DS21 & DS21M / DS19A & DS19MA Repair Manual

Cover p.1 DS21 p.4 Index p.5 Index of operations p.5 Characteristics and adjustments p.11 Engine p.17 Electrical p.20 General advice p.22 Work on hydraulic systems p.22 Tachometers p.25 Pressure gauges, checks p.26 LHS2 p.27 LHM p.28 Use of adhesives p.29 Engine p.33 Replace engine/gearbox p.33 Strip/assemble to replace engine p.40 Strip/assemble to replace g'box p.45 Overhaul engine p.50 Remove cylinder head p.50 Remove sump, camshaft p.51 Remove rods, pistons, barrels p.52 Remove crankshaft p.53 Preparation of components p.54 Block p.54 Crankshaft p.55 rods, pistons, barrels p.56 Distributor drive tower p.58 Timing gear p.58 Camshaft p.58 Clutch, water, oil pumps p.59 Sump. flywheel p.59 Assembly p.60 Crank end float p.60 Fit crankshaft p.61 Fit rods, piston, barrels p.62 Camshaft, oil pump p.63 Sump, timing gear p.64 Timing cover, cylinder head p.66 Distributor drive tower p.68 Flywheel p.68 Adjust tappets p.69 Replace cylinder head p.70 Overhaul cylinder head p.77 Dismantle p.77 Grind valves p.78 Assemble p.78 Replace inlet rocker assy. p.81 Replace exhaust rocker assy. p.83 Replace core plug p.85 Replace timing chain/pinion p.88 Replace camshaft p.90 Replace cam followers p.96 Replace inlet manifold p.98 Fuel system p.99 Adjust slow-running p.99 Replace carburettor p.101 Overhaul carburettor p.103 Replace accelerated idle device p.108 Replace control relay p.109 Replace carburettor pedal p.110 Replace air filter p.111 Overhaul air filter p.112 Replace petrol pump p.113 Overhaul SEV Marchal pump p.115 Replace petrol feed pipes p.117 Replace petrol tank p.120 Replace petrol tank filter p.123 Replace petrol gauge tank unit p.124 Replace air outlet/vent pipes p.125 Exhaust system p.126 Replace exhaust manifold p.126 Replace exhaust silencer p.127 Ignition system p.128 Adjust initial ignition advance p.128 Lubrication system p.128 Clean, adjust spark plugs p.130 Replace distributor p.131 Overhaul Ducellier distributor p.132 Overhaul SEV distributor p.135 Overhaul distributor drive tower p.137 Replace oil filter element p.140 Replace oil pump p.141 Overhaul oil pump p.144 Belts, pulleys, cooling system p.146 Adjust pulleys and belts p.146 Replace water pump p.150 Replace water pump belts p.152 Replace HP pump belts p.153 Replace Centrif. Reg. belt p.154 Replace main drive pulley p.155 Replace drive pulley bearing p.156 Replace radiator p.157 Replace fan p.158 Replace thermostat p.159 Replace fan cowl p.160 Clutch p.161 Remove/refit p.162 Overhaul p.164 Adjust p.167 Bleed centrif. regulator p.168 Check cylinder for leaks p.168 Replace clutch cylinder p.169 Replace pipe: p.170 Centr. reg/clutch lock p.170 Selector/centrifugal reg. p.171 Selector-clutch eng. control-clutch p.172 Selector-clutch lock p.174 Replace clutch lock p.175 Replace re-engagement control p.176 Replace centrifugal reg. p.177 Replace clutch fork p.179 Overhaul clutch cylinder p.180 Gearbox p.181 Overhaul p.183 Replace diff shaft, disc, bearing p.206 Replace brake disk p.212 Replace gearbox cover p.215 Overhaul gearbox cover p.217 Replace mech. gear selector p.219 Replace hydr. gear selector p.221 Replace change speed regulator p.224 Overhaul mech. gear selector p.225 Overhaul change-speed reg. p.229 O/haul hydr. gear selector p.230 Replace pipes: p.235 gearchange pipe assy. p.235 Front pipe assy. on g/box cover p.236 Rear pipe assy on g/box cover p.237 Cylinder piston assy for g/change control p.239 Replace ring seals in gear control cylinders p.246 Drive shafts p.247 Replace p.248 Source and reserve of pressure p.251 Replace HP pump p.253 Overhaul pump p.254 Replace press. reg. / accumulator p.262 Overhaul pressure reg. p.264 Replace pipe pump-press reg. p.268 Replace brake accumulator p.269 Overhaul brake accu. p.270 Replace press. distributor p.273 Replace hydraulic reservoir p.274 Overhaul press. distributor p.276 Front axle p.279 Adjust camber p.281 Adjust tracking p.282 Adjust steering centre point p.283 Replace half axle p.284 Overhaul half axle p.289 Replace upper pivot ball pin p.293 Replace lower pivot ball pin p.295 Rear axle p.297 Replace half axle p.299 Overhaul half axle p.304 Replace stub axle/bearing p.312 Replace bearing seal/thrust collar p.315 Suspension p.317 Adjust heights p.317 Adjust anti-roll bar p.321 Spheres p.323 Replace p.325 Replace suspension cylinder p.327 Replace fr. height corrector p.330 Overhaul damper valve p.332 O/haul suspension cylinder p.334 Check sphere pressure p.337 Overhaul height corrector p.338 Fill height corrector p.340 Replace anti-roll bar p.341 Replace fr. suspn. feed pipe p.344 Replace sphere/damper p.345 Replace r. suspn. cylinder p.347 Replace r. height corrector p.350 Replace r. anti-roll bar p.353 Adjust manual ht. control p.354 Replace manual ht control p.357 Steering p.358 Adjust lateral position p.361 Adjust angular position p.361 Adjust track p.362 Adjust straight-ahead posn. p.363 Adjust lock p.363 Adjust crossover pressure p.364 Replace steering wheel p.365 Replace centralising cam p.367 Replace steering column bracket p.368 Replace steering rack p.370 Replace rack hydraulic control p.372 Replace pinion assembly p.376 Overhaul rack p.378 Overhaul rack control p.388 O/haul pinion assembly p.394 Replace steering relay p.397 Overhaul steering relay p.399 Brakes p.401 Adjust hydraulic brakes p.402 Adjust mechanical brakes p.403 Adjust rear brakes p.404 Replace hydraulic brake units p.406 Replace hydraulic brake pads p.408 O/haul hydraulic brake unit p.409 Replace brake drum, shoes p.410 Replace brake backplate p.412 Replace wheel cylinder p.412 Bleed brake system p.414 Adjust brake pressure distribution p.415 Check pressure switch p.416 Adjust stop lamp switch p.416 Replace hydraulic brake pedal gear p.417 Replace brake press. distributor p.420 O/haul brake pedal gear p.423 Replace r. brake pivoting pipe assy. p.425 Adjust parking brake p.427 Mechanical brake p.428 Replace caliper p.428 Replace pedal gear p.429 Replace cable p.430 Electrical p.432 Wiring DS21, DS21M p.433 Replace facia panel p.444 Replace dynamo p.449 Replace starter motor p.450 Adjust headlights p.452 Pre-adjust headlamp control p.453 Adjust headlamps p.458 Replace QI headlight bulb p.459 Remove/refit screen wiper p.460 Replace heating/vent assy. p.465 Replace heater control valve p.466 O/haul heater control valve p.468 Body p.469 Replace front wing p.470 DS21M p.472 Index p.473 General characteristics p.479 Engine p.481 Replace engine, gearbox p.481 Strip for replacement p.488 Strip for replaing gearbox p.492 Replace cylinder head p.496 Strip/assemble cylinder head p.498 Replace inlet manifold p.503 Adjust idling p.504 Replace carburettor p.505 Clutch p.506 Replace p.507 Adjust p.508 Gearbox p.509 Overhaul p.511 Replace g/box cover p.527 Gearchange p.529 Adjust gearchange p.529 Replace gear lever, cable p.530 Replace gear control rod p.532 Replace control tube, housing p.533 Replace HP pump p.538 Overhaul press. distrib. unit p.539 Replace steering column bearing p.546 Replace steering rack p.548 Replace hydraulic brake pads p.551 Replace hydraulic calipers p.552 Adjust mech. brake p.554 Replace brake cable p.555 Special tool drawings p.559 DS19A p.564 Index p.565 Characteristics, adjustments p.572 Engine p.575 Engine data p.575 Replace engine/gearbox p.579 Strip/assemble to replace engine p.587 Strip/assemble to replace g/box p.593 Overhaul engine p.599 Replace cylinder head p.618 Replace timing chain or pinion p.625 Replace camshaft p.627 Replace tappets p.634 Replace inlet manifold p.635 Overhaul carburettor p.637 Replace air filter p.638 Adjust static advance p.639 Replace distributor p.641 Overhaul distributor p.642 Check oil pressure p.645 Replace oil pump p.646 Clutch p.649 Replace p.650 Replace re-engagement control p.651 Gearbox data p.653 Replace front half axle p.658 Replace rear half axle p.663 Suspension p.668 Pre-adjust heights p.669 Adjust heights p.670 Replace front anti-roll bar p.673 Replace rear anti-roll bar p.677 Replace hydraulic brake pads p.680 Electrical p.681 Bulb chart p.681 Wiring diagram p.682 Schedule of parts p.683 Schedule of wiring p.685 Replace dynamo p.694 Adjust headlights p.695 Replace heater control valve p.696 DS19MA p.699 Index p.700 Characteristics p.707 Engine replacement p.709 Strip/assemble to replace engien p.717 Strip/assemble to rplace g/box p.723 Replace cylinder head/gasket p.728 Replace carburettor mounting block p.734 Replace exhaust heat shield/manifold p.735 Replace silencer p.736 Clutch data p.737 Replace clutch p.738 Replace clutch fork p.739 Gearbox p.740 Replace starter motor p.750