CITROEN DS 19 - Stripping and assembling

DS 19 OPERATION No. DS 100-2 : Stripping and assembling an engine-gearbox assembly for replacement of the engine 40
TOOLS
STRIPPING AND ASSEMBLING (for replacement of the engine).
Stripping.
1 Place the engine gearbox assembly on the stand Z497-T (see Pl. 19) Stand 2497-T
2 Disengage the high pressure pump feed pipe from its attachment plate on the water tube.
Remove the radiator tie-rod and remove the radiator.
Remove the driving belts from the dynamo and water pump. Remove the dynamo tie-rod.
Remove the dynamo. Remove the rear fixing screw. Unscrew the front screw 8-12-14 box spanners
12-14 mm spanners
3 Disconnect the high pressure pump tie-rod from the water pump 12mm box spanner
4 Remove the starter motor cable 14mm box spanner
5 Disconnect the feed pipe from the clutch cylinder (spanner 2219-T or 2221-T, see Pl. 72, fig. 4).
Disconnect the gearbox from the engine (spanners 1677-T, see P1. 65, fig. 4 and spanner 2431-T, see Pl.
72, fig. 1). Pass the spanner through the holes of the driving pulley.
Leave the gearbox on the truck Spanners 1677-T, 2431-T,
2219-T or 2221-T.
IMPORTANT NOTE - Do not roll the gearbox on the brake discs Rubber protectors
6 To strip the engine :
a) Drain the engine (oil) 21 mm box spanner
b) Remove the air cleaner and tube assembly 12-17 mm box spanners
c) Remove the carburettor (spanner 1623-T, see P1. 16, fig. 2) Spanner 1623-T
d) Remove the petrol pump 14 mm spanner or
spanner 1621-T
e) Remove the water and heater pipe assembly, right side 8 mm box spanner
f) Remove the inlet manifold. Remove the oil dipstick to allow the removal of the manifold 12mm box spanner
g) Remove the contact breaker, its plate and return spring 12mm ring spanner
h) Remove the crankcase breather 12 mm box spanner
1) Remove the plates fixing the exhaust manifold shield 12mm box spanner
j) Remove the starter motor 17mm spanner
14mm box spanner
k) Remove the sparking plugs (spanner 1603-T, see P1. 16, fig. 7) Spanner 1603-T
l) Remove the fan 12mm spanner
m) Remove the low pressure pump feed pipe (spanner 2220-T, see P1. 72, fig. 4) Spanner 2220-T or
14 mm spanner
n) Remove the gearbox dowel pins from the engine crankcase.