Choose a section…
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)
DS21 p.4–471
›
DS21M p.472–558
›
DS19A p.564–698
›
DS19MA p.699–750
›
Special Tools p.559–563
Operation
DX 000–851
›
DJ 000–851
›
DY 000–851
›
DL 000–391
N°518
EXTRACTED TEXT — FOR REFERENCE ONLY
\N cal ZZ Lis ae BiGe SPECIAL POINTS IMPORTANT NOTE:- Replacement of the gearbox can only be carried out by removing the engine-gearbox assembly (see Op. DL. 100-1 and 100-2). Clutch housing. Bevel pinion. Tightening torque for end nut: 144 - 158 Distance between thrust race guide screw and housing joint face = 94 - 95 mm. (20 - 22 m. kg) 4.4) (445 Mainshaft Forks Synchro clearance (3rd and 4th) j = 0.10 mm maximum
Choose a section…
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)
