Contents

Operating instructions

Maintenance

• Vehicle identification numbers
• Recommended lubricants and fluids

Gasoline engines

• Specifications
• General description
• Basic actions possible with the engine stationary in the car
• Basic operations on a removed engine
• Engine removal methods
• Engine - removal (with transmission)
• Engine - removal (without transmission)
• Engine disassembly (general)
• Ancillary engine components - removal
• Cylinder head - removal (engine in car)
• Cylinder head - removal (engine removed from vehicle)
• Dismantling the cylinder head - removing the camshaft and tappets
• Valves - removal
• Flywheel and pallet - removal
• Drive cover, chain and sprockets - removing
• Pistons, connecting rods and lower end bearings - removing
• Crankshaft and main bearings - removal
• Piston pins - removal
• Piston rings - removal
• Lubrication system - general description
• Oil pump - disassembly, inspection and assembly
• Pressure reducing valve - removal, inspection and installation
• Oil filter - change
• Engine components - determine wear
• Crankshaft - check and reconstruction
• Crankshaft, main and connecting rod bearings - check and reconstruction
• Cylinder channels - check and reconstruction
• Pistons and piston rings - inspection and reconstruction
• Cranks - inspection and reconstruction
• Camshaft and its bearings - check and reconstruction
• Hydraulic pushers - description
• Hydraulic pushers - inspection and reconstruction
• Valve and valve seats - inspection and reconstruction
• Cylinder head and piston heads - carbon removal
• Valve guides - inspect
• Pallet - inspection
• Sprockets, chain and covers - inspection and reconstruction
• Flywheel ring - inspection and reconstruction
• Engine assembly - general instructions
• Crankshaft - installation
• Pistons and connecting rods - assembly
• Piston rings - installation
• Pistons and connecting rod assemblies - installation
• Connecting rods / connecting rod bearings - crankshaft mounted
• Flywheel - installation
• Drive chain, cover and drip tray - installation
• Valve assemblies - cylinder head installation
• Camshaft and hydraulic pushers - installation
• Cylinder head - installation
• Hydraulic pushers - adjustment after installation
• Ancillary engine components - installation
• Engine (with manual transmission) - reconnection
• Engine (with automatic transmission) - reconnection
• Engine - installation
• Engine - starting after bulkhead or overhaul
• Hydraulic pushers - final adjustment after bulkhead

Diesel Engines

• Specifications
• Cylinder head - removal and installation
• Cylinder head disassembly and assembly
• Valves and seats - grind and launch
• Engine - removal and installation
• Engine - disassembly and assembly
• Rear crankshaft oil seal - replacement
• Camshaft - removal and installation
• Camshaft drive cover - replace
• Drive chain and crankshaft sprocket - replacement
• Oil pump - check
• Oil pump pressure reducing valve - check
• Oil filter bypass valve - replace
• Oil pressure - check
• Oil sump gaskets - replacement

Cooling system

• Specifications
• General description
• Routine maintenance
• Cooling system - draining fluid
• Cooling system - flushing
• Cooling system - filling
• Radiator - removal and installation
• Thermostat - removal and installation
• Thermostat - test
• Water pump - removal and installation
• Water pump - bulkhead
• V-belt - removing, installing and tensioning
• Temperature gauge and temperature sensor - removal, installation and inspection
• Antifreeze
• Diesel engine cooling system

Fuel and exhaust systems

• Specifications
• General description
• Air filter - description and action
• Air filter - check operation
• Air filter - removal, service and installation
• Fuel pump - description
• Fuel pump - service
• Fuel pump - test
• Fuel pump - removal and installation
• Fuel tank - removal and installation
• Fuel tank - cleaning
• Fuel level sensor - removal and installation
• Throttle rod - adjustment
• Accelerator cable - removal and installation
• Fuel control pedal - removal and installation
• Carburetor - general description
• Carburetor - how it works
• Carburetor adjustment - general description
• Carburetor - adjustment
• Carburetor - removal and installation
• Disassembly and assembly of the carburetor - general description
• Carburetor - disassembly, cleaning and inspection
• Carburetor - assembly
• Automatic air damper - adjustment
• Exhaust system - general description
• Exhaust system - replacement
• Diesel fuel system - bleeding
• High pressure fuel pump - principle of operation
• Centrifugal regulator injection pump
• Injection timing regulator
• Injection pump - removal and installation
• Injection advance angle - check and adjust
• Injection pump - adjustment
• The increased frequency of cold. stroke - adjustment
• Injectors - removal and installation
• Injectors - disassembly and assembly
• Injectors - check
• Fuel control lever - adjust
• Metering valve actuator - check and adjust
• Metering valve - checking operation
• Control thrust with increased frequency of cold stroke - adjustment
• Starting candles

Ignition system

• Specifications
• General description
• Breaker contact plates - adjustment
• Breaker contact plates - removal and installation
• Capacitor - removal, inspection and installation
• Distributor - removal and installation
• Distributor - disassembly
• Valve - check and repair
• Distributor - assembly
• Distributor - lubrication
• Spark plugs and high voltage wires
• Ignition timing - adjustment
• Ignition system - damage detection

Clutch

• Specifications
• General description
• Clutch play - adjustment
• Clutch release bearing - removal and installation
• Clutch assembly - removal and installation
• Clutch - inspect
• Clutch cable - removal and installation
• Clutch pedal - removal and installation

Transmission

• Specifications
• General description
• Gearbox - removal and installation
• Gearbox disassembly
• Gearbox components - inspect
• Input shaft - disassembly and assembly
• Output shaft - disassembly and assembly
• Gearbox - assembly
• Automatic transmission - general description
• Automatic transmission - check fluid level
• Automatic transmission - removal and installation
• Gear shift mechanism - adjustment
• Kickdown cable - adjustment
• Kickdown cable - removal and installation
• Automatic transmission gear selection mechanism - removal and installation
• Starter / reverse inhibitor switch - removal and installation

Cardan shaft

• Specifications
• General description
• Propeller shaft - inspect
• Cardan shaft - removal and installation
• Propshaft rubber drive coupling - removal and installation

Rear axle

• Specifications
• General description
• Rear axle - removal and installation
• Axle shaft, bearings and oil seal - removal and installation
• Differential pinion oil seal - removing and installing
• Wheel stand - removal and installation

Braking system

• Specifications
• General description
• Brake system - adjustment
• Hydraulic system - pumping
• Front brake pads - removal and installation
• Front disc brake caliper - removal and installation
• Front brake disc - removal and installation
• Front caliper - bulkhead
• Rear brake drums and shoes - removal, inspection and installation
• Rear working brake cylinders - removal, bulkhead and installation
• Rear drum brake shield for - removal and installation
• Handbrake cable - adjustment
• Handbrake cable - removal and installation
• Hand brake lever - removal and installation
• Hydraulic pipes and hoses - inspection, removal and installation
• Master cylinder - removal and installation
• Master cylinder - bulkhead
• Brake booster - general description, maintenance and adjustment
• Brake booster - removal and installation
• Brake and clutch pedals - removal and installation
• Pressure regulating valve in the brake system - removing and installing

Electrical system

• Specifications
• General description
• Battery - removal and installation
• Battery - service and inspection
• Battery - charging and refilling electrolyte
• Generator - general description, removal and installation
• Alternator - troubleshooting and repair
• Alternator brushes (Delco Remy) - inspection, removal and installation
• Alternator brushes (Bosch) - inspection, removal and installation
• Starter - general description
• Starter - check on engine
• Starter - removal and installation
• Starter traction relay - removal and installation
• Starter brushes - inspect and replace
• Starter - drive mechanism
• Starter - checking armature and field windings
• Wiper mechanism - troubleshooting and repair
• Wiper components - removal and installation
• Wiper motor - reconstruction
• Rear door wiper components (station wagon) - removal and installation
• Windshield washer pump - removal and installation
• Rear door washer pump (station wagon) - removal and installation
• Sound signal - check, remove and install
• Horn pushbutton switch - remove, check and install
• Interrupter for direction indicators and alarm - removal and installation
• Steering column combination switch - removal and installation
• Ignition socket contact block and lock cylinder - removal and installation
• Headlights - alignment and adjustment
• Headlight and side light bulbs - removal and installation
• Headlamp lens unit - removal and installation
• Front direction indicator lamps - removal and installation
• Reversing light bulbs - removal and installation
• Rear license plate lamp - removal and installation
• Interior lights - removal and installation
• Light switch and dashboard switches - removal and installation
• Reversing light switch - removal and installation
• Door switches - removal and installation
• Brake light and clutch warning lamp switches - removal and installation
• Hand brake warning lamp switch - removal and installation
• Dashboard - removal and installation
• Devices, alarm lamps, printed circuit and voltage stabilizer - removal and installation
• Speedometer cable - removal and installation
• Lighter - removal and installation
• Fuses and relays

Suspension and steering

• Specifications
• General description
• Service and inspection
• Front hub bearing - adjustment
• Front hub bearing and hub - removal and installation
• Front suspension strut - removal and installation
• Upper suspension support - removal and installation
• Coil spring - removal and installation
• Front shock absorbers - removal and installation
• Front anti-roll bar - removal and installation
• Suspension arm - removal and installation
• Equal velocity joint (CV joint) - removal and installation
• Stretch and bushings - removal and installation
• Front cross member - removal and installation
• Rear spring - removal and installation
• Rear suspension lower control arm - removal and installation
• Rear suspension upper control arm - removal and installation
• Rear anti-roll bar - removing and installing
• Diagonal thrust - removal and installation
• Rear shock absorbers - removal, inspection and installation
• Front wheels - adjustment
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering column assembly - removal and bulkhead
• Steering gear housing - removal and installation
• Steering housing - bulkhead
• Tie rod ends - test and replacement
• About side tie rod - removal and installation
• Pendulum arm - removal and installation
• Power steering - general
• Power steering drive belt - removal, installation and adjustment
• Power steering - bleeding
• Power steering pump - removal and installation
• Power steering drive - removal and installation
• Wheels and tires

Body

• General description
• Bodywork and subframe - service
• Upholstery and rugs - service
• Hinges, door latches and locks - service
• Doors - rattling and fixing
• Door curtains - removal and installation
• Door lock latch - adjustment
• Interior door handles and trim group - removal and installation
• External door fastening - removal and installation
• Front lowering glass drive - removing and installing
• Rear door sliding glass drive mechanism - removal and installation
• Front door window glass - removal and installation
• Rear door window glass - removal and installation
• Luggage compartment lock and lock cylinder - removal and installation
• Hood and luggage compartment lid - removal and installation
• Bonnet cable - removal and installation
• Rear door lock and lock cylinder - removal and installation
• Rear door holder pillars - removal and installation
• Windshield and rear window - removal and installation
• Bumpers and exterior trim - removal and installation
• Hatch - removal, installation and adjustment
• Center console - removal and installation
• Central air duct and side fume extractor valves - removal and installation
• Additional dashboard trim - removal and installation
• Heater assembly - removal and installation
• Heater radiator core - removal and installation
• Heater blower motor - removal and installation

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

• Specifications
• Introduction
• Towing
• Routine maintenance
• Engine - general description
• 1.8 l carburetor engine - bulkhead
• Engine 1.8 l. ONS - modifications
• Engine 2.0 and 2.2 CIH
• Cooling system
• Fuel and exhaust systems
• Ignition system
• Clutch
• Overdrive block
• Manual transmission (5-speed)
• Automatic transmission
• Rear axle
• Braking system
• Electrical system
• Suspension and steering
• Body

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Ignition system
• Clutch
• Manual transmission
• Cardan shaft
• Rear axle
• Braking system
• Electrical system
• Suspension and steering
• ABS system

Wiring diagrams