Content

Foreword

Operating instructions

Maintenance

• Dimensions, weight and capacity
• Vehicle identification number
• General information
• Every 400 km or weekly
• Every 15,000 km or annually
• Every 20,000 km or annually
• Recommended lubricants and fluids
• Every 40,000 km or 24 months
• Every 60,000 km or 24 months
• Every 24 months - regardless of mileage
• Every 100,000 km

Engine

• Specifications
• Gasoline engines
• General description
• Maintenance
• Engine oil and oil filter - change
• Valve clearances - check and adjust
• Crankcase ventilation system - description and service
• Basic operations that can be carried out without removing the engine from the car
• Basic operations that can only be performed on a removed engine
• Engine removal method
• Engine - removal without transmission
• Engine / manual transmission assembly - removal and separation
• Engine - installation (manual transmission in the car)
• Engine / manual transmission assembly - connection and installation
• Engine / transmission mounts - replacement
• Disassembly of the engine - general description
• Toothed belt and sprockets - removal and installation
• Timing belt tension - check and adjust
• Toothed belt covers - removing and installing
• Front camshaft oil seal - replacement
• Camshaft cover, camshaft and tappets - removal and installation
• Camshaft cover, camshaft and tappets - disassembly, inspection and assembly
• Cylinder head - removal and installation (engine in a car)
• Cylinder head - removal and installation (engine removed)
• Cylinder head - bulkhead
• Cylinder head - inspection and service
• Intermediate shaft - removal, inspection and installation
• Flywheel - removal, inspection and installation
• Front crankshaft oil seal - replacement
• Rear crankshaft oil seal - replacement
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pump - disassembly, inspection and assembly
• Pistons and connecting rods - removal and installation
• Pistons and connecting rods - inspection and maintenance
• Crankshaft and main bearings - removal and installation
• Crankshaft and bearings - inspection and maintenance
• Cylinder block and cylinder bores - inspection and maintenance
• Inspection and maintenance - general description
• Engine assembly - general description
• First start-up after a bulkhead or major overhaul
• Part B: Diesel engines
• General description
• Engine - removal and installation
• Engine - disassembly and assembly
• Cylinder head - removal and installation
• Toothed belt - installation
• High pressure fuel pump - installation
• Cylinder head - repair
• Connecting rods and pistons
• Connecting rods - replacement
• Pistons - check and replace
• Flywheel - repair
• Cylinder block
• Lubrication system
• Oil pump - repair
• Gas distribution system
• Gas distribution system - adjustment
• Power system
• Heating starter

Cooling system

• Specifications
• General description
• Maintenance
• Cooling system - draining fluid
• Cooling system - flushing
• Cooling system - filling
• Coolant - main characteristics
• Radiator - removal and installation
• Radiator - inspect and clean
• Thermostat - removal and installation
• Thermostat - check
• Water pump - removal and installation
• Water pump / generator drive belt - check, replace and tension
• Fan - removal and installation
• Coolant temperature gauge sensor - removing and installing
• Cooling fan thermal switch - removal and installation

Fuel and exhaust systems

• Specifications
• General description
• Fuel system precautions
• Maintenance
• Air filter element - replace
• Air filter - removal and installation
• Air filter temperature control - description and test
• Fuel filter - change
• Fuel priming pump - test
• Fuel priming pump - removal and installation
• Fuel tank - removal and installation
• Fuel level sensor - removal and installation
• Gas pedal - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Choke cable - removal, installation and adjustment
• Carburetor (Weber TIDE type) - description
• Carburetor - removal and installation
• Carburetor - idle and mixture frequency adjustment
• Carburetor - cleaning
• Float regulator needle and float - removal, installation and adjustment
• Valve diaphragm - carburetor economizer - replacement
• Diaphragm of the accelerator pump of the carburetor - replacement
• Thermocontrolled diaphragm of the carburetor accelerator pump - replacement
• Vacuum diaphragm of the carburetor accelerated idling device - replacement and adjustment
• Pull-down block vacuum diaphragm damper - replacement
• Carburetor damper - adjustment
• Vacuum valve with thermal control - removal and installation
• Intake manifold blower components - description, removal and installation
• Collectors - removal and installation
• Exhaust system - check, removal and installation
• Part B: Injection systems
• General information
• Bosch central injection system
• Weber IAW multi-position injection system - general description

Ignition system

• Specifications
• General description
• Ignition system - precautions
• Maintenance
• Spark plugs - inspection and replacement
• Ignition coil - health check
• Ignition coil - removal and installation
• Breaker cover, slider and high voltage wires - remove, check and install
• Ignition distributor - removal and installation
• Distributor - disassembly, inspection and assembly
• Ignition timing - check and adjust
• Ignition timing - trim for unleaded fuel
• Electronic blocks - removal and installation
• Crankshaft speed / position sensor (Diyiplex 2 system) - removal and installation
• Fuel cut system components - check, remove and install
• Troubleshooting - ignition system
• Troubleshooting - Digiplex 2 system

Clutch

• Specifications
• General description
• Maintenance
• Clutch cable adjustment
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Clutch - removal
• Clutch - inspect
• Clutch - installation
• Release bearing and lever - removal, inspection and installation

Manual transmission

• Specifications
• General description
• Maintenance
• Gear selector rods - removal, bulkhead and installation
• Gear lever - removal and installation
• Gearbox - removal and installation (engine remains in the car)
• Transmission bulkhead - main features
• Gearbox - dismantling for basic consideration
• Input shaft - bulkhead
• Output shaft - bulkhead
• Synchronizer bulkhead
• Differential - bulkhead
• Input shaft oil seal - replacement
• Selector lever assembly bulkhead
• Overhaul of the gearbox housing
• Gearbox assembly

Drive shafts

• Specifications
• General description
• Maintenance
• Drive shaft - removal and installation
• Protective cover for inner CV joint - replacement
• Protective cover for inner CV joint - replacement
• Trioid CV joint - inspection, removal and installation
• SHRUS - inspection, removal and installation
• Internal CV joint cover bearing - inspection, removal and installation
• Drive shaft vibration damper - removal and installation

Braking system

• Specifications
• General description
• Maintenance
• Hydraulic brake system - bleeding
• Front brake pads - inspection and replacement
• Rear brake pads - inspection and replacement
• Front brake caliper - removal, bulkhead and installation
• Brake disc - inspection, removal and installation
• Brake drum - removal, inspection and installation
• Rear wheel cylinder - removal, bulkhead and installation
• Rear brake shield - removal and installation
• Front brake disc guard - removal and installation
• Master cylinder - removal and installation
• Master cylinder - bulkhead
• Vacuum booster - description and functional check
• Vacuum booster - removal and installation
• Brake pipes and hoses - removal and installation
• Handbrake - adjustment
• Handbrake cable - removal and installation
• Hand brake lever - removal and installation
• Brake pedal - removal and installation

Suspension and steering

• Specifications
• General description
• Maintenance
• Front wheel bearing - replacement
• Front wheel hub - removal and installation
• Steering knuckle - removal and installation
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front suspension lower arm - removal and installation
• Front lower arm bushings - replacing
• Sub-frame - removal and installation
• Front anti-roll bar - removal and installation
• Front anti-roll bar bushings - replacement
• Rear wheel bearing - replacement
• Rear wheel hub - removal and installation
• Rear shock absorber - removal and installation
• Rear leaf spring - removal and installation
• Trailing arm suspension - removal and installation
• Rear suspension assembly - removal and installation
• Rear anti-roll bar - removal and installation
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering covers - replacement
• Steering gear without amplifier - removal and installation
• Steering gear without power - bulkhead
• Power steering - removal and installation
• Power steering - bulkhead
• Hydraulic power steering - bleeding
• Power steering pump drive belt - inspect, replace and tension
• Power steering pump - removal and installation
• Power steering hydraulic reservoir - removal and installation
• Tie rod end - removal and installation
• Tie rod - removal and installation
• Front wheel alignment - check and adjust
• Wheels and tires - service

Body

• Specifications
• General description
• Body and frame maintenance
• Upholstery and rugs - service
• Repair of minor damage to the body
• Repair of serious damage to the body
• Hood - removal and installation
• Bonnet release cable - removal and installation
• Bonnet lock - removal and installation
• Rear doors - removal and installation
• Tailgate lock - removal and installation
• Tailgate lock core - removal and installation
• Rear door pillars - removal and installation
• Door - removal and installation
• Door trim - removal and installation
• Lower door frame - removal and installation
• Inner door handle - removal and installation
• External door handle - removal and installation
• Door lock - removal and installation
• Windshield, rear window and rear wall windows - removal and installation
• Door window - removal and installation
• Door window lifter - removal and installation
• Side mirror - removal and installation
• Bumper - removal and installation
• Radiator grille panel - removing and installing
• Windshield side hood trim - removal and installation
• Wheel arch liners - removal and installation
• Engine and transmission mud flaps - removal and installation
• Fuel filler flap - removal and installation
• Luke - removal and installation
• Interior trim panels - general description
• Interior trim panels - removal and installation
• Dashboard - removal and installation
• Center console - removal and installation
• Ceiling - removal and installation
• Seats - removal and installation
• Seat belts - removal and installation
• Heater control panel - removal and installation
• Heater controls - adjustment
• Heater matrix - removal and installation
• Temperature control flap - removal and installation
• Heater blower motor - removal and installation

Electrical system

• Specifications
• General description
• Electrical system precautions
• Maintenance
• Battery - check and charge
• Battery - removal and installation
• Generator - description
• Alternator drive belt - check, replace and tension
• Generator - removal and installation
• Alternator - troubleshooting and testing
• Alternator brushes - removal, inspection and installation
• Starter - general description
• Starter - check in the car
• Starter - removal and installation
• Starter - bulkhead
• Fuses and relays - basic description
• Ignition lock and lock cylinder - removal and installation
• Multifunction switch - removal and installation
• Dashboard switches - removal and installation
• Hazard switch - removal and installation
• Electric external mirror regulator - removal and installation
• Electric exterior mirror motor - removal and installation
• Interior lighting switch - removal and installation
• card reading light switch - removal and installation
• Sunroof control switch - removal and installation
• Brake light switch - removal and installation
• Hand brake warning lamp switch - removal and installation
• Reversing light switch - removal and installation
• Oil pressure warning lamp switch - removing and installing
• Cigarette lighter - removal and installation
• Dashboard - removal and installation
• Dashboard components - removal and installation
• Control system components - removal and installation
• Sound signal - removal and installation
• Interior lighting - removal and installation
• Luggage compartment light - removal and installation
• Flashlight for reading the map - removal and installation
• Interior lamps - replacement
• headlight - removal and installation
• Headlights - adjustment
• Front direction indicator lamp - removal and installation
• Side repeater front turn signal - removal and installation
• Rear light assembly - removal and installation
• License plate light - removal and installation
• Ambient light bulbs - replacement
• Wiper blades - replacing
• Wiper arms - removal and installation
• Washer jets - removal and installation
• Wiper motor and bracket - removing and installing
• Rear door wiper motor - removal and installation
• Headlamp wiper motor - removing and installing
• Washer fluid reservoir - removal and installation
• Washer pump - removal and installation
• Power window components - removal and installation
• Central door locking components - removal and installation
• Radio antenna - removal and installation
• Speakers - removal and installation
• Radio tape recorder - removal and installation
• Sunroof engine - removal and installation
• Speedometer cable - removal and installation
• Digital speedometer sensor - removal and installation
• Economizer pointer sensor - removal and installation
• Wiring diagrams - explanatory notes

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Manual transmission
• Drive shafts
• Brake hydraulics
• Suspension and steering
• Electrical system
• Malfunctions of individual electrical components

Wiring diagrams