| Contents
Operating instructions
Maintenance
Dimensions and weight
Vehicle identification numbers
Weekly checks
Lubricants and fluids
Part A: Maintenance - gasoline models
Service specifications - gasoline models
Service plan - gasoline models
Part B: Maintenance - diesel models
Service specifications
Service plan - diesel models
4 cyl. gasoline engines - repair operations in the car
Specifications
General description
Compression check - description
Engine block and valve stroke labels - general description and use
Camshaft cover - removal and installation
Crankshaft pulley / vibration damper and hub - removal and installation
Drive chain cover - removal and installation
Drive chain - inspect and replace
Drive chain tensioner, sprockets and guides - removal, inspection and installation
Auxiliary shaft - removal, inspection and installation
Valve train, tappets and camshaft - removal, inspection and installation
Cylinder head - removal, inspection and installation
Pallet - removal and installation
Oil pump - removal, inspection and installation
Flywheel / drive disc - removal, inspection and installation
Crankshaft oil seals - replacement
Crankshaft bushing bearing - replacement
6 cyl. SOHC petrol engines - in-car repair operations
Specifications
General description
Compression check - description
Engine block and valve stroke labels - general description and use
Camshaft cover - removal and installation
Crankshaft pulley / vibration damper and hub - removal and installation
Drive chain covers - removal and installation
Drive chain - inspect and replace
Drive chain tensioner, sprockets and guides - removal, inspection and installation
Valve train, valve lifters and camshaft - removal, inspection and installation
Cylinder head - removal, inspection and installation
Pallet - removal and installation
Oil pump and drive chain - removal, inspection and installation
Flywheel / drive disc - removal, inspection and installation
Oil seals - replacement
6 cyl. DDHC gasoline engines - in-car repair operations
Specifications
General description
Compression check - description
Engine block and valve stroke labels - general description and use
Camshaft cover - removal and installation
Crankshaft pulley / vibration damper and hub - removal and installation
Drive chain covers - removal and installation
Drive chain - inspect and replace
Drive chain tensioner, sprockets and guides - removal, inspection and installation
Intake camshaft adjustment parts - removing and installing
Camshafts and valve lifters - removal, inspection and installation
Camshaft home position - check and adjust
Cylinder head - removal, inspection and installation
Pallet - removal and installation
Oil pump and drive chain - removal, inspection and installation
Flywheel drive disc - removal, inspection and installation
Specifications
Diesel engine - repair operations in the car
General description
Compression test and pressure hold - description
Engine and tags - general description and usage
Camshaft cover - removal and installation
Crankshaft pulley / vibration damper and hub - removal and installation
Drive chain cover - removal and installation
Drive chain - inspect and replace
Drive chain tensioner, sprockets and guides - removal, inspection and installation
Camshaft and valve lifters - removal, inspection and installation
Cylinder head - removal, inspection and installation
Pallet - removal and installation
Oil pump and drive chain - removal, inspection and installation
Flywheel / drive disc - removal, inspection and installation
Crankshaft oil seals - replacement
Engine removal and rebuilding procedures
Specifications
General description
Engine bulkhead - general description
Removing the engine - methods and precautions
Petrol engines with 4 cylinders - removal and installation
Petrol engines with 6 cylinders - removal and installation
Diesel engines - removal and installation
Dismantling the engine - dismantling sequence
Cylinder head disassembly
Cylinder head and valves - cleaning and inspection
Cylinder head assembly
Piston / connecting rod assembly - removal
Crankshaft - removal
Cylinder block / crankcase - cleaning and inspection
Piston / connecting rod assembly - cleaning and inspection
Crankshaft - inspection
Main and connecting rod bearings and cap bolts - inspection
Engine assembly sequence
Piston rings - installation
Crankshaft - installing the main bearing and checking the working clearance
Piston / connecting rod assembly - installing connecting rod bearing and checking working clearance
Engine - preparing to start after bulkhead
Cooling, heating and ventilation systems
Specifications
General description and precautions
Coolant hoses - disconnecting and replacing
Radiator - removal, inspection and installation
Thermostat - removal, testing and installation
Cooling fan - test, removal and installation
Electrical sensors of the cooling system - removal and installation
Cooling pump - removal and installation
Heating / ventilation system components - removal and installation
Air conditioning system - general description and precautions
Carburetor fuel systems
Specifications
General description and precautions
Air filter assembly and filter element - removal and installation
Air filter temperature control system - component test and replacement
Fuel pump - removal and installation
Fuel level indicator sensor - removal and installation
Fuel tank - removal and installation
Accelerator cable - removal, installation and adjustment
Carburetor Stromberg 175 CDT - general description and replacement of components
Pierburg 2E-E carburetor - general description and replacement of components
Carburetor - removal and installation
Intake manifold - removal and installation
Intake manifold heater - removal and installation
Fuel injection system Bosch KE-Jetronic
Specifications
General description and precautions
Accelerator cable - removal, installation and adjustment
Air filter and filter element - removal and installation
Fuel filter - removal and installation
Fuel accumulator - removal and installation
Fuel level indicator sensor - removal and installation
Fuel pump - removal and installation
Fuel tank - removal and installation
Throttle body - removal and installation
Intake manifold - removal and installation
KE-Jetronic injection system components - removal and installation
Fuel injection system - pressure relief
Adjusting the idle speed and CO content in the exhaust gas
Fuel injection system HFM Bosch (petrol engines)
Specifications
General description and precautions
Accelerator cable - removal, installation and adjustment
Air filter and filter element - removal and installation
Fuel filter - removal and installation
Fuel level sensor - removal and installation
Fuel pump - removal and installation
Fuel tank - removal and installation
Throttle body - removal and installation
Intake manifold - removal and installation
Bosch HFM fuel injection system components - removal and installation
Fuel injection system - pressure relief
Adjusting the idle speed and CO content in the exhaust gas
Diesel fuel injection systems
Specifications
General description and precautions
Air filter - removal and installation
Fuel level sensor - removal and installation
Fuel tank - removal and installation
Intake manifold - removal and installation
Accelerator cable - removal, installation and adjustment
High pressure fuel pump - removal and installation
Fuel suction pump - removal and installation
Injection timing adjustment mechanism and sprocket - removal and installation
Start of injection of high-pressure fuel pump - general description, check and adjustment
Injectors and high pressure fuel lines - removal and installation
ELR electronic idle speed control system - removing and installing components
Electronic anti-knock control system ARA - removal and installation of units
Electronic diesel management system (EDS) - removing and installing components
Engine overload protection system - removing and installing components
Fuel thermostat - removal and installation
Exhaust system and exhaust gas aftertreatment system
Specifications
General description
Fuel vapor recovery system - general description and replacement of components
Blow-by-blow system - general description
Exhaust manifold - removal and installation
Waste turf re-incineration (EGR) system - general description and component replacement
Turbine generator - removal and installation
Exhaust system - general description and replacement of components
Catalytic converters - general description and precautions
Starting and charging systems
Specifications
General description and precautions
Battery - check and charge
Battery - removal and installation
Alternator / charging system - car test
Generator - removal and installation
Alternator - brush holder / voltage regulator unit replacement
Engine starting system - test
Starter - removal and installation
Starter - bulkhead
Ignition system - 4 cyl. gasoline engines
Specifications
General description
Ignition system - test
High voltage ignition coil - removal and installation
Distributor - removal and installation
Distributor slider - removal and installation
Ignition timing - check and adjustment
Ignition control system assemblies - removal and installation
Ignition system - 6 cyl. gasoline engines
Specifications
General description
Ignition system - test
High voltage ignition coil - removal and installation
Distributor and distributor slider - crumpled and installed
Ignition timing - check and adjustment
Ignition system control units - removal and installation
Preheating system - diesel engines
Specifications
General description
Glow plug control unit - removal and installation
Glow plugs - test, removal and installation
Coolant temperature sensor - removal and installation
Clutch
Specifications
General description
Clutch assembly - removal, inspection and installation
Bearing and clutch release lever - removal, inspection and installation
Slave cylinder - removal, bulkhead and installation
Master cylinder - removal, bulkhead and installation
Hydraulic system - pumping
Clutch pedal - removal and installation
Mechanical transmission
Specifications
General description
Manual transmission fluid drain and filling
Gear selector components - removal, installation and adjustment
Oil seals - replacement
Reversing light switch - checking, removing and installing
Mechanical transmission - removal and installation
Mechanical transmission overhaul - general description
Automatic transmission
Specifications
General description
Gear selector lever - removal and installation
Gear shift rod - adjustment, removal and installation
Pressure control cable - adjust
Starter lock / reversing light switch - removal, installation and adjustment
Automatic transmission - removal and installation
Bulkhead automatic transmission - general description
Main gear, drive and cardan shafts
Specifications
General description
Final drive unit - fluid drain and filling
Final drive block - removal and installation
Final drive block oil seals - replacement
Drive shaft - removal and installation
Protective covers for drive shaft CV joints - replacement
Cardan shaft - removal and installation
Propshaft rubber coupling - check and replace
Propshaft bearing - check and replacea
Universal joint for propshaft - check and replace
Braking system
Specifications
General description
Hydraulic system - pumping
Hydraulic pipes and hoses - replacement
Front brake pads - replacement
Rear brake pads - replacement
Front brake disc - inspection, removal and installation
Rear brake disc - inspection, removal and installation
Front brake caliper - removal, bulkhead and installation
Rear brake caliper - removal, bulkhead and installation
Master cylinder - removal, bulkhead and installation
Vacuum booster - check, removal and installation
Check valve of the vacuum booster. - removal, check and installation
Parking brake - adjustment
Parking brake shoes - removal and installation
Parking brake pedal - removal and installation
Parking brake cables - removal and installation
Brake light switch - removal and installation
Anti-lock braking system (ABS) - general description
ABS system components - removal and installation
Brake vacuum pump (diesel models) - check, removal and installation
Suspension and steering
Specifications
General description
Front hub bearing - check and adjust
Front hub assembly - removal, bulkhead and installation
Front steering knuckle - removal and installation
Front suspension shock absorber - removal, bulkhead and installation
Front suspension coil spring - removal and installation
Front suspension lower arm - removal, bulkhead and installation
Front suspension anti-roll bar - removal and installation
Rear hub retainer - removing and installing
Rear hub bearing - replacement
Rear suspension shock absorber - removal, testing and installation
Rear suspension coil spring - removal and installation
Rear suspension arms - removal and installation
Rear suspension lower arm - removal, bulkhead and installation
Rear suspension anti-roll bar - removal and installation
Anti-roll bar linkage - removal and installation
Rear suspension self-adjusting system (station wagon) - general description
Self-leveling rear suspension components (station wagon) - removal and installation
Steering wheel - removal and installation
Steering column - removal, check and installation
Steering column lock / ignition switch - removal and installation
Steering column rubber sleeve - removal and installation
Steering box - removal, bulkhead and installation
Steering arm of the steering box - removal and installation
Steering block lower gasket - replacement
Power steering pump - removing and installing
Power steering system - bleed
Steering damper - removal and installation
Tie rod - removal and installation
Intermediate steering lever - removal and installation
Tie rod ball joints - removal and installation
Tie rod - removal and installation
Wheel alignment and steering angles - general description
Body
Specifications
General description
Front bumper - removal and installation
Rear bumper - removal and installation
Hood - removal, installation and adjustment
Bonnet cable - removal and installation
Bonnet lock - removal and installation
Doors - removal, installation and adjustment
Interior door trim panel - removal and installation
Door handle and lock components - removal and installation
Door glass and window regulator - removal and installation
Trunk lid - removal and installation
Trunk lid lock - removal and installation
Rear door - removal and installation
Rear door lock components - removal and installation
Central locking components - removal and installation
Window electrical components - removal and installation
Exterior mirrors and related components - removal and installation
Windshield and rear window - general description
Luke - general description
External body parts - removal and installation
Seats - removal and installation
Seat belt tensioning mechanism and front seat - general description
Seat belt components - removal and installation
Central pools - removal and installation
Electrical system
Specifications
General description and precautions
Finding a short circuit in an electrical circuit - general description
Fuses and relays - general description
Switches - removal and installation
Incandescent pumps external lighting fixtures - replacement
Interior lighting pumps - replacement
Blocks of external lighting - removal and installation
Headlight range control - general description
Dashboard - removal and installation
Dashboard components - removal and installation
Speedometer cable - removal and installation
Cigarette lighter lighting - removal and installation
Sound signal - removal and installation
Wiper arm - removing and installing
Electric motor and wiper gear - removal and installation
Rear door wiper motor - removal and installation
Windshield / headlamp washer system components - removal and installation
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Clutch
Mechanical transmission
Automatic transmission
Differential and propeller shaft
Braking system
Suspension and steering
Electrical system
Wiring diagrams |
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