Contents

Operating instructions

Maintenance

• Dimensions and weight
• Vehicle identification numbers
• Weekly checks
• Lubricants and fluids
• Part A: Maintenance - gasoline models
• Service specifications - gasoline models
• Service plan - gasoline models
• Part B: Maintenance - diesel models
• Service specifications
• Service plan - diesel models

4 cyl. gasoline engines - repair operations in the car

• Specifications
• General description
• Compression check - description
• Engine block and valve stroke labels - general description and use
• Camshaft cover - removal and installation
• Crankshaft pulley / vibration damper and hub - removal and installation
• Drive chain cover - removal and installation
• Drive chain - inspect and replace
• Drive chain tensioner, sprockets and guides - removal, inspection and installation
• Auxiliary shaft - removal, inspection and installation
• Valve train, tappets and camshaft - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Flywheel / drive disc - removal, inspection and installation
• Crankshaft oil seals - replacement
• Crankshaft bushing bearing - replacement

6 cyl. SOHC petrol engines - in-car repair operations

• Specifications
• General description
• Compression check - description
• Engine block and valve stroke labels - general description and use
• Camshaft cover - removal and installation
• Crankshaft pulley / vibration damper and hub - removal and installation
• Drive chain covers - removal and installation
• Drive chain - inspect and replace
• Drive chain tensioner, sprockets and guides - removal, inspection and installation
• Valve train, valve lifters and camshaft - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump and drive chain - removal, inspection and installation
• Flywheel / drive disc - removal, inspection and installation
• Oil seals - replacement

6 cyl. DDHC gasoline engines - in-car repair operations

• Specifications
• General description
• Compression check - description
• Engine block and valve stroke labels - general description and use
• Camshaft cover - removal and installation
• Crankshaft pulley / vibration damper and hub - removal and installation
• Drive chain covers - removal and installation
• Drive chain - inspect and replace
• Drive chain tensioner, sprockets and guides - removal, inspection and installation
• Intake camshaft adjustment parts - removing and installing
• Camshafts and valve lifters - removal, inspection and installation
• Camshaft home position - check and adjust
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump and drive chain - removal, inspection and installation
• Flywheel drive disc - removal, inspection and installation
• Specifications

Diesel engine - repair operations in the car

• General description
• Compression test and pressure hold - description
• Engine and tags - general description and usage
• Camshaft cover - removal and installation
• Crankshaft pulley / vibration damper and hub - removal and installation
• Drive chain cover - removal and installation
• Drive chain - inspect and replace
• Drive chain tensioner, sprockets and guides - removal, inspection and installation
• Camshaft and valve lifters - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump and drive chain - removal, inspection and installation
• Flywheel / drive disc - removal, inspection and installation
• Crankshaft oil seals - replacement

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Removing the engine - methods and precautions
• Petrol engines with 4 cylinders - removal and installation
• Petrol engines with 6 cylinders - removal and installation
• Diesel engines - removal and installation
• Dismantling the engine - dismantling sequence
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Cylinder block / crankcase - cleaning and inspection
• Piston / connecting rod assembly - cleaning and inspection
• Crankshaft - inspection
• Main and connecting rod bearings and cap bolts - inspection
• Engine assembly sequence
• Piston rings - installation
• Crankshaft - installing the main bearing and checking the working clearance
• Piston / connecting rod assembly - installing connecting rod bearing and checking working clearance
• Engine - preparing to start after bulkhead

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - disconnecting and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, testing and installation
• Cooling fan - test, removal and installation
• Electrical sensors of the cooling system - removal and installation
• Cooling pump - removal and installation
• Heating / ventilation system components - removal and installation
• Air conditioning system - general description and precautions

Carburetor fuel systems

• Specifications
• General description and precautions
• Air filter assembly and filter element - removal and installation
• Air filter temperature control system - component test and replacement
• Fuel pump - removal and installation
• Fuel level indicator sensor - removal and installation
• Fuel tank - removal and installation
• Accelerator cable - removal, installation and adjustment
• Carburetor Stromberg 175 CDT - general description and replacement of components
• Pierburg 2E-E carburetor - general description and replacement of components
• Carburetor - removal and installation
• Intake manifold - removal and installation
• Intake manifold heater - removal and installation

Fuel injection system Bosch KE-Jetronic

• Specifications
• General description and precautions
• Accelerator cable - removal, installation and adjustment
• Air filter and filter element - removal and installation
• Fuel filter - removal and installation
• Fuel accumulator - removal and installation
• Fuel level indicator sensor - removal and installation
• Fuel pump - removal and installation
• Fuel tank - removal and installation
• Throttle body - removal and installation
• Intake manifold - removal and installation
• KE-Jetronic injection system components - removal and installation
• Fuel injection system - pressure relief
• Adjusting the idle speed and CO content in the exhaust gas

Fuel injection system HFM Bosch (petrol engines)

• Specifications
• General description and precautions
• Accelerator cable - removal, installation and adjustment
• Air filter and filter element - removal and installation
• Fuel filter - removal and installation
• Fuel level sensor - removal and installation
• Fuel pump - removal and installation
• Fuel tank - removal and installation
• Throttle body - removal and installation
• Intake manifold - removal and installation
• Bosch HFM fuel injection system components - removal and installation
• Fuel injection system - pressure relief
• Adjusting the idle speed and CO content in the exhaust gas

Diesel fuel injection systems

• Specifications
• General description and precautions
• Air filter - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Intake manifold - removal and installation
• Accelerator cable - removal, installation and adjustment
• High pressure fuel pump - removal and installation
• Fuel suction pump - removal and installation
• Injection timing adjustment mechanism and sprocket - removal and installation
• Start of injection of high-pressure fuel pump - general description, check and adjustment
• Injectors and high pressure fuel lines - removal and installation
• ELR electronic idle speed control system - removing and installing components
• Electronic anti-knock control system ARA - removal and installation of units
• Electronic diesel management system (EDS) - removing and installing components
• Engine overload protection system - removing and installing components
• Fuel thermostat - removal and installation

Exhaust system and exhaust gas aftertreatment system

• Specifications
• General description
• Fuel vapor recovery system - general description and replacement of components
• Blow-by-blow system - general description
• Exhaust manifold - removal and installation
• Waste turf re-incineration (EGR) system - general description and component replacement
• Turbine generator - removal and installation
• Exhaust system - general description and replacement of components
• Catalytic converters - general description and precautions

Starting and charging systems

• Specifications
• General description and precautions
• Battery - check and charge
• Battery - removal and installation
• Alternator / charging system - car test
• Generator - removal and installation
• Alternator - brush holder / voltage regulator unit replacement
• Engine starting system - test
• Starter - removal and installation
• Starter - bulkhead

Ignition system - 4 cyl. gasoline engines

• Specifications
• General description
• Ignition system - test
• High voltage ignition coil - removal and installation
• Distributor - removal and installation
• Distributor slider - removal and installation
• Ignition timing - check and adjustment
• Ignition control system assemblies - removal and installation

Ignition system - 6 cyl. gasoline engines

• Specifications
• General description
• Ignition system - test
• High voltage ignition coil - removal and installation
• Distributor and distributor slider - crumpled and installed
• Ignition timing - check and adjustment
• Ignition system control units - removal and installation

Preheating system - diesel engines

• Specifications
• General description
• Glow plug control unit - removal and installation
• Glow plugs - test, removal and installation
• Coolant temperature sensor - removal and installation

Clutch

• Specifications
• General description
• Clutch assembly - removal, inspection and installation
• Bearing and clutch release lever - removal, inspection and installation
• Slave cylinder - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Hydraulic system - pumping
• Clutch pedal - removal and installation

Mechanical transmission

• Specifications
• General description
• Manual transmission fluid drain and filling
• Gear selector components - removal, installation and adjustment
• Oil seals - replacement
• Reversing light switch - checking, removing and installing
• Mechanical transmission - removal and installation
• Mechanical transmission overhaul - general description

Automatic transmission

• Specifications
• General description
• Gear selector lever - removal and installation
• Gear shift rod - adjustment, removal and installation
• Pressure control cable - adjust
• Starter lock / reversing light switch - removal, installation and adjustment
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description

Main gear, drive and cardan shafts

• Specifications
• General description
• Final drive unit - fluid drain and filling
• Final drive block - removal and installation
• Final drive block oil seals - replacement
• Drive shaft - removal and installation
• Protective covers for drive shaft CV joints - replacement
• Cardan shaft - removal and installation
• Propshaft rubber coupling - check and replace
• Propshaft bearing - check and replacea
• Universal joint for propshaft - check and replace

Braking system

• Specifications
• General description
• Hydraulic system - pumping
• Hydraulic pipes and hoses - replacement
• Front brake pads - replacement
• Rear brake pads - replacement
• Front brake disc - inspection, removal and installation
• Rear brake disc - inspection, removal and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake caliper - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Vacuum booster - check, removal and installation
• Check valve of the vacuum booster. - removal, check and installation
• Parking brake - adjustment
• Parking brake shoes - removal and installation
• Parking brake pedal - removal and installation
• Parking brake cables - removal and installation
• Brake light switch - removal and installation
• Anti-lock braking system (ABS) - general description
• ABS system components - removal and installation
• Brake vacuum pump (diesel models) - check, removal and installation

Suspension and steering

• Specifications
• General description
• Front hub bearing - check and adjust
• Front hub assembly - removal, bulkhead and installation
• Front steering knuckle - removal and installation
• Front suspension shock absorber - removal, bulkhead and installation
• Front suspension coil spring - removal and installation
• Front suspension lower arm - removal, bulkhead and installation
• Front suspension anti-roll bar - removal and installation
• Rear hub retainer - removing and installing
• Rear hub bearing - replacement
• Rear suspension shock absorber - removal, testing and installation
• Rear suspension coil spring - removal and installation
• Rear suspension arms - removal and installation
• Rear suspension lower arm - removal, bulkhead and installation
• Rear suspension anti-roll bar - removal and installation
• Anti-roll bar linkage - removal and installation
• Rear suspension self-adjusting system (station wagon) - general description
• Self-leveling rear suspension components (station wagon) - removal and installation
• Steering wheel - removal and installation
• Steering column - removal, check and installation
• Steering column lock / ignition switch - removal and installation
• Steering column rubber sleeve - removal and installation
• Steering box - removal, bulkhead and installation
• Steering arm of the steering box - removal and installation
• Steering block lower gasket - replacement
• Power steering pump - removing and installing
• Power steering system - bleed
• Steering damper - removal and installation
• Tie rod - removal and installation
• Intermediate steering lever - removal and installation
• Tie rod ball joints - removal and installation
• Tie rod - removal and installation
• Wheel alignment and steering angles - general description

Body

• Specifications
• General description
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation and adjustment
• Bonnet cable - removal and installation
• Bonnet lock - removal and installation
• Doors - removal, installation and adjustment
• Interior door trim panel - removal and installation
• Door handle and lock components - removal and installation
• Door glass and window regulator - removal and installation
• Trunk lid - removal and installation
• Trunk lid lock - removal and installation
• Rear door - removal and installation
• Rear door lock components - removal and installation
• Central locking components - removal and installation
• Window electrical components - removal and installation
• Exterior mirrors and related components - removal and installation
• Windshield and rear window - general description
• Luke - general description
• External body parts - removal and installation
• Seats - removal and installation
• Seat belt tensioning mechanism and front seat - general description
• Seat belt components - removal and installation
• Central pools - removal and installation

Electrical system

• Specifications
• General description and precautions
• Finding a short circuit in an electrical circuit - general description
• Fuses and relays - general description
• Switches - removal and installation
• Incandescent pumps external lighting fixtures - replacement
• Interior lighting pumps - replacement
• Blocks of external lighting - removal and installation
• Headlight range control - general description
• Dashboard - removal and installation
• Dashboard components - removal and installation
• Speedometer cable - removal and installation
• Cigarette lighter lighting - removal and installation
• Sound signal - removal and installation
• Wiper arm - removing and installing
• Electric motor and wiper gear - removal and installation
• Rear door wiper motor - removal and installation
• Windshield / headlamp washer system components - removal and installation

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Differential and propeller shaft
• Braking system
• Suspension and steering
• Electrical system

Wiring diagrams