Contents

Foreword

Operating instructions

Adjustment and maintenance

• Specifications
• Introduction and routine maintenance schedule
• Engine adjustment
• Tire condition and pressure check
• Liquid level checks
• Battery check and maintenance
• Inspection, adjustment and replacement of the drive belt
• Checking the cooling system operation
• Checking and replacing hoses in the engine compartment
• Inspection and replacement of wiper blades
• Lubrication
• Exhaust system inspection
• Suspension and steering test
• Checking the brakes
• Checking the carburetor choke operation
• Checking and adjusting the frequency and proportion of the idle mixture
• Changing the engine oil and filter
• Fuel system check
• Replacing the fuel filter
• Checking and adjusting the throttle rod
• Checking the tightness of the carburetor fasteners
• Checking the thermostatic air filter
• Inspection of transmission output shaft oil seals and drive shaft covers
• Rearrangement of wheels
• Clutch pedal adjustment
• Mechanical transmission oil change
• Cooling system maintenance (draining, flushing and refilling)
• Rear wheel bearing inspection and maintenance
• Change automatic transmission fluid
• Replacing the filter element of the air filter and the filter of the crankcase ventilation system
• Replacing the oxygen sensor
• Checking and replacing the crankcase ventilation system valve
• Checking the exhaust gas recirculation (EGR) valve
• Checking the fuel vapor recovery system
• Checking and adjusting the ignition timing
• Inspection and replacement of spark plugs
• Checking and replacing spark plug wires, cap and distributor runner
• Valve adjustment and checking the cylinder head bolts for tightness
• Compression test
• Checking the additional air supply system

Engine

• Specifications
• General information
• Camshaft cover - removal and installation
• Toothed belt cover - removing and installing
• Oil pump housing oil seal - replacement
• Toothed drive belt - removal, installation and adjustment
• Camshaft sprocket - removal and installation
• Crankshaft pulley - removal and installation
• Toothed belt sprocket - removal and installation
• Camshaft - removal and installation
• Rear cover - removing and installing
• Rocker arm assembly - removal and installation
• Front casing oil seal - replacement
• Valves, springs and valve stem seals - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Cylinder head - removal and installation
• Front cowl cover - removing and installing
• Oil pump - removal and installation
• Oil pump - disassembly, inspection and assembly
• Flywheel / drive disc and rear cover oil seal - removal and installation
• Flywheel ring gear - replacement
• Oil cooler - removal and installation
• Pallet - removal and installation
• Engine mounts - replacement with the engine installed on the vehicle
• Engine - removal and installation
• Engine and transmission - separation and connection

General engine rebuild procedures

• Specifications
• General description
• Repair operations possible on an engine installed on a vehicle
• Engine repair - general description
• Engine rebuilding options
• Engine removal - methods and precautions
• Engine repair - dismantling sequence
• Cylinder head - dismantling
• Cylinder head - cleaning and inspection
• Valve - service
• Cylinder head - bulkhead
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Engine block - cleaning
• Engine block - inspection
• Camshaft - inspect
• Piston / connecting rod assembly - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Piston rings - installation
• Crankshaft - setting and checking the main bearing running clearance
• Piston / connecting rod assembly - setting and checking bearing working clearance
• Rear cover & oil seal - installation
• Engine bulkhead - assembly sequence
• Startup and break-in after bulkhead

Cooling, heating and ventilation systems

• Specifications
• General description
• Antifreeze - general description
• Thermostat - replacement
• Thermostat - check operation
• Radiator - removal, service and installation
• Fan - removal and installation
• Electric fan and related components - description, inspection and replacement of components
• Water pump - check operation
• Water pump - removal and installation
• Heater blower motor - removal and installation
• Air conditioning system - service

Fuel and exhaust systems

• Specifications
• General description
• Fuel pump - check
• Fuel pump - removal and installation
• Fuel line - installation and replacement
• Fuel tank - removal and installation
• Fuel tank - repair
• Carburetor - removal and installation
• Carburetor - repair and adjustment
• Exhaust system components - removal and installation
• Cold mode stabilization system stroke - check and adjust
• Choke cable - removal, installation and adjustment

Engine electrical system

• Specifications
• Ignition system - general description and precautions
• Battery - removal and installation
• Battery - start from external source
• Battery connection cables - check and replace
• Ignition system - check
• Distributor - removal and installation
• Slider - replacement
• Distributor - removal and bulkhead
• Ignition coil - test
• Ignition coil - removal and installation
• Charging system - general description and precautions
• Charging system - check
• Generator - removal and installation
• Generator - brush replacement
• Generator - bulkhead
• Engine starting systems - general description
• Starter - car test
• Starter - removal and installation
• Starter traction relay - removal and installation
• Starter - changing brushes
• Starter - test

Emissions control systems

• General description
• Contactless ignition system
• Air intake system
• Coastal leaning system
• Positive crankcase ventilation (PCV) system
• Intake temperature control system
• Deceleration control system
• Economy mode indication system

Mechanical transmission

• Specifications
• General description
• Transmission brackets - inspect and replace
• Gear lever assembly - removal and installation
• Transmission - removal and installation
• Transmission - bulkhead
• Output shaft assembly - inspection and bulkhead
• Input shaft assembly - inspection and bulkhead
• Differential - inspection and bulkhead
• Transmission - assembly
• Transmission oil seals - replacement

Automatic transmission

• Specifications
• General description
• Diagnostics - general information
• Vacuum diaphragm - function check and replacement
• Kickdown mechanism - operation check and adjustment
• Forced reverse shift solenoid (kickdown) - check operation
• Blocker - check and replace
• Transmission - removal and installation
• Transmission seals - replacement
• Drive mode switch rod - check and adjust
• Oil pan gasket - replace

Clutch and drive shafts

• Specifications
• Clutch - general description
• Clutch - checking operation
• Clutch pedal - removal and installation
• Clutch cable - removal and installation
• Clutch - removal, inspection and installation
• Drive shaft - general description
• Drive shaft and connecting shaft - removal and installation
• Drive shaft cover - replacement

Braking system

• Specifications
• General description
• Disc brake pads - replacement
• Disc brake caliper - removal and installation
• Disc brake caliper - bulkhead
• Brake disc - inspection, removal and installation
• Drum brake pads - replacement
• Drum brake slave cylinder - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Brake hoses and pipes - inspect and replace
• Parking brake - check operation and adjustment
• Brake pedal assembly - removal and installation
• Parking brake assembly - removal and installation
• Parking brake cables - removal and installation
• Brake booster - inspection, removal and installation
• Hydraulic system - pumping
• Brake fluid level sensor - check operation
• Double pressure regulator valve - check operation, remove and install

Suspension and steering

• Specifications
• Wheels and tires - general information
• Wheel and tire - removal and installation
• Suspension adjustment - general information
• Suspension system - general description
• Suspension system - inspect
• Anti-roll bar - removing and installing
• Front lower control arm - removal, repair and installation
• A-pillar shock absorber assembly - removal and installation
• Rear post assembly - removal, inspection and installation
• Rear suspension, side and longitudinal balancers - removal and installation
• Three-way damper control switches - check, removal and installation
• Steering system - general description
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering knuckle and hub - removal and installation
• End of connecting rod - removal and installation
• Rack and pinion cover seals - replacement
• Rack and steering gears assembly - removal and installation
• Power steering pump - removing and installing
• Bleeding the power steering system
• Suspension strut / shock absorber assembly - removal and repair
• Rear hub bearings - replacement
• Rear stub axle fastener - removal and installation

Body

• General description
• Body - service
• Upholstery and rugs - service
• Vinyl finishing - service
• Hinges and locks - service
• Body repair - minor damage
• Body repair - serious damage
• Hood - removal and installation
• Bonnet lock mechanism and release cable - removal and installation
• Rear door shock absorber - removal and installation
• Rear door - removal, installation and adjustment
• Trunk lid - removal and installation
• Rear compartment lid lock assembly - removing and installing
• Rear compartment lid strike plate - removing and installing
• Fuel filler / rear compartment opening lever - removal - refitting
• Door trim panel - removal and installation
• Trim connectors - removal and installation
• Door glass and window regulator - removal and installation
• Glass triangular interior vents (coupe models) - removal and installation
• Console - removal and installation
• Dashboard - removal and installation
• Radiator grill - removal and installation
• Radiator grille cover - removing and installing
• Hood panel - removal and installation
• Skirt front panel - removal and installation
• Bumpers - removal and installation
• Replacing fixed glasses
• External door handle - removal and installation
• Outside mirror - removal and installation
• Central locking - general description
• Doors - removal, installation, adjustment
• Seats - removal and installation
• Seat heaters - item inspection and replacement
• Luke - general description

Electrical system

• Specifications
• General description
• Electrical troubleshooting - general description
• Fuses - general description
• Fusible links - general description
• 3-Pin adjustable suspension shock actuator - check
• Combination switch - removal and installation
• Ignition lock / steering wheel lock - removal and installation
• Headlight - removal and installation
• Headlight adjustment
• Replacing a light bulb
• Radio and speakers - removal and installation
• Dashboard board - removal and installation
• Front panel instruments - removal and installation
• Dashboard switches - removal and installation
• Heater control - removal, installation and adjustment
• Windshield wiper motor and linkage assembly - removal and installation
• Rear window wiper assembly - removal and installation
• Electric radio antenna - removal and installation
• Heated rear window (electric type) - check and repair
• Audible warning system - general description
• Bulb inspection system - precautions
• Speed ??control system - general description
• Interrupter for direction indicators and alarm - removal and installation
• Fuel level and temperature indicators - check
• Castle lighting system - general description
• Reversing light board - lens replacement
• Relay - identification and replacement
• Speedometer drive cable - removal and installation
• Washer pumps - removal and installation
• Wiring diagram information

Appendix: Information about later models

• Specifications
• View
• Adjustments and routine maintenance
• Engine
• Fuel and exhaust systems
• Engine electrical systems
• Emission control systems
• Brakes
• Suspension and steering
• Corpus
• Chassis electrical system

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Suspension and steering
• Electrical system

Wiring diagrams (wiring diagrams)