Microcar MC1 Technical Manual
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Microcar MC1 Technical Manual

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WORKSHOP TECHNICAL MANUAL

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Summary of Contents for Microcar MC1

  • Page 1 WORKSHOP TECHNICAL MANUAL...
  • Page 2 We advice you to read very carefully the paragraphes linked to your interventions. Our After Sales department stays at your disposal for any further information. With the aim of improving its models, MICROCAR specifies this whole brochure is not contractual and keeps the right to change (without warning) its car specifications.

  • Page 3: Table Of Contents

    SUMMARY Pages Pages SUPPLYING ............ 4 P . AINTING COMPONENTS AND REPAIRING..56 IDENTIFICATION ..........5 SO UNDPROOFING ENGINE PANEL REMOVAL... 58 LIFTING ............5 TR ANSMISSION REMOVAL........60 TECHNICAL CHARACTERISTICS ....6 TRANSMISS S ION GAITER CHANGING........ 61 D ...OOR REMOVAL..........8 VARIATO R REMOVAL ..........

  • Page 4: Supplying

    SUPPLYING QUANTITIES SUPPLYING TYPE CERAMIC SYMBOL 5W40 1,50 liter Engine oil 0,50 liter TRANS EPA 80W90 Box oil DOT 4 blue ribbon Brake liquid 3 liters TRANSFLUID Coolant The level in the liquid radiator must be 1cm above the radiator fins Windscreen washer IGOL 1 liter Windscreen washer...

  • Page 5: Identification

    CAR IDENTIFICATION Constructor plate The constructor plate is situated inside the car on the front right pillar (under the instrument panel below the passenger seat). 1 - V i n n u m b e r 2 - H o m o l o g a t i o n n u m b e r 3 - P a i n t i n g r e f e r e n c e n u m b e r vin number The vin number is put on the right side member...

  • Page 6: Technical Characteristics

    TECHNICAL CHARACTERISTICS Engine Brand ................LOMBARDINI Type ................LDW 502/M3 Cycle ................Diesel (4 times) Cubic capacity................. 505 cm Cylinders ................2 in lines Coolant ................Liquid Used fuel ................. Diesel Feed type ................ Injection (electric pump) Fuel tank capacity ............16 liters Electric feed ..............
  • Page 7 SIZES : (in mm)

  • Page 8: D ...Oor Removal

    DOOR REMOVAL To take out the door, open the bonnet and unplug the battery using the red speed disconnecting cable terminal (+). Before intervening on any components of the electric setting, unplug the positive cable (red) of the battery. Take off the ducts of the body pillar, take out and unplug the 2 connectors of the window winder beam and central locking It depends on the version Hold the door with the handle and put the 2 fixing screws...

  • Page 9: In Terior Door Maintenance

    INTERVENTIONS ON THE INTERIOR DOOR EQUIPEMENTS Take the fixing screw out of the interior door opening switch. Take out the cap of the handle. With a screwdriver, unclip the opening tip on the handle. Take out the command. Take off the trim starting in a conner (fixed with a VELCRO strip) We advice you to hold the sticker VELCRO to avoid that it comes undone.
  • Page 10 LOCK AND CYLINDER LOCK DOORS NOTA :to make the following operations easier, we advice you to take the door out. (see chapter "door removal" page 8) Take out the central locking rod inside the door. Take out the cylinder lock, pulling up its fixing fork and taking off the cylinder lock from its place.

  • Page 11: Door Window

    CENTRAL LOCKING ENGINE Tha nks to a drilling machine (drill Ø 5) take out the 2 rivets of the fixing of the central locking engine mounting plate. Take out the plate and engine and unplug the electric beam. Take off the 2 engine fixing screws. DOOR POCKET Withe a screwdriver, take off the 3 black plastic rivets and take out the door pocket.
  • Page 12 Take out the door frame pulling it up. Undo the fixing axle of the window. Lean slightly the window of the interior of the door to take it out of the fixing axle. Take out the window pulling it up. Take off the joints.
  • Page 13 ELECTRIC WINDOW WINDER Take out the inferior fixing screw of the window winder runner. Take out the superior fixing screw of the window winder runner. Take off the 2 screws of the window winder engine. Unplug the electric beam and take out the window winder of the interior door.

  • Page 14: Rear Door

    REAR DOOR REAR DOOR REMOVAL Unplug the battery using the red speed disconnecting cable terminal (+). Open the hatchback. Unplug the hatchback electric beam, behind the right side trim and take it out of the trim. Hold the hatchback and take off the 2 fixing screws of the hinges on the body.
  • Page 15 Take off the hatch. Unplug the beam of the 3d parking light. Take out the 2 fixing screws of 3d parking light. Take off the 3d parking light. After having taken out the 3d parking light, you will be able to reach the defrosting back window beam.
  • Page 16 BACK WINDSCREEN WIPER After having unplugged the battery and taken out the hatch of the back window (see paragraph "3d parking light" page 14) take out the fixing nut of the wiper arm under the nut cover. Take out the wiper arm and the nut cap. Take out the M16 fixing nut of the windscreen wiper engine.

  • Page 17: Rear Door

    PLATE LIGHT After having unplugged the battery, thanks to a screwdriver, undo the plate light and take it out from its place. Unplug the beam from the light plate. HATCHBACK HINGE After having taken out the hatchback (see paragraph hatchback removal), take off the fixing nut and take out the hinge.
  • Page 18 Loosen the 2 compass ball joints. (Set screw when fitting again 4,2 N/m). Take out the 2 ball joints with nuts and washers. Unglue the window from the hatchback. Use the piano rope given in the gluing window kit (réf. 0 700 200). Make the cable slided between the window and the hatchback on all length.

  • Page 19: Fro Nt Bumpers Removal

    FRONT BUMPER REMOVAL Open the bonnet and take out the superior soundproofing. Thanks to a screwdriver, take out the 2 black plastic rivets inferior fixing. Take out the 2 black plastic rivets from the wings Fall over the bumper to the front and make it turn around its superior fixing pegs on the sealed beam units.

  • Page 20: Front Wings Removal

    FRONT WINGS REMOVAL Take out the door. Take out the front bumper (voir page 19). Take off the gaiter nut cover which fixes the door mirror. With a combination pliers, take out the plastic nut from the door mirror fixing. Take out the door mirror.
  • Page 21 Take out the black plastic superior front fixing rivet. Take out the black plastic inferior front fixing rivet. Take out the door joint. Take out the aerial of the left wing (1 fixing screw) Remove the outside temperature sensor of the right wing (Cyanocrylate glue) Take out the wing.

  • Page 22: Door Hinges Removal

    DOOR HINGES REMOVAL Take out the door (see page 8). Take out the front bumper (see page 19). Take out the front wing (see page 20). Take out the door hinges, 3 fixing screws per hinge (set screw when fitting again 7 N/m). BONNET REMOVAL Unlock the bonnet without opening and take out the 2 fixing bolts of the hinges from the front pillar.

  • Page 23: Ba Ck Bumpers Removal

    Take off the 3 inferior fixing nuts of the sealed beam unit. Take out the sealed beam unit. The fitting is made at the reverse from the removal operations. BACK BUMPER REMOVAL Open the rear window. With a screwdriver, take out the black plastic inferior fixing rivet of the back bumper.
  • Page 24 OPENING HATCHBACK SWITCH REMOVAL Bumper removal (see page 23). Take out the 2 fixing screws of the hatchback lock with its 2 spacer rings. (set screw when fitting 5 N/m). Take the cable out of the lock. WIth a drilling machine (drill Ø 5) take the 2 fixing rivets out of bumper support, undo the duct from the switch cable and take the support out.

  • Page 25: Interior Trim Removal

    When assembling, to make the passage of the cable easier, take locally the hatchback joint out and rise up the interior trim to put the cable in the back pillar hole. Make the cable come out of the profile tube of the back pillar and assemble at the reverse from the removal operations.
  • Page 26 Take out the superior fixing screw, inking belt. (set screw when reassembly 35 N/m). Take the 2 fixing screws out of the bench seat support. (set screw when reassembly 10 N/m). With a screwdriver, take out the plastic cover of the inferior catch of the belt.

  • Page 27: Safety Belt Retractor Removal

    Take out partly the joint of the door. Take out the trim and take out the belt and the beam. The fitting is made at the reverse from the removal operations SAFETY BELT RETRACTOR REMOVAL Take out the interior trim (see page 25). Take out the fixing screw of the safety belt retractor (set screw when fitting back 35 N/m).
  • Page 28 PREPARATION OF THE NEW ROOF TRIM Cut the 4 corners of the roof trim at 45°. 10mm in front and 5mm in back following the drawing. Put 4 lines of glue (ref 0700200) following the drawing. Fit the trim and hold it with strips. Stop the car a half day (the necessary time to dry the glue)

  • Page 29: Ashboard Removal

    INSTRUMENT PANEL REMOVAL Open the bonnet. Unplug the battery. Take out the gaiter which hides the nut of the left door mirror. With a combination pliers, take out the fixing palstic nut of the left door mirror. Remove the left side door mirror. Take out the left side interior cover.
  • Page 30 Remove the central cover of the steering wheel. Take out the central fixing screw of the steering wheel. (set screw when fitting 30 N/m). Take out the steering wheel of the steering column. With a screwdriver, take out the 3 black fixing plastic rivets of the column covers.
  • Page 31 Take out the inferior column cover. Take out the superior column cover. Unplug the connectors of the electric beam from the lever. Take out the 3 cruciform fixing screws of the lever. Take out the lever.
  • Page 32 EVENTUAL STARTER SWITCH REMOVAL Take out the fixing screw of the starter switch. Position the ignition key between the mark M and A and with 2 screwdrivers, retract the 2 holding lugs of the stater switch. Take out the starter of its sleeve. Take out the radio.
  • Page 33 Unplug the connectors on the distress signal switch and the 2 connectors of the cigar lighter. Take out the bulb of heating switch support. Take out the button of the distress signal. Take out the ventilation switch cover. Take out the central fixing nut of the ventilation switch Take out the reverser lever gaiter...
  • Page 34 Take out and unplug the 2 loud speakers of the instrument panel. With a screwdriver, take out the black plastic inferior fixing rivet of the instrument panel. Take out the 2 left and right black fixing plastic rivets of the instrument panel.

  • Page 35: Reverser Lever Removal

    Take out lightly the instrument panel and unplug the instruments from the back. Disconnect the 2 ducts of the fans. Take out the instrument panel. The reassembly is made at the reverse from the removal operations. REVERSER LEVER REMOVAL Take out the instrument panel (see page 29). Take out the 3 fixing screws of the reverser lever unit.

  • Page 36: Ear Quarter Panel Removal

    REAR QUARTER PANELWINDOW REMOVAL Insert a piano rope between the door pillar and the rear quarter panel. The piano rope is inside the window glue kit ref 0700200 Cut the glue joint on the side of the window and take it out. Take care not to cut the inside trim.

  • Page 37: Back Wing Removal

    BACK WING REMOVAL Remove the hatchback (see page 14) Remove the back bumpers (see page 23) Remove the inside trim (see page 25) Remove the back lights. Remove the quarter light (see page 36) Unglue and take off the rear side panel groove. BACK WHEEL TRIM REMOVAL With damaged wood scissors and a thermal scrapper unglue the wheel trim rear quarte panel from the back wing.
  • Page 38 Warm up the last points where the glue catches respecting the maximum temperature not to damage the other ABS pieces and take out the back wheel trim. NOTA : When reassembly, the wheel trim must imperatively be replaced by a new piece. Take out the striker plate.
  • Page 39 Unglue the lower part. From the inside of the car, remove the wing from the floor. Do not burn the carpet. Unglue the wing from the waterproof chute piece. Remove the wing from the back door pillar starting from the top. Take out the back wing.
  • Page 40 BACK WATERPROOF PIECE REMOVAL With wood scissors, remove the back waterproof pieces. NOTA: Those operations do not necessarily require the use of a thermal scrapper. Remove the piece from the back carcase pillar. Remove the low part on the back cross beam. Take out the back waterproof pieces.
  • Page 41 Act step by step. Glue and position each piece holding in position with a clamp during 4 hours. All the ABS and Alu surfaces which must be glued will have to be degreased with the cleaner- degreaser (ref 1002659) All the Sandwiform surfaces will have to be fired before being glued.

  • Page 42: Windscreen Removal

    WINDSCREEN REMOVAL Take out all the frame joints of the windscreen. Take out the inside door mirror. With a pliers, insert a piano rope delivered in the kit (ref 0700200) between the pillar and the windscreen and cut the glue fixing joint of the windscreen all around it.
  • Page 43 Fit the inside door mirror on its support. Clean all the glue residues which stay on the body. Apply the ABS primary (ref 1002818) on the upper part of the apron cover. Alll the alu surfaces which must be glued will have to be degreased with the product in the kit (ref 1002659).

  • Page 44: Roof Removal

    ROOF REMOVAL Remove the hatchback (see page 14). Remove the windscreen (see page 42). Remove the 2 finishing joints of the roof. With damaged wood scissors and regulated thermal scrapper, warm up the back part of the hatchback (maximum temperature 60°) and remove the roof from the back cross beam.
  • Page 45 Apply the ABS primary (ref 1002818) all around the parts of the roof which must be glued. Put a line of glue (ref 0700200) all around the support surface of the roof. Put the roof. Check its well position on the body, hold it in pressure in its definitive and let it dry 6 hours.
  • Page 46 SIDE BODY REMOVAL • Remove the door (see page 8). • Remove the hatchback (see page 14). • Remove the front bumper (see page 19). • Remove the back bumper (see page 23). • Remove the bonnet (see page 22). •...
  • Page 47 Take out the upper fixing screw of the back shock absorber (set screw when assembling 40N/m) With damaged wood scissors and an adjustable thermal scrapper (maximum heating temperature 60°), unglue the floor from the side frame). Unglue very carefully the apron cover from the frame Take care not to damage the dash panel cover because this one is weaker than the floor.
  • Page 48 Remove the 2 fixing screws of the instrument panel cross beam (set screw when fitting again 7N/m) Remove the 2 fixing screws of the low back cross beam (set screw when reassembly 9,5N/m) Remove the 4 fixing screws of the rear axle support (set screw when fitting again 9,5N/m) Remove the 3 fixing screws of the upper back cross beam (set screw when fitting again 9,5N/m)
  • Page 49 Remove the side of the body The reassembly of the side of the body is made at the reverse from the removal operations. When reassembling, check very carefully the geometric dimensions of the body.
  • Page 50 FLOOR SOUNDPROOF KIT GLUING The soundproof floor kit is fixed with glue (Neoprene, Sicaflex...) Put some glue on the soundproof kit components Position the components and plaster them down well on the floor to spread the glue.

  • Page 51: Sou

    SOUNDPROOF APRON KIT GLUING The soundproof apron kit is available under the reference 1002454. The gluing of the soundproof apron kit is made with glue (Neoprene, Sicaflex...) as for the soundproof kit floor. Soundproof greneral view after gluing.

  • Page 52: Abs Repairing

    ABS REPAIRING When the ABS is broken or deeply scratched, with a drilling machine, make a hole at the 2 ends to stop the break. Do a milling on a deep scratch (see drawing) Scratch Always use an appropriate cut speed to avoid making the ABS melted down.

  • Page 53: Aluminium Repairing

    Inside,fill in again the break using the ABS repairing kit (D) apply the Kalico fiber (B) on the glue to reinforce the repairing. Drying time : 3 hours After drying : Take off the sticky strip outside and sand the repairing to obtain the original form of the part.

  • Page 54: Floor Repairing

    FLOOR REPAIRING The floor material(Sandwiform) is made with a cellular plate (A) (smocking) recovered with 2 Twintex sheets (B) and 1 of it is recovered with a finishing carpet inside. In case of shock or break, it is necessary to make the repairing as said above.

  • Page 55: Carpet Repairing

    Put the black twintex part on the roof part which is to repair and apply the repairing kit glue (ref 1002657) Hold the parts in contact, plastered down. Be carefull to the gluing way. The glued sid emust be the flamed side. The flaming ensures the glues, mastic and paint to stay.

  • Page 56: Ainting Components And Repairing

    PAI INTING FORMULA AND COMPOSITION : MC1 water formula SIKKENS ICI AUTOCOLOR DU PONT STANDOX SPIES HECKER GLASURIT AKZO NOBEL Sous couche 361,7 1401W 504,5 Sous couche Under coat 731,6 1421W Sous couche 681,1 WB372 223,6 WB801 564,8 1406W 592,3...
  • Page 57 PAIINTING FORMULA AND COMPOSITION : MC1 Solvant formula STANDOX SPIES HECKER SIKKENS ICI AUTOCOLOR DU PONT GLASURIT AKZO NOBEL Under coat Under coat Under coat 114,7 MB501 606,4 MB563 AUTOBASE + 170,3 MB527 838,5 MB570 841,8 AM21 203,6 352-91 172,5...

  • Page 58: So Undproofing Engine Panel Removal

    SOUNDPROOF ENGINE PANEL REMOVAL Remove the front bumper (see page 19). Remove the 2 lower flaps of the bumper support Take off the 2 lower fixing screws of the front soundproof panel. Take out the 2 upper fixing screws of the panel. Take out the fixing screw on the right side.
  • Page 59 Take out the 3 fixing screws of the lower left soundproof panel. Take out the 3 fixing screws of the lower lright soundproof panel. Take out the 3 fixing screws of the upper left soundproof panel. Take out the waterproof radiator sheet metal and take off the soundproof right panel taking it out to the front.

  • Page 60: Transmission Removal

    TRANSMISSION REMOVAL Place the car on an elevator or on a chassis stand. Remove the front wheel. (set screw when fitting again 120N/m) Take out the suspension arm fixing screw. (set screw when reassembling 40N/m) With a hub puller (FACOM ref U16B), uncouple the suspension arm from the hub.

  • Page 61: Transmiss S Ion Gaiter Changing

    TRANSMISSION GAITER CHANGE Remove the fixing gaiter collars. Drag the gaiter on the shaft to free the joint. Separate the fixing circlips from the transmission shaft. Take out the gaiter. After having greased the joint and fitted a new gaiter, fit all back at the reverse from the removal operations.

  • Page 62: Variator Removal

    VARIATOR REMOVAL The complete variator is adjusted in the factory and in case of repairing, it is necessary to use the MICROCAR original pieces. It doesn't require a lot of maintenance but to obtain a maximum performance, it is important that the mobile flanges slide freely.
  • Page 63 Take out the 3 blocks with their flyweights and sounproof springs Replace the springs in case of wear. Be carefull to the fitting way of the blocks, they must run freely in their place. Take out the half pulley of its axle. Clean the parts with compressed air.
  • Page 64 POWER PULLEY SPRING SETTING ADJUSTMENT IN THE FACTORY 1ST VERSION MODEL • Position the belt setting washers (A) (Réf. 0 782 373 et 0 782 374) on the shaft of the fixed half pulley. • Position 4 adjustment spring spacers (B) thickness 1,2mm (Réf. 0 780 352) in the lower bearing (D) •...
  • Page 65 POWER PULLEY SPRING SETTING (ADJUSTMENT IN THE FACTORY) 2nd VERSION MODEL • Position 5 adjustment spring spacers (B) thickness 1,2mm (Réf. 0 780 352) in the lower bearing (D) • fit the spring (Réf. 1 000 660). • Position 5 other adjustment spacers (B) thickness 1,2mm (Réf. 0 780 352) in the upper bearing (E) •...

  • Page 66: Receptor Pulley Removal

    RECEIVER PULLEY DISMANTLING Take off the fixing nut of the receiver pulley (set screw when fitting back 60N/m) Take out the receiver pulley of the axle box and take out the key. Find the spring position. Take off the inside circlips compressing the fixed came. Take out the fixed came and the spring.
  • Page 67 1ST VERSION RECEIVER PULLEY FITTING For the fitting, put the mobile half pulley on its axle, position the spring on the mobile pulley in the hole (C) and position the other spring end in the hole (2) of the fixed came.

  • Page 68: Re . Verser Drive Axle Removal

    CHANGER BRIDGE REMOVAL Unplug the battery using the red speed (+) disconnecting cable cable terminal. Take off the lower soundproof panel. (see page 58). Take off the fixing screws of the suspension arms of the hub. (set screw when fitting back 40N/m). With a hub puller (FACOM ref U16B) uncouple the suspension arms from the hub.
  • Page 69 Take out the receiver pulley of the variator (see page 66). Uncouple the changer bridge switch command Unplug the speed sensor. Before untightening all the fixing of the changer bridge wedge the underneath of the engine sump to prevent it from tipping. Take out the 2 fixing bolts of the changer bridge on the back rubber mounting.
  • Page 70 Left housing bridge Transmitter joint Right housing bridge Digital meter transmeter Housing bridge joint M4 x 12 screw 10 x 10 x 0,9 socket 12 x 1,5 level screw Ball bearing 12 x 18 x 1,5 washer Waterproof ring Drain plug Entry shaft Ball 2nd reduction shaft bearing...
  • Page 71 REVERSER TRANSAXLE REMOVAL Before opening the door , we advice you to clean it with petroleum or diesel and to dry it with compressed air. Drain the gearbox oil by its oil change hole (27) Take out the holding screw (31), the spring (29) and the ball (28). Take out the 8 screws that gather the 2 half housing Separate the 2 half housing (1) and (2) lightly hiting with a rubber hammer in the axle of the entry shaft (7).
  • Page 72 Left housing bridge Transmitter joint Right housing bridge Digital meter transmeter Housing bridge joint M4 x 12 screw 10 x 10 x 0,9 socket 12 x 1,5 level screw Ball bearing 12 x 18 x 1,5 washer Waterproof ring Drain plug Entry shaft Ball 2nd reduction shaft bearing...
  • Page 73 Take out the intermediate gearing and the differential (34). Take out the different bearings with a universal hub puller We advice you not to do anything on the differential (34) In case of anomaly, replace the differential. must change the waterproof joint (3) of the half housing when fitting back.

  • Page 74: Starter Removal

    STARTER REMOVAL Unplug the battery using the disconnecting speed red cable terminal (+). Take out the air filter. Take out the electric feed of the starter Take out the variator (see page 62). Take out the flywheel. Take out the fixing starter support : 3 fixing screws on the engine and 2 fixing screwson the bridge.

  • Page 75: Engine Removal

    ENGINE REMOVAL Unplug the battery using the speed red (+)disconnecting cable terminal. Take out the front bumper (see page 19). Take out the soundproof engine panel (see page 58). Take out the front cross beam (2 fixing screws) and the engine hold cable.

  • Page 76: Engine Cradle Removal

    ENGINE CRADLE REMOVAL Unplug the battery using the red speed disconnecting (+) cable terminal. • Remove the front bumper (see page 19). • Remove the soundproof engine (see page 58). • Remove the 2 doors (see page 8) • Remove the 2 front wings (see page 20). •...
  • Page 77 Take out the fixing screws of the cradle on the engine, right side (set screw when fitting back 22N/m) Take out the fixing screws of the cradle on the engine, left side (set screw when fitting back 22N/m) With the trolley, take out the cradle of the body.

  • Page 78: Engine . Cradle Equipemement

    ENGINE CRADLE EQUIPMENT Fit the waterproof joint between the manifold and the exhaust tube Be carefull to the fitting way, (boss up) Fix the tubulure on the exhaust manifold with 2 M8 screws without blocking them. Fix the M12 lower fixing screw of the exhaust tube on the engine, without blocking it.
  • Page 79 Fit the interference eliminator wire on the engine housing. Fit the holding belt clamp on the changer bridge with its washer and its fixing screw. Block the fixing screw of the holding belt clamp (set screw 8N/m) Put a circlip on the 2 exit changer bridge axles. Settle, without driving them in, the 2 fixing screws of the changer bridge with their washers.
  • Page 80 Fit the changer bridge on their support and introduce the 2 fixing screws. Tighten the fixing screws of the changer bridge. (set screws 60N/m) Grease the 2 axles of the exit transmission and the entry shaft of the changer bridge. On the front of the engine cradle, fit a spacer washer on the 4 fixing inserts of the elastic plots.
  • Page 81 At the back of the engine cradle, fix 4 spacer washers on the fixing axles of the elastic plots. Fit the inside screws of the elastic plots and fix them on the cradle with 4 screws and washers. (set screw 12N/m) Fit the fixed battery clamp.
  • Page 82 Fit the 2 suspension triangles on the engine cradle (set not 70N/m) With a hoist or a workshop crane, fit the engine on the cradle. Fit the anti-couple stop support clamp Fit the conical stop on the anti-couple stop support clamp.
  • Page 83 Fix the engine on the front elastic plots with screws and washers. (set screw 30 N/m). Fit the receiver pulley on the changer bridge axle with its key. Fix the pulley with a washer and a nut. (set screw 60N/m) Fit the power pulley with the belt on the axle of the flywheel.
  • Page 84 Fit the exhaust tube rubber mounting. Position the radiator on the engine cradle and fix it to the front l w ith a screw and a fixing washer. Fix the radiator to the back with 2 screws and fixing washers. Fix the upper hose between the radiator and the engine with 2 serflex collars.
  • Page 85 Fit the hose Ø 10 with 2 collar clips. Fit together the 2 transmissions on the axles of the changer bridge. Fit the lengther on the variator side. Fit the shock absorbers in the 2 hubs, fix them with a nut and washers (set screw 25N/m) Fit the banjo of the brake hose with a copper joint on each side and fit it with its screw on the brake caliper.
  • Page 86 Fit the hub and the right shock absorbers on the transmission (steering lever to the back). Fix it on the suspension triangle with a screw (set screw 40N/m) Fit the hub and the left shock absorbers on the transmission (steering lever to the back). Fix it on the suspension triangle with a screw (set screw 40N/m) Put the mudflap on the shock absorbers.
  • Page 87 Fix the 2 mudflaps on the engine craddle withe 4 black plastic rivets. Fix the 2 steering ball joints on the levers. (set screw 22N/m) Fit the screws + the hub axle wahers (set screw 120N/m) Fix the 2 brake fuses on the engine craddle Fit the steering transmission on the rack, a fixing bolt + washers (set screw 22N/m)

  • Page 88: Br .Ake Pad Replacing

    BRAKE PADS CHANGING Always replace the brake pad complet train. Lift up the car and take off the wheels (set screw 60N/m) On the front, unplug the wear light wire. Take out if necessary, a bit of braking liquid of the tank thanks to a syringue.
  • Page 89 Take off the 2 brake pads • Control the waterproofness of the piston and the good condition of the brake caliper and the weak of the discs (the thickness of the discs must be between 4 to 5mm on the front and 3 to 4mm at the back).

  • Page 90: Fr Ont Hub Bearing Replacing

    FRONT HUB BEARING CHANGING Lift up the car on an elevator Take off the wheel Take off the brake pads (see page 88) With a 6 sides key, take off the 2 fixing screws of the brake caliper Take off the fixing nut of the steering joint. (set screw when fitting back 22N/m) Take out the steering joint, use a hub puller FACOM Réf.
  • Page 91 Take out the fixing nut of the transmission on the hub. (set screw when fitting back 120N/m) Take out the transmission of hub Take out the fixing screw of the shock absorbers on the hub (set screw when fitting back 25N/m) Take out the half train.
  • Page 92 FRONT BRAKE H UB...
  • Page 93 With a circlips pliers, take off the circlips which hold the bearing. With a press, take out the bearing from its place Replace the bearing and make the fitting at the reverse from the removal operations.

  • Page 94: Fron T Hub Bearing Replacing

    BACK HUB BEARING CHANGE Put the car on an elevator Take off the back wheel (set screw 60N/m) Take out the brake pads (see page 88) WIth a 6 sides key, take out the 2 fixing screw of the back caliper. Take out the caliper of the disc.
  • Page 95 B C K...

  • Page 96: Steering

    STEERING STEERING RACK REMOVAL Place the car on an elevator Take out the 2 front wheels (set screw when fitting back 60N/m) Take out the 2 front wheels (set screw when fitting back 22N/m) Take out the 2 hub with a hub puller FACOM réf.
  • Page 97 Take out the rack The fitting back is made at the reverse from the removal operations GAITER CHANGE ON THE RACK After having taken down the hubs. Cut the fixing plastic collar gaiters and make the gaiters slided to the exterior. Fit back the new gaiters taking care to grease the rack Use a standard grease.
  • Page 98 ALIGNMENT Make the alignment controlwith a specific machine. The regulating is made at the level of the steering hubs The repartition of the steering must be equal on the right and on the left and the steering wheels in straight position.

  • Page 99: B Raking System Bleeding

    BRAKING HYDRAULIC CIRCUIT BLEEDING Fill in the tank with braking liquid Nota : make the bleeding after : every repairing during which one the braking circuit has been opened, and when it is necessary to push several times on the pedal to obtain the braking or if you feel an elasticity in the pedal.

  • Page 100: P Arking Brake Regulating

    PARKING BRAKE ADJUSTMENT • After having settled the 2 cables in the compensator and be sured that the main circuit is correctly drained • Press several times on the pedal. • Control the untightened parking brake, the rotation of the back wheels. First adjustment: Make a lever on the compensator and adjust the tension of the cables with the regulating nuts of the compensator.

  • Page 101: Ba Ck Exhaust

    REAR EXHAUST To take out the back exhaust line, put the car on an elevator Take out the back bumper (see page 23). Take out the 2 back wheels Take out the 2 fixing nuts of the back axle (set screw when fitting back)) and make the axle drop to the front.

  • Page 102: E Lectric System

    ELECTRIC EQUIPMENT BATTERY Without maintenance Tension : 12 Volts in a normal use, there is no level control to do. REMOVAL Unplug the battery using the red speed (+) disconnecting cable terminal Untighten the holding angle bracket to take out the battery from its support.

  • Page 103: Fuses

    FUSES The fuses box is situated under the instrument panel behind the central pillar of the console, take out the protecting grille and check if the fuses are ok. To facilitate the removal and the fitting, use a needle nosed pliers. Divided filament Rig ht 7,5A...

  • Page 104: Load Voltage Control

    LOAD VOLTAGE CONTROL • Regulate the measure field of the voltmeter in continue voltage(volt). • Put the voltmeter between the terminal + and the terminal - of the battery • Put the ampermetric pliers ont the 20B wire (battery <--> alternator). •...

  • Page 105: F Ront Windscreen

    FRONT WINDSCREEN WIPER Unplug the battery using the disconnecting red speed (+) cable terminal. Take out the fixing screw of the wiper arm and take out the arm. Unplug the windscreen washer tube. Take out the nut cover and the fixing nut of the axle with its waterproof washer.
  • Page 106 Unplug the electric beam and take out the fixing screw of the mass wire. Take out all. The fitting back is made at the reverse from the removal operations.

  • Page 107: Instrument Adjustment

    INSTRUMENT PANEL REGULATING For all the regulations of the instrument panel, follow very carefully the instructions HOW TO ZERO THE MAINTENANCE KILOMETER INDICATOR • See technical information N° 249 (enclosed page 109) HOW TO REGULATE THE INSTRUMENT PANEL •Open the left and right door and let it opened during the following handlings. •...

  • Page 108: Ventilation Connecting

    VENTILATION SWITCH PLUG wire N° 22 wire N° 27 wire N° 24 free wire N° 16 Back view of the ventilation switch...
  • Page 109 ENCLOSURE...

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