OF OPERATIONS APPEARING IN THE CHAPTER: ~ NUMBER > C/) C1A H1A K1A K2A DESCRIPTION

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1 LST OF OPERATONS APPEARNG N THE CHAPTER: REAR AXLE UNT VEHCLE ENGNE TYPE 1 C/) - -' GT 0 X en Petrol Petrol Petrol Petrol OPERATON w - DESCRPTON ~ NUMBER > C/) C1A H1A K1A K2A 420/ / / / / /1 ; / / / /1 Tools X X X X X Characteristics and particular features of the rear axle unit X X X X Characteristics and particular features of the rear axle unit X X Removing and refitting the rear axle unit X X X X X Removing and refitting a rear arm X X X X X Reconditioning a rear arm X X X X :':J.. " ~j~";'. ; Reconditioning a rear arm X 1"'<' ~.~~ Overhauling the rear axle silent block mountings X X X 'l~. X Removing and refitting a rear wheel hub X, X.., X X X ".~ ", ~l"<l Reconditioning a rear wheel hub X X X.' '*X w \,i~ :.,..,:" X,0 r. 1. r... :p

$..J 10 11 14 0 X m Petrol Petrol Petrol OPERATON w DESCRPTON - ~ NUMBER > CJ) C1A H1A K1A 420/1 420-00/1 Tools X X' X X Characteristics and particular features of the rear axle unit X X X X \ Remo\ng \.$

2 VEHCLE LST OF OPERATONS APPEARNG N CHAPTER: 1 REAR AXLE UNT ENGNE TYPE CJ) -...J X m Petrol Petrol Petrol OPERATON w DESCRPTON - ~ NUMBER > CJ) C1A H1A K1A 420/ /1 Tools X X' X X Characteristics and particular features of the rear axle unit X X X X \ Remo\ng \. and re f ttlng. the rear ax ' e unit X X X X 421-1/ R emovlng\n \ d ref' ttlng a rear arm X X X X 422-3/ /1 Reconditioni~rear arm X X X X Removing and ref~i~ a rear wheel hub X X X X 426-3/1 Reconditioning,,e" w~ hob X X X X, /

LST OF OPERATONS TO BE FOUND N THE SECTON: REAR AXLE UNT VEHCLE ENGNETVPE ENGNE DENTFCATON A ENGNE FAMLY TU TUD XU XUD B CUBC CAPACTY (cc) 9 900 to 999 (TU) 1 1100 to 1199 2 1200 to 1299 3 1300 to

3 LST OF OPERATONS TO BE FOUND N THE SECTON: REAR AXLE UNT VEHCLE ENGNETVPE ENGNE DENTFCATON A ENGNE FAMLY TU TUD XU XUD B CUBC CAPACTY (cc) to 999 (TU) to to to to to to to to 2199 C NUMBER OF CARBURETTOR CHOCKES 1 Single choke 2 Twin choke 4 Four choke No ref.: D FUEL SYSTEM TYPE Carbu rettor letter J Multipoint inj. CP Piloted carbo M Monopoint inj. T : Turbo E Heat exchanger D : A.CAV. (1) ~~~~~~ ~~LJ~l-J/~ ~~~~~~ ~~~~l-j/~ ~ (1) Variable Acoustics Characteristics nduction EMSSON STANDARDS G * Modification levels Antipollution E MODFCATON LEVElS A: mproved S Superior C: Compact F NUMBER OF VALVES 2 : 2 valves 3 : 3 valves 4 : 4 valves 2 K nd.generation W Y US 87 3 Z US 83 3'd. generation N Davignon - 15 (class C) etc... S Japan (Petrol) R :' Japan (Diesel) V Europe ~l C 8922

2 VEHCLE ENGNE TYPE g LST OF OPERATONS APPEARNG N THE CHAPTER: @ REAR AXLE UNT OPERATON NUMBER DESCRPTON 420/1 Tools. 420-00/1 Characteristics and particular features of the rear axle unit.

4 2 VEHCLE ENGNE TYPE g LST OF OPERATONS APPEARNG N THE REAR AXLE UNT OPERATON NUMBER DESCRPTON 420/1 Tools /1 Characteristics and particular features of the rear axle unit /2 Characteristics and particular features of the rear axle unit. AX /3 Characteristics and particular features of the rear axle unit /1 Removing and refitting the rear axle unit /1 Removing and refitting a rear arm (Sport, GT, GT : see removing and refitting an anti-roll, bar 435-1/7) /1 Reconditioning a rear arm /2 Reconditioning a rear arm /1 Overhauling the rear axle silent block mountings /1 Removing and refitting a rear wheel hub. AX 426-1/2 Removing and refitting a rear wheel hub. C

5 @ LST VEHCLE OF OPERATONS APPEARNG N THE CHAPTER: REAR AXLE UNT ~ ENGNE TYPE /91 07/ GT Sport Diesel GT GT Diesel Cyl (ee) Engine C1A H1A K1A K2A M4A K9A C1A H1A K2D K2A K6B K9A K1G Q[,]lxl X X X X X X X X X X X /1 X X X X X X X X /2 X X X AX /3 X 142~/1 X X X X X X X X X X X X 42~~/l X X X X xl Qg X X X X X X X 42~~/2 X X X X 42~~/1 X X X X X X X X X X X X 42~/1 X X X X X X X X X i X X 42:~/2 X C 8922

6 4 ENGNE TYPE REAR AXLE UNT VEHCLE LST OF OPERATONS APPEARNG N THE L1 OPERATON NUMBER DESCRPTON 426-3/1 Reconditioning a rear wheel hub /2 Reconditioning a rear wheel hub. c

7 LST OF OPERATONS APPEARNG N THE CHAPTER: REAR AXLE UNT... 07/91 07/91... VEHCLE ENGNE TYPE GT Sport Diesel GT GT Diesel Cyl (ee) Engine C1A H1A K1A K2A M4A K9A C1A H1A K2D K2A K6B K9A K1G /1 ~ X X X X X X X X X X X 426-3/2 ~ X C 8922

8 2)--) ~ a 1671-T - 05 ~ E 4087.T.A (~ r-- - '10=--- C T.F r=-""" C1 C3 ~ ~ 4087.T.B 4522-T T T T T Q% 04 ~ 4522.T.05 MR / r-: = mm ~ E4 QE K A MR /23 e 8922

9 ~-) ~ ~ 04 ~A~ T ~ ~ P \ffij (2 ~ F ( (] \0 ((J MR / T *

$) 420-1 04 / ~A ~ ~ ~05 ij (J]J / / 2070-T 86-485 ~ \lj)j (2$

10 ) / ~A ~ ~ ~05 ij (J]J / / 2070-T ~ \lj)j (2 (3 [] [J ([J MR / T *

11 D----O /1 23 mm MAX G6 Vis. M /90 ~- //, / \./ l 09/ /90 Vis. M12 Z Z (j) 410-0/1 A Ess A<B 14 Ess 1,8 it 5,4 mm,..., ~ B 14 Dies C 8922

12 0 D /1 1 f F /; ~m.dan G6 Z 42-1 <t:::: /1 A A = ~ B = 1 0 :t 20' 1:t1mm,..., K1A 2:t1 mm C1A - H1A ~ *

$1 420-00/2 D-G 1 ~ --11 ; 1- +- ~5,5m.daN ~ --tt-4, / \ ' / L' J /.$

13 /2 D-G 1 ~ --11 ; ~5,5m.daN ~ --tt-4, / \ ' / L' J /. 11 m.dan,- Z 42-2 <Jt:::: (j) 410-0/1 A A= ~ B = 1 :t 20' 1:t1mm K2A,..1

$0--0 420-00/1 1 23 mm MAX ~d.n \ Z 42-1 \ \ \ \ \ \ 410".$

14 / mm MAX ~d.n \ Z 42-1 \ \ \ \ \ \ 410".0/1, A A= B = 1 0 :!:: 20' 1:t1mm K1A * 2:t1mm C1A,..., - H1A ~

15 o~o /2 G6 ~6 Vis. M12 8 mdan 11 mdan (j) 410-0/1 A GT SPORT A<B 1,8 a 5,4 mm GT SPORT B= B ~ e 8922

16 0---0 AX /3 G6 G6 9 mdan 8 mdan Z.42-6 (j) 410-0/1 A A<B B= 1,8 a 5,4mm B.1 A"". 8922

17 REAR AXLE UNT 421-1/1 TOOLS TO BE USED MR /27 Workshop jack adaptor (refer 420-1) REMOVNG AND REFTTNG A REAR AXLE UNT C 8922

18 /1 REMOVNG AND REFTTNG A REAR AXLE UNT REMOVAL Remove the rear bench seat. Uncouple the exhaust pipe. Raise the vehicle, support it on stands so that the height at shield type bumper level is 0.60 m, Fig.. Disconnect from the brake pressure limiters, the pipes supplying fluid to brakes. Extract the exhaust pipe. Position, Fig., the jack provided with MR.630/44/87, n the centre of the rear crossmember and exert a pressure on it, Loosen the hand brake cables at (al. Fig. and ; unclip them all along, at (b). Extract the four screws (1) securing the rear axle unit to the bodyshell, Fig.. Slowly lower the jack and withdraw the rear axle unit assembly from the rear of the car, Fig. V. c

19 421-1/1 3 z V e 8922

20 / Z.42-4 FXATON AVANT FXATON ARR~RE

21 REMOVNG AND REFTTNG A REAR AXLE UNT 421-1/1 5 RE-ASSEMBLY Position the rear axle crossmember onto the jack equipped with MR /27, Fig.. Slide the rear axle under the vehicle. Bring attachments (A) into contact. Place thrust washers (31 and (21. Fig., back in position. Reconnect the pipes supplying the brake limiter(s). Recouple and adjust the handbrake cables: (see (jj) /1). nsert screws (1 Fig., without forcing. Fit the exhaust pipe. Place attachments (B using the jack, Fig.. Bleed the brakes: 453-0/1), nstall thrust washer (41. Fig /2). Locate, Fig., screws (5). Lower the vehicle to the ground. lighten, Fig., screws (1 and (51 : - } M 10 : to 5.5mdaN. - } M 12 : to 8 mdan. Refit the front seat and the rear bench seat. Check the vehicle heights: 430-0/1). e 8922

22 REAR AXLE UNT 421-1/1 REMOVNG AND REFTTNG A REAR AXLE UNT, '

2 421-1/1 REMOVNG AND REFTTNG A REAR AXLE UNT REMOVAL Remove the rear bench seat. Raise the vehicle; support it on stands so that the height at shield type bumper level is 0.60 m, Fig.

23 /1 REMOVNG AND REFTTNG A REAR AXLE UNT REMOVAL Remove the rear bench seat. Raise the vehicle; support it on stands so that the height at shield type bumper level is 0.60 m, Fig.. Disconnect, Fig. V et V: - screws (3) fixing the exhaust pipe to the exhaust manifold, - screws (4) of the clamp situated between the exhaust pipe and the silencer. Extract the exhaust pipe. Disconnect from the brake pressure limiter, Fig., the pipes (1) and (2) supplying fluid to brakes. Position, Fig., the jack in the centre of the crossmember and while exerting a pressure on it, along, at (b). at (a), Fig, and ; - extract the four screws (5) securing the rear axle unit to the bodyshell, Fig. V, slowly lower the jack and withdraw the rear axle unit assembly from the rear of the car, Fig. V. /

24 421-1/1 3 V *

25 /1 b

26 REMOVNG AND REFTTNG A REAR AXLE UNT 421-1/1 5 RE-ASSEMBLY Position the rear axle crossmember onto the jack. Slide the rear axle under the vehicle. Bring attachments (a) (b) into contact, Fig.. Place thrust washers (1) and (2), Fig.. nsert screws (3) without forcing. Place attachments (c) and (d) using the jack, Fig.. Reconnect pipes (6) and (7) supplying the brake limiter, Fig. ; tighten to 1.3 m.dan. Fit, Fig. V et V : - a new seal, - the exhaust pipe (nuts (8) tightened to 3 m.dan). - the clamp between exhaust pipe and silencer, (nuts (9) tightened to 1.2 m.dan.) nstall thrust washer (4), Fig.. Screw up: - screws (5) : tighten to 5.5 m.dan - screws (3) : tighten to 5.5 m.dan Recouple the handbrake cables: /1). Bleed the brakes: 453-0/1). Lower the vehicle to the ground. Refit the front seat and the rear bench seat. Check the vehicle (See@ 430-0/1). heights:

REMOVNG AND REFTTNG A REAR AXLE UNT 421-1/1 5 RE-ASSEMBLY Position the rear axle crossmember onto the jack. Slide the rear axle under the vehicle. Bring attachments (a) and (b) into contact, Fig.

27 REMOVNG AND REFTTNG A REAR AXLE UNT 421-1/1 5 RE-ASSEMBLY Position the rear axle crossmember onto the jack. Slide the rear axle under the vehicle. Bring attachments (a) and (b) into contact, Fig.. Place thrust washers (1) and (2), Fig.. nsert screws (3) without forcing. Place attachments (c) and (d) using the jack, Fig.. nstall thrust washer (4), Fig.. Screw up: - screws (5) : tighten to 7 m.dan - screws (3) : tighten to 7 m.dan // / Reconnect pipes (6) and (7) supplying the brake limiter, ::: ~:~. t::h::" Vto 'ld'n - a new seal, / - the exhaust pipb (nuts (8) tightened to 3 m.dan). - the clamp between / exhaust pipe. and'i Sl encer ( nuts. / ) (9) tightened to 1.2 m.dan. / Recouple the hand brake cables: /1). / Bleed the brakes: 453-0/1). ;{ower the vehicle to the ground. / J/ / Refit the rear bench seat. Check the vehicle heights: (See /1). /

28 REAR AXLE UNT 422-1/1 1 TOOLS TO BE USED TOOL BOX 4502-T: 4502-T.A :. Dummy shock absorber REMOVNG AND REFTTNG A REAR AXLE ARM

2 422-1/1 REMOVNG AND REFTTNG A REAR AXLE ARM REMOVAL Slacken off the rear wheel nuts. Raise and support the vehicle, Fig.. Remove the four TORX screws (3). Fig. V et V.

29 /1 REMOVNG AND REFTTNG A REAR AXLE ARM REMOVAL Slacken off the rear wheel nuts. Raise and support the vehicle, Fig.. Remove the four TORX screws (3). Fig. V et V. Liberate the brake backplate; attach it inside the wheelarch. Withdraw the damper unit. Remove the wheel. Uncouple, Fig. and : - spring (1) from the brake pressure limiter, - screw (2) securing the hydraulic brake hose. Extract the rear wheel hub: /1). Adjust and install tool 4502.T.A so as to keep the axle arm its initial position when refitting it. Take off, Fig. V : - TORX screw (4). - washer (5). Remove the screw (6) attaching the tool to the axle arm, Fig. V. Loosen handbrake cable at (a). Fig. V. Free the arm. Unclip the cable at (b). Fig. V.

30 /1 3 v *.. j

31 /1,.r.' 23 mm v.

32 REMOVNG AND REFTTNG A REAR AXLE ARM 422-1/1 5 REFDNG Check that the seal is placed 23 mm max. from the cup, Fig.. NOTE. Make sure: - that both sides of the steel cup are clean and bear no trace of impact or scratching, - that the rear axle arm bearing contact surfaces show no sign of seizure or damage. Fit the steel cup with a new seal (1), Fig. (coat the seal' lips with grease). Lubricate the needle cages. Using tool 4502 T.A which has been set for the removal operation, slide the arm simultaneously over the axle cros~member tube and the torsion bar. nstall, Fig. : - washer (2) - screw (3) Tighten screw (3) progressively to enable the fitment of the seal on the arm to be carried out. Tightening value: 2 m.dan NOTE f the distance of 23 mm has not been observed, bring the seal in contact with the cup using a screwdriver. Refit, Fig. : - the brake backplate, - the four screws (4), tightened to 3.5 m.dan, - the wheel hub 426-' / ') Reinstall, Fig., the screw (5) securing the hydraulic brake hose; tighten to 2 m.dan. Recouple, Fig. V, spring (6) to the brake pressure limiter. Clip, Fig. V, the handbrake cable and adjust it /'1). Remove tool 4502-T.A. Refit: - the damper unit, - the wheel. Lower the vehicle to the ground; tighten the rear wheel nuts. 'j For the damper tightening operation refer 434-' /2.,' t; " ;'.'

33 @ D--O 422-3/ ) 1671-T 2070-T x 3, *. ;~ 8921.

34 /1 o L, ~,1.

35 422-3/ * j

36 /1

37 422-3/1 3 /, / / *

38 /1.l.

39 422-3/ *

40 /

0-0 422-3/2 87.533 ) 1671-T 4502-T ajp (1 13-551 1.

41 / ) 1671-T 4502-T ajp ( ,4 x 3,2-80 ~ ( T GJJp ( MR /23 *

42 / ,

43 3 Z 42-3 t ' ~ G T.C 1 "'1 *

44 / T.C /,.. '\ o

45 422-3/2 5 ~ G6 *

0------0 424-3/1 -+ 09/90 4502-T 01 02 03 04 05

46 / / T T Z D...--O e 8922

47 / c...

D------O 424-3/1 3 10-11.14 Ess. 14 Die.

48 D------O 424-3/ Ess. 14 Die. Z.42-1 GT Sport Z.42-2 GT Z.42-6 e

49 /1 0-0 GT C 8922

50 / D-O *

51 / T.D T.D

52 424-3/ T.D T.D T.D *

53 REAR AXLE UNT 426-1/1 REMOVNG AND REFTTNG A REAR WHEEL HUB

2 426-1/1 REMOVNG AND REFTTNG A REAR WHEEL HUB REMOVAL REFiniNG Stacken off the rear wheel nut. Brake drum and shoes must be free of traces of grease, oil.. Raise and support Fig.

54 /1 REMOVNG AND REFTTNG A REAR WHEEL HUB REMOVAL REFiniNG Stacken off the rear wheel nut. Brake drum and shoes must be free of traces of grease, oil.. Raise and support Fig.. the rear part of the vehicle Remove, Fig. : - the wheel. - the sealing cap (1). loosen and take off, Fig. and V: - nut (2), - washer (3). - drum (4). - seal (5). Fit, Fig., and V: - seal (5) a new seal; lubricate the lip and the stub axle, - drum (4). - washer (3). - nut (2) new: tighten to 14 m.dan ;lock the nut by means of a smooth-edged tool. - plug (1), new plug. Refit the wheel. Note. Fig. and V Should the drum removal prove difficult, act upon the automatic wear adjustment ratchet (6) with a screwdriver, through orifice (a) for wheel fixing. Lower the vehicle to the ground and retighten the rear wheel nut.

55 426-1/1 3 -, V

56 REAR AXLE UNT AX 426-1/2 1 TOOLS RECOMMENDED K Locking punch. REMOVNG AND REFTTNG A REAR WHEEL HUB A 8922

2 AX 426-1/2 REMOVNG AND REFTTNG A REAR WHEEL HUB REMOVAL REFiniNG Slacken off the rear wheel screws. Brake drum and shoes must be free of traces of grease,oil.

57 2 AX 426-1/2 REMOVNG AND REFTTNG A REAR WHEEL HUB REMOVAL REFiniNG Slacken off the rear wheel screws. Brake drum and shoes must be free of traces of grease,oil... Raise and support the rear part of the vehicle. Remove the road wheel. Extract, Fig. - the sealing cap (1). Loosen and take off, Fig. and : - Nut (2), - Washer (3), - Drum (4), - Seal (5), - Spacer (6). Fit, Fig., and : - Spacer (6), Seal (5), a NEW seal, (lubricate the lip and the stub axle). Drum (4), Washer (3, Nut (2), NEW. lighten to : 14 mdan lock the nut with the help of punch K - Plug (1). NEW plug - the road wheel. Lower the vehicle to the ground. Retighten the rear wheel screws. NOTE: Fig. and V : Should the drum removal prove difficult, act upon the automatic wear adjustment ratchet (7) with screwdriver, through orifice (a) for fixing the wheel. A

58 AX 426-1/ V A 8922

59 426-3/ T *

60 2, 426-3/

61 426-3/ *

62 0---0 AX 426-3/2 1 2) ) ~ ~ ~ A"". 8922

63 2 AX 426-3/ A.J

64 AX 426-3/ A"". 8922

SECTION D REAR SUSPENSION. Section Description Page D.1. REMOVING AND REFITTING A REAR SUSPENSION UNIT 5

SECTION D REAR SUSPENSION. Section Description Page D.1. REMOVING AND REFITTING A REAR SUSPENSION UNIT 5 SECTION D REAR SUSPENSION Section Description Page D.1. REMOVING AND REFITTING A REAR SUSPENSION UNIT 5 D.2. REMOVING AND REFITTING THE COMPONENTS OF THE REAR SUSPENSION 8 D.3. CHECKING AND OVERHAULING