Contents

Operating instructions

Maintenance

• Dimensions and weight
• Lubricants and fluids
• Vehicle identification numbers
• Routine maintenance schedule
• Petrol models up to 1993
• Petrol models since 1994
• Diesel models
• Service procedures
• Introduction
• Intensive service
• Change oil and oil filter
• Checking fluid level in automatic transmission
• Checking and replacing the accessory drive belt
• Checking leaks and condition of hoses
• Checking the engine ventilation hoses
• Fuel filter maintenance and replacement
• Checking and adjusting the throttle actuator
• Checking and adjusting idle speed and mixture quality
• Replacing spark plugs
• Checking the clutch adjustment and lubricating the control mechanism
• Checking the protective covers of the drive shafts
• Checking the front and rear brake pads
• Checking and adjusting the parking brake
• Checking the steering and suspension
• Checking the drain holes in the body
• Lubrication of hinges and locks
• Air conditioner refrigerant check
• Coolant replacement
• Replacing the air filter
• Ignition system
• Changing fluid in an automatic transmission
• Replacing the brake fluid
• Replacing the timing belt
• Checking the oil level in the manual transmission
• Rear brake pad check - rear drum brake models
• Replacing the dust filter
• Checking the environmental protection system
• Road test

Repair of the TU gasoline engine in the engine compartment

• Specifications
• General description
• Cylinder compression test
• Camshaft timing holes - general description and use
• Valve cover - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - general description, removal and installation
• Timing belt tensioner and sprockets - removal, inspection and installation
• Camshaft oil seal - replacement
• Valve clearances - check and adjust
• Camshaft and rocker arms - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, check and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / transmission mounts - inspect and replace

Repair of the XU gasoline engine in the engine compartment

• Specifications
• General description
• Compression test
• Valve timing holes - general description and use
• Valve cover - removal and installation
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - general description, removal and installation
• Timing belt tensioner and sprockets - removal, inspection and installation
• Camshaft oil seals - replacement
• Camshaft and tappets - removal, inspection and installation
• Valve clearances - check and adjust
• 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 / transmission mounts - inspect and replace

Diesel engine repair in the engine compartment

• Specifications
• General description
• Checking the compression and tightness of component joints - description
• Camshaft timing holes - general description and use
• Cylinder head cover - removing and installing
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - removing, inspecting, installing and tensioning
• Toothed belt sprockets - removal and installation
• Right engine mount and timing belt tensioner - removal and installation
• Toothed belt guide roller - removing and installing
• Camshaft and tappets - removal, inspection and installation
• Valve clearances - check and adjust
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump and drive chain - removal, inspection and installation
• Engine oil cooler - removal and installation
• Oil seals - replacement
• Oil level and pressure sensors - main characteristics
• Flywheel - removal, inspection and installation
• Engine / transmission brackets - inspect and replace

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Removing engine / transmission - methods and precautions
• Engine and manual transmission - crushing, separation and installation
• Engine and automatic transmission - removal, separation and installation
• Engine disassembly sequence
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head - assembly
• Piston / connecting rod assemblies - removal
• Crankshaft - removal
• Cylinder block - cleaning and inspection
• Piston / connecting rod assemblies - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine 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

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - removal and replacement
• Radiator - removal, inspection and installation
• Thermostat - removal, check and installation
• Electric fan - check, removal and installation
• Electrical switches and sensors of the cooling system - check, removal and installation
• Water pump - removal and installation
• Interior heating and ventilation system - general description
• Heating / ventilation system components - removal and installation
• Heater / fuel filter housing (diesel models) - removal and installation

Fuel and exhaust systems - carburetor models

• Specifications
• General description and precautionary measure
• Air filter - removing arming
• Air filter temperature control system - general description and component replacement
• Fuel pump - check, removal and installation
• Fuel level sensor - removal and replacement
• Fuel tank - removal and installation
• Accelerator cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Air damper actuator - removal, installation and adjustment
• Unleaded gasoline - usage information
• Carburetor - general description
• Carburetor - removal and installation
• Carburetor - troubleshooting, disassembly and adjustment
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description, removal and installation

Fuel system - central fuel injection models

• Specifications
• General description and precautions
• Air filter and air intakes - removal and installation
• Intake air temperature control system - general description and component replacement
• Accelerator cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general information and applications
• Fuel injection systems - general description
• Fuel injection 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 system - check and adjust
• Fenix ??system components - removal and installation
• Bosch monopoinl system components - removal and installation
• Magneti marclli system components - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation

Fuel system - multiport fuel injection models

• Specifications
• General description and precautions
• Air filter and air intake hovody - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general information and applications
• Fuel injection systems - general description
• Fuel injection system - depressurization
• Fuel pump - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - check and adjust
• Throttle body - removal and installation
• Electronic control module - removal and installation
• Bosch L3.1-Jetronic system components - removal, installation and adjustment
• Bosch LU2-Jetronic system components - removal, installation and adjustment
• Bosch Motronic system components - removal, installation and adjustment
• Magneti Marclli system components - removal, installation and adjustment
• Intake manifold - removal and installation
• Variable intake system ACAV (16 valve engines) - general description, removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description, removal and installation

Emissions prevention systems - gasoline models

• General description
• Emission prevention systems - component inspection and replacement
• Catalytic converter - general description and precautions

Fuel and exhaust systems, exhaust gas aftertreatment system - diesel models

• Specifications
• General description and precautions
• Fuel system - filling and bleeding
• Maximum engine speed - check and adjust
• Fast idle temperature sensor - removal, installation and adjustment
• Fuel cut-off valve - description, removal and installation
• High pressure fuel pump - removal and installation
• Injection timing - test and adjustment methods
• Injection timing (Lucas fuel pump) - check and adjust
• Injection timing (Bosch fuel pump) - checks and adjustments
• Fuel injectors - serviceability check, removal and installation
• Accelerator cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Collectors - removal and installation
• Turbine generator - description and precautions
• Turbine generator - removal and installation
• Turbine generator - inspection and maintenance
• Intercooler - removal and installation
• Air filter and related components - removal and installation
• Exhaust system - general description and replacement
• Exhaust gas aftertreatment systems - general description
• Exhaust gas aftertreatment systems - check and replace

Starting and charging systems

• Specifications
• General description and precautions
• Electrical fault detection - general description
• Battery - health check and charging
• Battery - removal and installation
• Charging system - functional check
• Alternator drive belt - removal, installation and tension
• Generator - removal and installation
• Generator - health check and bulkhead
• Launch system - health check
• Starter - removal and installation
• Starter - health check and bulkhead
• Ignition lock - removal and installation
• Oil pressure warning lamp switch - removing and installing
• Oil level sensor - removal and installation
• Oil temperature sensor - removal and installation

Ignition system - petrol models

• Specifications
• Ignition system - general description
• Ignition system - check
• Ignition coil - removal, check and installation
• Distributor - removal and installation
• Ignition system amplifiers - removal and installation
• Ignition timing - check and adjust

Preheating system - diesel models

• Specifications
• Preheating system - description and functional check
• Glow plugs - removal, inspection and installation
• Control unit for preheating system - removal and installation
• Post heating switch - adjustment, removal and installation

Clutch

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

Mechanical transmission

• Specifications
• General description
• Manual transmission - oil draining and filling
• Shift rod - general description and adjustment
• Gear shift lever and rod, reverse gear release cable - removal and installation
• Oil seals - replacement
• Reversing light switch - checking, removing and installing
• Speedometer drive - removal and installation
• Mechanical transmission - removal and installation
• Mechanical transmission bulkhead - general description

Automatic transmission

• Specifications
• General description
• Shift cable - adjustment
• Gear shift cable - removal and installation
• Select lever assembly - removal and installation
• Kickdown cable - adjustment
• Kickdown cable - replacement
• Speedometer drive - removal and installation
• Oil seals - replacement
• Transmission fluid cooler - removal and installation
• Starter lock / reversing light switch - information, removal and installation
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• Protective covers for drive shafts - replacement
• Drive shaft repair - general description
• Right drive shaft intermediate bearing - replacement

Braking system

• Specifications
• General description
• Hydraulic system - pumping
• Hydraulic pipes and hoses - replacement
• Front brake pads - replacement
• Rear disc brake pads - replacement
• Rear drum brake pads - replacement
• Front brake disc - inspection, removal and installation
• Rear 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 wheel cylinder - removal, bulkhead and installation
• Brake master cylinder - removal, bulkhead and installation
• Brake pedal - removal and installation
• Vacuum booster - serviceability check, removal and installation
• Brake booster vacuum valve - removal, service check and installation
• Parking brake - check and adjust
• Parking brake lever - removal and installation
• Parking brake cable - removal and installation
• Parking brake warning lamp switch - removal and installation
• Rear brake pressure regulator (mounted on the bottom) - removal and installation
• Brake light switch - removal, installation and adjustment
• Anti-lock braking system (ABS) - general description
• Anti-lock braking system parts - removal and installation

Suspension and steering gear

• Specifications
• General description
• Front steering knuckle - removal and installation
• Front hub bearings - removing
• Front suspension strut - removal and installation
• Front suspension strut - disassembly
• The lower arm of the front suspension - removal, repair and installation
• Lower suspension ball joint - removal and installation
• Front anti-roll bar components - removing and refitting
• Front suspension subframe - removal and installation
• Rear hub - removal and installation
• Rear hub bearing - replacement
• Rear suspension components - general
• Rear shock absorber - removal, inspection and installation
• Rear axle assembly - removal and installation
• Vehicle ground clearance - check
• Steering wheel - removal and installation
• Steering column - removal, check and installation
• Ignition switch / steering column lock - removal and installation
• Steering gear - removal, bulkhead and installation
• Protective rubber covers for steering gear - replacement
• Power steering - bleeding
• Power steering pumpla - removal and installation
• Tie rod end - removal and installation
• Tie rod - removal and installation
• Wheel and steering angles - general description

Body and trim

• General description
• Body and subframe - service
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Serious damage to the body - refurbishment
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation and adjustment
• Bonnet lock cable - removal and installation
• Bonnet lock - removal and installation
• Front body panel - removal and installation
• Door - removal, installation and adjustment
• Interior door trim - removal and installation
• Details of the handle and door lock - removal and installation
• Glass and window regulator - removal and installation
• Trunk lid (Sedan models) - removal, installation and adjustment
• Details of the boot lid lock (Sedan models) - removal and installation
• Tail door and door stops (Universal models) - removal, installation and adjustment
• Details of the lock of the door of the lock (models "Universal") - removal and installation
• Central locking parts - removal and installation
• Power window components - removal and installation
• Exterior mirrors and related components - removal and installation

Body electrical equipment

• Specifications
• General description and precautions
• Troubleshooting electrical circuits - general description
• Fuses and relays - general description
• Switches - removal and installation
• External light bulbs - replacement
• Interior lighting lamps - replacement
• External lights - removal and installation
• Headlight beam adjustment - general description and component replacement
• Instrument panel - removal and installation
• Instrument cluster components - removal and installation
• Watch - removal and installation
• Cigarette lighter - removal and installation
• Light on warning system - general description
• Sound signal - removal and installation
• Speedometer cable - removal and installation
• Wiper arm - removing and installing
• Windshield wiper motor and linkage - removal and installation
• Rear wiper motor - removing and installing
• Windshield and headlight washer components - removal and installation
• Car radio - removal and installation
• Speakers - removal and installation
• Radio antenna - removal and installation
• Intruder alarm system - general description
• Airbags - general description, precautions and system shutdown
• Security details - removal and installation

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Steering and suspension
• Electrical system

Wiring diagrams