Contents

General Information

• General Precautions
• Safety Instructions
• Measures to protect the environment
• General installation instructions
• Ball and roller bearings
• Oil seals
• Joints and joints
• Blocking devices
• Screw thread
• Fastener identification
• Flexible pipes and hoses
• Fuel Handling Precautions
• Electrical Precautions
• Additional containment precautions
• SRS Component Replacement Policy
• Precautions when using the air conditioning system
• Replacing the air conditioning compressor

Vehicle identification number

• Vehicle identification
• Identification plate locations

Lifting and towing

• Rise
• Car restoration

Lubrication and maintenance

• Volumes
• Liquids
• Grease

Engine

• The mechanical part of the engine 1.8
• Specifications
• Torque
• Help
• Description and operation
• Engine component layout
• Description
• Operation
• Service Order
• Overhaul of the cylinder head
• Removing the cylinder head
• Crankshaft overhaul - with engine removed
• Conrod bearing overhaul
• Pistons and liners
• Rear crankshaft oil seal
• Front crankshaft oil seal
• Flywheel - manual transmission
• Torque Converter Drive Plate - Automatic Transmission
• Overhaul of the cylinder head gasket - with the engine removed
• Camshaft cover gasket
• Valves
• Hydraulic tappets
• Camshafts - intake or exhaust
• Intake manifold gasket
• Exhaust manifold gasket
• Oil pump
• Engine oil and oil filter
• Checking engine oil pressure
• Oil sump filter
• Engine sump
• Camshaft timing belt cover - front top
• Camshaft Timing Belt Cover - Rear Upper
• Crankshaft pulley
• Engine mount - right
• Engine mount lower tie rod
• Front Camshaft Oil Seal - Exhaust
• Front camshaft oil seal - inlet
• Camshaft drive belt
• Engine and manual transmission
• Engine and automatic transmission
• Cylinder head gasket
• Turbocharger
• Hose - Coolant drain - Turbocharger
• Hose - Coolant inlet - Turbocharger
• Pipe - Oil return - Turbocharger
• Hose - air intake - turbocharger
• Pipe - Oil supply - Turbocharger
• Hose - air intake - electronic
• Throttle body
• Intercooler
• Hose - air intake - intercooler
• Special tools
• The mechanical part of the engine-1.8 VKT
• Specifications
• Torque
• Help
• Description and operation
• Component layout
• Description
• Operation
• Service Order
• Cylinder head overhaul - with cylinder
• Head removed
• Crankshaft overhaul - with engine removed
• Conrod bearing overhaul
• Pistons and liners
• Rear crankshaft oil seal
• Front crankshaft oil seal
• Flywheel - manual transmission
• Torque Converter Drive Plate - Automatic Transmission
• Overhaul of the cylinder head gasket - with the engine removed
• Camshaft cover gasket
• Valves
• Hydraulic tappets
• Camshafts - intake or exhaust
• Intake manifold gasket
• Exhaust manifold gasket 1.8VCT
• Oil pump
• Engine oil and oil filter
• Checking engine oil pressure
• Oil sump filtera
• Engine sump
• Camshaft timing belt cover - front top
• Camshaft Timing Belt Cover - Rear Upper
• Crankshaft pulley
• Engine mount - right
• Engine mount lower tie rod
• Front Camshaft Oil Seal 1.8VCT - Exhaust
• Front Camshaft Oil Seal 1.8VCT - Inlet
• Camshaft drive belt 1.8VCT (new)
• Camshaft Phase Shifter 1.8VCT
• 1.8VCT engine and manual transmission
• 1.8VCT engine and automatic transmission
• Solenoid 1.8VCT - exhaust camshaft
• Solenoid 1.8VCT - intake camshaft
• Solenoid housing 1.8VCT - exhaust camshaft
• Solenoid housing 1.8VCT - intake camshaft
• Cylinder Head Gasket 1.8VCTNew
• Special tools

Engine cooling system

• Specifications
• Torque
• Help
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Coolant - draining and refilling
• Expansion tank cap - pressure test
• System - pressure test
• Coolant expansion tank
• Fan assembly
• Cooling fan resistor
• Radiator assembly
• coolant hose - Auautomatic transmission
• Fluid cooler return hose - automatic transmission
• Thermostat
• Coolant pump
• Special tools

Engine manifold and exhaust system

• Specifications
• Torque
• Description and operation
• Layout of system components - intake and exhaust system 1.8 tons
• Location of system components - intake and exhaust system 1.8VCT
• Description - intake and exhaust system 1.8 t.
• Description - 1.8VCT inlet and outlet system
• Inlet and outlet system Operation-1.8T
• Intake and exhaust system Operation-1.8VCT
• Service Order
• Air cleaner
• Element - Air Cleaner
• Tail pipe and silencer
• Intermediate pipe
• Front pipe - turbocharger
• Heat Shield - Generator
• Heat shield - rear muffler
• Heat shield - exhaust pipe and fuel tank
• Electric choke - enable setting

Engine fuel and control system

• Specifications
• Torque
• Description and operation-1.8T
• Diagram of system components
• Control Diagram-1.8T
• Description
• Operation
• Cruise control 1.8T
• Description and operation - 1.8 VCT
• System Component Diagram - 1.8 VCT
• Control Chart-1.8 VCT
• Description
• Operation
• Cruise control-1.8 VCT
• Service Order
• Spark plugs
• Ignition coils
• Engine control module (ECM)
• Sensor - engine coolant temperature (ECT)
• Switch - Oil pressure
• Sensor - crankshaft position (CKP)
• Sensor - Camshaft Position (CMP) - VCT
• Intake Camshaft Position (CMP) Sensor - VCT
• Sensor - exhaust camshaft position (CMP) - VCTv
• Sensor - temperature and manifold absolute pressure (TMAP)
• Sensor - Manifold Absolute Pressure (MAP)
• Knock sensor (KS)
• Sensor - Heated Oxygen (HO2S) - Front - Turbocharger
• Sensor - heated oxygen (H02S) - rear - turbocharger
• Solenoid - Boost control - Turbocharger
• Fuel rail
• Nozzles
• Charcoal canister
• Purge control valve
• Pipe assembly - fuel lines under the hull floor
• Tank - Fuel
• Fuel pump
• Fuel system - relieve pressure
• Fuel system - pressure test
• Draining and refilling the tank
• Fuel filter
• Filler neck
• Switch - inertia - fuel shutoff
• Special tools

Engine electrical system

• Specifications
• Torque
• Description and operation
• Component layout
• Control scheme
• Description
• Operation
• Service Order
• Belt - pump PAS
• Generator
• Bracket - Alternator - Upper
• Bracket - Alternator - Lower
• Drive belt
• Starter
• Battery compartment and support bracket
• Tensioner - alternator drive belt

Gearbox

• Shift Lock + Ctrl + AT
• Specifications
• Torque
• Description and operation
• Description
• Service Order
• Knob - selector - automatic
• Rod / Rope Assembly - Switch - Automatic
• Lever - shift assembly - automatic
• Shift Lock Control-MT
• Specifications
• Torque
• Service Order
• Handle - Shift Lever - Manual
• Remote control - shifting - manually
• Transmission-AT
• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• System management system
• Description
• Operation
• Service Order
• Automatic transmission - pressure test
• Neutral start (inhibitor) - switch
• Neutral start (inhibitor) - switch - check and adjustment
• Transmission and Converter
• Automatic transmission fluid - draining and refilling
• Automatic transmission - replenishment
• Control unit - automatic
• Transfer
• Belt - automatic transmission
• Sensor - speed input
• Sensor - speed output
• Dipstick - oil level
• Oil seal - differential - left
• Oil seal - differential - right
• Torque converter
• Side cover
• Oil seal - oil pump
• Special tools
• Transmission-MT
• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Oil seal - shift rod
• Lubrication system - draining and refilling
• Manual transmission assembly
• Lamp switch - reverse
• Lid - Re-access - Reseal
• Lubrication system - Manual transmission - Refueling
• Oil seal - differential - left
• Oil seal - differential - right
• Removing the manual transmission
• <Whether> Input shaft assembly
• Output Shaft Assembly
• Idle reverse
• Differential Assembly
• Assembling the control
• Fittings and release mechanism
• Special tools

Clutch

• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Clutch assembly
• Clutch Release Bearing
• Clutch master cylinder (A)
• Clutch master cylinder (B)
• Clutch slave cylinder (A)
• Clutch slave cylinder (B)
• Bleeding the clutch system
• Special tools

HVAC system

• Structure of HVAC
• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Recovery, recycling and refrigerant charging
• If recharging was successful/failed
• Compressor
• Evaporator
• Thermostatic expansion valve
• Capacitor
• Desiccant pack
• Pressure sensor - air conditioning
• Hose - Compressor to Condenser
• A/C tube - from evaporator to compressor, from evaporator to connection
• A/C pipe - from evaporator to compressor B - from compressor to connection
• A/C pipe - from condenser to evaporator A - from condenser to connection
• A/C pipe - condenser to evaporator B - connection to evaporator
• Filter housing - Fresh air intake
• Fresh air filter
• Heater Assembly
• Blower Assembly
• Heater
• Power regulator

HVAC-ETC

• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Service Order
• Assembling the control

HVAC-ATC

• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Assembling the control
• Evaporator temperature sensor
• Sunlight sensor
• Ambient temperature sensor-ATC
• Left transition damper - servomotor
• Heater coolant temperature sensor
• Right mixing flap - servomotor
• Fresh air recirculation damper - servomotor
• Distribution damper - servomotor

Steering system

• Front wheel steering
• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Pressure sensor
• Power Steering System - Pressure Test
• Bleeding the power steering system
• Power steering pump
• PAS pump tensioner
• Power steering
• Tie Rod Ball Joint
• Pipe - PAS pump to steering rack
• Pipe - from the steering rack to the oil cooler
• Oil Cooler - Steering
• Special tools
• Steering wheel and pillar
• Specifications
• Torque
• Description and operation
• Diagram of system components
• Description
• Service Order
• Steering wheel adjustment - Adjustment
• Switch - cruise control
• Steering column cover
• Steering wheel
• Steering column
• Switch assembly - steering column

Suspension system

• Wheel alignment
• Specifications
• Torque
• Specifications
• Service Order
• Wheel alignment
• Front suspension
• Specifications
• Torque
• Specifications
• Description and operation
• Diagram of system components
• Description
• Service Order
• Lower arm front
• Outer ball joint boot - front lower control arm
• Front lower arm bushing and bracket
• Front shock absorber
• Front subframe
• Front subframe
• Front hub subframe
• Front anti-roll bar
• Mounting rubber pads - anti-roll bar
• Anti-roll bar
• Hub-Front
• Front hub bearings
• Special tools
• Rear suspension
• Specifications
• Torque
• Rear suspension
• Description and operation
• Diagram of system components
• Description
• Service Order
• Upper arm - back
• Bushing Kit - Rear Upper Arm
• Lower arm back
• Rear lower control arm bush
• Rear shock absorber
• Spring rear suspension
• Rear Anti-roll Bar
• Anti-roll bar pads
• Anti-roll bar
• Rear wheel bearing
• Special tools
• Tires and wheels
• Specifications
• Torque
• Specifications
• Service Order
• Wheel

Brake system

• Tormoz
• Specifications
• Torque
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Front brake pad
• Brake Disc - Front
• Caliper housing - front
• Rear brake pad
• Rear brake disc
• Rear plate - rear brake disc
• Rear brake pad
• Caliper housing - rear
• Checking rear brake disc thickness and runout
• Thickness and Runout Check - Front Brake Disc
• Pedal unit - automatic transmission
• Pedal unit - manual transmission
• Vacuum servo brake
• Brake switch
• Bleeding the brake system
• Low Brake Fluid Indicator Relay
• Master cylinder and fluid reservoir
• Special tools
• Parking brake
• Specifications
• Torque
• Description and operation
• Diagram of system components
• Description
• Service Order
• Handbrake cable
• Handbrake adjustment
• Handbrake lever
• Front handbrake cable
• Brake module
• Specifications
• Torque
• Description and operation
• Diagram of system components
• Description
• Service Order
• ABS

Drive / Bridge

• Drive axle
• Specifications
• Torque
• Description and operation
• Diagram of system components
• Description
• Operation
• Service Order
• Right shaft and both joints
• Left shaft and both joints
• Outer CV joint
• SHRUS outer gaiters
• Inner join
• Inner gaiters
• Special tools

Interior decoration

• Instrument panel and console
• Specifications
• Torque
• Service Order
• Switch - cruise control
• Panel assembly - Fascia covering the panel on the driver's side
• Wood trim - Center console - Rear
• Glove box assembly
• Fascia
• Fan - right
• Console Assembly
• Assembling the center bezel
• Panel assembly - lower steering column cover - base
• Fan - left
• Seats
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Seat assembly - passenger
• Squab Foam - Passenger - Front
• Cover - Passenger Compartment - Front
• Cushion - rear seat
• Cover - Cushion - Rear seat
• Squab - backseat
• Cover - Bracket - Rear Seat
• Forward - Brace - Backseat
• Outer Side Panel - Power Seat
• Lumbar support assembly - front seat
• Switch box assembly - driver's seat
• Cover - driver airbag - front
• Seat assembly - driver
• Foam - driver's seat - front
• Driver airbag cover - front
• Door trim
• Service Order
• Plastic sheet - tailgate
• Casing trim - tailgate
• Plastic sheet - entrance door
• Enclosure trim - front door
• Interior trim and panels
• Specifications
• Torque
• Service Order
• Trim Finisher - Column A - Top - Each
• Trimming Finisher - A-post - Lower - Each
• Trim Finisher - Column BC - Top - Each
• Trimming Finisher - BC Stand - Lower - Each
• Finishing machine - D-pillar - top - each - sedan
• Finishing machine - D-pillar - lower - each - sedan
• Handle - Grip - Each
• Headlining - Sunlight / Sliding roof - Salon
• Carpet - main floor
• Parcel tray - Rear - Salon
• Parcel tray - Rear - Sunblinds
• Glasses - driver
• Cover trim - Cargo area - Threshold
• Trim trim - Luggage compartmentie

Appearance

• Fixed windows
• Service Order
• Glass - rear light
• Windshield
• Backlight
• Bumpers, trims and grille
• Specifications
• Torque
• Service Order
• Bumper assembly - front
• Bumper assembly - rear
• Bumper assembly - rear - with installed parking control system
• Exterior trim and cladding
• Service Order
• Pallet - Assembly
• Liner - rear wheel arch - each
• Plenum - air intake
• Lining - Front wheel arch - Front - Each
• Mirrors
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Mirror - Exterior - Electrical
• Mirror - Interior - Immersion
• Roof
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System management system
• Description
• Operation
• Service Order
• Sun/sliding roof assembly
• Glass panel - Sun / sliding roof
• Sun visor assembly - sun/sliding roof
• Windshield wipers and washer
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Lever - Wiper - Each
• Engine and clutch - Wiper
• Blade - Wiper - Each
• Reservoir - washer
• Washer pump
• Sensor - rain

Lighting systems

• Lighting
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Master light switch (MLS)
• Lamp Assembly - CHMSL
• Lamp assembly - Interior provision - Rear
• Lamp assembly - Provided from inside - Front
• Lamps
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Bulb - Direction - Indicator
• Lamp - Reversing light - Interior
• Lamp - License plate lamp
• Lamp - Rear fog light
• Lamp - Rear DI
• Bulb - Dip Beam
• Cover assembly - front fog lamp
• Headlight assembly - front fog
• Headlights - low beam, high beam
• Headlight assembly
• Lamp - front turn signal
• Lamp - Side light
• Lamp assembly - tail
• Lamp - Main Beam

Body

• Doors
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Handle - outside - entrance door
• Door assembly - front
• Hinge - entrance door - top
• Hinge - entrance door - lower
• Door - Front - Hinge Align
• Private lock - front door
• Latch - entrance door
• Door - Front - Detent Adjustment
• Handle - outside - tailgate
• Door assembly - rear
• Hinge - tailgate - upper
• Hinge - tailgate - lower
• Door - rear - hinged
• Latch - tailgate
• Door - Rear - Adjustable on the latch
• Dividing strip - quarter light - back
• Rubber / felt - Glass channel - Tailgate - Each
• Seal - Inner Waist - Tailgate - Each
• Seal - Outer Waist - Tailgate - Each
• Glass / glass cassette - Rear door - Adjustment
• Glass - Tailgate - Each
• Switch - Power Window - Tailgate - Each
• Engine and blockboard - tailgate - each
• Release handle - Interior - Tailgate - Each
• Enclosure trim - front door
• Casing trim - tailgate
• Switch box - power window driver's door
• Rubber / felt - glass channel - front door - each
• Seal - inner waist - front door - each
• Seal - outer waist - front door - each
• Glass / glass cassette - front door - adjustment
• Glass - Entrance door - Everyone
• Engine and control unit - entrance door - each
• Release handle - Inside - Entrance door
• Switch - Power Window - Front Door - Passenger
• Fasteners at the front
• Specifications
• Torque
• Service Order
• Wing - Front - Each
• Element Front
• Bonnet - Alignment - Checking and adjusting
• Hood
• Safety latch - hood
• Lock - hood
• Control cable assembly - cover
• Zippers at the back
• Specifications
• Torque
• Service Order
• Solenoid / engine - fuel filler flap opening
• Tailgate
• Trunk lid - hinged
• Trunk Lid - Align Striker
• Trim shroud - trunk lid
• Latch - trunk lid
• Horns
• Specifications
• Torque
• Service Order
• Horn - each
• Body Control Module
• Specifications
• Torque
• Description and operation
• Body Control Module (BCM) Component Locations
• Body Control Module (BCM) Component Locations
• Description
• Operation
• Service Order
• Body Control Module (BCM)

Body repair

• Body size
• Service Order
• Basic Information
• Floor Information
• Information about the external interface
• Additional Information
• Point to point dimension information
• Information about the sides and roof
• Internal Information
• Information about the external interface
• Rear Information
• Under "Body Information"
• Whitespace Information
• Additional Information
• Information about the external interface
• Rear Information
• Fuel Shutter Information
• Paints and coatings
• Description and operation
• General
• Collision elimination
• Description and operation
• General Welding Precautions
• Housing seal
• Corrosion prevention
• Diagnostics
• Water leaks
• Service Order
• Front panel
• Door panel
• Rear floor panel
• Roof panel
• Sidebar
• Front floor panel
• Wheel arch panel

Security and restrictions

• Access by car
• Description and operation
• Alarm and interlock component
• Alarm and lock control diagram
• Immobilization system control scheme
• Description
• Seat belts
• Specifications
• Torque
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Adjustable attachment - seat belt - BC rack - Eachv
• Seat Belt Assembly - Front - Each
• Additional invalid restrictions
• Specifications
• Torque
• Service Order
• Airbag - Fascia - Passenger
• Airbag - Steering wheel - Driver
• Electronic control unit SRS SRS
• Curtain airbag - head
• Parking assistance
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Control unit (ECU) - PDC

Information and Entertainment

• EntertainmentViews and navigation
• Description and operation
• ICE component layout
• ICE - Control Scheme
• IN CAR ENTERTAINMENT
• ICE - Description
• IN CAR ENTERTAINMENT
• (ICE) -Operation
• Layout of navigation system components
• Navigation system control scheme
• Description of the navigation system
• Navigation system - Work
• Service Order
• Woofer - tailgate
• Woofer - front door
• Speaker - Tweeter - Front
• Displays and sensors
• Description and operation
• Diagram of system components
• System control scheme
• Description
• Operation
• Service Order
• Toolbox
• List of glossaries