Contents

Operating instructions

• Maintenance
• General characteristics of the car
• Vehicle identification numbers
• Maintenance
• Recommended lubricants and fluids

Engine

• Specifications
• Part A: Gasoline engine
• General description
• Maintenance
• Basic work possible without removing the engine from the car
• Valve clearances - adjustment
• Toothed belt and tensioner - removal and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Pistons and connecting rod bearings - replacement
• Engine / transmission mounts - replacement and adjustment
• Engine - removal method
• Engine / manual transmission - removal and separation
• Engine / automatic transmission - removal and separation
• Disassembly of the engine - general description
• Ancillary engine components - removal
• Engine - complete disassembly
• Cylinder head - disassembly and cleaning of carbon deposits
• Engine - inspection and reconstruction
• Engine assembly - general description
• Engine - assembly
• Engine accessories - installation
• Engine / mechanical transmission - connection and installation
• Engine / automatic transmission - coupling and installation
• Engine - preparing to start after repair
• Compression check - description
• Troubleshooting - engine
• Part B: Diesel engine
• General description
• Engine technical condition assessment
• Removing the engine
• The main systems and mechanisms of the engine
• Compression test
• Checking the oil pressure in the system
• Fuel supply system
• High pressure fuel pump
• Removal and installation of injection pump
• Operating adjustments of the injection pump
• Fuel filter
• Injectors
• Preheating system
• Preheating plugs
• Fuel supply system malfunctions

Cooling system

• Specifications
• General description
• Maintenance
• Cooling system - draining fluid
• Cooling system - flush
• Cooling system - filling
• Coolant mixture
• Drive belt - adjustment, removal and installation
• Cooling system hoses and connections - removal, installation and inspection
• Radiator and expansion tank - removal, inspection and installation
• Electric cooling fan - check, remove and install
• Thermostat - removal, check and installation
• Electrical switches of the cooling system - check, removal and installation
• Water pump - removal and installation
• Troubleshooting - cooling system

Fuel and exhaust systems

• Specifications
• Part A: Carbureted engines
• General description
• Fuel system maintenance precautions
• Maintenance
• Air filter element - replace
• Air filter - removal and installation
• Automatic temperature control (ATC) in the air filter - general description
• Fuel filter - change
• Fuel pump - check, removal and installation
• Fuel level sensor - removal, check and installation
• Fuel tank - removal, repair and installation
• Fuel vapor management system - general description
• Accelerator cable - adjustment
• Accelerator cable - removal and installation
• Accelerator pedal - removal and installation
• Unleaded petrol - general description
• Carburetor - description
• Carburetor - adjustment and inspection
• Controlled deceleration device (BCDD) - general description
• Carburetor idle system - general description
• Carburetor - removal and installation
• Bulkhead carburetor
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - removal and installation
• Crankcase ventilation (PCV) - general description
• Troubleshooting - fuel system
• Part B: Turbocharged engines
• General description
• Fuel injection service precautions
• Reducing pressure in the fuel system
• Maintenance
• Air filter element - replace
• Air filter - removal and installation
• Fuel filter - change
• Fuel pump / fuel level sensor - removal, check and installation
• Fuel tank - removal, repair and installation
• Fuel vapor management system - general description
• Accelerator cable - adjustment
• Accelerator cable - removal and installation
• Accelerator pedal - removal and installation
• Unleaded petrol - general description
• Fuel injection systems - adjustment
• ECCS control unit - general description
• Air flow meter - removal and installation
• Air intake and resonator unit - removal and installation
• Throttle chamber - removal and installation
• Throttle valve switch - removal and installation
• IAA block - removal and installation
• Air regulator - removal, inspection and installation
• Intake manifold - removal and installation
• Safety valve - removal and installation
• Fuel line / pressure regulator assembly - removal and installation
• Fuel injectors - check, removal and installation
• Turbine generator - precautions
• Turbine generator - removal and installation
• Turbine generator - check
• Exhaust manifold - removal and installation
• Exhaust system - removal and installation
• Fuel injection system - self-diagnosis
• Positive crankcase ventilation (PCV) system - general description
• Troubleshooting - fuel injection system
• Part C: 2.0 liter fuel injection engines
• General description
• Fuel injection service precautions
• Relief of pressure in the fuel system
• Maintenance
• Air filter element - replace
• Air filter - removal and installation
• Fuel filter - change
• Fuel pump / fuel level sensor - removal, check and installation
• Fuel tank - removal, repair and installation
• Fuel vapor management system - general description
• Accelerator cable - adjustment
• Accelerator cable - removal and installation
• Accelerator pedal - removal and installation
• Unleaded petrol - general description
• Fuel injection system adjustment
• ECCS control unit - general description
• Air flow meter - removal and installation
• Air intake duct - removal and installation
• Throttle chamber - removal and installation
• Throttle switch - removal and installation
• IAA block - removal and installation
• Air regulator - removal, inspection and installation
• Collectors - removal and installation
• Pressure / fuel line regulator assembly - removal and installation
• Fuel injectors - check, removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - removal and installation
• Vehicle speed sensor - check, removal and installation
• Fuel injection system - self-diagnosis
• Positive crankcase ventilation (PCV) system - general description
• Troubleshooting - fuel injection system

Ignition system

• Specifications
• Part A: Carburetor models
• General description
• Maintenance
• Ignition distributor - removal and installation
• Ignition distributor - bulkhead
• Ignition timing - check and adjust
• Ignition coil - general description
• Troubleshooting - ignition system
• Part B: Fuel injection models
• General description
• Maintenance
• Distributor / crankshaft angle sensor - removal and installation
• Distributor / crankshaft angle sensor - bulkhead
• Ignition timing - check and adjust
• Ignition coil - general description
• Power transistor - general description
• Knock sensor - general description (Turbo models only)
• ECCS control unit - general description
• Troubleshooting - ignition system

Clutch

• Specificications
• General description
• Maintenance
• Clutch pedal - removal and installation
• Clutch cable - removal and installation
• Clutch hydraulic system - bleeding
• Clutch master cylinder - removal and installation
• Clutch master cylinder - bulkhead
• Clutch slave cylinder - removal and installation
• Clutch slave cylinder - bulkhead
• Hydraulic lines and hose - inspect, remove and install
• Clutch block - removal and installation
• Clutch assembly - inspect
• Clutch release mechanism - removal and installation
• Troubleshooting - clutch
• Clutch release mechanism - check

Mechanical transmission

• Specifications
• Part A: All models
• General description
• Maintenance
• Gear lever and rod - removal, check and installation
• Speedometer drive - removal and installation
• Oil seals - removal and installation
• Reversing lamp / gear position switch - removing, installing and checking
• Transmission - removal and installation
• Part B: 1.6l models (RS5F31A)
• Transmission - disassembly
• Transmission - check
• Transmission - assembly
• Transmission - adjustment
• Part C: 1.8 L models (including Turbo) and 2.0 liters (RS5F50A)
• Transmission - disassembly
• Transmission - inspection
• Transmission - assembly
• Transmission - adjustment
• Part D: All models
• Troubleshooting - manual transmission

Automatic transmission

• Specifications
• General description
• Maintenance
• Transmission fluid - check
• Gear shift mechanism - check and adjust
• Rod and cable for gear shifting - removal and installation
• Selection lever - removal and installation
• Starter inhibitor / reversing lamp switch - install and check
• Starter inhibitor / reversing lamp switch - removal and installation
• Speedometer drive - removal and installation
• Oil seals - replacement
• Transmission fluid cooler - general description
• Transmission - removal and installation
• Troubleshooting - automatic transmission

Drive shafts

• Specifications
• General description
• Maintenance
• Drive shafts - removal and installation
• Drive shafts - bulkhead
• Drive shaft protective covers - removal and installation
• Troubleshooting - drive shafts

Braking system

• Specifications
• General description
• Maintenance
• Brake pedal - removal and installation
• Vacuum booster - check
• Vacuum booster - removal and installation
• Vacuum booster check valve - removal and installation
• Vacuum booster check valve - check
• Brake system - bleeding
• Hydraulic pipes and hoses - inspection, removal and installation
• Master cylinder - removal and installation
• Master cylinder - bulkhead
• Front brake pads - check and replace
• Front brake caliper - removal and installation
• Front brake caliper - bulkhead
• Front brake discs - check, removal and installation
• Front brake shield - removal and installation
• Pressure relief valve - removal and installation
• Rear brake pads - check and replace
• Rear brake slave cylinder - removal and installation
• Rear brake slave cylinder - bulkhead
• Rear brake drum - removal, inspection and installation
• Rear drum brake shield - removal and installation
• Rear brake pads - check and replace
• Rear brake caliper - removal and installation
• Rear brake caliper - bulkhead
• Rear brake disc - inspection, removal and installation
• Rear brake disc shield - removal and installation
• Hand brake lever - removal and installation
• Handbrake cables - removal and installation
• Troubleshooting - brake system

Suspension and steering

• Specifications
• General description
• Maintenance
• Front hub retainer - removing and installation
• Front hub and bearings - removal and installation
• Ball joint of the lower arm of the front suspension - removal and installation
• Front suspension strut and spring - removal and installation
• Front suspension strut and spring - bulkhead
• Front suspension lower arm - removal and installation
• Front lower arm mounting plate - removal and installation
• Front anti-roll bar and wings - removing and installing
• Adjustable suspension damping system - general description
• Rear hub bearings - adjustment
• Rear hub and bearings - removal and installation
• Rear suspension strut and spring - removal and installation
• Rear suspension strut and spring - bulkhead
• Longitudinal balancer and rear suspension bushings - removal and installation
• Rear anti-roll bar and wings - removing and installing
• Rear suspension transverse link - removal and installation
• Rear suspension cross member - removal and installation
• Steering wheel - removal and installation
• Steering column lock / ignition switch - removal and installation
• Steering column - removal and installation
• Steering column - bulkhead
• Lower steering column connection - removal and installation
• Tie rod outer ball joint - removal and installation
• Tie rod and inner ball joint - removal and installation
• Protective rubber covers for steering gear - removal and installation
• Steering gear - removal and installation
• Steering gear - check in the car
• Steering gear - bulkhead
• Power steering pump drive belt - removal, installation and adjustment
• Power steering pump - removing and installing
• Power steering pump - bulkhead
• Power steering pressure switch, pipes and reservoir - check, remove and install
• Power steering fluid - fill and bleed
• Toe and wheel angles - check and adjust
• Wheels and tires - service
• Troubleshooting - suspension and steering

Body

• Specifications
• General description
• Body structure and subframe - service
• Upholstery and rugs - service
• Hinges, locks and door latches - service
• Seat belts - service
• Minor damage to the body - repair
• Body repair - serious damage
• Hood - removal and installation
• Hood lock and release cable - removal, installation and adjustment
• Radiator grille and trim panels - removing and installing
• Spoilers - removal and installation
• Bumpers - removal and installation
• Mudguards and guards - removal and installation
• Side molding fasteners - removal and installation
• Windshield, rear window / tailgate window and rear triangular interior vents - removal and installation
• Luke - general description
• Trunk lid (Sedan) - removal and installation
• Rear door (Hatchback) - removal and installation
• Rear door pillar (Hatchback) - removal and installation
• Trunk lid / tailgate and fuel filler flap - remove, install and adjust
• Rear door / tailgate strike and strike plate - removal, installation and adjustment
• Rear door / trunk lid lock cylinder - removing and installing
• Fuel tank flap lock bushing - removal and installation
• Door - removal, installation and adjustment
• Door catch, impact plate and handles - removal and installation
• Front door lock cylinder - removal and installation
• Door window glass and regulator of its rise - removal and installation
• Central locking - general information
• Power glass windows - general information
• Mirrors - removal and installation
• Outside mirror glass - replacement
• Trim panels and joints - removal and installation
• Seats - removal and installation
• Seat belts - removal and installation
• Center console - removal and installation
• Dashboard - removal and installation
• Heating and ventilation system - description
• Heater controls - removal, installation and adjustment
• The heater and its radiator - removal and installation
• Heater fan and inlet box - removing and installing
• Heating pipes and valves device - removal and installation
• Air conditioning system - general information and precautions
• Air conditioning system - service

Electrical system

• Specifications
• General description
• Maintenance
• Generator - description and precautions
• Charging system / alternator - vehicle test
• Generator - removal and installation
• Alternator brushes and voltage regulator - replacement
• Generator - bulkhead
• Starter - check on the car
• Starter - removal and installation
• Starter - bulkhead
• Relays - general description
• Fuses, plugs and backfeed relays - general description
• Washing system - general description
• Suspension damping adjustment system - general description
• Central locking - general description
• Direction indicator and hazard warning system - general description
• Electric hatch - general description
• Electrically operated exterior mirrors - general description
• Seat safety system - general description
• Window regulators - general description
• Time control unit (TCU) - general description
• Wiring diagrams - explanatory notes
• Troubleshooting - electrical system

Wiring diagrams