| Contents
Operating instructions
Maintenance
Vehicle identification numbers
Recommended lubricants and fluids
Gasoline engines
Specifications
General description
Basic actions possible with the engine stationary in the car
Basic operations on a removed engine
Engine removal methods
Engine - removal (with transmission)
Engine - removal (without transmission)
Engine disassembly (general)
Ancillary engine components - removal
Cylinder head - removal (engine in car)
Cylinder head - removal (engine removed from vehicle)
Dismantling the cylinder head - removing the camshaft and tappets
Valves - removal
Flywheel and pallet - removal
Drive cover, chain and sprockets - removing
Pistons, connecting rods and lower end bearings - removing
Crankshaft and main bearings - removal
Piston pins - removal
Piston rings - removal
Lubrication system - general description
Oil pump - disassembly, inspection and assembly
Pressure reducing valve - removal, inspection and installation
Oil filter - change
Engine components - determine wear
Crankshaft - check and reconstruction
Crankshaft, main and connecting rod bearings - check and reconstruction
Cylinder channels - check and reconstruction
Pistons and piston rings - inspection and reconstruction
Cranks - inspection and reconstruction
Camshaft and its bearings - check and reconstruction
Hydraulic pushers - description
Hydraulic pushers - inspection and reconstruction
Valve and valve seats - inspection and reconstruction
Cylinder head and piston heads - carbon removal
Valve guides - inspect
Pallet - inspection
Sprockets, chain and covers - inspection and reconstruction
Flywheel ring - inspection and reconstruction
Engine assembly - general instructions
Crankshaft - installation
Pistons and connecting rods - assembly
Piston rings - installation
Pistons and connecting rod assemblies - installation
Connecting rods / connecting rod bearings - crankshaft mounted
Flywheel - installation
Drive chain, cover and drip tray - installation
Valve assemblies - cylinder head installation
Camshaft and hydraulic pushers - installation
Cylinder head - installation
Hydraulic pushers - adjustment after installation
Ancillary engine components - installation
Engine (with manual transmission) - reconnection
Engine (with automatic transmission) - reconnection
Engine - installation
Engine - starting after bulkhead or overhaul
Hydraulic pushers - final adjustment after bulkhead
Diesel Engines
Specifications
Cylinder head - removal and installation
Cylinder head disassembly and assembly
Valves and seats - grind and launch
Engine - removal and installation
Engine - disassembly and assembly
Rear crankshaft oil seal - replacement
Camshaft - removal and installation
Camshaft drive cover - replace
Drive chain and crankshaft sprocket - replacement
Oil pump - check
Oil pump pressure reducing valve - check
Oil filter bypass valve - replace
Oil pressure - check
Oil sump gaskets - replacement
Cooling system
Specifications
General description
Routine maintenance
Cooling system - draining fluid
Cooling system - flushing
Cooling system - filling
Radiator - removal and installation
Thermostat - removal and installation
Thermostat - test
Water pump - removal and installation
Water pump - bulkhead
V-belt - removing, installing and tensioning
Temperature gauge and temperature sensor - removal, installation and inspection
Antifreeze
Diesel engine cooling system
Fuel and exhaust systems
Specifications
General description
Air filter - description and action
Air filter - check operation
Air filter - removal, service and installation
Fuel pump - description
Fuel pump - service
Fuel pump - test
Fuel pump - removal and installation
Fuel tank - removal and installation
Fuel tank - cleaning
Fuel level sensor - removal and installation
Throttle rod - adjustment
Accelerator cable - removal and installation
Fuel control pedal - removal and installation
Carburetor - general description
Carburetor - how it works
Carburetor adjustment - general description
Carburetor - adjustment
Carburetor - removal and installation
Disassembly and assembly of the carburetor - general description
Carburetor - disassembly, cleaning and inspection
Carburetor - assembly
Automatic air damper - adjustment
Exhaust system - general description
Exhaust system - replacement
Diesel fuel system - bleeding
High pressure fuel pump - principle of operation
Centrifugal regulator injection pump
Injection timing regulator
Injection pump - removal and installation
Injection advance angle - check and adjust
Injection pump - adjustment
The increased frequency of cold. stroke - adjustment
Injectors - removal and installation
Injectors - disassembly and assembly
Injectors - check
Fuel control lever - adjust
Metering valve actuator - check and adjust
Metering valve - checking operation
Control thrust with increased frequency of cold stroke - adjustment
Starting candles
Ignition system
Specifications
General description
Breaker contact plates - adjustment
Breaker contact plates - removal and installation
Capacitor - removal, inspection and installation
Distributor - removal and installation
Distributor - disassembly
Valve - check and repair
Distributor - assembly
Distributor - lubrication
Spark plugs and high voltage wires
Ignition timing - adjustment
Ignition system - damage detection
Clutch
Specifications
General description
Clutch play - adjustment
Clutch release bearing - removal and installation
Clutch assembly - removal and installation
Clutch - inspect
Clutch cable - removal and installation
Clutch pedal - removal and installation
Transmission
Specifications
General description
Gearbox - removal and installation
Gearbox disassembly
Gearbox components - inspect
Input shaft - disassembly and assembly
Output shaft - disassembly and assembly
Gearbox - assembly
Automatic transmission - general description
Automatic transmission - check fluid level
Automatic transmission - removal and installation
Gear shift mechanism - adjustment
Kickdown cable - adjustment
Kickdown cable - removal and installation
Automatic transmission gear selection mechanism - removal and installation
Starter / reverse inhibitor switch - removal and installation
Cardan shaft
Specifications
General description
Propeller shaft - inspect
Cardan shaft - removal and installation
Propshaft rubber drive coupling - removal and installation
Rear axle
Specifications
General description
Rear axle - removal and installation
Axle shaft, bearings and oil seal - removal and installation
Differential pinion oil seal - removing and installing
Wheel stand - removal and installation
Braking system
Specifications
General description
Brake system - adjustment
Hydraulic system - pumping
Front brake pads - removal and installation
Front disc brake caliper - removal and installation
Front brake disc - removal and installation
Front caliper - bulkhead
Rear brake drums and shoes - removal, inspection and installation
Rear working brake cylinders - removal, bulkhead and installation
Rear drum brake shield for - removal and installation
Handbrake cable - adjustment
Handbrake cable - removal and installation
Hand brake lever - removal and installation
Hydraulic pipes and hoses - inspection, removal and installation
Master cylinder - removal and installation
Master cylinder - bulkhead
Brake booster - general description, maintenance and adjustment
Brake booster - removal and installation
Brake and clutch pedals - removal and installation
Pressure regulating valve in the brake system - removing and installing
Electrical system
Specifications
General description
Battery - removal and installation
Battery - service and inspection
Battery - charging and refilling electrolyte
Generator - general description, removal and installation
Alternator - troubleshooting and repair
Alternator brushes (Delco Remy) - inspection, removal and installation
Alternator brushes (Bosch) - inspection, removal and installation
Starter - general description
Starter - check on engine
Starter - removal and installation
Starter traction relay - removal and installation
Starter brushes - inspect and replace
Starter - drive mechanism
Starter - checking armature and field windings
Wiper mechanism - troubleshooting and repair
Wiper components - removal and installation
Wiper motor - reconstruction
Rear door wiper components (station wagon) - removal and installation
Windshield washer pump - removal and installation
Rear door washer pump (station wagon) - removal and installation
Sound signal - check, remove and install
Horn pushbutton switch - remove, check and install
Interrupter for direction indicators and alarm - removal and installation
Steering column combination switch - removal and installation
Ignition socket contact block and lock cylinder - removal and installation
Headlights - alignment and adjustment
Headlight and side light bulbs - removal and installation
Headlamp lens unit - removal and installation
Front direction indicator lamps - removal and installation
Reversing light bulbs - removal and installation
Rear license plate lamp - removal and installation
Interior lights - removal and installation
Light switch and dashboard switches - removal and installation
Reversing light switch - removal and installation
Door switches - removal and installation
Brake light and clutch warning lamp switches - removal and installation
Hand brake warning lamp switch - removal and installation
Dashboard - removal and installation
Devices, alarm lamps, printed circuit and voltage stabilizer - removal and installation
Speedometer cable - removal and installation
Lighter - removal and installation
Fuses and relays
Suspension and steering
Specifications
General description
Service and inspection
Front hub bearing - adjustment
Front hub bearing and hub - removal and installation
Front suspension strut - removal and installation
Upper suspension support - removal and installation
Coil spring - removal and installation
Front shock absorbers - removal and installation
Front anti-roll bar - removal and installation
Suspension arm - removal and installation
Equal velocity joint (CV joint) - removal and installation
Stretch and bushings - removal and installation
Front cross member - removal and installation
Rear spring - removal and installation
Rear suspension lower control arm - removal and installation
Rear suspension upper control arm - removal and installation
Rear anti-roll bar - removing and installing
Diagonal thrust - removal and installation
Rear shock absorbers - removal, inspection and installation
Front wheels - adjustment
Steering wheel - removal and installation
Steering column - removal and installation
Steering column assembly - removal and bulkhead
Steering gear housing - removal and installation
Steering housing - bulkhead
Tie rod ends - test and replacement
About side tie rod - removal and installation
Pendulum arm - removal and installation
Power steering - general
Power steering drive belt - removal, installation and adjustment
Power steering - bleeding
Power steering pump - removal and installation
Power steering drive - removal and installation
Wheels and tires
Body
General description
Bodywork and subframe - service
Upholstery and rugs - service
Hinges, door latches and locks - service
Doors - rattling and fixing
Door curtains - removal and installation
Door lock latch - adjustment
Interior door handles and trim group - removal and installation
External door fastening - removal and installation
Front lowering glass drive - removing and installing
Rear door sliding glass drive mechanism - removal and installation
Front door window glass - removal and installation
Rear door window glass - removal and installation
Luggage compartment lock and lock cylinder - removal and installation
Hood and luggage compartment lid - removal and installation
Bonnet cable - removal and installation
Rear door lock and lock cylinder - removal and installation
Rear door holder pillars - removal and installation
Windshield and rear window - removal and installation
Bumpers and exterior trim - removal and installation
Hatch - removal, installation and adjustment
Center console - removal and installation
Central air duct and side fume extractor valves - removal and installation
Additional dashboard trim - removal and installation
Heater assembly - removal and installation
Heater radiator core - removal and installation
Heater blower motor - removal and installation
Changes and additions to the designs of models of later years of release
Specifications
Introduction
Towing
Routine maintenance
Engine - general description
1.8 l carburetor engine - bulkhead
Engine 1.8 l. ONS - modifications
Engine 2.0 and 2.2 CIH
Cooling system
Fuel and exhaust systems
Ignition system
Clutch
Overdrive block
Manual transmission (5-speed)
Automatic transmission
Rear axle
Braking system
Electrical system
Suspension and steering
Body
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Ignition system
Clutch
Manual transmission
Cardan shaft
Rear axle
Braking system
Electrical system
Suspension and steering
ABS system
Wiring diagrams |
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