Contents

Maintenance

• Service specifications
• Vehicle identification numbers
• Routine maintenance
• Service plan
• Weekly checks
• Lubricants and fluids
• Service procedures
• Introduction
• Every 9,000 km
• Changing the engine oil and filter
• Intensive service
• Every 18,000 km
• Checking the automatic transmission fluid level
• Check for leaks
• Checking and replacing the auxiliary drive belt
• Checking the air conditioner system
• Checking and adjusting the idle speed
• Suspension and steering test
• Checking the front brake pad
• Rear brake pad check
• Parking brake test
• Checking the exhaust system
• Checking the oil level in the manual transmission
• Checking the oil level in the final drive mechanism
• Checking the drive shaft coupling
• Seat belt check
• General lubrication
• Checking the beam direction adjustment
• Checking the windscreen / headlight washer system
• Every 55,000 km
• Replacing the air filter element
• Test in motion
• Replacing the fuel filter and the filter installed on the fuel pump
• Automatic transmission fluid and filter replacement
• Every 12 months
• Replacing the brake fluid
• Checking the clutch friction disc - manual transmission models
• Every 3 years
• Coolant replacement

Engines 601 and 602

• Specifications
• Engine - removal and installation
• Disassembly of the engine - general description and sequence
• Cylinder head - general description
• Cylinder head - removal and installation
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head - repair
• Timing gear cover - removing and installing
• Pistons and connecting rods - removal
• Measurement of cylinders
• Pistons and connecting rods - cleaning and inspection
• Pistons and connecting rods - assembly
• Pistons and connecting rods - installation
• Cylinder block - cleaning and inspection
• Crankshaft and flywheel - general description
• Crankshaft - removal
• Crankshaft - check
• Crankshaft - installation
• Flywheel / drive disc - removal and installation
• Belt pulley and crankshaft hub
• Rear crankshaft oil seal and oil seal housing - replacement
• Front crankshaft oil seal - replacement
• Distribution mechanism - general description
• Chain tensioner - removal and installation
• Main drive chain - removal and installation
• Tensioner rail - removing and installing
• Anti-roll bar - removal and installation
• Crankshaft sprocket - removal and installation
• Camshaft - removal and installation
• Hydraulic push rod expansion joints - general description
• Checking pushers
• Pushers - removal and installation
• Engine lubrication system - general description
• Oil pump - removal and installation
• Oil pan - removal and installation
• Oil filter
• Changing the engine oil
• Checking oil pressure
• Compression test and pressure hold - description
• Engine - preparing to start after bulkhead

Engine 616

• Specifications
• Engine - removal and installation
• Compression test and pressure hold - description
• Disassembly and assembly of the engine - general description
• Cylinder head - general description
• Cylinder head - removal and installation
• Cylinder head disassembly
• Cylinder head - repair
• Pistons and connecting rods - removal
• Measurement of cylinders
• Pistons and connecting rods - check
• Pistons and connecting rods - assembly
• Pistons and connecting rods - installation
• Cylinder block - bulkhead
• Crankshaft - removal
• Crankshaft - check
• Crankshaft - installation
• Flywheel / drive disc - removal and installation
• Belt pulley and crankshaft hub - removal and installation
• Rear crankshaft oil seal and its cover - removing and installing
• Front crankshaft oil seal - replacement
• Camshaft and rocker arms - general description
• Rocker arm mechanism - removal and installation
• Camshaft - removal and installation
• Chain tensioner - removal and installation
• Timing chain - replacement
• Tensioner strips - removal and installation
• Anti-roll bar - removal and installation
• Camshaft drive
• Valve clearance adjustment
• Engine lubrication system
• Oil pump - removal and installation
• Oil pan - removal and installation
• Oil filter
• Engine - preparing to start after bulkhead

Cooling, heating and ventilation systems

• Specifications
• General description
• Coolant - draining and filling the system
• Antifreeze - general description
• Expansion tank cap - leak test
• Radiator - removal, inspection and installation
• Viscous fan clutch - removal and installation
• Water pump - removal and installation
• Water pump belt - inspection, removal and installation
• Thermostat - removal, operation check and installation
• Coolant hoses - disconnecting and replacing
• Heater - removal and installation
• Heater blower - removal and installation
• Heater matrix - replacement

Diesel fuel system

• Specifications
• General description
• High pressure fuel pump - removal and installation
• Checking the injection moment
• Nozzle body and nozzle - removal and installation
• Injector repair
• Idle speed adjustment
• Gas drive adjustment
• Pneumatic idle speed increasing device
• Air filter
• Electronic regulation of idle speed
• Fuel pump
• Fuel filter
• Stopping the engine
• Fuel heating system
• Injection system on models for Switzerland and Austria
• Exhaust Gas Recirculation
• Fuel injection pump service (engine 616)
• High pressure fuel pump repair - general description (engine 616)
• High pressure fuel pump - removal and installation (engine 616)
• The moment of the start of fuel injection of the high pressure fuel pump (engine 616)
• Removing air from the system (engine 616)

Electrical equipment

• Specifications
• General description and precautions
• Battery - health check and charging
• Battery - removal and installation
• Generator - checking operation without removing from the vehicle
• Generator - removal and installation
• Generator - bulkhead and component health check
• Starter - functional check
• Starter - removal and installation
• Starter - bulkhead
• Starter - diagnostics
• Glow plugs - general description
• Glow plugs - removal and installation
• Heating system - diagnostics
• Electrical troubleshooting - general description
• Fuses and Relays - general description
• Headlights - changing bulbs
• Headlights - replacement
• Headlights - adjusting the direction of the light beam
• Windscreen wipers - component removal and installation

Clutch

• Specifications
• General description
• Clutch components - removal, inspection and installation
• Release mechanism components - removal and installation
• Clutch friction disc - check for wear (without removing)
• Clutch master cylinder - removal and installation
• Clutch slave cylinder - removal and installation
• Hydraulic clutch - bleeding

Manual transmission

• Specifications
• General description
• Manual transmission - oil drain and filling
• Gearbox - removal and installation
• Transmission front cover - oil seal removal, replacement and installation
• Transmission rear cover - oil seal removal, replacement and installation
• Speedometer drive mechanism - removal and installation
• Gear lever linkage - adjust
• Oil - level measurement
• Gear lever - removal and installation

Automatic transmission

• Specifications
• General description
• Lever select ra of the driving mode - removal and installation
• Drive mode switching 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

Drive shafts, final drive and propeller shaft

• Specifications
• General description
• Final drive block - removal and installation
• Cardan shaft - removal and installation
• Drive shaft - removal and installation
• Drive Shaft - Bulkhead
• Main drive bevel gear oil seal - replacement
• Final drive unit - oil level measurement and oil change

Braking system

• Specifications
• General description
• Rear brakes - adjustment
• Disc brake pads - replacement
• Brake caliper - removal and installation
• Brake caliper - bulkhead
• Drum brake pads - replacement and position adjustment (models with automatic governors)
• Wheel brake cylinders - removal, bulkhead and installation
• Brake master cylinder - removal, bulkhead and installation
• Parking brake - adjustment
• Handbrake cables - replacement
• Brake booster - removal and installation
• Hydraulic brake system - bleeding
• Brake fluid - replacement
• Brake force regulator - adjustment
• Brake pads - thickness check

Suspension and steering gear

• Specifications
• General description
• Front axle - removal and installation
• Front axle - bulkhead
• Front wheel bearings - end play adjustment
• Front wheel hub - removal and installation
• Front wheel bearings - replacement
• Front suspension steering knuckle - removal and installation
• Wheel alignment - general description
• Front wheel alignment - adjustment
• Rear axle - removal and installation
• Rear axle - bulkhead
• Assembly of the brake drum / rear wheel hub - removal and installation
• Rear wheel bearings - replacement
• Springs - replacement
• Shock absorbers - replacement
• Anti-roll bar - removing and installing
• Steering gear without amplifier - removal and installation
• Steering rods and steering arm - removal and installation
• Power steering - removal and installation
• Power steering hydraulic system - bleeding
• Steering wheel - removal and installation
• Steering gear without power steering - measuring oil level

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Cardan shaft
• Rear axle
• Braking system
• Suspension and steering
• Electrical system

Wiring diagrams