Page 202 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 330-3 d) Remove the spring cup (60) from the 4th speed selector shaft (61) (spring compressor 1798-T, see Pl. 56, fig. 1). TOOLS Slide the shaft (61) towards the front until the front cup (62) is on the small diameter of the shaft in the area “a”.
Page 203 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS Assembly. To assemble the clutch housing (see Pl. 58) a) Fit the thrust race support hub (76) (spring washers under the heads of the screws, previously smeared with Hermetic, see Pl.
Page 204 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS b) Fit the planet gear (47) in the box. Insert a fibre washer, the oil groove towards the planet wheel, and a satellite wheel (48), a thrust washer (49) (the locking tab in the slot in the box) a spindle.
Page 205 To prepare the mainshaft (see Pl. 53, fig. 1): IMPORTANT REMARK (see Pl. 53A, fig. 1) - Since production commenced on DS 19 cars, we have fitted two types of 3rd and 4th speed pinions (pinion on mainshaft and intermediate train). The two types of assemblies should be carefully noted.
Page 206 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS Our Spare Parts Department only sell parts for the second type assembly. If one of the two pinions (3rd speed pinion on the mainshaft or double pinion of the intermediate train) is to be renewed, it is necessary to renew the other pinion of this assembly.
Page 207 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS f) (Cars produced since October 1957, see Pl. 52.) To adjust the clearance of the front bearing. Fit a paper joint and tighten the cap (7) on the housing, in order to compress the joint. Remove the cap.
Page 208 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS c) To adjust the setting of the front bearing. Carry out the same procedure as in paragraph 28 “e” or “f”. To assemble the intermediate train (see Pl. 52): Place in the box the intermediate train and the 1st speed loose pinion (85) together with its sliding pinion (86).
Page 209 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS To assemble the mainshaft (see Pl. 52): a) Fit on the mainshaft prepared in paragraph 28, the 3rd and 4th speed synchromesh (90) (the shouldered face against the 3rd speed), the 4th speed loose pinion (36) with its needle bearing cage.
Page 210 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 330-3 TOOLS c) Put the adjusting fixture on a surface plate, resting on the two ground bearing pads. (In this position, the pointer of the dial gauge is at 55 mm from the centre line of the ground semi-circular bearing faces).
Page 211 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 330-3 TOOLS Fit the cover, the 3rd and 4th speed selector fork together with its thrust pads (smear with grease to prevent them falling out of position) Make sure that the forks are properly engaged in the grooves of the sliding pinions. Fix the cover by the two centring screws.
Page 212 DS 19 OPERATION No. DS 330-3 Overhauling a gearbox. Op. DS 330-3 TOOLS On cars produced before January 1957. put on the mainshaft (22), the circlip, the distance piece and the oil seals in the bearings. On cars produced since January 1957. fit the distance tube (15).
Page 213 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS f) To measure the clearance between the teeth. Fit the dial gauge support on the box (see Pl. 59, fig. 2). Fit the extension 2439-T on the dial gauge. Then fix the dial gauge on to the support 2039-T.
Page 214 DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 TOOLS To fit the cover plate on the box. Insert a paper joint stuck with grease on the cover plate. Fit the centring screws. Put the expanding washers in position, using Hermetic. Fit the other screws. Fit the pipe assembly bracket and the silentbloc bracket.
Page 215 Replacement of a differential shaft - brake disc or a differential shaft housing DS 19 OPERATION No. DS 330 - 4 Op. DS 330 - 4 or a front support arm PARTICULAR POINTS Removal. Mark the position of the steering in its bearings and the position of the wheel in relation to the pinion before removing the steering.
Page 216 Replacement of a differential shaft - brake disc or a differential shaft housing DS 19 OPERATION No. DS 330 - 4 Op. DS 330 - 4 or a front support arm TOOLS d) Disconnect the “bibax” from the brake disc...
Page 217 Replacement of a differential shaft - brake disc or a differential shaft housing DS 19 OPERATION No. DS 330 - 4 Op. DS 330 - 4 or a front support arm TOOLS Put the distance piece (4) and the differential bearing adjusting washer (5) in position (see Pl. 54).
Page 218 DS 19 OPERATION No. DS 331-1: Replacement of a gearbox cover. Op. DS 331-1 PARTICULAR POINTS. Removal. Mark the position of the steering in its bearings and the position of the steering wheel in relation to the pinion, before removing the steering.
Page 219 DS 19 OPERATION No. DS 331-1 Replacement of a gearbox cover. Op. DS 331-1 TOOLS REMOVAL. Hold the bonnet open (stop MR-4158, see Pl. 16, fig. 1). Remove the spare wheel, the spare wheel support, the front wings, the air deflection panel and the battery tray. Release the pressure in the hydraulic systems ..
Page 220 DS 19 OPERATION No. DS 331-1 : Replacement of a gearbox cover. Op. DS 331-1 TOOLS c) Insert the 3rd and 4th speed selector shaft (61) and its return spring. Fit the locking plungers (66), the rocker (63) and the 3rd and 4th speed selector fork (64).
Page 221 DS 19 OPERATION No. DS 331-1 : Replacement of a gearbox cover. Op. DS 331-1 TOOLS Fit the fork return spring cups (compressor 1798-T, see Pl. 56, fig. 1) ........
Page 222 DS 19 OPERATION No. DS 331-3 : Overhauling a gearbox cover. Op. DS 331-3 PARTICULAR POINTS Assembly. (a) Remove the pistons from the cylinders with compressed air. (c) It is permissible to lightly clean the pistons with No. 600 abrasive paper moistened with alcohol.
Page 223 DS 19 OPERATION No. DS 331 - 3 Overhauling a gearbox cover. Op. DS 331 3 TOOLS ASSEMBLY (see Pl. 55). NOTE - Except for the replacement of seals (which is an obligatory procedure) no work can be carried out on the control cylinders, except for cleaning in alcohol.
Page 224 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 PARTICULAR POINTS Important remark. Before carrying out any work on the gearbox or its controls, check the following adjustments: (a)The adjustment of the slow running, of the clutch clearance, clutch drag, and clutch engagement control.
Page 225 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 To adjust the clamps fixing the pipe assemblies. When the cylinders are in position with their adjusting washers, the flange should rest on the cylinders to within 03 mm precisely.
Page 226 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 PRELIMINARY CHECKS TOOLS In the case of difficulty in operating the gears, before removing the gearbox or the hydraulic gear selector, one should carry out the following checks : a) Make sure that the following adjustments are correct :- Adjust the slow running (see Op.
Page 227 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 TOOLS REMARK - Before each alteration to the pipe, make sure that the gear lever is in the neutral position. If for one or several gears, the pressure indicated is not obtained, check the functioning of the hydraulic gear selector (see paragraphs 6 and onwards, this operation).
Page 228 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 TOOLS Tighten the bleed screw (b). Operate the pump in order to build up the pressure to 2490 p.s.i. (170 kg/cm ). Check the pressure gauge which should not show a drop in pressure.
Page 229 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 TOOLS Carry out the same procedure on the corresponding cylinder of the new pipe assembly. For this, the dimension “d” = 15.8 mm.
Page 230 DS 19 OPERATION No. DS 334-0 Checking and adjustments on the change speed control. Op. DS 334-0 TOOLS (Cars produced since March 1957.) (see fig. 3). As indicated in paragraph 28, measure the dimensions “r’” and “s’” in order to obtain the difference of the height: Select from the adjusting washers sold by our Spare Parts Department, a washer which will bring this difference to a maximum of 0.3 mm.
Page 231 DS 19 OPERATION No. DS 334-1 : Work on the gear control. Op. DS 334-1 PARTICULAR POINTS Replacement of a gear selector lever. Removal. In order to carry out this operation it is necessary to remove the facia board. Put the selector lever in the 1st speed position. Place the setting rod (2429- T) in the hydraulic gear selector.
Page 232 DS 19 OPERATION No. DS 334-1 : Work on the gear control. Op. DS 334-1 TOOLS Put the change speed lever in the 1st speed position. Insert in the locating hole a rod 3.94 mm diameter (rod 2429-T, see Pl. 67, fig. 2) .
Page 233 DS 19 OPERATION No. DS 334-1 Work on the gear control. Op. DS 334-1 TOOLS REPLACEMENT OF A HYDRAULIC GEAR SELECTOR Removal (see Pl. 67). Remove the facia board (see paragraph 1, this operation). To release the pressure: unscrew the bleed screw on the pressure control valve ( a turn approximately).
Page 234 DS 19 OPERATION No. DS 334-1 Work on the gear control. Op. DS 334-1 TOOLS Put the gear selector lever in the 1st speed position. Put the hydraulic gear selector in position and with care, pass the auxiliary clutch control rod (12) through the hole in the selector flange, then in the trunnion (13) of the auxiliary clutch control lever.
Page 235 DS 19 OPERATION No. DS 334-1 Work on the gear control. Op. DS 334-1 TOOLS Start the engine, let it idle for a few minutes. Tighten the bleed screw in order to put the systems under pressure. Check the joints for leakage. Change into each gear in succession in order to check the sealing of the flanges . .
Page 236 DS 19 OPERATION No. DS 334-3 Work on the gear control. Op. DS 334-3 PARTICULAR POINTS To overhaul a gear selector lever assembly. Assembly. All the joints and moving parts should be greased (Antar Cardrex EP grease). To adjust the selector gate.
Page 237 DS 19 OPERATION No. DS 334-3 Work on the gear control. Op. DS 334-3 TOOLS OVERHAULING A GEAR SELECTOR LEVER ASSEMBLY Dismantling (see Pl. 68). Unscrew the screw (1) and remove the clamp (2) coupling the lever control rod (3) to the sliding valve on the hydraulic gear selector .
Page 238 DS 19 OPERATION No. DS 334-3 Work on the gear control. Op. DS 334-3 TOOLS Refitting (see Pl. 68). NOTE - When refitting, all joints and moving parts should be greased (ANTAR Cardrex EP grease only). To connect the control rod (3) to the lever (24) a) Put the felt joint, previously soaked in engine oil, in the recess in the yoke of the control rod (3).
Page 239 DS 19 OPERATION No. DS 334-3 : Work on the gear control. Op. DS 334-3 TOOLS To adjust the tension in the reverse speed position : a) Put the lever (24) in the 1st speed position (the locking ball being in position in the corresponding hole in the sector).
Page 240 DS 19 OPERATION No. DS 334-3 Work on the gear control. Op. DS 334-3 TOOLS b) New model gear change speed control with flat base. Assemble the parts in the following order 1 filter (57). 1 distance piece (60). 1 disc with a central hole (58).
Page 241 DS 19 OPERATION No. DS 334-3 Work on the gear control. Op. DS 334-3 TOOLS D - Make sure that the distribution of pressure is correct for each gear. Raise the front of the car with the engine running at accelerated idling speed. Engage 1st gear and observe the clutch fork;...
Page 242 DS 19 OPERATION No. DS 334-3 : Work on the gear control. Op. DS 334-3 TOOLS Remove the ring seals (27) from the synchronising pistons. Use a brass wire hook. Be careful not to scratch the bore or damage the groove, the edge of which must be a sharp angle.
Page 478 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration ENGINE ......Longitudinal section. Cross section. Valve seats. Fitting of valves. Calibration of springs.
Page 479 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration WATER PUMP ....Low pressure pump and water pump. Low pressure pump and water pump. Ignition advance curve.
Page 480 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration GEARBOX CONTROLS (cont’d) ..Hydraulic gear selector.. Hydraulic gear selector. Gearbox. Checking non-return valve. SOURCE OF RESERVE OF PRESSURE ..High pressure system.
Page 481 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration REAR AXLE ..... . Hub drum assembly. Articulating bearing. Locking the articulating bearing. Holding the arm in a vice.
Page 482 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration RELAYS (cont’d) ....Various tools. BRAKES ......Hydraulic system for brakes.
Page 483 INDEX ILLUSTRATIONS No. of COMPONENT DESCRIPTION Illustration HYDRAULIC (CONT’D) ... . Dynamic test bench assembly. Hydraulic gear selector. Regulator feed. High pressure pump. Accumulator –pressure distribution block – suspension spheres. Steering.

CITROEN DS 19 Repair Manual

Table of Contents

Related Manuals for CITROEN DS 19

Summary of Contents for CITROEN DS 19

Page 3: General Classification

Page 5: Table Of Contents

Page 7: Engine

Page 8: Timing Gear

Page 9: Air Filter

Table of Contents