Contents

Basic electrical diagrams

Operating instructions

Maintenance

• Car care
• Starting the engine using a booster battery
• Vehicle towing
• Jacking up the car
• Maintenance - works
• Cooling system - check
• Brake system - check
• Suspension and steering - check
• Exhaust system - visual inspection
• Gearbox - visual leak check
• Replaceable air filter element - replace

EW and ES series gasoline vehicles

• Specifications
• General information
• Timing belt - removal and installation
• Accessory drive belt - removal and installation, tension adjustment
• Cylinder head - removal and installation
• Camshafts - removal and installation
• Power block - removal and installation
• Engine - disassembly and assembly

Diesel vehicles of the DW series

• Specifications
• General information
• Compression - check
• Ribbed belt of accessory drive - removal and installation
• Timing belt - removal and installation
• Cylinder head - removal and installation
• Camshafts - removal and installation
• Engine - disassembly and assembly
• Balancing shafts - removal and installation
• Engine - removal and installation

Cooling, ventilation and heating system

• General description
• Radiator - removal and installation
• Water pump - removal and installation
• Coolant - draining, filling and venting
• Heater - removal and installation
• Interior blower - removal and installation
• Air conditioner - general information

Fuel injection system - gasoline engines

• General information
• Fuel injection system - general check
• Intake manifold - removal and installation
• ES9J4S engine intake manifold intake pipe - removal and installation

Power system - diesel engines

• General information
• Power system - check
• High pressure fuel pump - removal and installation
• Turbocharger - removal and installation
• Preheat system - check
• Vacuum pump - general information

Fuel system

• General provisions
• Fuel tank, fuel pump and fuel gauge sensor - removal and installation
• Fuel filter - removal and installation
• Fuel rail and fuel injectors - removal and installation
• Fuel injectors - check
• Soot prevention system - functioning
• Additive reservoir and reservoir pump - removal and installation
• Diesel temperature sensor - general information
• Fuel filler flap - removal and installation
• Fill cap sensor - general information

Exhaust system

• General description
• Exhaust manifold - removal and installation
• Silencer intake pipes - removal and installation. Cars with ES9J4S petrol engine
• Particulate filter - removal and installation
• Diesel exhaust system sensors - general information
• Exhaust gas recirculation - general information
• Mechanical valve for exhaust gas recirculation - removing and installing

Ignition system

• General description and precautions
• Spark plugs - removal and installation
• Ignition system - troubleshooting

Clutch

• General description
• Coupling - removal, installation and inspection
• Clutch release fork and release bearing sleeve - removal and installation
• Clutch drive - removal and installation
• Clutch actuator - bleeding

Mechanical transmission

• Specifications
• General information
• Gearbox - removal and installation
• Gear shift mechanism - removal and installation
• Transmission cover - removing and installing
• Differential housing - removal and installation

Automatic transmission

• Specifications
• General information
• Gearbox - removal and installation
• Transmission oil - check level, change
• Torque converter - removal and installation
• Modulator - removal and installation
• Transmission sensors - removal and installation
• Radiator for transmission oil cooling - removing and installing

Braking system

• Specifications
• General description
• Front brake caliper - removing and installing
• Rear wheel brake caliper - removal and installation
• Front wheel brake pads - removal and installation
• Rear brake pads - removal and installation
• Brake discs - check, removal and installation
• Vacuum brake booster - removal and installation
• Parking brake - adjustment
• Brake system - fluid filling and bleeding
• Additional car safety systems - general information

Suspension and steering

• Specifications
• Front suspension - general information
• Shock absorber - removal, installation and bulkhead
• Front wheel hub and hub bearing - removal and installation
• Lower wishbone - removal and installation
• Steering knuckle - removal and installation
• Anti-roll bar - removing and installing
• Rear suspension - general information
• Rear axle cross member - removal and installation
• Rear hub and hub bearing - removal and installation
• Drive shafts - removal, installation and replacement
• Steering - general information
• Steering column - removal and installation
• Steering gear - removal and installation
• Tie rod - removal and installation

Body and interior trim

• General description and precautions
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Front wing - removal and installation
• Rear wing - removal and installation
• Subframe - removal and installation
• Front door - removal, disassembly, installation
• Window regulator - removal and installation
• Tailgate trim - removal and installation
• Sliding door - removal and installation
• Front seats - removal and installation
• Gloves - removal and installation
• Heater / air conditioner switch panel - removal and installation
• Dashboard - removal and installation

Electrical system

• General description
• Battery - check
• Starter - removal, disassembly, inspection and installation
• Generator - check, remove and install
• Lighting - removal and installation of bulbs
• Front glass cleaner - removing and installing

Troubleshooting

Basic electrical diagrams