Content

Operating instructions

Maintenance

• Weight and dimensions
• Specifications
• Capacities
• Lubricants and fluids
• Maintenance
• Service
• Vehicle identification numbers
• Service procedures
• General description
• Intensive service
• Weekly checks
• Checking fluid levels
• Tire check
• Tire wear pattern
• Every 10,000 km or every 6 months
• Changing engine oil and filter
• Checking the electrical system
• Oil filler cap cleaning - OHV and HCS engines
• Check for leaks
• Exhaust manifold nuts tightness test - RS turbocharged models
• Adjustment of frequency of idling and quality of mix
• Checking ignition system components
• Distributor lubrication - contact breaker models
• Breaker contact plate adjustment - contact breaker models
• Checking the ignition timing - models with contact breaker
• Changing spark plugs - RS turbocharged models
• Checking the brake pads of the front brake
• Checking the brake pads of the rear brake
• Suspension and steering test
• Check seat belts
• Checking the alternator drive belt
• Every 20,000 km or after 12 months
• Valve clearance adjustment - OHV and HCS engines
• Exhaust system check
• Checking the tightness of the turbogenerator nuts to the manifold - RS turbocharged models
• Replacing spark plugs
• Replacing breaker contact plates
• Checking the gearbox oil level
• Automatic transmission fluid level check
• Testing the automatic transmission selection mechanism
• Drive shaft check
• Checking the wheels
• Lubricating doors, bonnet and locks
• Road test
• Every 40,000 km or after 2 years
• Coolant replacement
• Replacing the air filter element
• Crankcase ventilation filter replacement - CVH Engines
• Replacing the fuel filter - engines with fuel injection system
• Every 60,000 km or after 3 years
• Timing belt replacement - CVH engines
• Inspecting brake components
• Brake fluid replacement

OHV and HCS gasoline engines

• Specifications
• General description
• Repair work in the engine compartment
• Basic operations requiring engine removal
• Cylinder head - removing and installing
• Pallet - removal and installation
• Valve mechanism - bulkhead
• Crankshaft front oil seal - replacement
• Piston / connecting rod assembly - removing and installing
• Engine / transmission mounts - removing and installing
• Oil pump - removal - refitting
• Engine / driveline - removal and separation
• Engine - disassembly
• Inspection and maintenance
• Cylinder head and pistons - carbon cleaning
• Engine assembly
• Engine / driveline - coupling and installation

CVH gasoline engines

• Specifications
• General description
• Repair work in the engine compartment
• Basic operations requiring engine removal
• Timing belt - removing, installing, and adjusting
• Glands - replacement
• Camshaft - removing and installing
• Cylinder head - removing and installing
• Pallet - removal and installation
• Pistons / connecting rods - removal and installation
• Engine / transmission mounts - removing and installing
• Engine / driveline - removal and separation
• Engine - disassembly
• Inspection and maintenance
• Cylinder head and pistons - carbon cleaning
• Engine assembly
• Engine / driveline - coupling and installation
• Engine oil cooler - removing and installing

Diesel engine

• Specifications
• General description
• Service and inspection
• The main operations performed without removing the engine from the car
• Engine oil and oil filter - replacement
• Timing drive belt - inspecting and checking tension
• Timing belt - removing, installing and tensioning
• Valve clearances - check and adjust
• Camshaft - removing and installing
• Installation of gas distribution phases - check and adjustment
• Cylinder head - removing and installing
• Cylinder head - bulkhead
• Cylinder head and pistons - carbon cleaning
• Glands - replacement
• Pallet - removal and installation
• Drive and gear cover - removal and installation
• Drive cover - removing and installing
• Oil pump - removing, inspecting, and installing
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Engine / transmission mounts - removing and installing
• Engine removal methods
• Engine and transmission - removal
• Engine and transmission - separation
• Dismantling the engine - a general description
• Engine - complete disassembly
• Inspection and maintenance - general description
• Engine components - inspection and maintenance
• Engine assembly - general description
• Engine assembly
• Engine - transmission connection
• Engine and transmission - installation
• Engine - startup after bulkhead
• Compression testing - description

Cooling, heating and ventilation systems

• Specifications
• General description
• Fan - removing and installing
• Radiator - removal, inspection and installation
• Thermostat - removing, inspecting and installing
• Water pump - removal and installation
• Fan thermal switch - check, remove h installation
• Thermal sensor - removing and installing
• Heating and ventilation system - description
• Panel and heater control cables - adjustment
• Heater control panel and cables - removal and installation
• Heater - removal - refitting
• Heater matrix - removing and installing
• Supercharger motor / impeller - removal and installation

Carburetor fuel system

• Specifications
• General information and precautions
• Air filter assembly - removal and installation
• Air temperature control in the air filter - description and verification
• Fuel priming pump - cleaning
• Fuel priming pump - inspection, removal and installation
• Fuel tank - removal and installation
• The gas pedal cable - adjustment, removal and installation
• Gas pedal - removal and installation
• Choke lever cable - removing, installing, and adjusting
• Manual air damper block on a carburetor Ford VV - removal, inspection and installation
• Components of an automatic air damper carburetor Ford VV - removal, inspection and installation
• Carburetor Ford VV - removing and installing
• Weber 2V carburetor - adjustment
• Weber 2V carburetor automatic choke unit - adjustment
• Block Weber 2V carburetor automatic air damper - removal, inspection and installation
• Weber 2V carburetor - removal and installation
• Carburetor bulkhead - general description

Mechanical fuel injection systems Bosch K - Jetronic and Bosch KE - Jetronic

• Specifications
• General description and precautions
• Air filter - removal - refitting
• Fuel tank - removal and installation
• Gas cable - adjustment, removal and installation
• Gas pedal - removal and installation
• Fuel pump - removal - refitting
• Fuel accumulator - removal - refitting
• Fuel nozzles and fuel supply pipes to them - removal and installation
• Cold start valve - removing and installing
• Additional air supply unit - removal and installation
• Fuel dispenser - removing and installing
• Throttle body - removing and installing
• Fuel pressure regulator - removing and installing
• Warm-up regulator - removal and installation
• Electromagnetic pressure regulator actuator - removal - refitting
• Fuel injection control module - removal - refitting
• Air temperature sensor - removing and installing
• Fuel launcher switch - removing and installing
• The idle speed compensator - removal and installation
• Turbo generator - general description
• Charge control valve - removing and installing
• Intercooler - removing and installing
• Turbogenerator - removal and installation

Central fuel injection system (CFI)

• Specifications
• General description and precautions
• Air filter - removal - refitting
• Fuel tank - removal and installation
• Gas cable - adjustment, removal and installation
• Gas pedal - removal and installation
• Fuel system - depressurization
• Fuel pump - removal - refitting
• The block of the central injection of fuel - removal and installation
• Fuel pressure regulator - removing and installing
• Fuel injector - removal and installation
• Throttle position sensor - removing and installing
• Throttle drive motor - removing and installing
• Air temperature sensor - removing and installing
• Coolant temperature sensor - removing and installing
• Knock sensor - removing and installing
• Manifold pressure sensor - removing and installing
• Oxygen sensor (HEGO) - removal - refitting
• Fuel supply switch (inertial) - removal and installation
• Speed ??sensor - removing and installing
• The EEC IV control unit - removal and installation

Electronic distributed fuel injection system (EP1)

• Specifications
• General description and precautions
• Air filter - removal - refitting
• Fuel tank - removal and installation
• Gas cable - adjustment, removal and installation
• Gas pedal - removal and installation
• Fuel system - depressurization
• Fuel pump - removal - refitting
• Fuel pressure regulator - removing and installing
• Throttle body - removing and installing
• Fuel injectors - removing and installing
• Throttle position sensor - removing and installing
• Idle speed ??control valve - removing, cleaning, and installing
• Manifold pressure sensor - removing and installing
• Intake air temperature sensor - removing and installing
• Coolant temperature sensor - removing and installing
• Speed ??sensor - removing and installing
• Potentiometer for adjusting the mixture - removal and installation
• Fuel switch (inertial) - removal and installation
• The EEC IV control unit - removal and installation

Manifolds, exhaust system and exhaust gas aftertreatment system

• Specifications
• General description
• Intake manifold - removing and installing
• Exhaust manifold - removing and installing
• Exhaust system - replacement
• Components of a fuel vapor extraction system (CFI engines) - removal and installation
• Crankcase gas aftertreatment system components - removal and installation
• Exhaust gas aftertreatment system components - removal and installation

Diesel fuel system

• Specifications
• General description
• Service and inspection
• Air filter - element replacement
• Fuel filter - draining the fluid and replacing the element
• Idle frequency - check and adjust
• Maximum engine speed - check and adjustment
• Injection moment - check and adjustment
• High pressure fuel pump - removal - refitting
• Injection tubes - removing and installing
• Fuel injectors - removing, inspecting and installing
• Fuel shutoff valve - removing and installing
• Cold start item - replacement
• Preheating system - description and verification
• Glow plugs and relays - removing and installing
• The gas pedal cable - removal and installation
• Fuel tank - removal and installation
• Collectors - Removing and Installing
• Exhaust system - inspect, remove, and install

Launch and charging systems

• Specifications
• General description and precautions
• Troubleshooting circuit - general description
• Battery - check and charge
• Battery - removing and installing
• Generator - removal - refitting
• Alternator brushes and voltage regulator - replacement
• Starter - check on the car
• Starter - removing and installing
• Starter - brush replacement
• Ignition switch - removing and installing

Ignition system

• Specifications
• General description and precautions
• Ignition system - health check
• Capacitor (contact breaker system) - check, remove and install
• Ignition coil - inspect, remove, and install

Grip

• Specifications
• General description
• Clutch cable - removing and installing
• Clutch pedal - removal and installation
• Clutch assembly - removing, inspecting, and installing
• Release bearing - removing, inspecting, and installing

Manual transmission

• Specifications
• General description
• Gear shift - removing, installing and adjusting
• Glands - replacement
• Reversing light switch - checking, removing and installing
• Speedometer driven gear - removing and installing
• Mechanical transmission block - removing and installing
• Mechanical transmission bulkhead - general description

Automatic transmission

• Specifications
• General description
• Downshift link - adjustment
• Downshift link - removing and installing
• The mechanism of the choice of the driving mode - removal and installation
• The cable for switching the driving mode - removal, installation and adjustment
• Starter lock - removing, installing and adjusting
• Automatic transmission - removing and installing
• Automatic transmission bulkhead - general description

Drive shafts

• Specifications
• General description
• Protective cover of the inner CV joint - replacement
• Protective cover of the outer CV joint - replacement
• Drive shaft - removing and installing
• Drive shaft assembly - bulkhead

Brake system

• Specifications
• General description
• Front brake pads - replacement
• Front brake caliper - removing, bulking and installing
• Front brake disc - inspection, removal and installation
• Rear brake pads - replacement
• The cylinder of a back brake - removal, a partition and installation
• Brake drum - inspection and replacement
• Handbrake - adjustment
• Hand brake cables - replacement
• Hand brake lever - removing and installing
• Hydraulic brake system - bleeding (models without ABS)
• The main cylinder - removal, a partition and installation
• Valve for adjusting the pressure in the brake system (Sedan and Wagon models) - removal and installation
• Brake force compensator (box models) - adjustment, removal and installation
• Brake tubes and hoses - replacement
• The block of the vacuum amplifier and draft - removal and installation
• Brake pedal - removal, installation and adjustment
• Warning lamps and brake sensors - removal and installation
• ABS description
• Modulator drive belt (ABS) - removing and installing
• Modulator (ABS) - removal and installation
• Brake force compensator depending on vehicle load (ABS) - removal and installation
• Hydraulic brake - bleeding (ABS)

Suspension and steering

• Specifications
• General description
• Front wheel bearings - replacement
• Lower front suspension arm (cast) - removal, overhaul and installation
• Lower front suspension arm (stamped) - removal, overhaul and installation
• Front anti-roll bar - removal - refitting
• Front stretch - removing and installing
• A rack of a forward suspension bracket - removal, a partition and installation
• Rear wheel bearings - adjustment
• Rear wheel bearings - replacement
• The rear shock absorber (Sedan and Station wagon models) - removal, health check and installation
• Rear shock absorbers (box models) - removal, health check and installation
• The rear extension (sedan and station wagon models) - removal and installation
• Rear spring springs (Sedan and Wagon models) - removal and installation
• Rear spring (Box Models) - removal and installation
• The lower lever of a back suspension bracket (Sedan and Station wagon models) - removal and installation
• Rear steering knuckle (sedan and station wagon models) - removal and installation
• Beam of a back axis (Van model) - removal and installation
• The rear anti-roll bar (Sedan and Wagon models) - removal and installation
• Rear wheel angles - general description
• Steering gear covers - replacement
• Outer ball joint steering link - replacement
• Steering wheel - removal and installation
• Steering wheel - position adjustment
• The steering column lock - removal and installation
• Steering column - removing, bulkhead and installing
• Steering gear - removing, reassembling, and installing
• Wheel alignment

Body

• Specifications
• General description
• Body and engine frame - service
• Upholstery and rugs - service
• Body repair - minor damage
• Significant damage to the body - repair
• Bumper components - removing and installing
• Hood - removing and installing
• Bonnet lock cable - removing and installing
• Bonnet lock - removal and installation
• Radiator grille - removing and installing
• Door trim panel - removal and installation
• Doors - removing and installing
• Door handle and lock components - removal and installation
• Door window glass and power window - removal and installation
• The back door opening upwards - removal and installation
• The lock and cylinder of the rear door / trunk lid - removal and installation
• Trunk lid (Cabriolet models) - removal and installation
• Components of a central locking system for doors - removal and installation
• Outside Mirror - Removing and Installing
• Windshield and not falling windows - removal and installation
• Manhole components - removal, installation and adjustment
• Sliding roof (Cabriolet models) - removal and installation
• Hydraulic sliding roof - check fluid level and bleed
• Hydraulic sliding roof components - removing and installing

Electrical system

• Specifications
• General description and precautions
• Troubleshooting electrical system - general description
• Fuses, relays and reverse current relays - general description
• Switches - removal and installation
• Lamps (external lamps) - replacement
• Lamps (interior lighting) - replacement
• External headlights and lanterns - removal and installation
• Headlights and additional lights - checking the direction of the light beam
• Dashboard - removal - refitting
• Dashboard components - removing and installing
• Cigarette lighter - removing and installing
• Speedometer drive cable - removing and installing
• Clock - removing and installing
• Fuel computer components - removing and installing
• Auxiliary warning system components - removing and installing
• Sound signal - removal and installation
• Windshield wiper blades and levers / rear door - removing and installing
• Wiper and traction motor - removing and installing
• Rear door wiper motor - removing and installing
• Washer / wiper system components - removing and installing
• Radio and graphic equalizer - removal and installation

Troubleshooting

• Engine
• Cooling system
• Clutch
• Automatic transmission
• Manual gearbox
• Drive shafts
• Brake system
• Suspension and steering
• Electrical system

Wiring diagrams