Contents

Table of contents

Foreword

Operating instructions

• Entering and recalling data from a computer

Maintenance

• Specifications
• Service
• General description
• Routine maintenance
• Intensive service
• Weekly checks
• Liquid level checks
• Wheel protectors and tire pressure check
• Tread wear patterns
• Every 10,000 km or every 6 months
• Change engine oil and filter
• Checking the power steering fluid level
• Checking the transmission fluid level
• Swapping tires
• Checking and replacing hoses
• Checking, adjusting and replacing the drive belt
• Checking and adjusting the idle speed and CO
• Every 18,000 km or 12 months
• ?Check, maintain and charge the battery
• Checking and replacing spark plugs
• High voltage spark plug wires, interrupter cap and runner - check and replace
• Checking the manual transmission oil level
• Checking the lubrication level of the differential
• Valve clearances - check and adjust
• Throttle link - check and lubricate
• Replacing the air filter
• Fuel system check
• Cooling system check
• Checking the exhaust system
• Checking the steering and suspension
• Checking the protective cover for the drive shaft
• Brake system check
• Every 40,000 km or 2 years
• Change transmission fluid and filter
• Windscreen wiper blades - check and replace
• Cooling system - draining, flushing and filling
• Replacing the fuel filter
• Mechanical transmission oil change
• Differential oil change
• Checking the fuel vapor recovery system
• Reset service indicator data
• Every 90,000 km
• Replacing the engine timing belt

Repair of a gasoline engine in a car

• Specifications
• General description
• Repair operations performed without removing the engine from the car
• Installing the piston of cylinder No. 1 at top dead center (TDC)
• Valve cover - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Drive chain covers - removal and installation
• Drive chain and sprockets - removal, inspection and installation
• Toothed belt covers - removing and installing
• Toothed belt and sprockets - removal, inspection and installation
• Front oil seals - replacement
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Flywheel / drive disc - removal and installation
• Rear crankshaft oil seal - replacement
• Engine mount brackets - inspect and replace

Bulkhead gasoline engine

• Specifications
• General information
• Engine overhaul - general information
• Compression test
• Engine removal - methods and precautions
• Engine - removal and installation
• Engine bulkhead - ways
• Engine bulkhead - sequence
• Cylinder head disassembly
• Cylinder head and its components - cleaning and inspection
• Valves - service
• Cylinder head - assembly
• Pistons / connecting rods - removal
• Crankshaft - removal
• Intermediate shaft - removal and inspection
• Engine block - cleaning
• Engine block - inspection
• Honing a cylinder
• Pistons / connecting rods - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine overhaul - assembly sequence
• Piston rings - installation
• Intermediate shaft - installation
• Crankshaft - installing and checking the main bearing running clearance
• Rear crankshaft oil seal - installation
• Pistons / connecting rods - installing and checking connecting rod bearing running clearance
• Initial engine start after bulkhead

Diesel engines

• Specifications
• Diesel engine management system - general description
• Clearance between rocker arms and camshaft cams - adjustment
• Fuel system - bleeding
• Fuel filter - sediment drain
• Fuel filter - change
• High pressure fuel pump - removal and installation
• Initial fuel injection timing - adjustment
• Idling frequency - check
• Turbine generator - removal and installation
• Pressure reducing valve - check and adjust
• Toothed drive belt - replacing and adjusting tension
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Engine - removal and installation
• Engine disassembly
• Crankshaft & main bearings - installation
• Pistons and connecting rods - assembly and installation
• Engine - final assembly and installation
• Oil pump - removal and installation
• Oil pump - check
• Water pump - replacement
• Coolant - replacement

Cooling, heating and air conditioning systems

• Specifications
• General description
• Antifreeze - general description
• Thermostat - check and replace
• Radiator - removal and installation
• Fans - serviceability check, removal and installation
• Water pump - functional check
• Water pump - removal and installation
• Coolant temperature gauge sensor - check and replace
• Heater and air conditioner blower motor - removal, service check and installation
• Heater / air conditioner control panel assembly - removal and installation
• Heater matrix - removal and installation
• Air conditioning system - precautions and service
• Air conditioner compressor - removal and installation
• Air conditioner condenser - removal and installation
• Filter accumulator - removal and installation
• Evaporator matrix - removal and installation

Fuel and exhaust systems - petrol models

• Specifications
• General information
• Fuel injection system - depressurization
• Fuel priming pump / fuel pressure - check
• Fuel pump, priming pump and fuel level sensor - removal and installation
• Fuel lines and connections - repair and replacement
• Fuel tank - removal and installation
• Fuel tank cleaning and repair - general information
• Air filter - removal and installation
• Gas pedal cable - check, adjustment and replacement
• Fuel injection system - general information
• Fuel injection systems
• Fuel injection system - check
• Air flow meter - check, removal and installation
• Throttle body - check, removal and installation
• Fuel pressure regulator - check and replace
• Cold start injector and start fuel mode switch - check and replace
• Fuel injectors - check and replace
• Idle air stabilizer valve - check
• Exhaust system maintenance - general information

Engine electrical systems

• Specifications
• General information
• Battery - start from external source
• Battery - removal and installation
• Battery wires - check and replace
• Ignition system - general information and precautions
• Ignition system - check
• Ignition timing (TCI system) -check and adjust
• Distributor - removal and installation
• Ignition coil - check and replace
• Pulse generator and ignition control unit - check and replace (TCI system)
• Air gap (TCI system) - check and adjust
• Ignition sensors (Motronic system) - check and replace
• Charging system - general information and precautions
• Charging system - check
• Generator - removal and installation
• Voltage regulator - replacement
• Alternator brushes - check and replace
• Launch systems - general information and precautions
• Starter - check in the car
• Starter - removal and installation
• Starter traction relay - removal and installation

Engine management and exhaust gas treatment systems

• General description
• Self-diagnosis of the Motronic engine management system - general description
• Electronic control unit (ECU) - removal and installation
• Information sensors
• Positive crankcase ventilation (PCV)
• Fuel vapor emission control system (EVAP)
• Catalytic converter

Mechanical transmission

• Specifications
• General description
• Gear lever - removal and installation
• Oil seals - replacement
• Transmission brackets - inspect and replace
• Transmission - removal and installation
• Transmission bulkhead - general description

Automatic transmission

• Specifications
• General description
• Troubleshooting - general information
• Gear lever linkage - adjustment
• Kickdown cable adjustment
• Starter lock / reversing light switch - check and replace
• Automatic transmission - removal and installation
• Seals - replacement

Clutch and drive

• Specifications
• General description
• Clutch - general description and inspection
• Clutch master cylinder - removal and installation
• Clutch pedal - adjustment
• Launcher (where installed) - health check and replacement
• Clutch slave cylinder - removal and installation
• Clutch hydraulic system - bleeding
• Clutch components - removal, inspection and installation
• Cardan shaft - removal and installation
• Elastic coupling - inspection and replacement
• Center bearing - check and replace
• Universal joints - inspection and replacement
• Front center rail - inspect and replace
• CV joint for propeller shaft - replacement
• Drive shafts - removal and installation
• CV joints and their covers - inspection and replacement
• Differential housing side oil seals - replacement
• Differential housing - removal and installation
• Main drive pinion shaft oil seal - replacement

Braking system

• Specifications
• General description
• Anti-lock braking system (ABS) - general description
• Disc brake pads - replacement
• Disc brake caliper - removal, bulkhead and installation
• Brake disc - inspection, removal and installation
• Master cylinder - removal and installation
• Vacuum brake booster - serviceability check, removal and installation
• Handbrake cable - replacement
• Hand brake - adjustment
• Hand brake assembly - inspection, removal and installation
• Brake pedal - adjustment
• Brake light switch -check operation and adjust position
• Brake hoses and pipes - inspection and replacement
• Hydraulic brake system - bleeding

Suspension and steering gear

• Specifications
• General description
• Front anti-roll bar - removal and installation
• Lower and thrust arms - inspection, removal and installation, bushing replacement
• A-pillar assembly - removal and installation
• Front suspension struts and shock absorber / spring blocks - replace
• Ball joints - inspection and replacement
• Front wheel hub and bearing assembly - removal and installation
• Rear shock absorber / spring spring assembly - removal and installation
• Rear anti-roll bar - removal and installation
• Rear suspension trailing arms - removal and installation
• Rear wheel bearings - replacement
• Steering - general description
• Tie rod ends - removal and installation
• Steering rods - inspection, removal and installation
• Steering gear unit - removal and installation
• Power steering pump - removing and installing
• Hydraulic power steering - bleeding
• Steering wheel - removal and installation
• Wheels and tires - general description
• Wheel alignment - general description

Body

• General description
• Body and sub-frame - service
• Interior finishing - service
• Upholstery and rugs - service
• Body repair - minor damage
• Body repair - serious damage
• Hinges and locks - service
• Installed glass - replacement
• Radiator grill - removal and installation
• Hood - removal, installation and adjustment
• Bumpers - removal and installation
• Door trim panel - removal and installation
• Door - removal, installation and adjustment
• Trunk lid / tailgate - removal, installation and adjustment
• Latch, lock cylinder and handles - removal, installation and adjustment
• Door window glass - removal and installation
• Door window opening regulator - removal and installation
• Outside mirror - removal and installation
• Steering column covers - removal and installation
• Seats - removal and installation
• Seat belt check

Electrical system

• General description
• Electrical fault detection - general description
• Fuses - general description
• Relays - general description
• Direction indicator / hazard warning light - check and replace
• Steering column switches - removal and installation
• Ignition lock - removal and installation
• Radio - removal and installation
• Antenna - removal and installation
• Instrument panel - removal and installation
• Service signal panel (SI) - general description
• Headlights - changing bulbs
• Headlights - adjustment
• Headlamp housing - removal and installation
• Replacing lamps
• Windshield / rear door wiper motor - removing and installing
• Heated rear window - check and repair
• Supplemental security system (SRS.) - general description
• Speed ??control system - description and check
• Central locking - description and check
• Electric windows - description and check
• Wiring diagrams - general description
• Troubleshooting
• Engine
• Engine electrical system
• Fuel system
• Fuel injection system
• Cooling system
• Clutch
• Mechanical transmission
• Automatic transmission
• Braking system
• Suspension and steering

Wiring diagrams