Contents

Operating instructions

Maintenance

• Maintenance
• Dimensions and weight
• Lubricants and fluids
• Volumes
• Service specifications
• Vehicle identification numbers
• Weekly checks
• Routine maintenance schedule
• Gasoline models
• Diesel models
• Introduction
• Intensive service
• Replacing the coolant - general information
• Draining water from the fuel filter (diesel only)
• Checking and adjusting idle speed (diesel only)
• Checking the vacuum pump
• Checking the automatic transmission fluid level
• Checking the functioning of electrical equipment
• Checking, caring for and charging the battery
• Checking the condition and functioning of seat belts
• Checking the condition of the auxiliary drive belt
• Checking for signs of leaks and condition of hoses in the engine compartment
• Checking the condition of the wiring in the engine compartment
• Checking the functioning of the air conditioning system
• Change engine oil and oil filter
• Checking the oil level in the manual transmission
• Checking steering, suspension and wheels
• Checking the condition of CV joints and protective covers of drive shafts
• Checking the status of the exhaust system
• Checking the condition of the vehicle underbody and fuel / brake lines
• Brake system check
• Checking the condition and lubrication of doors and hood
• Checking the tightening forces of the wheel nuts
• Running trials
• Replacing the fuel filter (diesel only)
• Replacing the air filter element
• Replacing the dust filter of the ventilation system
• Replacing the coolant
• Checking the functioning of the crankcase ventilation (PCV) system and cleaning the filter
• Replacing spark plugs
• Replacing the camshaft and fuel pump drive belt (diesel only)
• Valve clearance check (diesel only)

Repair of gasoline engines in the engine compartment

• Specifications
• General description
• Repair operations in the engine compartment
• Compression check - description of execution and interpretation of results
• Installing the piston of the first cylinder in the position of the top dead center (TDC)
• Cylinder head covers - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal, inspection and installation
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed Drive Belt - removing, installing and tension adjustment
• Belt tensioner and sprockets - remove, check and install
• Camshaft oil seals - replacement
• Camshafts and hydraulic tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Oil pan - removal and installation
• Oil pump - removal, check and installation
• Oil cooler - removal and installation
• Oil level sensor - removal and installation
• Oil pressure warning lamp switch - removal and installation
• Crankshaft oil seals - replacement
• Flywheel / drive disc - removal, inspection and installation

Removal and overhaul of gasoline engines

• Specifications
• General description
• Engine overhaul - general description
• Powertrain removal methods and basic precautions
• Engine / transmission - removal and installation
• Engine disassembly procedure
• Dismantling the cylinder head
• Cylinder head components - cleaning and inspection
• Cylinder head assembly
• Connecting rod and piston assemblies - removal
• Crankshaft - removal
• Cylinder block / crankcase - cleaning and checking
• Piston and rod assemblies - check condition
• Crankshaft - check condition
• Main and connecting rod bearings - condition check
• Engine assembly procedure after overhaul
• Piston rings - installation
• Crankshaft - installing and checking main bearing clearances
• Connecting rod and piston assemblies - installing and checking clearances in connecting rod bearings
• Starting the engine after the end of the cap repair

Diesel engines

• Specifications
• General description and modifications
• Basic operations performed without removing the engine from the car
• Engine oil and oil filter - change
• Accessory drive belt - inspect, replace, and adjust tension
• Camshaft and high pressure fuel pump drive belts - inspect
• Camshaft and fuel pump drive belts - removal, installation and tension
• Valve clearances - check and adjust
• Camshaft - removal and installation
• Camshaft timing - check and adjust
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Cylinder head and pistons - carbon removal
• Water pump and thermostat - removal and installation
• Oil seals - replacement
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Engine oil cooler - removal and installation
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Engine / transmission mounts - inspection, removal and installation
• Engine / transmission - check, removal and installation
• Engine / transmission - removal
• Engine / transmission - split
• Disassembly of the engine - general description
• Engine - complete disassembly
• Inspection and restoration - general description
• Engine components - inspection and refurbishment
• Engine assembly - general description
• Engine - assembly
• Engine - transmission connection
• Engine / transmission - installation
• Engine - starting after bulkhead
• Compression check - description and execution

Cooling, heating and ventilation systems

• Specifications
• General description
• Antifreeze - general description
• Coolant hoses - removal and replacement
• Thermostat and water pump - removal and installation
• Cooling fan - serviceability check, removal and installation
• Sensors, indicator and switches of the cooling system - serviceability check, removal and installation
• Radiator and expansion tank - removal, inspection and installation
• Interior heating / ventilation system components - removal and installation
• Interior heating / air conditioning control panel - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel and exhaust systems

• Specifications
• General description and precautions
• Air filter - element replacement
• Air filter cover - removal and installation
• Fuel filter - draining fluid and replacing element
• Fuel filter assembly - removal and installation
• Fuel system - bleeding
• Fuel system - pollution
• Idle speed - check and adjust
• Idle speed boost system - check, adjust and replace
• Maximum engine speed - check and adjust
• Injection timing - check and adjust
• High pressure fuel pump - removal and installation
• Injector tubes - removal and installation
• Fuel injectors - removal, inspection and installation
• Fuel cutoff solenoid valve - removal and installation
• Gas pedal cable - removal and installation
• Shock absorber of the throttle lever on the fuel pump - removal and installation
• Turbocharger - removal and installation
• Turbocharger intercooler - removal and installation
• Fuel heater - removal and installation
• Fuel tank - removal and installation
• Collectors - removal and installation
• Exhaust system - inspection

Engine electrical equipment

• Specifications
• General information, precautions and disconnecting the battery
• Battery - removal and installation
• Battery wires - check condition and replace
• Ignition system - general information and precautions
• Ignition system - diagnostics
• Ignition coil - removal and installation
• Ignition module - removal and installation (only for models with AT)
• Ignition timing - check installation
• RPM / crankshaft position sensor - removal and installation
• Charging system - general information and precautions
• Charging system - diagnostics
• Generator - removal and installation
• Alternator brushes and voltage regulator - replacement
• Launch system - general information and precautions
• Starter - diagnostics
• Starter - removal and installation
• Preheating system - description and serviceability check
• Glow plugs, relay and fuse - removal and installation
• Glow plug warning lamp unit - replace
• Cold startup element - replace
• Starter - changing brushes

Exhaust gas neutralization system

• Specifications
• General description
• Electronic control systems - description and precautions
• Diagnostic system - general information and testing
• Information sensors - general description
• Gasoline vapor recovery system - general description and functional check
• Exhaust gas recirculation (EGR) system - general information, function check and component replacement
• Pulsating exhaust gas mixing system - general description
• Crankcase ventilation (PCV) - general description
• Catalytic converter - general description and precautions

Mechanical transmission

• Specifications
• General description
• Shift rod - adjustment
• Gearbox control lever and gear shift rods - removal and installation
• Speedometer drive gear - removal and installation
• Oil seals - replacement
• Reversing light switch - removal and installation
• Mechanical transmission - removal and installation
• Mechanical transmission mounts - inspect and replace
• Mechanical transmission overhaul - general description

Automatic transmission

• Specifications
• General description
• Troubleshooting - general description
• Selector drive cable - removal, installation and adjustment
• Selector assembly - removal and installation
• Speedometer drive gear - removal and installation
• Selector lever position sensor - removal, installation and adjustment
• Oil seals - replacement
• Removal and installation of transmission
• Transmission mounts - inspect and replace
• Bulkhead automatic transmission - general description

Clutch and drive shafts

• Specifications
• General description
• Clutch - general description and troubleshooting
• Clutch adjustment - check
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Clutch components - removal, inspection and installation
• Clutch release bearing - removal, inspection and installation
• Shaft and bushing of the clutch release lever - removal and installation
• Drive shafts - general description
• Drive shafts - removal and installation
• Protective covers for the inner CV joints of the drive shafts - replacement
• Drive shaft outer CV joint protective cover - replacement
• Drive shaft joints - check condition and replace

Braking system

• Specifications
• General description
• Front brake pads - replacement
• Front brake caliper - removal, bulkhead and installation
• Front brake disc - inspection, removal and installation
• Rear brake drum - removal, inspection and installation
• Rear brake shoes - replacement
• Rear wheel brake cylinders - removal, bulkhead and installation
• Rear disc brake pads - replacement
• Rear disc brake caliper - removal, bulkhead and installation
• Rear brake disc - inspection, removal and installation
• The main brake cylinder - removal and installation
• Brake pedal - removal and installation
• Hydraulic pipes and hoses - inspection, removal and installation
• Brake system - bleeding
• Vacuum brake booster unit - fault diagnosis, removal and installation
• Vacuum hose of the brake booster unit - removal, fault diagnosis and installation
• Pressure relief relief valve (PCR) (non-ABS models) - removal and installation
• PCR valve of models equipped with ABS - removal and installation
• Hydraulic block ABS - removal and installation
• ABS wheel sensors - fault diagnosis, removal and installation
• Anti-lock brake system (ABS) relay box - removal and installation
• Traction control (TCS) enable switch - removal and installation
• Actuator for changing the position of the throttle valve TCS - removing and installing
• Brake light switch - removal and installation
• Parking brake control lever - removal and installation
• Parking brake cables - removal and installation

Suspension and steering

• Specifications
• General description
• Steering knuckle and hub assembly - removal and installation
• Front hub and bearings - inspect and replace
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Stabilizer and its links - removal and installation
• Front suspension lower arm - removal, bulkhead and installation
• Ball joint of the lower arm of the front suspension - replacement
• Rear hub and bearings (Sedan and Hatchback Models) - inspect and replace
• Rear suspension knuckle (Sedan and Hatchback models) - removal and installation
• Rear suspension strut (Sedan and Hatchback models) - removal and installation
• Rear suspension strut (Sedan and Hatchback Models) - bulkhead
• Rear stabilizer bar and its links (Sedan and Hatchback models) - removal and installation
• Rear suspension lower arms (Sedan and Hatchback models) - removal and installation
• Rear suspension longitudinal bar (Sedan and Hatchback models) - removal and installation
• Rear suspension cross member (Sedan and Hatchback models) - removal and installation
• Rear hub and bearings (Station wagon models) - inspection and replacement
• Rear suspension fist (station wagon models) - removal and installation
• Rear shock absorber (Station wagon models) - removal, check and installation
• Rear stabilizer bar and its links (Station wagon models) - removal and installation
• Rear coil spring (Universal models) - removal and installation
• Rear lower arm of the rear suspension (Station wagon models) - removal and installation
• Front lower arm of the rear suspension (Station wagon models) - removal and installation
• Rear suspension upper arm (Station wagon models) - removal and installation
• Rear suspension longitudinal rod (Station wagon models) - removal and installation
• Rear suspension cross member (Station wagon models) - removal and installation
• Steering wheel - removal and installation
• Steering column - removal, inspection and installation
• Flexible steering column coupling - removal and installation
• Power steering (except LHD and ABS)
• Power steering gear (for models with left-hand drive and ABS) - removal and installation
• Rubber power steering covers - replace
• Power steering hydraulic system - bleeding
• Steering pump - removal and installation
• Tie rod end - replacement
• Front wheel alignment - general description

Body and trim

• Specifications
• General description
• Body and frame - service
• Interior upholstery and mats - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Bumpers - removal and installation
• Radiator grill - removal and installation
• Hood - removing, installing and adjusting position
• A cable and a lever of a drive of a lock of a bonnet - removal and installation
• Bonnet lock - removal, installation and position adjustment
• Interior door trim panels - removal and installation
• Door glass - removal and installation
• Window regulator - removal and installation
• Door handle and lock components - removal and installation
• Door - removal and installation
• Outside mirror - removal and installation
• Internal rear-view mirror - removal and installation
• Trunk lid - removal and installation
• Trunk lid lock components - removal and installation
• Tail door - removal and installation
• Tailgate stop - removal and installation
• Tailgate lock components - removal and installation
• Central door locking system components - testing, removal and installation
• Windshield and fixed glass - removal and installation
• Side moldings and adhesive emblems - removal and installation
• Glass sunroof and its adjustment - general description
• Seats - removal and installation
• Seat belts - removal and installation
• Internal trim panels - removal and installation
• Center console - removal and installation
• Top console - removal and installation
• Glove box - removal and installation
• Dashboard - removal and installation
• Wheel arch liners - removal and installation

Onboard electrical equipment

• Specifications
• General description
• Troubleshooting electrical circuits - general description
• Fuses, relays and timer unit - check and replace
• Switches - removal and installation
• Outdoor lamps - replacement
• Interior lighting and lamps - replacement
• Blocks of external lights - removal and installation
• Headlight beam direction - checking and adjusting
• Headlight adjustment motor - removing and installing
• Instrument panel - removal and installation
• Instrument cluster components - removal and installation
• Speedometer control cable - removal and installation
• Watch - removal and installation
• Klaxon - removal and installation
• Wiper arms - removal and installation
• Windshield wiper motor and drive - removal and installation
• Rear window wiper motor assembly - removal and installation
• On-board counter unit - removal and installation
• Auxiliary signaling system - general description and replacement of its components
• Anti-theft alarm system - general description
• Speed ??control system - general description
• Windshield / rear window washer system components - removal and installation
• Radio / car radio - coding, removal and installation
• Car radio amplifier - removal and installation
• CD player removal and installation
• Speakers - removal and installation
• Radio antenna - removal and installation
• Airbag unit (driver's side) - removal and installation
• Airbag control module - removal and installation
• Airbag coil spring - removal and installation

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Steering and suspension
• Electrical system

Wiring diagrams