Contents

Operating instructions

Maintenance

• Car care
• Starting the engine using a booster battery
• Jacking up the car
• Vehicle towing
• Maintenance
• Maintenance - work plan
• Maintenance - works
• Engine oil level - checking and filling
• Engine oil and oil filter - change
• Coolant - check level and fill
• Coolant - concentration check
• Diesel fuel filter - replace
• Replaceable air filter element - replace
• Toothed belt - condition inspection and tension check. Cars with a 2.5 liter diesel engine
• Exhaust system - visual inspection
• Spark plugs - removal, inspection and installation
• Transmission. Main gear
• Automatic transmission - final drive oil check
• Front suspension and steering
• Power steering oil level check and filling
• Brakes. Tires. Wheels
• Brake pad thickness - check
• Brake lines - check
• Brake fluid - replacement
• Wheels and tires
• Body. Salon equipment
• Dust filter - replace
• Electrical equipment
• Wiper arm angle - check and adjust

Engine

• Specifications
• General description
• Vehicle and engine identification
• Protective cover of the engine - removal and installation
• Timing belt - removal, installation and tension. Cars with 1.6 liter engines (102 hp)
• Cylinder head - removal and installation. Cars with 1.6 liter 102 hp engines
• Toothed belt - removal and installation. Cars with a gasoline engine AVJ / BFB / ALT with a volume of 1.8- / 2.0 liters and a capacity of 150/163/130 hp
• Toothed belt - removal and installation. Cars with AWA 2.0-liter petrol engine and 150 hp
• Cylinder head - removal and installation. Cars with a petrol engine of 1.8- / 2.0 liters
• Toothed belt of the timing mechanism drive - removal, installation and tension. Cars with a V-shaped gasoline engine BDV of 2.4 liters and 170 hp.
• Cylinder head - removal and installation. Cars with a V-shaped gasoline engine BDV of 2.4 liters and 170 hp
• Toothed belt of the timing mechanism drive - removal and installation. Cars with gasoline engine ASN 3.0 liter and 220 hp
• Cylinder head - removal and installation. Cars with gasoline ASN 3.0 liter engine and 220 hp
• Timing chain - removal and installation. Cars with a VVK engine of 4.2 liters and 344 hp
• Cylinder head - removal and installation. Cars with a VVK 4.2-liter 344 hp engine
• Toothed belt of the timing mechanism drive - removal and installation. Vehicles with 1.9 liter TDI AVB / AWX / AVF engine
• Cylinder head - removal and installation. Vehicles with 1.9 liter TDI AVB / AWX / AVF engine
• Toothed belt of the timing mechanism drive - removal, installation and tension. Cars with V-engine AYM / BCZ / BDG / AKE / BAU / BDH 2.5L TDI
• Cylinder head - removal and installation. Vehicles with 2.5 liter V-shaped TDI engine
• Engine - removal and installation
• Compression - check
• Ribbed belt - removal and installation
• Engine - Start
• Engine lubrication system - general
• Engine oil pressure and pressure sensor - check
• Oil pan - removal and installation
• Oil pump - removal and installation

Cooling, heating and ventilation system

• Engine cooling system
• Coolant - replacement
• Thermostat - removal and installation
• Thermostat - check
• Radiator - removal and installation
• Radiator blower fan - removal and installation
• Water pump - removal and installation
• Heating and air conditioning
• Radiator fan sensor - check
• Deflectors - removal and installation
• Air distribution flap motor - removal, installation and inspection
• Heater / air conditioner switch block - removal and installation
• Interior blower motor - removal and installation
• Coolant heater - removal and installation

Fuel injection system - gasoline engines

• Specifications
• General description and precautions
• Injection system - check

Power system - diesel engines

• How a diesel engine works
• Preheat unit - check, remove and install
• Glow plugs - removal and installation

Fuel system

• General provisions
• Fuel pump and fuel gauge sensor - removal and installation
• Fuel system - air removal. Cars with 1.8 l petrol engine
• Fuel filter - removal and installation. All petrol engines except 1.8L
• Fuel pump - performance check

Exhaust system

• General information
• Turbocharger - removal and installation
• Exhaust system - removal and installation
• Catalyst and lambda probe - removal and installation
• Exhaust System - Fit

Ignition system

• General information
• Spark plugs
• Petrol engine ignition and fuel injection system - general check
• Ignition lock and switch - removal and installation

Clutch

• General description
• Coupling - removal, installation and inspection
• Clutch master cylinder - removal and installation
• Clutch slave cylinder - removal and installation
• Clutch actuator - bleeding

Mechanical transmission

• Gearbox - general information
• Gearbox - removal and installation
• Gearshift mechanism - removal, installation and adjustment
• Differential - removal and installation

Automatic transmission

• General information
• Automatic transmission - removal and installation
• Automatic transmission - shift cable adjustment

Braking system

• Specifications
• General information
• Brake pads of disc brakes of front wheels with FN-3 caliper - removal and installation
• Brake pads for front disc brakes with caliper FNR-G60 - removal and installation
• Brake pads of disc brakes of front wheels with a caliper C54 - removal and installation
• Brake pads for rear wheels disc brakes with C38 caliper - removal and installation
• Brake pads for rear wheels disc brakes with C43 caliper - removal and installation
• Brake disc - check residual thickness
• Caliper and brake disc - removal and installation
• Parking brake - adjustment
• Brake system - bleeding
• Brake hoses - removal and installation
• Vacuum brake booster - check
• Brake light switch - removal and installation

Suspension and steering

• Specifications
• Front suspension
• Suspension strut - removal and installation
• Shock strut - disassembly and assembly
• Drive shaft - removal and installation
• Drive shaft - disassembly and assembly
• Rear suspension - general information
• Rear suspension coil spring - removal and installation
• Rear suspension shock absorber - removal and installation
• Steering - general information
• Driver's airbag unit - removal and installation
• Steering wheel - removal and installation
• Tie rod and tie rod end - removing and installing
• Tie rod cover - removing and installing

Body and interior trim

• General information
• Engine mudguard - removal and installation
• Bulkhead upper cross member - set to service position
• Fairing bulkhead - removal and installation
• Front bumper - removal and installation
• Front wing - removal and installation
• Front wheel arch liner - removal and installation
• Rear wheel arch liner - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation and fitting
• Bonnet lock cable - removing and installing
• Front door trim - removal and installation
• Rear side door trim - removal and installation
• Door - removal and installation
• External door handle - removal and installation
• Center console - removal and installation
• Front pillar trim - removal and installation

Electrical system

• General description and precautions
• Heated rear window - check
• Stop signal - check
• Sound signal - removal and installation
• Parking aid sensors - removal and installation
• Remote Control Batteries - Replacement
• Fuses - replacement
• Battery - removal and installation
• Battery - check
• Battery - charging and storage
• Generator - general, precautions and inspection
• Generator - removal and installation
• Alternator and voltage regulator carbon brushes - check and replace
• Starter - removal and installation
• Traction relay - removal, check and installation
• Windscreen wiper
• Front glass washer jet - removal, installation and adjustment
• Window washer reservoir and pump - removal and installation
• Windshield wiper arms - removal and installation
• Front glass wiper motor - removing and installing
• Rear window wiper motor - removing and installing
• Lighting devices - general information
• Headlight - removal and installation
• Additional brake light - removal and installation
• Rear headlamp - removal and installation
• Instrument panel - removal and installation
• Steering column switches - removal and installation

Troubleshooting

Basic electrical diagrams