Contents

Foreword

Operating instructions

Maintenance

• Dimensions and weight
• 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-cylinder gasoline engine - 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
• Engine / transmission brackets - inspect and replace

6-cylinder gasoline engine - 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 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

Diesel engine - repair operations in the car

• Specifications
• 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
• Crankshaft bushing bearing - replacement
• Engine / transmission brackets - inspect and replace
• Engine oil cooler - removal and installation

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
• Engine - disassembly sequence
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• 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 and checking the working th main bearing clearance
• Piston / connecting rod assembly - installing and checking connecting rod bearing running 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 - removing and installing

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

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 - removal and installation of knots
• 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 gas venting system - general description
• Exhaust manifold - removal and installation
• Exhaust gas recirculation (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
• Air injection system - component removal and installation

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-cylinder petrol 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-cylinder petrol engines

• Specifications
• General description
• Ignition system - test
• High voltage ignition coil - removal and installation
• Distributor and distributor slider - removal and installation
• 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 - bleeding
• Clutch pedal - removal and installation

Mechanical transmission

• Specifications
• General description
• Mechanical transmission - fluid draining 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 selection 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 - draining and filling fluid
• Final drive block - removal and installation
• Final drive block oil seals - replacement
• Drive shaft - removal and installation
• SHRUS protective covers - replacement
• Cardan shaft - removal and installation
• Propshaft rubber coupling - check and replace
• Propshaft bearing - check and replace
• 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
• Vacuum booster check valve - removal, check and installation
• Parking brake - adjustment
• Parking brake shoes - 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
• Rear suspension anti-roll bar link - removal and installation
• Steering wheel - removal and installation
• Steering column - removal, inspection 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
• Service - body and sub-frame
• Maintenance - upholstery and rugs
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Hood - removal and installation
• Hood - adjustment
• Bonnet hinge - removal and installation
• Bonnet support - removal and installation
• Bonnet cable - removal and installation
• Bonnet lock - removal and installation
• Radiator grill - removal and installation
• Emblem - removal and installation
• Trunk lid - removal and installation
• Trunk lid lock - removal and installation
• Front and rear bumpers - removal and installation
• Bumpers - disassembly and assembly
• Door trim panel - removal and installation
• Front door window regulator - removal and installation
• Front door window glass - removal and installation
• Rear door window regulator - removal and installation
• Rear door window glass - removal and installation
• Rear door window - removal and installation
• External front door handle - removal and installation
• Front door lock - removal and installation
• Rear door outer handle - removal and installation
• Rear door lock - removal and installation
• Door locking actuator (central locking system) - removal and installation
• Front and rear doors - removal and installation
• Windshield and rear window - removal and installation
• Outside mirror glass (manually adjustable) - replacement
• Assembly of the external mirror (with manual adjustment) - removal and installation
• Outside mirror glass (electrically adjustable) - replacement
• Outside mirror assembly (electrically adjustable) removal and installation
• Front seats - removal and installation
• Rear seat - removal and installation
• Seat belts - removal and installation
• Luke - general description
• Vacuum pump for central locking system - removing and installing
• Central control panel - removal and installation
• Glove box - removal and installation
• Panel - 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
• Central electric unit - removal and installation
• Steering column combination switch - removal and installation
• Panel and center console switches - removal and installation
• Interior door switches - removal and installation
• Dashboard - removal and installation
• Dashboard components - removal and installation
• Wire ropespeedometer drive - removal and installation
• Lamps (external) - replacement
• Lamps (internal) - replacement
• External lights - removal and installation
• Headlamp lens - removal and installation
• Headlights - adjustment
• Headlight beam height adjustment system - description
• Wiper blades and wiper arm - removal and installation
• Wiper motor and rod - removal and installation
• Wiper motor - removal and installation
• Windshield washer system - removal, installation and adjustment
• Sound signals - removal and installation
• Car radio - removal and installation
• Front and rear speakers - removal and installation
• Radio antenna - removal and installation
• Speed ??control components - removal and installation
• Anti-theft alarm system - general description
• Airbag system - general description and precautions
• Airbag system components - removal and installation
• Wiring diagrams - general description

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