Contents

Operating instructions

Maintenance

• Dimensions and weight
• Lubricants and fluids
• Service specifications
• Vehicle identification numbers
• Weekly checks
• Check points under the hood
• Engine oil level
• Coolant level
• Brake (and clutch) fluid level
• Power steering fluid level
• Battery
• Electrical equipment
• Condition and pressure of tires
• Examples of typical tire tread wear
• Washer fluid level
• Wiper blades
• Maintenance procedures
• Maintenance plan
• Introduction
• Regular maintenance
• Every 15,000 km
• Changing the engine oil and filter
• Checking the thickness of the front brake pads
• Checking the condition and tension of the auxiliary drive belt
• Every 12 months
• Checking the functioning of the windscreen / rear window / headlight washer system
• Check tire wear
• Checking the condition of the toothed drive belt
• Lubrication of hinges and locks
• Checking the electrolyte level in the battery
• Initializing the service interval display
• Reading fault codes from the memory of the electronic engine control module
• Checking the tightness of hoses and other components in the engine compartment / underbody
• Checking the concentration of antifreeze in the cooling system
• Checking the condition of the brake hoses and pipes
• Checking the thickness of the rear brake pad
• Checking the condition of the exhaust system and its attachments
• Checking the condition / tightness of the steering and suspension components
• Running trials
• Every 30,000 km
• Replacing the fuel filter
• Replacing the dust filter of the ventilation system
• Checking the underbody protection
• Checking the oil level in the manual transmission
• Adjusting the direction of the headlamp beam
• Every 60,000 km
• Replacing the air filter element
• Replacing spark plugs
• Checking oil level in final drive (automatic transmission)
• Changing transmission fluid
• Every 120,000 km
• Replacing the auxiliary drive belt
• Every 2 years (regardless of mileage)
• Replacing the brake fluid
• Coolant replacement
• Replacing the timing belt
• Checking emission control systems

Engine repair in the engine compartment

• Specifications
• General description
• Camshaft timing marks - general description and use
• Checking the compression in the engine cylinder
• Toothed drive belt - removal, inspection and installation
• Toothed belt tensioner and sprockets - removal, inspection and installation
• Accessory drive belts - removal and installation
• Valve cover - removal and installation
• Camshaft oil seal - replacement
• Intermediate shaft oil seal - replacement
• Crankshaft oil seals - replacement
• Cylinder head - removal and installation
• Hydraulic slack adjuster - functional check
• Flywheel / drive disc - removal, inspection and installation
• Engine mounts - inspection and replacement
• Pallet - removal and installation
• Oil pump and suction tube - removal, inspection and installation

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Engine removal - methods and precautions
• Engine - removal and installation
• Engine overhaul - preliminary information
• Cylinder head - disassembly, cleaning, inspection and assembly
• Connecting rod and piston assemblies - removal and inspection
• Crankshaft - removal and inspection
• Intermediate shaft - removal and installation
• Cylinder block / crankcase - cleaning and inspection
• Piston and connecting rod assemblies - condition check and selection
• Engine assembly procedure after overhaul
• Crankshaft - installing and checking main bearing clearances
• Pistons and piston rings - assembly
• Connecting rod-piston assemblies - installing and checking the clearances in connecting rod bearings
• Starting the engine after overhaul

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - disconnecting and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, service check and installation
• Fans - serviceability check, removal and installation
• Electrical switches and sensors of the cooling system - serviceability check, removal and installation
• Water pump - removal and installation
• Heating and ventilation system - general description
• Heating / ventilation system components - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel system - multipoint petrol injection

• Specifications
• General description and precautions
• Air filter and intake ducts - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Bosch motronic engine management system - removing and installing components
• Simos engine management system - component removal and installation
• Fuel filter - change
• Fuel pump / fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - depressurization
• Intake manifold - removal and installation
• Fuel injection system - health check and adjustment
• Turbine generator - general description, removal and installation
• Air cooler - removal and installation

Exhaust gas aftertreatment and exhaust system

• Specifications
• General description
• Fuel vapor retaining system - information and component replacement
• Blow-by gas venting system - general description
• Exhaust manifold - removal and installation
• Exhaust system - component replacement
• Catalytic converter - general description and precautions

Starting and charging systems

• Specifications
• General description and precautions
• Battery - health check and charging
• Battery - disconnect, remove and install
• Alternator / charging system - vehicle functional check
• Generator - removal and installation
• Alternator brush holder / voltage regulator - replace
• Launch system - health check
• Starter - removal and installation
• Starter - health check and bulkhead

Ignition system

• Specifications
• General description
• Ignition system - health check
• High voltage ignition coil - removal, service check and installation
• Distributor - removal, inspection and installation
• Ignition timing - check and adjust
• Ignition system sensors - removal and installation
• Distributor slider - removal and installation

Clutch

• Specifications
• General description
• Hydraulic system - pumping
• Clutch pedal - removal and installation
• Master cylinder - removal, bulkhead and installation
• Slave cylinder - removal, bulkhead and installation
• Friction and pressure plates of clutch - removal, inspection and installation
• Release bearing and clutch release lever - removal, inspection and installation

Mechanical transmission

• Specifications
• General description
• Shift rod - adjustment
• Mechanical transmission - removal and installation
• Mechanical transmission bulkhead - general description
• Multifunction switch - removal and installation
• Speedometer converter - removal and installation
• Oil seals - replacement

Automatic transmission

• Specifications
• General description
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description
• Drive mode selection cable - removal, installation and adjustment

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• Drive shafts - bulkhead
• Drive shaft overhaul - general description

Braking system

• Specifications
• General description
• Hydraulic brake system - bleeding
• Brake pipes and hoses - replacement
• Front brake pads - replacement
• Rear brake pads - replacement
• Front brake disc - inspection, removal and installation
• Rear brake disc - inspection, removal and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake caliper - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Brake pedal - removal and installation
• Vacuum booster unit - serviceability check, removal and installation
• Vacuum booster check valve - removal, serviceability check and installation
• Hand brake - adjustment
• Hand brake lever - removal and installation
• Handbrake cables - removal and installation
• Brake light switch - removal, installation and adjustment
• Anti-lock braking system (ABS) - general description
• ABS system components - removal and installation

Suspension and steering gear

• Specifications
• General description
• Front wheel hub bearings - replacement
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front suspension arms - removal, bulkhead and installation
• Anti-roll bar front suspension - removal and installation
• Sub-frame - removal and installation
• Rear wheel bearings - adjustment
• Rear wheel bearings - replacement
• Rear steering knuckle - removal and installation
• Rear suspension strut - removal and installation
• Rear suspension strut - bulkhead
• Rear axle assembly - removal and installation
• Steering wheel - removal and installation
• Steering column shaft - removal, inspection and installation
• Ignition switch / steering column lock - removal and installation
• Assembly of the steering gear, removal, bulkhead and installation
• Rubber steering covers - replacement
• Hydraulic power steering - bleeding
• Power steering pump - removal and installation
• Tie rod ball joint - removal and installation
• Tie rod - removal and installation
• Steering gear - adjustment
• Wheel alignment - general description

Body and trim

• Specifications
• General description
• Body and underbody - service
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Door vibration - troubleshooting
• The hood and its pillar - removal, installation and position adjustment
• Bonnet lock and its cable - removal and installation
• Bumpers - removal and installation
• Radiator frame upper cross member / subframe - removal and installation
• Front wheel arch liners - removal and installation
• Trunk lid - removal and installation
• Trunk lock and its cylinder - removal and installation
• Luggage compartment door (Station wagon models) - removal and installation
• Rear lid support - removal and installation
• Luggage compartment door lock and its cylinder (Station wagon models) - removal and installation
• Side door trim panel - removal and installation
• Central gaze - general description
• Door lock - removal and installation
• Door handles and lock cylinder - removal and installation
• Door glass and window regulator mechanism - removal and installation
• Electric windows - general description and replacement of the motor
• Doors - removal and installation
• Windshield, rear window and non-retractable side window - general description
• Luke - general description
• Outside mirror components - removal and installation
• Central control panel - removal and installation
• Dashboard and related panels - removal and installation
• Glove box - removal and installation
• Interior mirror - removal and installation
• Seats - removal and installation
• Interior trim - removal and installation
• Belt tensioner - general description
• Seat belts - general description

Onboard electrical equipment

• Specifications
• General description and precautions
• Troubleshooting - general description
• Fuses and relays - general description
• Ignition switch steering column lock / lock - removal and installation
• Steering column combination switch - removal and installation
• Switches - removal and installation
• External lighting fixtures and lamps - removal and installation
• Interior lights - replacement
• Headlights - removal, installation and beam adjustment
• Instrument panel - removal and installation
• Electric discharge headlights system - removal and installation of components
• Anti-icing system - removing and installing components
• Wiper components - removal and installation
• Washer system - general description
• Rear door wiper motor - removing and installing
• Sunroof motor - removal and installation
• Central locking system - general description and replacement of components
• Airbag system - general description and precautions
• Airbag system components - removal and installation
• Anti-theft alarm system - general description
• Radio tape recorder - removal and installation
• Radio antenna - removal and installation

Troubleshooting

• Introduction
• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Braking system
• Suspension and steering
• Electrical system

Wiring diagrams (electrical equipment diagrams)