Content

Operating instructions

Maintenance

• Dimensions and weight
• Capacities
• Specifications
• Lubricants and fluids
• Identification number
• Service schedule
• Service procedures
• Weekly checks
• Every 750 1 km or 6 months
• Every 15,000 km or 6 months
• Every 30,000 km or 12 months
• Every 60,000 km or 2 years

Repair of a 1.6 l petrol engine in the engine compartment

• Specifications
• General description
• Compression check - description
• Top dead center (TDC) for piston №1 - location
• Valve cover - removal and installation
• Crankshaft pulley - removal and installation
• Drive chain cover - removal and installation
• Drive chains - removal, inspection and installation
• Drive chain tensioners, guides and sprockets - removal, inspection and installation
• Valve clearances - check and adjust
• Camshafts and tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / transmission mounts - inspect and replace

Repair of 2.0 liter gasoline engine in the engine compartment

• Specifications
• General description
• Compression check - description
• Top dead center (TDC) for piston №1 - location
• Valve cover - removal and installation
• Crankshaft pulley - removal and installation
• Drive chain cover - removal and installation
• Drive chain - removal and installation
• Chain tensioner, guides and sprockets - removal, inspection and installation
• Camshafts - removal, inspection and installation
• Pushers and hydraulic regulators - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Engine oil cooler - removal and installation
• Crankshaft oil seals - replacement
• Flywheel / drive disc - removal, inspection and installation

Engine removal and bulkhead procedures

• Specifications
• General description
• Engine bulkhead - general description
• Removing the engine - methods and precautions
• Engine and mechanical transmission - removal, separation and installation
• Engine and automatic transmission - removal, separation and installation
• Engine overhaul - disassembly sequence
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Crankcase / crankcase - cleaning and inspection
• Piston / connecting rod assembly - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installing and checking the main bearing running clearance
• Piston / connecting rod assemblies - installing and checking connecting rod bearing running clearance
• Engine - starting after bulkhead

Repair of a diesel engine 2.0 l

• Specifications
• Toothed drive belt - removing and installing
• Compression - check
• Cylinder head / gasket - replace
• Valves - removal and installation
• Valve seals - replacement
• Valve guides - check
• Valve seats - lapping
• Cylinder head / valves - finishing
• Valve clearances - check and adjust
• Engine lubrication system
• Oil pan - removal and installation
• Oil pump

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - disconnecting and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, serviceability check and installation
• Electric fan - serviceability check, removal and installation
• Cooling system sensors / switches - serviceability check, removal and installation
• Water pump - removal, inspection and installation
• Heating system / interior ventilation - general description
• Heating / ventilation system components - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel and exhaust systems - carburetor models

• Specifications
• General description and precautions
• Air filter assembly - removal and installation
• Filter air temperature control system (ATC)
• Fuel priming pump - check, removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general description and use
• Carburetor - general description
• Carburetor - removal and installation
• Carburetor - diagnostics, bulkhead and adjustment
• Electronic carburetor control components
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description and component removal

Fuel and exhaust systems - center injection models

• Specifications
• General description and precautions
• Air filter assembly - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general description and use
• Fuel injection system - general description
• Fuel system - depressurization
• Fuel pump - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Throttle body - removal and installation
• Fuel injection / ignition system - diagnostics and adjustment
• Fuel injection system components - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description and removal

Fuel and exhaust systems - multipoint injection models

• Specifications
• General description and precautions
• Air filter assembly - removal and installation
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general description and use
• Fuel injection system - general description
• Fuel system - depressurization
• Fuel priming pump - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - diagnostics and adjustment
• Throttle body - removal and installation
• Fuel injection system components (1.6 l models) - removal and installation
• Fuel injection system components (2.0 l models) - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description and removal

Exhaust gas recirculation systems

• General description
• Recirculation systems - checking and replacing components
• Catalytic converter - general description and precautions

Diesel fuel system

• Specifications
• General description
• Injectors - removal and installation
• High pressure fuel pump injection timing - check and adjust

Engine electrical systems

• Specifications
• General description and precautions
• Finding a short circuit in an electrical circuit - general description
• Battery - check and charge
• Battery - removal and installation
• Ignition system - general description
• Ignition system - check
• High voltage ignition coil - removal, inspection and installation
• Distributor - removal and installation
• Ignition unit (carburetor models without catalytic converter) - removal and installation
• Transistor ignition unit - removal and installation
• Ignition timing - check and adjust
• Charging system - check
• Alternator drive belt - removal, installation and tension
• Generator - removal and installation
• Alternator brushes and regulator - inspect and replace
• Launch system - check
• Starter - removal and installation
• Starter - brush replacement
• Ignition lock - removal and installation
• Oil pressure warning lamp switch - removing and installing
• Preheating device
• Pre-heating system - check
• Glow plugs - removal and installation
• Fuel cut-off valve - check and replace

Clutch

• Specifications
• General description
• Clutch - adjustment
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation
• Clutch release mechanism - removal, inspection and installation

Mechanical transmission

• Specifications
• General description
• Gear linkage rod - general description
• Rod of gear shifting - removal and installation
• Oil seals - replacement
• Lever neutral position warning lamp switch - serviceability check, removal and installation
• Reversing light switch - serviceability check, removal and installation
• Speedometer drive - removal and installation
• Mechanical transmission - removal and installation
• Mechanical transmission overhaul - general description

Automatic transmission

• Specifications
• General description
• Drive mode switch cable - adjustment
• Drive mode switch cable - removal and installation
• Assembling the drive mode selection lever - removal and installation
• Transmission kickdown cable - adjustment
• Kickdown cable - removal and installation
• Speedometer drive - removal and installation
• Oil seals - replacing the drive shaft oil seal
• Starter lock / reversing light switch - check, remove and install
• Upshift button - serviceability check, removal and installation
• Automatic transmission - removal and installation

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• SHRUS protective covers - replacement

Braking system

• Specifications
• General description
• Hydraulic brake system - bleeding
• Brake pipes and hoses - replacement
• Front brake pads - replacement
• Rear brake pads - replacement
• Rear brake pads - replacement
• Brake disc - inspection, removal and installation
• Rear brake drum - removal, inspection and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake caliper - removal, bulkhead and installation
• Rear brake cylinder - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Brake pedal - adjustment, removal and installation
• Vacuum booster unit - removal and installation
• Check valve of the vacuum booster unit - removal, service check and installation
• Hand brake lever - removal and installation
• Handbrake cables - removal and installation
• Pressure control valves in the rear brake assemblies - adjustment, removal and installation
• Brake light switch - adjustment, removal and installation
• Hand brake warning lamp switch - removal and installation
• ABS system - general description

Suspension and steering gear

• Specifications
• General description
• Front wheel bearings - replacement
• Front suspension strut - removal, bulkhead and installation
• Front suspension lower arm - removal, bulkhead and installation
• Lower arm ball joint - replacement
• Front suspension intermediate arm assembly - removal, bulkhead and installation
• Front suspension anti-roll bar - removal and installation
• Rear wheel bearing - replacement
• Rear Suspension Components (Sedan and Hatchbsk Models) - removal, bulkhead and installation
• Rear Suspension Components (Station Wagon Models) - removal, bulkhead and installation
• Steering wheel - removal and installation
• Ignition / steering column lock - removal and installation
• Steering column - removal, inspection and installation
• Steering gear assembly - removal, bulkhead and installation
• Rubber protective covers for steering gear - replacement
• Power steering hydraulic system - bleeding
• Power steering pump spruce - removal and installation
• Tie rod end - removal and installation

Body and trim - 1st and 11th generation models

• Specifications
• General description
• Service - body and bottom
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• 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
• Door - removal, installation and adjustment
• Door trim panel - removal and installation
• Door lock drive handle and lock components - removal and installation
• Door glass and regulator - removal and installation
• Trunk lid and support legs (Sedan models) - removal, installation and adjustment
• Tailgate and support legs - removal, installation and adjustment
• Trunk lid lock components (Sedan Models) - removal and installation
• Tailgate lock and handle components - removal and installation

Body and trim - 3rd generation models

• General description
• Service - body and bottom
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• 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
• Door - removal, installation and adjustment
• Panel separated doors - removal and installation
• Door lock drive handle and lock components - removal and installation
• Door glass and regulator - removal and installation
• Trunk lid and support legs - removal, installation and adjustment
• Trunk door and support legs - removal, installation and adjustment
• Trunk lid lock components - removal and installation
• Components of the lock and tailgate handle - removal and installation
• Central locking system components - removing and installing
• External scribble and related components - removal and installation
• Glasses - general description
• Luke - general description
• External body components - removal and installation
• Seats - removal and installation
• Seat belt components - removal and installation
• Interior trim panels - removal and installation
• Center console - removal and installation
• Faceplates - removal and installation

Onboard electrical equipment - 1st and 2nd generation models

• Specifications
• General description and precautions
• Electrical troubleshooting - general description
• Fuses and relays - general description
• Switches - removal and installation
• Lamps (external lights) - replacement
• Lamps (interior lighting) - replacement
• Blocks of lamps of external lighting - removal and installation
• Adjusting the direction of the light beam - general description
• Instrument panel - removal and installation
• Instrument cluster components - removal and installation
• Light on warning system - general description
• Cigarette lighter - removal and installation
• Sound signal - removal and installation
• Speedometer cable - removal and installation
• Wiper arm - removing and installing
• Wiper motor and rod - removal and installation
• Tailgate wiper motor - removal and installation
• Windshield / rear window washer system components - removal and installation

Onboard electrical equipment - 3rd generation models

• Specifications
• General description and precautions
• Electrical troubleshooting - general information
• Fuses and relays - general information
• Switches - Removal and Installation
• Lamps (outdoor lights) - replacement
• Lamps (interior lighting) - replacement
• Outdoor lighting units - removal and installation
• Adjusting the direction of the light beam - general description
• Instrument panel - removal and installation
• Instrument cluster components - removal and installation
• Lighter - removal and installation
• Sound signal - removal and installation
• Wiper arm - removing and installing
• Wiper motor and rod -removal and installation
• Motor for cleaning glass in the tailgate - removing and installing
• Windshield / rear window washer system components - removal and installation
• Audio system - removal and installation
• Radio antenna - removal and installation
• Anti-theft alarm system - general description
• Heated front seat components - general description
• Airbag system - general description and precautions

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Suspension and steering gear
• Electrical system

Wiring diagrams