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Operating instructions
Maintenance
Weight and dimensions
Specifications
Capacities
Lubricants and fluids
Maintenance
Service
Vehicle identification numbers
Service procedures
General description
Intensive service
Weekly checks
Checking fluid levels
Tire check
Tire wear pattern
Every 10,000 km or every 6 months
Changing engine oil and filter
Checking the electrical system
Oil filler cap cleaning - OHV and HCS engines
Check for leaks
Exhaust manifold nuts tightness test - RS turbocharged models
Adjustment of frequency of idling and quality of mix
Checking ignition system components
Distributor lubrication - contact breaker models
Breaker contact plate adjustment - contact breaker models
Checking the ignition timing - models with contact breaker
Changing spark plugs - RS turbocharged models
Checking the brake pads of the front brake
Checking the brake pads of the rear brake
Suspension and steering test
Check seat belts
Checking the alternator drive belt
Every 20,000 km or after 12 months
Valve clearance adjustment - OHV and HCS engines
Exhaust system check
Checking the tightness of the turbogenerator nuts to the manifold - RS turbocharged models
Replacing spark plugs
Replacing breaker contact plates
Checking the gearbox oil level
Automatic transmission fluid level check
Testing the automatic transmission selection mechanism
Drive shaft check
Checking the wheels
Lubricating doors, bonnet and locks
Road test
Every 40,000 km or after 2 years
Coolant replacement
Replacing the air filter element
Crankcase ventilation filter replacement - CVH Engines
Replacing the fuel filter - engines with fuel injection system
Every 60,000 km or after 3 years
Timing belt replacement - CVH engines
Inspecting brake components
Brake fluid replacement
OHV and HCS gasoline engines
Specifications
General description
Repair work in the engine compartment
Basic operations requiring engine removal
Cylinder head - removing and installing
Pallet - removal and installation
Valve mechanism - bulkhead
Crankshaft front oil seal - replacement
Piston / connecting rod assembly - removing and installing
Engine / transmission mounts - removing and installing
Oil pump - removal - refitting
Engine / driveline - removal and separation
Engine - disassembly
Inspection and maintenance
Cylinder head and pistons - carbon cleaning
Engine assembly
Engine / driveline - coupling and installation
CVH gasoline engines
Specifications
General description
Repair work in the engine compartment
Basic operations requiring engine removal
Timing belt - removing, installing, and adjusting
Glands - replacement
Camshaft - removing and installing
Cylinder head - removing and installing
Pallet - removal and installation
Pistons / connecting rods - removal and installation
Engine / transmission mounts - removing and installing
Engine / driveline - removal and separation
Engine - disassembly
Inspection and maintenance
Cylinder head and pistons - carbon cleaning
Engine assembly
Engine / driveline - coupling and installation
Engine oil cooler - removing and installing
Diesel engine
Specifications
General description
Service and inspection
The main operations performed without removing the engine from the car
Engine oil and oil filter - replacement
Timing drive belt - inspecting and checking tension
Timing belt - removing, installing and tensioning
Valve clearances - check and adjust
Camshaft - removing and installing
Installation of gas distribution phases - check and adjustment
Cylinder head - removing and installing
Cylinder head - bulkhead
Cylinder head and pistons - carbon cleaning
Glands - replacement
Pallet - removal and installation
Drive and gear cover - removal and installation
Drive cover - removing and installing
Oil pump - removing, inspecting, and installing
Pistons and connecting rods - removal and installation
Flywheel - removal and installation
Engine / transmission mounts - removing and installing
Engine removal methods
Engine and transmission - removal
Engine and transmission - separation
Dismantling the engine - a general description
Engine - complete disassembly
Inspection and maintenance - general description
Engine components - inspection and maintenance
Engine assembly - general description
Engine assembly
Engine - transmission connection
Engine and transmission - installation
Engine - startup after bulkhead
Compression testing - description
Cooling, heating and ventilation systems
Specifications
General description
Fan - removing and installing
Radiator - removal, inspection and installation
Thermostat - removing, inspecting and installing
Water pump - removal and installation
Fan thermal switch - check, remove h installation
Thermal sensor - removing and installing
Heating and ventilation system - description
Panel and heater control cables - adjustment
Heater control panel and cables - removal and installation
Heater - removal - refitting
Heater matrix - removing and installing
Supercharger motor / impeller - removal and installation
Carburetor fuel system
Specifications
General information and precautions
Air filter assembly - removal and installation
Air temperature control in the air filter - description and verification
Fuel priming pump - cleaning
Fuel priming pump - inspection, removal and installation
Fuel tank - removal and installation
The gas pedal cable - adjustment, removal and installation
Gas pedal - removal and installation
Choke lever cable - removing, installing, and adjusting
Manual air damper block on a carburetor Ford VV - removal, inspection and installation
Components of an automatic air damper carburetor Ford VV - removal, inspection and installation
Carburetor Ford VV - removing and installing
Weber 2V carburetor - adjustment
Weber 2V carburetor automatic choke unit - adjustment
Block Weber 2V carburetor automatic air damper - removal, inspection and installation
Weber 2V carburetor - removal and installation
Carburetor bulkhead - general description
Mechanical fuel injection systems Bosch K - Jetronic and Bosch KE - Jetronic
Specifications
General description and precautions
Air filter - removal - refitting
Fuel tank - removal and installation
Gas cable - adjustment, removal and installation
Gas pedal - removal and installation
Fuel pump - removal - refitting
Fuel accumulator - removal - refitting
Fuel nozzles and fuel supply pipes to them - removal and installation
Cold start valve - removing and installing
Additional air supply unit - removal and installation
Fuel dispenser - removing and installing
Throttle body - removing and installing
Fuel pressure regulator - removing and installing
Warm-up regulator - removal and installation
Electromagnetic pressure regulator actuator - removal - refitting
Fuel injection control module - removal - refitting
Air temperature sensor - removing and installing
Fuel launcher switch - removing and installing
The idle speed compensator - removal and installation
Turbo generator - general description
Charge control valve - removing and installing
Intercooler - removing and installing
Turbogenerator - removal and installation
Central fuel injection system (CFI)
Specifications
General description and precautions
Air filter - removal - refitting
Fuel tank - removal and installation
Gas cable - adjustment, removal and installation
Gas pedal - removal and installation
Fuel system - depressurization
Fuel pump - removal - refitting
The block of the central injection of fuel - removal and installation
Fuel pressure regulator - removing and installing
Fuel injector - removal and installation
Throttle position sensor - removing and installing
Throttle drive motor - removing and installing
Air temperature sensor - removing and installing
Coolant temperature sensor - removing and installing
Knock sensor - removing and installing
Manifold pressure sensor - removing and installing
Oxygen sensor (HEGO) - removal - refitting
Fuel supply switch (inertial) - removal and installation
Speed ??sensor - removing and installing
The EEC IV control unit - removal and installation
Electronic distributed fuel injection system (EP1)
Specifications
General description and precautions
Air filter - removal - refitting
Fuel tank - removal and installation
Gas cable - adjustment, removal and installation
Gas pedal - removal and installation
Fuel system - depressurization
Fuel pump - removal - refitting
Fuel pressure regulator - removing and installing
Throttle body - removing and installing
Fuel injectors - removing and installing
Throttle position sensor - removing and installing
Idle speed ??control valve - removing, cleaning, and installing
Manifold pressure sensor - removing and installing
Intake air temperature sensor - removing and installing
Coolant temperature sensor - removing and installing
Speed ??sensor - removing and installing
Potentiometer for adjusting the mixture - removal and installation
Fuel switch (inertial) - removal and installation
The EEC IV control unit - removal and installation
Manifolds, exhaust system and exhaust gas aftertreatment system
Specifications
General description
Intake manifold - removing and installing
Exhaust manifold - removing and installing
Exhaust system - replacement
Components of a fuel vapor extraction system (CFI engines) - removal and installation
Crankcase gas aftertreatment system components - removal and installation
Exhaust gas aftertreatment system components - removal and installation
Diesel fuel system
Specifications
General description
Service and inspection
Air filter - element replacement
Fuel filter - draining the fluid and replacing the element
Idle frequency - check and adjust
Maximum engine speed - check and adjustment
Injection moment - check and adjustment
High pressure fuel pump - removal - refitting
Injection tubes - removing and installing
Fuel injectors - removing, inspecting and installing
Fuel shutoff valve - removing and installing
Cold start item - replacement
Preheating system - description and verification
Glow plugs and relays - removing and installing
The gas pedal cable - removal and installation
Fuel tank - removal and installation
Collectors - Removing and Installing
Exhaust system - inspect, remove, and install
Launch and charging systems
Specifications
General description and precautions
Troubleshooting circuit - general description
Battery - check and charge
Battery - removing and installing
Generator - removal - refitting
Alternator brushes and voltage regulator - replacement
Starter - check on the car
Starter - removing and installing
Starter - brush replacement
Ignition switch - removing and installing
Ignition system
Specifications
General description and precautions
Ignition system - health check
Capacitor (contact breaker system) - check, remove and install
Ignition coil - inspect, remove, and install
Grip
Specifications
General description
Clutch cable - removing and installing
Clutch pedal - removal and installation
Clutch assembly - removing, inspecting, and installing
Release bearing - removing, inspecting, and installing
Manual transmission
Specifications
General description
Gear shift - removing, installing and adjusting
Glands - replacement
Reversing light switch - checking, removing and installing
Speedometer driven gear - removing and installing
Mechanical transmission block - removing and installing
Mechanical transmission bulkhead - general description
Automatic transmission
Specifications
General description
Downshift link - adjustment
Downshift link - removing and installing
The mechanism of the choice of the driving mode - removal and installation
The cable for switching the driving mode - removal, installation and adjustment
Starter lock - removing, installing and adjusting
Automatic transmission - removing and installing
Automatic transmission bulkhead - general description
Drive shafts
Specifications
General description
Protective cover of the inner CV joint - replacement
Protective cover of the outer CV joint - replacement
Drive shaft - removing and installing
Drive shaft assembly - bulkhead
Brake system
Specifications
General description
Front brake pads - replacement
Front brake caliper - removing, bulking and installing
Front brake disc - inspection, removal and installation
Rear brake pads - replacement
The cylinder of a back brake - removal, a partition and installation
Brake drum - inspection and replacement
Handbrake - adjustment
Hand brake cables - replacement
Hand brake lever - removing and installing
Hydraulic brake system - bleeding (models without ABS)
The main cylinder - removal, a partition and installation
Valve for adjusting the pressure in the brake system (Sedan and Wagon models) - removal and installation
Brake force compensator (box models) - adjustment, removal and installation
Brake tubes and hoses - replacement
The block of the vacuum amplifier and draft - removal and installation
Brake pedal - removal, installation and adjustment
Warning lamps and brake sensors - removal and installation
ABS description
Modulator drive belt (ABS) - removing and installing
Modulator (ABS) - removal and installation
Brake force compensator depending on vehicle load (ABS) - removal and installation
Hydraulic brake - bleeding (ABS)
Suspension and steering
Specifications
General description
Front wheel bearings - replacement
Lower front suspension arm (cast) - removal, overhaul and installation
Lower front suspension arm (stamped) - removal, overhaul and installation
Front anti-roll bar - removal - refitting
Front stretch - removing and installing
A rack of a forward suspension bracket - removal, a partition and installation
Rear wheel bearings - adjustment
Rear wheel bearings - replacement
The rear shock absorber (Sedan and Station wagon models) - removal, health check and installation
Rear shock absorbers (box models) - removal, health check and installation
The rear extension (sedan and station wagon models) - removal and installation
Rear spring springs (Sedan and Wagon models) - removal and installation
Rear spring (Box Models) - removal and installation
The lower lever of a back suspension bracket (Sedan and Station wagon models) - removal and installation
Rear steering knuckle (sedan and station wagon models) - removal and installation
Beam of a back axis (Van model) - removal and installation
The rear anti-roll bar (Sedan and Wagon models) - removal and installation
Rear wheel angles - general description
Steering gear covers - replacement
Outer ball joint steering link - replacement
Steering wheel - removal and installation
Steering wheel - position adjustment
The steering column lock - removal and installation
Steering column - removing, bulkhead and installing
Steering gear - removing, reassembling, and installing
Wheel alignment
Body
Specifications
General description
Body and engine frame - service
Upholstery and rugs - service
Body repair - minor damage
Significant damage to the body - repair
Bumper components - removing and installing
Hood - removing and installing
Bonnet lock cable - removing and installing
Bonnet lock - removal and installation
Radiator grille - removing and installing
Door trim panel - removal and installation
Doors - removing and installing
Door handle and lock components - removal and installation
Door window glass and power window - removal and installation
The back door opening upwards - removal and installation
The lock and cylinder of the rear door / trunk lid - removal and installation
Trunk lid (Cabriolet models) - removal and installation
Components of a central locking system for doors - removal and installation
Outside Mirror - Removing and Installing
Windshield and not falling windows - removal and installation
Manhole components - removal, installation and adjustment
Sliding roof (Cabriolet models) - removal and installation
Hydraulic sliding roof - check fluid level and bleed
Hydraulic sliding roof components - removing and installing
Electrical system
Specifications
General description and precautions
Troubleshooting electrical system - general description
Fuses, relays and reverse current relays - general description
Switches - removal and installation
Lamps (external lamps) - replacement
Lamps (interior lighting) - replacement
External headlights and lanterns - removal and installation
Headlights and additional lights - checking the direction of the light beam
Dashboard - removal - refitting
Dashboard components - removing and installing
Cigarette lighter - removing and installing
Speedometer drive cable - removing and installing
Clock - removing and installing
Fuel computer components - removing and installing
Auxiliary warning system components - removing and installing
Sound signal - removal and installation
Windshield wiper blades and levers / rear door - removing and installing
Wiper and traction motor - removing and installing
Rear door wiper motor - removing and installing
Washer / wiper system components - removing and installing
Radio and graphic equalizer - removal and installation
Troubleshooting
Engine
Cooling system
Clutch
Automatic transmission
Manual gearbox
Drive shafts
Brake system
Suspension and steering
Electrical system
Wiring diagrams |
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