DS 19 OPERATION No. DS 100-1 : Replacement of an engine-gearbox assembly.. Op. DS 100-1 39
TOOLS
48 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
the leads to the sparking plugs 8 mm box spanner
49 Fit the cover plates for the steering
50 Fit the battery brackets. Fit the hydraulic fluid reservoir by means of its clips. Fit the battery tray. Fit the
battery, fix it by means of the tie-rods. Fit the channel for the electric cable harness on the outside tie-rod. 8-10-12 mm box spanners
Connect the cables to t he battery. Connect the cable control for the bonnet lock to the rods on the scuttle 8 mm spanner
51 Pass the feed pipe for the high pressure pump through the rubber grommet in the radiator tie-rod, then in the
rubber collar on the water pipe, and through the rubber grommet on the battery support. Couple the tube
to the outlet pipe on the reservoir. Fit the rubber bush. Fit the clip.
52 Fit the suspension spheres (tighten by hand). Insert the joints.
53 Fill up with water. During this operation, open the heater control vane and undo the bleed screw (46) (see Pl.
125) so as to let the air escape from the engine.
54 Unscrew the screw on the pressure control valve. Fill up the reservoir with hydraulic fluid. Start the engine,
let it run for some minutes. Retighten the bleed screw so as to put the hydraulic system under pressure.
Check all unions for leakage.
With the vane of the heater open, make sure that the pipe (48) is warm (see Pl. 25) 8 mm spanner
55 Adjust the clutch clearance (see Op. DS 314-0).
NOTE - It is sometimes necessary to remake this adjustment after running 30 to 40 miles.
56 Bleed the hydraulic gear selector: operate the auxiliary clutch control lever several times. Make successive
movements with the gear lever through all gears several times so as to bleed the gearbox and clutch
hydraulic system (see Op. DS 334-0).
57 Bleed the brakes (see Op. DS 453-0).
58 Adjust the idling speeds (see Op. DS 142-0).
59 Fit the air deflector panel and the front wings (plain and serrated washers). Couple up the bonnet lock 14 mm spanner
control; adjust the control cable if necessary 14 mm box spanner
60 Fit the air sleeves, fix them by means of the rubber clips.
Fit the crossmember supporting the spare wheel. Fit the spare wheel. Lower the car to the ground
(jacking bracket 2505-T, see Pl. 168) 12-14 mm box spanners
Jacking bracket 2505-T
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