Contents

General provisions

• Safety instructions
• Protection
• Other

Vehicle use and maintenance

• Familiarization with car models
• Operation and maintenance
• Key parameters and important torques

Engine 1 (car repair)

• Engine summary
• Removal and installation of engine - gearbox (MT)
• Removing and installing the accessory belt
• Removing and installing the power steering pump
• Removing and installing the air conditioning compressor
• Removing and installing the generator
• Removing and installing the starter
• Checking the oil pressure
• Replacing the oil filter
• Disassembling the oil pump
• Note the thermostat
• Removing and installing the cooling fan
• Complete release-filling-release of gas from the cooling system
• Replacing the active carbon filter
• Replacing the throttle pull cable
• Replacing the throttle pedal sensor
• Removing and installing the fuel pump
• Removing and installing the fuel level sensor
• Removing and installing the fuel tank
• Removing and installing the exhaust system (cold end)
• Removing the middle and last stage muffler
• Exhaust system characteristics
• Checking the gas distribution mechanism
• Removing and installing the timing belt
• Removing and installing the camshaft
• Removing and installing the cylinder cover
• Installing the camshaft oil seal
• Installation of front and rear crankshaft oil seals

Engine 2 (repair of removed unit)

• Characteristics of the cylinder cover
• Characteristics of the cylinder block gasket
• Camshaft Characteristics
• Valve characteristics
• Characteristics of valve spring
• Valve piping characteristics
• Characteristics of valve seat ring
• Characteristics of the cylinder body
• Characteristics of connecting rod
• Characteristics of the piston - piston ring
• Characteristics of the crankshaft liner
• Selection of crankshaft liner
• Repair of connecting rod piston
• Cylinder cover repair
• Engine disassembly
• Engine installation
• Engine reassembly (external engine accessories)
• Tightening torque of the engine assembly

Clutch

• Summary of clutch
• Removing and installing the clutch release cable
• Replacing the clutch pedal
• Removing and installing the clutch assembly

Manual transmission

• Gearbox summary
• Summary of the control of two flexible shafts of the gearbox
• Removing and installing the flexible shaft for selecting gears and shifting gears of the transmission
• Disassembling the gearbox
• Removing and installing rocker arm axles for gear selection and shifting
• Gearbox
• Removing and installing the input shaft
• Removing and installing the secondary shaft
• Removal and installation of differential
• Removal and installation of primary and secondary gear synchronizers
• Removing and installing the gearbox assembly

Automatic transmission

• Removing and installing an automatic transmission
• Replacing and adjusting the pull cable for shifting gears of an automatic transmission
• Replacing the gear selector
• Check - complete release - filling with oil for automatic transmission
• Checking and replacing the cooling pipe
• Checking and replacing the speed sensor
• Checking and replacing the input shaft speed sensor
• Replacing the automatic transmission oil filter
• Installing the left and right axle shaft seal and the torque converter seal

Axle shafts and wheels

• Summary of Axle
• Removing and installing the axle shaft (manual transmission)
• Removing and installing axle shaft (automatic transmission)
• Repair of axle shaft (manual transmission)
• Repair of axle shaft (automatic transmission)
• Summary of wheels

Front axle and front suspension

• Summary of the front axle and front suspension
• Removing and installing the front engine support
• Removing and installing the triangular lever
• Removing and installing the steering knuckle
• Repair of triangular lever
• Replacing the front wheel bearing
• Removing and installing the front shock absorber
• Disassembling the front shock absorber
• Removing and installing the front stabilizer bar

Rear axle and rear suspension

• Summary of rear axle and rear suspension system
• Removing and installing the rear axle
• Removing and installing the rear swing arm
• Removing and installing the rear swing arm shaft pin
• Removing and installing the rear swing arm shaft pipe
• Removing and installing the needle bearing (outer side) of the rear side member
• Removing and installing the needle bearing (on the inside) of the rear side member
• Removing and installing the rear hub bearing assembly
• Removing and installing the elastic thrust block of the rear axle
• Removing and installing the rear shock absorber bushing
• Removing and installing the rear shock absorber
• Removing and installing rear stabilizer bar
• Removing and installing torsion bar
• Checking and adjusting the height at the rear

Steering system

• Brief overview of the steering system
• Replacing power steering fluid
• Removing and installing the power steering pump
• Removal and installation of power steering
• Replacing the tie rod dust cover
• Removing and installing a transverse steering rod
• Removing and installing a rack shock absorber
• Replacing the distribution valve
• Removing and installing the steering wheel
• Removing and installing a combination switch
• Removing and installing the steering column
• Removing and installing an anti-theft steering lock

Brake system

• Brief summary of the braking system
• Full release - refueling - release of gas from the brake system
• Checking the front brake disc
• Checking the rear brake disc
• Replacement - adjusting the parking disc
• Replacing the brake pedal
• Removing and installing the front brake friction disc
• Removing and installing the front brake caliper
• Removing and installing the front brake disc
• Removing and installing the rear brake friction disc
• Removing and installing rear brake caliper
• Removing and installing the rear brake disc
• Removing and installing rear brake shoes (drum type)
• Removing and installing the rear wheel bearing (drum type)
• Removing and installing the main brake cylinder
• Removal and installation of vacuum hydraulic booster
• Front brake caliper repair
• ABS system summary
• Removing and installing the front wheel speed sensor
• Removing and installing the rear wheel speed sensor
• Removing and installing the hydraulic control unit
• Replacing the front brake wheel cylinder
• Replacing the rear brake wheel cylinder

Air conditioning

• Special notes for maintenance
• Description of the air conditioning system
• Checking the air conditioning system
• Recovery / circulation / refrigerant charging
• Removing and installing the air conditioner assembly
• Removing and installing the air conditioning harness
• Removing and installing the air conditioner servomotor
• Removing and installing the heat exchanger
• Removing and installing the dust filter
• Disassembling the evaporator tank
• Removing and installing a dry filter element
• Check and adjustment: compressor clutch clearance
• Removing and installing the compressor drive disk
• Removing and installing the compressor pulley and clutch

Safe equipment

• Safety rules
• Removing and installing driver airbags
• Removing and installing passenger airbags
• Removing and installing side airbags
• Removing and installing a pre-tensioning seat belt
• Removing and installing the airbag module
• Removing and installing the airbag rotation clutch
• Procedures for handling abandoned air bags

Luke

• Brief summary of the sunroof
• Removing and installing sunroof glass
• Removing and installing the sunroof electric machine
• Removing and installing the sunroof control module
• Removing and installing the hatch assembly
• Removing and installing the visor

Body kit (S30)

• Rear door disassembly
• Removing and installing the rear door
• Disassembling the front door
• Removing and installing the front door
• Removing and installing trunk interior trim elements
• Disassembling the trunk lid
• Removing and installing the trunk lid assembly
• Removing and installing lining under the windshield
• Removing and installing the front wing
• Removing and installing the hood
• Lifting and towing a vehicle
• General information
• Removing and installing the washer reservoir
• Removing and installing a windshield wiper
• Removing and installing the headlight
• Removing and installing the front fog lamp
• Removing and installing the rear light
• Removing and installing the third brake light
• Removing and installing the front interior ceiling light
• Removing and installing rear interior ceiling light
• Removing and installing the license plate light
• Removing and installing trunk lighting
• Removing and installing the front seat
• Disassembling the front seat
• Removing and installing the rear seat
• Rear seat disassembly
• Removal and installation of interior trim elements
• Removing and installing the inner roof lining
• Removing and installing carpet and sound insulation
• Removing and installing the front seat belt
• Removing and installing the rear seat belt
• Removing and installing the front bumper
• Removing and installing the rear bumper
• Removing and installing parking sensors
• Removing and installing the energy-absorbing buffer of the rear bumper with connecting parts
• Removing and installing the front mudguard
• Removing and installing the rear mudguard
• Removing and installing the dashboard
• Removing and installing the windshield
• Removing and installing rear window
• Removing and installing the outside rear view mirror
• Removing and installing the front wiring harness

Body kit (H30)

• Removing and installing the rear light
• Removing and installing the third brake light
• Removing and installing the license plate light
• Removing and installing trunk lighting
• Removing and installing the trunk lid
• Removing and installing components for the trunk
• Removing and installing the pneumatic stop
• Removing and installing trunk interior trim elements
• Removing and installing the interior decorative trim of the rear pillar
• Removing and installing the rear seat
• Removing and installing the rear bumper
• Removing and installing the rear mudguard
• Removing and installing the rear window washer nozzle
• Removing and installing trunk lid wiring harness
• Removing and installing triangular glass
• Removing and installing trunk lid glass

Body check

• Tolerances for gaps between body elements
• Unpainted body control points
• Location of control points
• Control points in spaces and relative locations of points

Body structure (S30)

• Coloring rules
• Recommended auxiliary materials and products for body repair
• Definition of body structural elements and distinctive features
• Conventional symbols
• Body sealing
• Replacement of the front fender inner trim
• Partial replacement of the front longitudinal beam
• Replacing the front longitudinal beam and front wheel visor
• Partial replacement of the front longitudinal beam and front wheel visor
• Partial replacement of the upper partition of the front body panel
• Replacing the front strut
• Partial replacement of the front pillar
• Replacing the middle pillar
• Partial replacement of the outer panel of the B-pillar
• Replacing the door threshold
• Replacing the outer side body panel assembly
• Replacing the inner trim of the side body panel
• Replacing the rear side body panel assembly
• Partial replacement of the rear side body panel
• Replacement of internalrear wing trim assembly
• Replacing the outer door panel
• Replacing the rear partition
• Replacing the rear light mounting shield
• Replacing the rear body panel
• Replacing the rear body panel (S30 2011)
• Partial replacement of the rear floor
• Replacing the entire rear floor
• Replacing the rear floor (S30 2011)
• Replacing the rear longitudinal beam
• Replacing the left rear longitudinal beam (S30 2011)
• Replacing the front and rear cross beams of the rear floor
• Roof replacement

Body structure (H30)

• Conventional symbols
• Definition of body structural elements and distinctive features
• Recommended auxiliary materials and products for body repair
• Coloring rules
• Body sealing
• Replacing the outer side body panel assembly
• Replacing the rear side body panel and stiffener
• Partial replacement of the outer rear side body panel
• Replacing the rear light mounting shield
• Replacing the rear body panel assembly
• Replacing the rear wheel visor assembly
• Replacing the rear floor
• Partial replacement of the rear transverse beam, rear longitudinal beam of the rear floor
• Roof replacement

Electrical circuit diagram

• List of wiring harnesses
• List of electrical elements
• Fuse box in the engine compartment
• Cabin fuse box
• Diagnostic connector
• Instrument cluster
• Contact layout
• List of contacts
• Electrical connection diagram for intermediate connectors
• List of intermediate connectors
• Layout of grounding points
• Wire harness layout
• Principles of working with electrical equipment

Electrical equipment repair

• Battery
• Generator
• Starter
• Fuel supply system with electronic engine control
• Instrument system
• Automatic air conditioning
• Airbag system
• Automatic transmission
• Anti-lock brake system