Content

Introduction

• How to use this manual
• Repair work and replacement of components
• Features
• Abbreviations and symbols

General information

• General safety rules
• Safe working practices
• Environmental protection measures
• General recommendations when performing plumbing work
• Ball and roller bearings
• Oil seals
• Joints and butt surfaces
• Locking parts of connections
• Parts with cylindrical threads
• Bolt symbols
• Nut designation
• Flexible lines and hoses
• Dedicated tool for repair and maintenance
• Using roller road test benches
• Fuel safety measures
• Electrical precautions
• Rules for working with airbags and seat belt pretensioners
• Forcing the SRS component
• Replacing SRS system components
• Air conditioning precautions
• Urgent assistance to the victim
• Maintenance precautions
• Replacing the air conditioning compressor

Specifications

• Diesel engine Td4
• Gasoline engine K18
• Gasoline engine КV6
• Fuel system of Td4 diesel engine
• Fuel system of the K18 gasoline engine
• Fuel system of the KV6 petrol engine
• Diesel engine cooling system Td4
• Cooling system of the gasoline engine K18
• Cooling system of the KV6 gasoline engine
• Clutch
• Getrag manual transmission
• Manual transmission PG1
• Intermediate crawler gear (IRD)
• Jatco automatic transmission
• Rear axle and final drive
• Steering
• Front suspension
• Rear suspension
• Braking system
• Wheels and tires
• Tire pressure
• Heating and ventilation
• Air conditioner
• Electrical equipment of diesel engine Td4
• Electrical equipment of the K18 gasoline engine
• Electric equipment of the gasoline engine KV6
• Dimensions
• Vehicle weight

Identification numbers

• Vehicle identification number
• Locations of identification numbers

Tightening torques for threaded connections

• Maintenance
• Td4 engine
• K18 engine
• KV6 engine
• Exhaust gas toxicity control
• Diesel engine management system
• Modular engine management system
• Siemens engine management system
• Fuel supply system diesel engine
• Gasoline engine power supply system
• Cooling system engine Td4
• Cooling system of the K18 engine
• Cooling system engine KV6
• Intake and exhaust manifolds and exhaust system Td4 engine
• Intake and exhaust manifolds and exhaust system K18 engine
• Intake and exhaust manifolds and exhaust system KV6 engine
• Clutch
• Manual transmission PG
• Getrag manual transmission
• Intermediate crawler gear
• Jatco automatic transmission
• Drive shafts
• Rear axle and final drive
• Steering
• Front suspension and subframe
• Rear suspension and subframe
• Braking system
• Airbag system
• Body
• Heating and ventilation
• Air conditioner
• Windscreen wiper and washers
• Electrical equipment

Towing and lifting a car on a lift

• Lifting the car on a jack
• Car towing
• Starting the engine with a discharged battery

Refueling containers, liquids and oils

• Refueling tanks
• Working fluids
• Lubrication system
• Sealants

Maintenance

• Td4 - diesel engine - top view with the hood removed
• K18 - gasoline engine - top view with the hood removed
• KV6 - petrol engine - top view with the hood removed
• Seats and seat belts
• Headlights, horn and warning lights
• Windscreen wipers and washers
• Parking brake
• Anti-theft alarm control panel battery
• Wheels
• Tires
• Brake pads and calipers
• Brake fluid
• Vehicle wheel speed sensors
• Fuel filter petrol engine
• Fuel filter car with diesel engine
• High pressure fuel pump and fuel filter assembly diesel engine (hereinafter 2003 car model)
• Diesel sludge diesel engine hereinafter car model year 2003
• Door locks, hinges, check of stops and bonnet latches
• Coolant for cooling system
• Cooling system and charge air intercooler
• Vent filter turbocharger boost pressure control solenoid valve Td4
• Spark plugs K18
• Spark plugs KV6
• Air cleaner for cars with gasoline engines
• Td4 ancillary drive belt
• K18 ancillary drive belt
• KV6 ancillary drive belt
• Timing belt K18
• Timing belt KV6
• Brake / clutch fluid reservoir
• Power steering fluid level (PAS)
• Intermediate final drive (IRD) for vehicles not supplied to the US and Canada
• Intermediate final drive (IRD) for vehicles supplied to the USA and Canada
• Manual transmission PG
• Manual transmission GETRAG
• Automatic transmission - JATCO
• Rear axle
• Clutch tubes and connections
• Capacity for windscreen and rear door washer fluid
• Battery
• Engine oil and oil filter - Td4
• Engine oil and oil filter - K18
• Engine oil and oil filter - KV6
• Fuel pipes and hoses
• Brake pipes and hoses
• Checking the exhaust system
• Car suspension
• Steering
• Road test
• More information

Td4 engine

• Adjustments
• Checking the protrusion of the pistons with the cylinder head removed
• Valve timing check and adjustment
• Checking oil pressure
• Intake and exhaust camshafts Intake and exhaust camshafts
• Crankshaft pulley
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Cylinder head gasket: manual transmission models
• Cylinder head gasket: automatic transmission models
• Hydraulic lifters, motor kit
• Valve cover gasket
• Soundproof engine cover, models manufactured before May 2002
• Engine and manual transmission
• Engine and automatic transmission
• Left engine mount
• Engine hydraulic support, right
• Engine mounting cross member, upper right
• Lower engine mounting cross member
• Flywheel
• Torque converter drive disc
• Oil filter head gasket
• Oil filter
• Oil collection tube with strainer
• Oil pump
• Pallet bottom gasket
• Pallet top gasket
• Contact oil pressure switch
• Engine oil cooling heat exchanger gasket
• Camshaft gear cover gasket
• Piston group Piston group
• Replacing the connecting rod bearings
• Crankshaft and main bearings
• Cylinder head

Engine modification K, volume 1.8

• Adjustments
• Checking oil pressure
• Exhaust camshaft front oil seal
• Exhaust camshaft front oil seal
• Exhaust camshaft rear oil seal
• Intake camshaft rear oil seal
• Integral camshaft cover: sealing and replacing oil seals
• Replacing the connecting rod bearings
• Crankshaft pulley
• Front crankshaft oil seal
• Crankshaft rear oil seal
• Cylinder head gasket
• Valve cover gasket
• Valve seals
• Engine and gearbox
• Bracket for the right engine support assembly
• Engine hydraulic support, right
• Flywheel
• Oil pump
• Oil pan sealing
• Contact oil pressure switch
• Pressure reducing valve for lubrication system
• Oil temperature sensor
• Timing Belt
• Top timing cover
• Rear timing belt cover
• Lower part of the front timing belt cover: vehicles without air conditioning
• Lower part of the front timing belt cover: vehicles with air conditioning
• Piston group
• Front crankshaft oil seal
• Crankshaft pulley
• Replacing the crankshaft rear oil seal
• Crankshaft and main bearings
• Cylinder head gasket
• Cylinder head overhaul
• Valve cover gasket
• Overhaul of the oil pump
• Pallet
• Timing Belt

KV6 engine, modification K

• Adjustments
• Checking oil pressure
• Camshafts, left cylinder head
• Right cylinder head camshafts
• Front intake camshaft oil seal
• Replacing the rear camshaft oil seal
• Crankshaft pulley
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Left cylinder head gasket
• Right cylinder head gasket
• Left cylinder head valve cover gasket: up to May 2003
• Left Cylinder Head Valve Cover Gasket: After May 2003
• Valve cover gasket, right cylinder head
• Soundproof engine cover
• Engine and automatic transmission: up to May 2003
• Engine and automatic transmission: after May 2003
• Right engine mount bracket assembly
• Left engine mount
• Engine hydraulic support, right
• Engine mounting cross member, upper right
• Lower engine mounting cross member
• Torque converter drive disc
• Oil filter
• Oil receiver strainer
• Oil pump gasket
• Pallet sealing
• Contact oil pressure switch
• Oil pump pressure reducing valve
• Engine oil cooling heat exchanger
• Timing belt
• Right front timing belt cover
• Left front timing belt cover
• Left rear timing belt cover
• Right rear timing belt cover
• Left rear timing belt
• Right rear timing belt
• Piston group
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Crankshaft
• Left cylinder head gasket
• Right cylinder head gasket
• Cylinder head overhaul and carbon removal
• Bulkhead oil pump
• Lower oil pan cover
• Timing belt

Toxicity reduction system

• Adjustments
• Fuel tank leakage detection system (EVAPS): leak detection for North American markets
• Positive crankcase ventilation valve: Td4 engine
• Positive crankcase ventilation valve: Td4 engine
• Evaporative emission canister purge solenoid valve: KV6 engine
• Coal adsorber of gasoline vapors: except for the countries of the North American market
• Coal adsorber: North American market countries
• Canister valve: K18 engine
• Exhaust gas recirculation valve: Td4 engine
• Recirculation modulator (vacuum valve): Td4 engine
• Recirculation thermostatic valve: Td4 engine, automatic transmission (hot countries), from May 2003
• Exhaust gas recirculation heat exchanger: Td4 engine
• Fuel tank tightness control unit (DMTL unit)
• Fuel tank leakage pump filter: KV6 engine North American
• Catalytic converter RH: KV6 engine, North American market

Control system engine influences: EDC

• Renovation work
• Engine control unit (ECM)
• Sensors: coolant temperature (ECT) sensor
• Sensors: crankshaft position sensor (CK18P)
• Sensors: camshaft position (CMP) sensor
• Sensors: combined mass air flow (MAF) and intake air temperature (IAT) sensor
• Throttle position sensor: Before May 2003
• Throttle position sensor: After May 2003

Engine management system: MEMS

• Renovation work
• Spark plugs
• Ignition coil
• Engine control module (ECM): ignition and fuel strategy implementation unit
• Idle air control (IAC)
• Sensors: coolant temperature (ECT) sensor
• Sensors: crankshaft position sensor (CK18P)
• Throttle position sensor
• Sensors: camshaft position (CMP) sensor
• Contact pedal position sensor
• Manifold absolute pressure (MAP) sensor

Engine management system: SIEMENS

• Renovation work
• Spark plugs: before May 2003
• Spark plugs: from May 2003
• Ignition coil (separate) for left cylinder head: up to May 2003
• Ignition coil (separate) left cylinder head: after May 2003
• Ignition coil (separate) right cylinder head: up to May 2003
• Ignition coil (separate) right cylinder head: after May 2003
• Engine control unit (ECM): except for the North American market
• Engine control module (ECM): North American Markets
• Idle air control (IACV)
• Intake air temperature (IAT) sensor: North American markets
• Sensors: coolant temperature (ECT) sensor
• Sensors: crankshaft position sensor (CK18P)
• Throttle position sensor
• Thermostat sensor, KV6 Engine: North American markets
• Sensors: camshaft position (CMP) sensor
• Knock sensor (K18S)
• Throttle pedal position sensor: except for the North American Market
• Integrated intake manifold pressure and intake air temperature (MAP / IAT) sensor
• Throttle position sensor, N American market: Before May 2003
• Throttle position sensor Non-N American markets: After May 2003

Diesel fuel supply system

• Adjustments
• Checking the pressure in the fuel system
• Draining fuel from the tank
• Renovation work
• Air cleaner filter element
• Fuel system bimetal valve: up to May 2003
• Fuel system bimetal valve: after May 2003
• Inertial fuel cut-off switch
• Low fuel pressure sensor: from May 2003
• Fuel pressure sensor
• Fuel priming pump relay: before May 2003
• Fuel priming pump relay: after May 2003
• Fuel line filter / sump: after May 2003
• Fine fuel filter: until May 2003
• Fine fuel filter: after May 2003
• Fuel cooling radiator: until May 2003
• Fuel cooling radiator: after May 2003
• High pressure fuel pump
• Turbocharger
• Radiator for intercooler air
• Solenoid (electrovacuum) boost pressure control valve
• Boost pressure sensor
• Elektrovacuum boost control valve atmospheric hose filter: Td4 engine
• Intake air ducts
• Fuel priming pump complete with filter: after May 2003
• Submersible fuel priming module: until May 2003
• Fuel pressure regulator
• Fuel priming pump: after May 2003
• Fuel priming pump: before May 2003
• Fuel tank
• Filling pipe
• Injector
• High pressure pipe
• Glow plug
• Glow plug electronics: up to May 2003
• Glow plug relay: after May 2003
• Nozzle cover: after May 2003
• Cruise control switch: until May 2003
• Mode resume switch (mode activation / deactivation): from May 2003
• Multifunction switch

Fuel supply system of a gasoline engine

• Adjustments
• Throttle cable check and adjust: KV6 engine
• Throttle control cable check and adjustment: K18 engine
• Depressurizing the fuel supply system, KV6 engine: Except for the North American market
• Fuel pressure relief, kv6 engine: North American markets
• Pressure relief in the fuel supply system: K18
• Fuel pressure measurement, KV6 engine: except for the North American market
• Fuel Pressure Measurement, KV6 Engine: North American market
• Pressure measurement in the fuel supply system: K18 engine
• Draining fuel from the tank
• Air purification filter, engine K18
• Air filter element, engine K18
• Air filter element, engine KV6
• Air Filter Element, KV6 engine: North American market
• Throttle cable, KV6 engine
• Inertial fuel cut-off switch
• Front left oxygen sensor, KV6 engine: except for the North American market
• Front Left Oxygen Sensor, KV6 Engine: North American market
• Front oxygen sensor, engine K18
• Front right oxygen sensor, KV6 engine: except for the North American market
• Front right oxygen sensor, KV6 Engine: North American market
• Mass air flow (MAF) sensor: North American Market
• Fuel pump relay
• Throttle body, K18 engine
• Throttle body, KV6 engine: except for the North American market
• Throttle Body, KV6 Engine: North American market
• Intake system flap motor: KV6
• Rear left oxygen sensor, KV6 engine: except countries rear left oxygen sensor, KV6 engine: North American market countries
• Rear oxygen sensor, engine K18
• Rear right oxygen sensor, KV6 Engine: North American market
• Main fuel filter
• Electric fuel pump
• Fuel tank: except for North American market
• Fuel Tank: North American Market Countries
• Filling pipe
• Fuel rail, KV6 engine: except for the North American market
• Fuel Rail, KV6 engine: North American market
• Injector, engine KV6
• Injectors (set), engine К18
• Cruise control actuator, KV6 engine: except for the North American market
• Vacuum pump for cruise control, KV6 engine: except for the North American market
• Cruise control switch, engine KV6: up to May 2003
• Mode resume switch (mode activation / deactivation): from May 2003
• Multifunction switch
• Cruise controller, engine KV6
• Cruise controller interface KV6 engine

Cooling system: Td4 engine

• Adjustments
• Draining the coolant, flushing the system and filling
• Cooling fan and fan motor: before May 2003 Cooling fan and fan motor: Before May 2003
• Cooling fan and fan motor: after May 2003
• Cooling fan controller: vehicles before May 2003
• Cooling fan controller: vehicles built after May 2003
• Radiator assembly
• Coolant pump and thermostat

Cooling system: modification K, volume 1.8

• Adjustments
• Draining the coolant, flushing the system and filling
• Filling the cooling system
• Expansion tank
• Cooling fan and fan motor: Non-A / C models
• Cooling fan and fan motor: air conditioned models
• Cooling fan controller
• Radiator assembly
• Thermostat

Cooling system: mod K, engine KV6

• Adjustments
• Draining the coolant, flushing the system and filling
• Renovation work
• Cooling fan and motor
• Cooling fan controller: vehicles from May 2003
• Radiator assembly
• Thermostat
• Coolant pump

Manifolds and exhaust system Td4

• Renovation work
• Downpipe
• Middle section of the exhaust system
• Rear exhaust section
• Intake manifold gaskets
• Exhaust manifold gaskets: vehicles with manual transmission
• Exhaust manifold gaskets: vehicles with automatic transmission

Manifolds and exhaust system: MOD K, volume 1.8

• Renovation work
• Downpipe
• Middle section of the exhaust system
• Rear exhaust section
• Replacing the left intake manifold gasket (s)
• Exhaust manifold heat shield: vehicles without air conditioning
• Exhaust manifold heat shield: vehicles with air conditioning
• Exhaust manifold gasket (s)

Manifolds and exhaust system: mod K, engine V6

• Renovation work
• Downpipe: except for the North American market
• Downpipe: North American countries
• Middle section of the exhaust system: except for the countries of the North American market
• Middle section of the exhaust system: countries of the North American market
• Rear section of exhaust system with silencer
• A / C Compressor heat shield: KV6 N American market
• Intake manifold gaskets, left side
• Right exhaust manifold gasket: except for North American market
• Right exhaust manifold gasket (s), KV6, North American market
• Left exhaust manifold gasket: except for North American market
• Left exhaust manifold gasket (s): North American Market
• Inlet receiver seals: vehicles built before May 2003
• Inlet receiver seals: vehicles built after May 2003
• Intake manifold gaskets, right side
• Inlet compressor seals: vehicles manufactured prior to May 2003 intake receiver seals: vehicles manufactured prior to May 2003
• Inlet receiver seals: vehicles built after May 2003

Clutch

• Renovation work
• Clutch assembly / driven plate and clutch release bearing (release) Td4
• Clutch assembly / driven plate and clutch release bearing (release) K18
• Hydraulic clutch: K18 right-hand drive vehicles
• Master cylinder: left hand drive Td4
• Master cylinder: Td4 right hand drive vehicles

Manual transmission PG

• Adjustments
• Changing the transmission oil in the box
• Gearbox Gearbox
• Gear selector shaft oil seal
• Reversing light switch
• Contact sensor for engaging the first gear

Mechanical transmission GETRAG

• Adjustments
• Changing the transmission oil in the box
• Back cover
• Gear selector: top link and ball joints
• Gearbox
• Input shaft oil seal
• Gear selector shaft oil seal
• Reversing light switch
• Contact sensor for engaging the first gear

Transfer case

• Adjustments
• Changing transmission oil in the transfer case: except for the North American market
• Changing Transmission Oil in the Transfer Case: North American market
• Renovation work
• Transfer case: models with Td4 engine
• Transfer case: models with K18 engine
• Transfer case: models with KV6 engine
• Transfer case rear cover gasket: Td4 models
• Rear cover gasket, transfer case: models with KV6 engine
• Transfer case rear cover gasket: models with K18 engine
• Transfer case drive shaft oil seal
• Left drive shaft oil seal: Td4 and KV6 models
• Left drive shaft oil seal: vehicles with K18 engine
• Right drive shaft oil seal
• Rear axle drive shaft oil seal: vehicles with Td4 engine
• Rear axle drive shaft oil seal: vehicles with K18 engine
• Rear axle drive shaft oil seal: vehicles with KV6 engine, excluding North American market
• Rear axle drive shaft oil seal: vehicles with KV6 engine, for countries of the North American market

Automatic transmission: JATCO

• Adjustments
• Adjusting the engine blocking switch
• Replacing the working fluid in the box
• Adjusting the selector cable
• Renovation work
• Selector body
• Selector knob
• Selector cable
• Selector lever position indicator: vehicles manufactured before May 2003
• Selector lever position indicator: vehicles built after May 2003
• Engine blocking switch
• Control unit (ECU)
• Torque converter oil seal
• Gearbox with KV6 engine
• (engine with gearbox removed)
• Gearbox: vehicles with KV6 engine
• Transmission: vehicle with Td4 engine
• Sealing the bottom of the gearbox
• A blown heat exchanger for working fluid cooling: vehicles with a Td4 engine (for hot climates)
• Heat exchanger for working fluid cooling: vehicles with Td4 engine
• Heat exchanger for working fluid cooling: vehicles with KV6 engine
• Heat exchanger hoses for working fluid cooling

Drive shafts

• Renovation work
• Left shaft with external and internal joints
• Right shaft with external and internal joints
• Protective cover outer front hinge of constant angular velocities
• Protective cover hinge of constant angular velocities outer left front
• Protective cover internal constant velocity hinge
• Rear shaft with external and internal joints
• Protective cover for outer rear hinge
• Outer rear constant velocity joint
• Protective cover inner constant velocity hinge rear
• Propeller shaft assembly
• Front propeller shaft
• Rear propeller shaft
• Bulkhead front and rear propeller shafts
• Cover of the sliding fork of the universal joint of the front propeller shaft
• Viscous clutch assembly
• Front intermediate support

Rear axle and final drive

• Renovation work
• Differential assembly
• Differential rear cover
• Differential housing front support bush
• Differential housing rear support bush
• Main drive shaft oil seal
• Rear drive shaft oil seal

Steering

• Adjustments
• Bleeding the power steering system
• Adjusting the ignition lock cable
• Checking and adjusting the alignment of the front wheels
• Checking and adjusting rear wheel alignment
• Checking the pressure in the power steering system
• Renovation work
• Steering gear
• Steering gear cover
• Power steering fluid cooler (for models with Td4 or K18 engine)
• Power steering fluid cooler (for models with KV6 engine)
• Drive belt (for models with K18 engine)
• Power steering pump (KV6 models)
• Power steering pump (models with K18 engine)
• Power steering pump (Td4 models)
• Steering column shroud
• Steering wheel lock and ignition switch
• Ignition lock cable
• Steering column assembly, inner and outer parts
• Tie rod end ball joint
• Steering rod
• Steering wheel

Front suspension

• Renovation work
• Anti-roll bar
• Stabilizer struts, transverse mustache sustainability
• Anti-roll bar rubber cushions
• Hub bearing
• Shock absorber
• Lower arm assembly
• Front subframe
• Front lower arm bushings
• Rear bushings of the lower arms

Rear suspension

• Renovation work
• Trailing arm bushing
• Hub bearing
• Shock absorber
• Trailing arm
• Trailing arm bushing
• Adjustable wishbone
• Non-adjustable wishbone
• Control arm bushing
• Stretcher

Braking system

• Adjustments
• Bleeding the brake system
• Checking and adjusting the parking brake cable
• Renovation work
• Rear brake drum
• Front brake disc
• Left front brake hose
• Rear brake hose
• Dual master cylinder for left-hand drive vehicles
• Double master cylinder for right-hand drive vehicles
• Parking brake lever assembly
• Parking brake cable
• Parking brake warning switch
• Brake light switch
• Accelerator pedal position sensor
• Front brake pads
• Rear brake pads
• Vacuum booster assembly for left-hand drive vehicles
• Vacuum booster assembly for right-hand drive vehicles
• Vacuum pump for vehicles with Td4 engine and manual gearbox
• Vacuum pump for vehicles with Td4 engine and automatic transmission
• Vacuum booster for vehicles with KV6 engine
• Front brake pad guide
• Rear brake wheel cylinder
• Brake fluid level sensor
• Front right wheel speed sensor and electrical cable
• Front left wheel speed sensor and its electrical cable
• Rear wheel speed sensor and its electrical cable
• ABS pressure regulator
• Downhill assist switch for model year 2004 and up
• Downhill assist switch for vehicles up to model year 2004

Passive safety systems

• Renovation work
• Front inertia seat belt
• door car
• 5-door front inertia seat belt
• Rear seat center seat belt
• Seat belt left seat in the back seat
• Height-adjustable intermediate seat belt loop located on the B-pillar
• Rear seat belt buckle, left
• door car
• Left seat belt buckle in the back seat of a 5-door car
• Front seat belt pretensioner
• Deploying the removed front seat belt pretensioner
• Rear seat center belt buckle
• Driver airbag
• Front passenger airbag for cars up to model year 2004
• Front passenger airbag for model year 2004 and later
• On-board diagnostic unit (DCU)
• The front passenger airbag removed from the vehicle is deployed
• Airbag rotary contactor
• Driver's airbag removed from the vehicle
• Driver's airbag deployment without removing it from the vehicle
• Deploying the front seat belt pretensioner without removing it from the vehicle

Doors

• Adjustments
• Adjusting the front or rear door lock striker
• Front door hinge adjustment
• Dismantling the front door assembly to provide access to other elements, installing the front door
• Dismantling the rear door assembly to provide access to other elements, installing the rear door
• Dismantling the complete tailgate to provide access to other elements, installing the door luggage compartment
• Front door glass
• Rear door glass
• Front door rubber / felt window seal
• Tailgate rubber / felt window seal
• Tailgate glass
• Small rear rear door window
• Tailgate window regulator
• Inner lower tailgate window seal
• Front door trim panel
• door car
• 5-door front door trim panel for vehicles up to model year 2004
• 5-door front door trim panel for model year 2004 and up
• Tailgate decorative panel for vehicles up to model year 2004
• Tailgate decorative panel for model year 2004 and up
• Tailgate trim panel
• Lower plastic trim for the front door of a 5-door car
• 5-door front door pocket
• Upper plastic trim for front door of 5-door car
• Plastic trim for tailgate
• Plastic trim for the front door of a 5-door car
• Rear door plastic trim
• 5-door front door lock
• 5-door front door lock
• Rear door lock
• Tailgate lock
• Front door lock release handle
• Rear door lock release handle
• Cable for the handle of unlocking the door lock of a 5-door car
• Side cover for rear window of 5-door car
• Tailgate outside handle
• Exterior tailgate handle
• Front door outside handle
• 5-door interior door handle for cars up to model year 2004

External parts

• Renovation work
• Front wing
• Front wheel arch liner
• Rear fender liner
• Lower engine shield
• Power outside mirror
• Adjustments
• Front mudguard
• Rear mudguard
• Spare wheel mounting bracket
• Side rail for the roof rack of a 5-door car
• Hood
• Bonnet release cable / pull rod
• Front bumper assembly for vehicles up to model year 2004
• Front bumper assembly for model year 2004 and Up
• Rear bumper assembly for vehicles up to model year 2004
• Rear bumper assembly for model year 2004 and up
• Sill trim
• 5 door car roof moldings
• Rear part of the rear wheel arch extender
• Small rear glass assembly
• door car

Interior trim parts

• Renovation work
• Sun visor
• Luggage compartment lower decorative panel for a 3-door car
• Luggage compartment lower trim panel 5-door
• Upper decorative panel for luggage compartment of a 3-door car
• 5-door luggage compartment upper decorative panel
• Replacing the A-pillar upper decoration panel
• Replacing the 'B / C' pillar top trim
• B-pillar lower trim panel for 5-door car
• Rear side decorative panel of a 3-door car
• Center console for vehicles up to model year 2004
• Front console assembly for model year 2004 and up
• Rear console
• Cup holder located in the control panel for model year 2004 and up
• Control panel for vehicles up to model year 2004
• Control panel for model year 2004 and up
• Control panel cup holder for vehicles up to model year 2004
• Detaching the control panel
• Luggage compartment flooring
• Glove box
• Ceiling panel of a 3-door car
• 5-door roof panel

Glass

• Renovation work
• Windshield
• Rear side glass

Seats

• Renovation work
• Front seat
• Rear seat left
• Rear seat right
• Cushion and backrest of the rear continuous seat of a 3-door car
• Front seat cushion padding
• Right rear seat cushion upholstery
• Left rear seat cushion padding
• Upholstery of a cushion of a rear non-cut seat of a 3-door car
• Front seat base linings
• Front seat cushion side pad
• Manual lumbar cushion, front seat
• Rear right seat backrest lock
• Left rear seat backrest lock
• Backrest upholstery, front
• Backrest upholstery, rear left
• Backrest upholstery, rear right
• Backrest upholstery of the rear solid seat of a 3-door car

Roof ventilation hatch

• Renovation work
• Ventilation hatch in the roof of a 3-door car
• Sunroof deflector for 3-door car
• Sunroof seal
• Ventilation hatch in the roof of a 5-door car
• Glass panel of the ventilation hatch in the roof of a 5-door car
• Seal for the glass cover of the ventilation hatch in the roof of a 5-door car
• Motor gearbox of the electric drive of the ventilation hatch in the roof of a 5-door car
• Cables and drive of the ventilation hatch of a 5-door car
• Front drain pipes of the ventilation hatch in the roof of a 5-door car
• 5-door rear roof drain pipes
• Internal decorative strip
• Deflector sunroof 5-door car
• Ventilation sunroof for 5-door car
• Roof vent control button
• Sealing gutter ventilation hatch in the roof of a 5-door car

Roof

• Renovation work
• Removable rigid roof for access to the repair site and refitting
• Frame and tarpaulin assembly removal for access to the place of repair and installation in place
• Awning
• Hardtop side glass
• Rigid roof seal
• Front latch and hardtop striker
• Rear Hard Top Latch & Striker
• Body geometry
• Control sizing information
• Body control charts
• Joint clearances and body profiles
• Dimensions of gaps and profiles
• Body parts repair
• Body repair
• General information
• Replaceable body parts
• Replaceable body parts
• Internal elements of the front part of the body
• Body side panels 3-door version
• Body side panels 5-door version
• Front inner panels of the sidewall of the 3-door version
• Front inner panels of the side of a body 5-door version
• Rear inner panels of a sidewall of a body 3-door version
• Rear inner panels of a sidewall of a body 5-door version
• Roof assembly 3-door version
• Roof assembly 5-door version
• Rear body parts
• Complete doors

Welding operations

• Location of electronic control units (the diagram shows a 3-door version, the location for a 5-door version is the same)
• General safety rules for welding
• Panel replacement procedure
• Front panel assembly
• Bonnet lock panel
• Headlight mounting bracket
• Front cross member, lower
• Front side member assembly
• Front spar (front)
• Engine compartment sidewall assembly
• Upper sidewall of the engine compartment
• Front panel of the sidewall of the engine compartment
• Reinforcement of the outer wheel arch panel
• Pillar "A" of the body, 3-door version
• Pillar "A" of the body 5-door version
• Threshold reinforcement 3-door version
• Sill reinforcement 5-door version
• B / S center pillar reinforcement panel 3-door version
• B / S center pillar reinforcement panel 5-door version
• Rear side panel assembly 3-door version
• Rear side panel assembly 5-door version
• Rear wheel arch outer panel 3-door version
• Outer panel of the rear wheel arch 5-door version
• Inner panel of "E" pillar
• door version
• E-pillar panel 5-door version
• Rear floor cross member assembly
• Rear underbody
• Rear underbody member
• Front roof section complete 3-door version
• Rear roof section complete 5-door version
• Roof assembly 5-door version
• Estimated time of repair operations
• Time norms
• Body Sealing Materials
• Materials and their applications
• Approved Content
• Application equipment

Corrosion protection and sealing

• Corrosion protection
• Coating hollow spaces with protective wax and spray holes 3-door body version
• Legend for the figure "Coating hollow cavities with protective wax and spray holes 5-door version of the body"
• Openings to protect the internal cavity of the sill 5-door version of the body
• Covering the hollow spaces of the doors with protective wax and spray holes 5-door version of the body
• Corrosion protection
• Sealant application process
• Places of the underbody treated with sealing materials
• Underbody sealing materials
• Internal sealing
• Foam acoustic insulation
• Foam acoustic insulation
• Water ingress into the body

Painting

• Working with body panels
• Panel preparation
• Painting operations
• Preparation for painting

Heating and ventilation

• Renovation work
• Heater control panel for vehicles up to model year 2004
• Heater Control Panel for Model Year 2004 and Up
• Cabin air recirculation gear motor
• Interior air recirculation switch
• Fan speed controller
• Control panel left vent
• Air intake box
• Heater
• PTC electric heater heating element for Td4 models
• PTC electric heater cable for Td4 models
• PTC electric heater microswitch for Td4 models
• Heater fan assembly
• Fan motor resistor unit
• Heater radiator
• PTC electric heater power relay for Td4 models
• PTC electric heater control relay for Td4 models
• Oil heater (FBH)
• Outside air temperature sensor (OT)
• Oil heater fuel pump for models before model year 2004
• Oil heater fuel pump for models 2004 and up

Air conditioning system

• Emptying the air conditioner, recovering refrigerant and charging
• Emptying the air conditioner, recovering refrigerant and charging
• A / C compressor drive belt for models with Td4 engine
• Air conditioning compressor for Td4 engine models
• Air conditioning compressor for models with KV6 engine
• Air conditioning compressor for models with K18 engine
• Capacitor
• Receiver moisture separator
• Air conditioner switch
• Refrigerant pressure sensor
• Thermostatic expansion valve (TXV)
• Evaporator

Screen wipers and washers

• Renovation work
• Washer reservoir
• One washer nozzle
• Washer pump
• One wiper arm
• One cleaning brush
• Cleaner motor and linkage
• Washer / wiper switch
• Washer pump
• Cleaner lever
• Cleaning brush
• Electric motor cleaner
• Combined wiper / washer switch
• Relay glass cleaner, cargo compartment door 5-door models

Engine starting and battery charging system

• Attachment drive belt K18 engine
• Attachment drive belt K18 engine with air conditioning
• Renovation work
• Generator engine Td4
• Generator KV6
• Generator K18
• Ancillary drive belt Td4 engine
• Attachment drive belt K18 engine without air conditioning
• Attachment drive belt K18 engine with air conditioning
• Attachment belt KV6 engine
• Tensioner attachment belt Td4 engine
• Battery
• Battery support tray
• Relay main relay
• Starter engine Td4
• Starter motor KV6
• Starter engine K18
• Starter relay

Lighting

• Adjustments
• Headlamps, pair of headlights for cars up to model year 2004
• Headlights headlights pair light adjustment cars from model year 2004
• Headlight assembly up to model year 2004
• Headlight assembly from model year 2004
• Turn signal repeater
• Combination rear lamp
• License plate light
• Combined fog light / dimensions from model year 2004
• Combined rear lamp
• Central upper brake light (CHMSL)
• Glove box lamp
• Lantern cargo compartment
• Headlight dimmer switch
• Glove box switch
• Alarm switch
• Combined switch, direction indicators / headlights / sound signal
• Rear fog lamp switch

Control modules

• Renovation work
• Window regulator control module
• Relay folding mirrors model 02MY
• Central control unit (CCU)
• Control module for folding mirrors up to 02MY

Security system

• Renovation work
• Electromagnet / electric motor, cargo compartment door
• Non-latching switch beep
• Sound signal
• Immobilizer electronic control unit (ECU)
• Volume control sensor alarm system 3-door models
• Module (ECU) volume control alarm system 5 and door models models without hatch
• Module (ECU) volume control alarm system 5 and door models models with sunroof
• Alarm system receiver
• Coil passive immobilizer alarm system
• Windows
• Renovation work
• Electric motor & window regulator mechanism front door 3-door model
• Electric motor & window regulator mechanism front door 5-door model
• Window regulator switch 5 and door models 02MY models
• Load compartment door glass control relay
• Microswitch determination of hardtop installation 3-door models
• Heated windshield relay
• Load compartment door glass heater switch

Entertainment systems

• Renovation work
• Radio receiver up to 02MY
• Radio / CD player 02MY model
• Rear speaker 3-door models
• Rear speaker 5-door models
• Front speaker
• Aerial mechanical 3-door models
• Aerial mechanical 5-door models
• Coaxial wire front antenna 3-door models
• Coaxial wire front antenna 5 and door models
• High frequency front loudspeaker
• Loudspeaker high-frequency rear 3-door models
• Amplifier power amplifier
• Subwoofer
• Coaxial wire extension

Cable harnesses

• Renovation work
• Passenger compartment fuse box
• Main wiring harness
• Cable harness, load compartment door
• Cable harness interior lighting 5 door models
• Cable harness front door 5t door models
• Rear door cable harness

Governing bodies

• Renovation work
• Audio system remote control switch
• Park assist switch (PDC) 04MY models
• Electronic control unit (ECU) parking assist model 04MY
• Rear parking aid sensor from 04MY
• Acoustic warning system parking aid rear model from 04MY
• Parking brake warning switch
• Alarm switch for 04MY model
• Front cigarette lighter
• Outside rearview mirror control switch

Navigation system

• Renovation work
• Remote control interface module
• Display navigation system

Devices

• Renovation work
• Clock
• Control panel up to 04MY
• 04MY model toolbar
• Cover for instrument panel up to 04MY
• Dashboard cover for model 04MY
• Fuel level gauge
• Meter fuel tank model with Td4 engine model from 03MY