Content

Foreword

Operating instructions

• Devices
• Body elements
• Structural safety of the body
• Lighting devices
• Windows, sliding sunroof
• Heating, ventilation
• Air conditioner
• Automatic transmission
• Driving advice
• Fuels
• Catalyst
• Exhaust fumes
• Chassis, speed control
• Braking system
• Wheels, tires
• Self-help
• Maintenance

Maintenance

• Overall dimensions, weight and capacity
• Identification numbers
• Maintenance
• Part A: Service procedures - gasoline models
• Part B: Maintenance procedures - diesel engines
• Introduction
• Every 400km
• Checking the engine oil level
• Checking the coolant level
• Every 5000 km
• Changing the engine oil and filter
• Exhaust quality check
• Checking the glow plug warning lamp
• Draining water from the fuel filter
• Every 7,500 km
• Changing the engine oil and filter
• Every 10,000
• Checking and adjusting the idle speed
• Draining water from the fuel filter
• Replacing the fuel filter
• Replacing the air filter element
• Checking the condition of the auxiliary drive belt
• Checking the concentration of antifreeze in the coolant
• Checking systems for leaks
• Every 15,000 km
• Checking and adjusting the idle speed
• Checking and adjusting the maximum engine speed
• Every 30,000 km
• Replacing the fuel filter
• Every 100,000 km
• Replacing glow plugs
• Checking the condition of the auxiliary drive belt
• Throttle lever rod lubrication
• Checking the concentration of antifreeze in the coolant
• Every 2 years, regardless of mileage
• Replacing the coolant

Gasoline engines

• Specifications
• General description
• Maintenance
• Basic operations possible with the engine in the car
• Basic operations requiring removal of the engine
• Engine removal method
• Engine - removal
• Disassembly of the engine - general description
• Ancillary engine parts - removal
• Engine - complete disassembly
• Pallet - removal and installation with the engine in the car
• Engine mount brackets - replacing
• Cylinder head - removal and installation with engine in a car
• Toothed belt drive - replacement with engine in car
• Engine components - inspect and rebuild
• Cylinder head - bulkhead
• Engine - final assembly
• Engine accessories - installation
• Engine - installation
• Engine - preparation for start-up after overhaul
• Troubleshooting - engine

Diesel engine

• Specifications
• General description
• Compression check - description
• Basic actions possible with the engine in the car
• Basic steps to remove the engine
• Engine removal method
• Engine - removal
• Disassembly of the engine - general description
• Ancillary engine parts - removal
• Engine - complete disassembly
• Pallet - removal and installation with the engine in the car
• Engine mount brackets - replacing
• Cylinder head - removal and installation (engine in a car)
• Valve clearances - check and adjust
• Engine components - inspect and rebuild
• Cylinder head - bulkhead
• Engine - assembly
• Engine accessories - installation
• Engine - installation
• Preheating system - description and functional check
• Engine - preparation for the first start after overhaul

Cooling system

• Specifications
• General description
• Routine maintenance
• Cooling system - draining fluid
• Cooling system - rinsing
• Cooling system - filling
• Antifreeze mixture - general description
• Radiator - removal and installation
• Radiator - inspection and repair
• Thermostat - removal and installation
• Thermostat - test
• Thermo-viscous cooling fan - removing and installing
• Water pump - removal and installation
• Alternator / fan drive belt - replacement and adjustment
• Troubleshooting - cooling system
• Expansion tank - removal and installation
• Temperature gauge sensor - removal and installation

Fuel and exhaust systems - petrol models

• Specifications
• General description
• Routine maintenance
• Plugged adjustment screws - general description
• Air filter and element - removal and installation
• Fuel pump (carburetor models) - removal, inspection and installation
• Fuel pump (fuel injection models) - check, removal and installation
• Fuel filter (fuel injection models) - replace
• Fuel tank - removal and installation
• Fuel level sensor - removal and installation
• Diaphragm damper (fuel injection engines) - removal and installation
• Accelerator cable - removal, installation and adjustment
• Fuel control pedal - removal and installation
• Carburetor - description
• Carburetor - idle and mixture frequency adjustment
• Carburetor - removal and installation
• Bulkhead carburetor
• Carburetor throttle damper (automatic transmission models) - adjust
• Carburetor - adjusting the increased idle speed
• Thermal carburetor valve - check.
• Intake manifold heater element (carburetor models) - removal, inspection and installation
• Fuel injection system - description
• Fuel injection system - precautions
• Fuel injection system - idle speed and mixture adjustment
• Fuel injection throttle switch - check and adjust
• Bosch L3 Jetronic fuel injection system components - removal and installation
• Bosch Motronic ML4 fuel injection system components - removal and installation
• Speed ??control system - general description
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - removal and installation
• Troubleshooting - fuel and exhaust systems

Fuel and exhaust systems - diesel models

• Specifications
• General description
• Glow plugs - check
• Fuel system - bleeding
• Injectors - removal and installation
• The moment the injection pump starts - check
• Gas turbine supercharger - general description
• Exhaust system - removal and installation

Ignition system

• Specifications
• General description and precautions
• Routine maintenance
• The cover of the breaker-distributor and the distributor runner - removal and installation
• Ignition timing - check
• Octane plug - adjustment
• Ignition coil - test, removal and installation
• Inductive impulse transmitter - test, removal and installation
• Ignition control unit (models 1.8) - removal and installation
• Spark plugs - removal, service and installation
• High voltage wires - general description
• Troubleshooting - ignition system

Clutch

• Specifications
• General description
• Routine maintenance
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Clutch - removal
• Clutch - inspect
• Release bearing and lever - removal and installation
• Troubleshooting - clutch
• Clutch - installation

Mechanical and automatic transmissions

• Specifications
• General description
• Routine maintenance
• Manual transmission - removal and installation
• Manual transmission - disassembly into main blocks
• Manual transmission - inspection
• Output shaft of a manual transmission - disassembly and assembly
• Manual transmission input shaft - disassembly and assembly
• Rear crankcase of a manual transmission - disassembly and assembly
• Manual transmission main shroud - disassembly and assembly
• Manual transmission - assembly
• Manual transmission shift lever - removal, bulkhead and installation
• Selector lever mounting bracket - removal and installation
• Gear shift rod manual gearbox - adjustment
• Automatic transmission - removal and installation
• Automatic transmission kickdown cable - replace
• Automatic transmission kickdown cable - adjustment
• Automatic transmission select lever linkage - adjustment
• Automatic transmission selection lever - removal and installation
• Inhibitor switch - removal and installation
• Troubleshooting - mechanical and automatic transmissions

Cardan shaft

• Rear brake pads - inspection and replacement
• Front brake caliper - removal, repair and installation
• Rear brake caliper - removal, repair and installation
• Brake disc - inspection, removal and installation
• Hand brake shoes - inspection and replacement
• Handbrake cable - removal and installation
• Hand brake lever - removal and installation
• Nice cylinder - removal, adjustment and installation
• Rear brake pressure limiter - removal and installation
• Hydraulic system - pumping
• Brake pipes and hoses removal and installation
• Vacuum booster - test
• Amplifier vacuum hose and one-way valve - replace
• Vacuum booster - removal and installation
• Brake pedal - removal and installation
• Anti-lock braking system (ABS) - precautions
• Hydraulic ABS modulator - removal and installation
• Electronic control unit ABS - removal and installation
• ABS wheel speed sensor - removal and installation
• ABS relay - replacement

Suspension and steering

• Specifications
• General description
• Maintenance
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front suspension lower arm - removal and installation
• Front suspension lower ball joint - replacement
• Front anti-roll bar - removal and installation
• Front anti-roll bar - removal and installation
• Steering knuckle - removal and installation
• Front hub and bearings - removal and installation
• Front suspension cross member - removal and installation
• Rear shock absorber rod - removal and installation
• Rear diagonal arm - removal and installation
• Rear coil spring - removal and installation
• Rear anti-roll bar - removing and installing
• Rear axle (complete) - removal and installation
• Rear suspension cross member - removal and installation
• Rear suspension crossbar installation - replacement
• Rear hub and bearing - removal and installation
• Rear suspension leveling system components - removal and installation
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering column (without height adjustment) - bulkhead
• Steering column (height adjustable) bulkhead
• Steering gear - removal and installation
• Steering gear - on-site adjustment
• Steering rods - removal and installation
• Intermediate steering gear - removal and installation
• Power steering pump - removing and installing
• Installing wheels - checking and adjusting
• Wheels and tires - care and maintenance

Body

• Specifications
• General description
• Maintenance
• Body and subframe - service
• Upholstery and rugs - service
• Repair of minor damage to the body
• Body repair - serious damage
• Hood - removal and installation
• Trunk lid - removal and installation
• Rear door - removal and installation
• Rear door trim panel - removing and installing
• Radiator grill - removal and installation
• Door trim panel - removal and installation
• Door speaker - removal and installation
• Inner door handle - removal and installation
• External door handle - removal and installation
• Front door lock cylinder - removal and installation
• Door lock - removal and installation
• Door - removal and installation
• Windshield and rear door window / rear window - removal and installation
• Front door window - removal and installation
• Rear door window - removal and installation
• Outside door mirror - removal and installation
• Rear side window - removal and installation
• Fixed rear door window - removal and installation
• Headrest guides - removing and installing
• Seat belts - removal and installation
• Bumpers - removal and installation
• Seats - removal and installation
• Luke - general information
• Dashboard - removal and installation
• Center console - removal and installation
• Heater dashboard - removal and installation
• Heater radiator - removal and installation
• Heater - removal and installation
• Heater fan motor - removal and installation
• Central air / heating deflectors - removal, installation and adjustment
• Side deflectors of airflow and heating - removal and installation
• Air conditioning system - description and warnings
• Air conditioning system parts - removal and installation

Electrical system

• General description
• Maintenance
• Electrical system precautions
• Battery - removal and installation
• Battery - charging
• Generator - test in a car
• Generator - removal and installation
• Alternator brushes and voltage regulator - removal and installation
• Starter - general description
• Starter - check in the car
• Starter - removal and installation
• Starter bulkhead - general description
• Starter traction relay - removal and installation (starter removal)
• Starter brushes - inspection and removal
• Starter - disassembly and assembly
• Fuses and relays - general description
• Steering column combination switches - removal and installation
• Panel switches - uninstall and install
• Interior lighting switch - removal and installation
• Watch - removal and installation
• Cigarette lighter lighting - removal and installation
• Heater control switch - removal and installation
• Ignition lock - removal and installation
• Dashboard removal and installation
• Speedometer cable - replacement
• Sound signal - removal and installation
• Lamps - replacement
• Front direction indicator lamp - removal and installation
• Headlight - removal and installation
• Headlight - directional adjustment
• Wiper blades and arms - removal and installation
• Wiper motor and rod - removal and installation
• Windshield washer pump - removal and installation
• Rear door wiper motor - removal and installation
• Rear door washer pump - removal and installation
• Central locking system - general description
• On-board computer - general description
• Heated seats - general description
• Control system - general description
• Radio equipment - noise reduction (interference elimination)
• Wiring diagrams - general description

Changes and additions to the designs of models of later release years

• Introduction
• Specifications
• Fuel and exhaust systems - 2.0 liter models
• Ignition system - 1.8 liter carburetor models
• Automatic transmission
• Final drive and drive shafts
• Braking system
• Body
• Electrical system

Troubleshooting

Wiring diagrams