Content

Operating instructions

Maintenance

• Car care
• Starting the engine using a booster battery
• Car towing
• Jacking up the car
• Maintenance plan
• Engine oil and oil filter - change
• Ancillary drive ribbed belt - check and replace
• Coolant - check level, concentration, change
• Transmission oil - check level
• Brake fluid - check level, change
• Brake lines and hoses - check
• Spark plugs - replacement
• Air filter element - replace
• Fuel filter - change
• Exhaust system - visual inspection
• Suspension and steering
• Gearbox
• Body
• Cabin filter - replacement
• Wheels and tires
• Battery - checking electrolyte level

Gasoline engines - repair without dismantling

• Specifications
• General information
• Vehicle identification number
• Compression test
• Timing belt - removal and installation
• Front camshaft oil seal - replacement
• Rear camshaft oil seal - replacement
• Camshafts and pushers - removal, inspection, installation
• Cylinder head - removal and installation
• Crankshaft oil seals - replacement
• Oil pump - removal, check, installation
• Flywheel / drive disc - removal, inspection, installation
• Engine mounts - removal and installation

Gasoline engines - removal and installation, general bulkhead procedures

• Specifications
• Engine overhaul - general information
• Engine / gearbox - removal, disconnection, installation
• Cylinder head - disassembly, cleaning, inspection and assembly
• Oil pan - removal and installation
• Connecting rod-piston group - removal, check and installation
• Crankshaft - removal, check, - installation
• Cylinder block - cleaning and inspection
• Main and connecting rod bearings - check
• Piston rings - installation
• Engine - preparing to start after bulkhead

Diesel vehicles

• Specifications
• General information
• Power block - removal and installation. Diesel engine D49T
• Cylinder head - removal, inspection and installation
• Compression - check
• Valve clearance - adjustment
• Timing belt and ribbed accessory drive belt - removing and installing
• Camshaft oil seal - removal and installation
• Rear crankshaft oil seal - removing and installing
• Power block - removal and installation. Diesel engine D49T
• Cylinder block - bulkhead
• Engine oil pressure - check
• Oil pan - removal and installation
• Oil pump - removal and installation
• Oil cooler - removal and installation

Cooling, heating and ventilation system

• Specifications
• Cooling system - general information
• Radiator - removal, check, installation
• Thermostat - removal and installation
• Radiator blower - removal and installation
• Coolant temperature sensor - removal and installation
• Coolant pump (water pump) - removal and installation
• Heating and air conditioning - general information
• Heating system components - removal and installation

Injection system - petrol engines

• Specifications
• General information
• Fuel injection system - general check
• Fenix ??5.1 injection system components - removal and installation
• EMS 2000 injection system components - removal and installation
• Intake manifold - removal and installation

Power system - diesel engines

• The principle of operation of a diesel engine
• Preheating unit - checking, removing and installing glow plugs
• Preheating unit relay - removal and installation

Fuel system

• Specifications
• General information
• Air filter and air ducts - removal and installation
• Charge air cooling radiator (intercooler) - removal and installation
• Accelerator cable - removal, installation, adjustment
• Fuel pump / fuel level sensor - removal and installation
• Fuel filler neck - removal and installation
• Fuel tank - removal and installation

Exhaust system

• Specifications
• General information
• Exhaust system - removal and installation
• Catalyst - general information
• Exhaust manifold - removal and installation
• Turbocharger - general information
• Turbocharger - removal and installation
• Oxygen sensor (lambda probe) - replacement
• Exhaust system - leak test

Ignition system

• Specifications
• General information
• Ignition coil - removal and installation
• Knock sensor - removal and installation
• Ignition timing - check

Clutch

• Specifications
• General information
• Clutch pedal - removal, installation, adjustment
• Clutch master cylinder - removal and installation
• Clutch slave cylinder - removal and installation
• Hydraulic clutch system - bleeding
• Coupling - removal, inspection and installation
• Release bearing - removal, inspection and installation

Mechanical transmission

• Specifications
• General information
• Protective cover for gear lever - removal and installation
• Gear shift cables / pull rod - removal and installation
• Oil seals - replacement
• Reversing light switch - removal and installation
• Transmission oil - change
• Manual transmission - removal and installation

Automatic transmission

• Specifications
• General information
• Transmission oil - change
• Gear selector cable - removal, adjustment and installation
• Protective cover for gear lever - removal and installation
• Transmission control system sensors - removal and installation
• Kick down switch - removal and installation
• Electronic transmission control unit (ECU) - removal and installation
• Oil seals - replacement
• Automatic transmission - removal and installation

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• Outer CV joint protective cover - replacement
• Protective cover for inner CV joint - replacement
• Right drive shaft intermediate support (vehicles with turbocharger) - replacement
• Wheel alignment angles

Braking system

• Specifications
• General information
• Brake system - bleeding
• Brake hoses and lines - replacement
• Front brake pads - replacement
• Rear brake pads - replacement
• Brake discs - check, removal and installation
• Front wheel brake caliper - removal, disassembly and installation
• Rear wheel brake caliper - removal, disassembly and installation
• The main brake cylinder - removal, disassembly, installation
• Brake pedal - removal and installation
• Vacuum brake booster - check, removal and installation
• Unidirectional valve of the vacuum brake booster - removal, check, installation
• Parking brake - adjustment
• Parking brake lever - removal and installation
• Parking brake cable - removal and installation
• Rear wheel brake force regulator - checking, removing and installing
• Brake light switch - removal, installation, adjustment
• Anti-lock braking system (ABS) - general information
• Anti-lock braking system components - removal and installation

Suspension and steering

• Specifications
• General information
• Steering knuckle / front wheel hub - removing and installing
• Front wheel hub bearings - replacement
• Front suspension strut - removal and installation
• Front Suspension Strut - Disassembly
• The lower arm of the front suspension - removal, disassembly, installation
• Front suspension anti-roll bar support - removal and installation
• Front suspension anti-roll bar - removal and installation
• Front suspension subframe - removal and installation
• Rear wheel hub / knuckle - removal and installation
• Rear wheel hub bearings - replacement
• Rear suspension strut - removal and installation
• Rear suspension strut - disassembly
• Rear suspension upper arm - removal and installation
• Rear suspension longitudinal balancer - removal and installation
• Rear suspension lower arm - removal, disassembly, installation
• Rear suspension trailing arm - removal, disassembly, installation
• Anti-roll bar support - removal and installation
• Rear suspension anti-roll bar - removal and installation
• Steering wheel - removal and installation
• Steering column - removal and installation
• Ignition switch / steering column lock - removal and installation
• Steering gear - removal and installation
• Steering cuff - replacement
• Power steering - bleeding
• Power steering pump - removal and installation
• Tie rod ball joint - removing and installing
• Tie rod - removal and installation

Body and interior trim

• Specifications
• General information
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation, fitting
• Bonnet opening cable - removal and installation
• Bonnet lock - removal, installation, adjustment
• Door - removal, installation, fitting
• Door trim - removal and installation
• Handle and door lock - removal and installation
• Door glass and window regulator - removal and installation Trunk lid - removal and installation
• Trunk lock - removal and installation
• Rear hinged door - removal and installation
• Tailgate lock - removal and installation
• Central locking components - removal and installation
• Exterior mirrors - removal and installation
• Seats - removal and installation
• Safety belt tensioner precautions
• Seat belts - removal and installation
• Center console - removal and installation
• Dashboard - removal and installation

Electrical system

• Specifications
• General information
• Battery - removal and installation
• Generator - removal and installation
• Starter - removal and installation
• Troubleshooting electrical equipment
• Fuse and relay box - general information
• Switches - removal and installation
• Outdoor bulbs - replacement
• Interior light bulbs - replacement
• Outdoor lighting - removal and installation
• Instrument panel - removal and installation
• Speedometer drive cable - removal and installation
• Cigarette lighter - removal and installation
• Sound signal - removal and installation
• Windshield / tailgate wiper levers - removal and installation
• Electric motor and wiper drive rods - removal and installation
• Tailgate glass wiper motor (station wagons) - removal and installation
• Windshield / headlamp / tailgate washer components - removal and installation
• Radio receiver - removal and installation
• Speakers - removal and installation
• Radio antenna - removal and installation
• Airbag - precautions, removal and installation

Troubleshooting

• Identification of engine faults and their elimination
• Identification of malfunctions of the engine lubrication system and their elimination
• Identification of engine cooling system malfunctions and their elimination
• Determination of malfunctions of the petrol injection system and their elimination
• Determination of malfunctions of the diesel engine power system and their elimination
• Determination of malfunctions of the brake system and their elimination
• Clutch troubleshooting
• Battery troubleshooting
• List of starter malfunctions and their elimination
• Identify and troubleshoot generator faults
• Identifying and fixing wiper faults

Basic electrical diagrams