Contents

Operating instructions

Maintenance

• Overall dimensions and weight
• Lubricants and fluids
• Tire pressures (cold)
• Part A: Maintenance - gasoline models
• Service schedule
• Engine
• Cooling, heating and ventilation systems
• Fuel and exhaust systems
• Ignition system
• Manual transmission and automatic transmission
• Drive shafts
• Hydraulic brake system
• Suspension and steering
• Body
• Electrical system
• Part B: Maintenance - diesel models
• Service Schedule
• Every 10,000 or 15,000 km
• Every 30,000 or 35,000 km
• Every 60,000 or 65,000 km
• Every 115,000 or 130,000 km

Repair of the E series gasoline engine in the engine compartment

• Specifications
• General description
• Compression check - description
• Top dead center (TDC) for piston #1 - location
• Valve clearances - adjustment
• Cylinder head - removal and installation
• Toothed drive belt - removal, inspection and installation
• Sprockets and tensioner - removal, inspection and installation
• Camshaft oil seal - replacement
• Camshaft - removal, inspection and installation
• Pallet - removal and installation
• Oil pump and sprockets - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine mounts - replacement
• Flywheel / drive disc - removal, inspection and installation

Repair of a C series gasoline engine in the engine compartment

• Specifications
• General description
• Compression check - description
• Top dead center (TDC) for piston #1 - location
• Valve clearances - adjustment
• Cylinder head - removal and installation
• Drive cover, chain and sprockets - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine mounts - replacement
• Flywheel - inspection removal and installation

Repair of the F series gasoline engine in the engine compartment

• Specifications
• General description
• Compression check - description
• Top dead center (TDC) for piston #1 - location
• Valve clearances - adjustment
• Cylinder head - removal, inspection and installation
• Toothed drive belt - removing and installing
• Sprockets and tensioners - removal, inspection and installation
• Camshaft oil seal - replacement
• Camshaft - removal, inspection and installation
• Intermediate shaft - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine mounts - replacement
• Flywheel / drive disc - removal, inspection and installation

Diesel engine repair in the engine compartment

• Specifications
• General description
• Checking the compression and tightness of the component joints - description
• Top dead center (TDC) for piston #1 - location
• Valve clearances - check and adjust
• Toothed drive belt - removal, inspection and installation
• Drive belt sprockets and tensioner - removal and installation
• Camshaft oil seals - replacement
• Camshaft and tappets - removal, inspection and installation
• Cylinder head - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine / transmission mounts - replacement
• Oil cooler - removal and installation
• Intermediate shaft oil seal - replacement
• Flywheel - removal, inspection and installation

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Removing the engine - methods and precautions
• Gasoline engine (C series) - removal and installation (without transmission)
• Gasoline engine - removal and installation (with transmission)
• Diesel engine and gearbox - removal and installation
• Engine overhaul - disassembly sequence
• Cylinder head disassembly
• Block headcylinders and valves - cleaning, inspection and maintenance
• Cylinder head assembly
• Intermediate shaft - removal and installation
• Camshaft and tappets (C series engine) - removal, inspection and installation
• Piston / connecting rod assemblies - removal
• Crankshaft - removal
• Cylinder block / crankcase and cylinders - cleaning and inspection
• Piston / connecting rod assemblies - inspection and assembly
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine overhaul - assembly sequence
• 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 air conditioning systems

• Specifications
• General description
• Electric fan assembly - removal and installation
• Fan thermal switch - serviceability check, removal and installation
• Coolant temperature gauge sensor - removing and installing
• Radiator - removal, inspection, cleaning and installation
• Thermostat - removal, check and installation
• Water pump - removal and installation
• Alternator / water pump drive belt - replace and adjust
• Heater block - removal and installation
• Heater blower unit - removal and installation
• Heater matrix - removal and installation
• Heater resistor block - removal and installation
• Heater control panel - removal and installation
• Heater control cables - removal and installation
• Air conditioning components - removal and installation

Fuel and exhaust systems - carburetor models

• Specifications
• General description and precautions
• Air filter housing assembly - removal and installation
• Fuel priming pump - check, removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel filler pipe - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Choke cable - removal, installation and adjustment
• Unleaded gasoline - general description and use
• Carburetor - general description
• Carburetor - removal and installation
• Carburetor - troubleshooting, bulkhead and adjustment
• Intake manifold heater (F engine) - removing and installing
• Intake / exhaust manifold (engine C) - removal and installation
• Intake and exhaust manifolds (engine F) - removal and installation
• Intake manifold (engine E) - removal and installation
• Exhaust manifold (engine E) - removal and installation
• Exhaust system - general description and replacement of components
• Crankcase ventilation system - general description

Fuel and exhaust systems - injection models

• Specifications
• General description and precautions
• Air filter assembly and intake ducts - removal and installation
• Air temperature control system (central injection) - general description
• Gas pedal cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Unleaded gasoline - general description and use
• Fuel injection systems - general description
• Fuel injection system - depressurization
• Fuel priming 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
• Central injection system components - removal and installation
• Distributed injection system components - removal and installation
• Collectors - removal and installation
• Exhaust system - general description, removal and installation

Fuel and exhaust systems diesel models

• Specifications
• General description and precautions
• Air filter cover - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Fuel system - filling and bleeding
• Maximum engine speed - check and adjust
• Thermal actuator and cable for fast idle -removing, installing, checking and adjusting
• Fuel cut-off valve - description, removal and installation
• Fuel pump - removal and installation
• Injection timing - check and adjustment methods
• Injection timing - check and adjust
• Fuel injectors - check, removal and installation
• Collectors - removal and installation
• Turbine generator - description and precautions
• Turbine generator - inspection and maintenance
• Exhaust system - general description and replacement of components

Ignition system - petrol models

• Specifications
• Transistorized ignition system with interrupter
• General description
• Ignition system - health check
• Distributor - removal, bulkhead and installation
• Contactless ignition system
• General description and precautions
• Ignition coil - removal and installation
• Transistor block - removal and installation
• Ignition system - health check
• Distributor - removal, bulkhead and installation
• Ignition coil - removal and installation
• Control unit - removal and installation
• Position / speed sensor - removal and installation

Preheating system - diesel models

• Specifications
• Preheating system - description and check
• Glow plugs - removal, inspection and installation
• Control unit for preheating system - removal and installation
• Post-heating stop microswitch - check, adjust, remove and install
• Fuel filter heating system - general description and component replacement

Clutch

• Specifications
• General description
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation
• Release bearing - removal, inspection and installation

Mechanical transmission

• Specifications
• General description
• Gear shift mechanism - adjustment
• Gear lever / rod assembly - removal and installation
• Speedometer drive - removal and installation
• Differential drive shaft oil seal - replacement
• Reversing light switch - removal and installation
• Mechanical transmission - removal and installation
• Mechanical transmission overhaul - general description

Automatic transmission

• Specifications
• General description
• Gear selection mechanism - adjustment
• Lever and cable for selecting the driving mode - removal and installation
• Speedometer drive - removal and installation
• Differential drive shaft oil seal - replacement
• Multifunction switch - removal and installation
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description

Drive shafts

• Specifications
• General description
• Drive shaft - removal and installation
• Protective cover for external tripoid CV joint - replacement
• Protective cover for external ball joint - replacement
• Protective cover for inner CV joint of the right drive shaft (G1 62) - replacement
• Protective cover for inner CV joint for right drive shaft (RC 490) - replacement
• Inner protective cover and bearing of the left driveshaft - replacement
• Plastic protective cover - replacement

Braking system

• Specifications
• General description
• Brake pedal - removal and installation
• Vacuum booster unit - serviceability check, removal and installation
• Unidirectional valve of the vacuum booster - removal, service check and installation
• Vacuum booster air filter - replace
• Hydraulic brake system - bleeding
• Brake pipes and hoses - inspection, removal and installation
• Master cylinder (models without ABS) - removal and installation
• Front brake pads - replacement
• Front brake caliper - removal, bulkhead and installation
• Front brake disc - inspection, removal and installation
• Rear brake drum - removal, inspection and installation
• Rear drum brake pads - replacement
• Rear brake cylinder - removal and installation
• Rear disc brake pads - replacement
• Rear brake caliper - removal, bulkhead and installation
• Rear brake disc - inspection, removal and installation
• Lever black brake - removal and installation
• Handbrake cable - removal and installation
• Brake light switch - removal and installation
• ABS - general description

Suspension and steering gear

• Specifications
• General description
• Front wheel knuckle - removal and installation
• Front wheel bearing - check, removal and installation
• Front suspension strut - removal and installation
• Front suspension strut - disassembly, inspection and assembly
• Front anti-roll bar - crush and install
• Removal and installation of the lower arm of the front suspension
• Front suspension ball joint - replacement
• Rear wheel hub bearings - check, removal and installation
• Rear shock absorber - removal, service check and installation
• Rear anti-roll bar (rear axle with closed torsion bars) - removal and installation
• Rear suspension torsion bar - removal and installation
• Rear suspension trailing arm (with closed torsion bars) - removal and installation
• Rear suspension traverse bearings (closed torsion bars) - replacement
• Rear suspension bearing bracket bushings (enclosed torsion bars) - replacement
• Rear axle (with open torsion bars) - removal, bulkhead and installation
• Underbody / suspension overhang - check and adjust
• Steering wheel - removal and installation
• Steering column shaft - removing, checking length and installing
• Steering gear cover - replacement
• Steering gear (models without amplifier) - removal and installation
• Steering gear (power-assisted models) - removal and installation
• Power steering pump - removal and installation
• Power steering hydraulic system - bleeding
• Tie rod end ball joint - removal and installation
• Wheel alignment angles - general description

Body

• Specifications
• General description
• Service - body and bottom
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Front and rear bumpers - removal and installation
• Hood - removal, installation and adjustment
• Bonnet cable - removal and installation
• Bonnet lock - removal and installation
• Interior door trim panel - removal and installation
• Door glass and regulator - removal and installation
• Door lock, lock cylinder and handles - removal and installation
• Door - removal, installation and adjustment
• Outside mirror and its casing - removal and installation
• Trunk lid - removal, installation and adjustment
• Trunk lid support - removing and installing
• Trunk lid lock and lock cylinder - removal and installation
• Rear door, opening upwards - removal, installation and adjustment
• Rear door support pillar - removal and installation
• Luggage compartment door lock and lock cylinder - removal and installation
• Luke - general description
• Center console - removal and installation
• Panel - remove n install

Electrical system

• Specifications
• General description and precautions
• Troubleshooting - electrical system - general description
• Battery - test and charge
• Battery - removal and installation
• Charging system - functional check
• Generator - removal and installation
• Alternator brushes and regulator - check and replace
• Launch system - health check
• Starter - removal and installation
• Starter brushes - check and replace
• Fuses and relays - general description
• Switches - removal and installation
• Lamps (external) - replacement
• Lamps (internal) - replacement
• Blocks of external lights - removal and installation
• Dashboard - removal and installation
• Dashboard components - removal and installation
• Cigarette lighter - removal and installation
• Watch - removal and installation
• Sound signal - removal and installation
• Speedometer cable - removal and installation
• Wiper motor and rod - removal and installation
• Wiper motor and rear door rod - removal and installation
• Windshield / tailgate / headlight washer system components - removal and installation
• Radio tape recorder - removal and installation
• Radio antenna - removal and installation

Troubleshooting

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

Wiring diagrams (wiring diagrams)