| Contents
Table of contents
Foreword
Operating instructions
Entering and recalling data from a computer
Maintenance
Specifications
Service
General description
Routine maintenance
Intensive service
Weekly checks
Liquid level checks
Wheel protectors and tire pressure check
Tread wear patterns
Every 10,000 km or every 6 months
Change engine oil and filter
Checking the power steering fluid level
Checking the transmission fluid level
Swapping tires
Checking and replacing hoses
Checking, adjusting and replacing the drive belt
Checking and adjusting the idle speed and CO
Every 18,000 km or 12 months
?Check, maintain and charge the battery
Checking and replacing spark plugs
High voltage spark plug wires, interrupter cap and runner - check and replace
Checking the manual transmission oil level
Checking the lubrication level of the differential
Valve clearances - check and adjust
Throttle link - check and lubricate
Replacing the air filter
Fuel system check
Cooling system check
Checking the exhaust system
Checking the steering and suspension
Checking the protective cover for the drive shaft
Brake system check
Every 40,000 km or 2 years
Change transmission fluid and filter
Windscreen wiper blades - check and replace
Cooling system - draining, flushing and filling
Replacing the fuel filter
Mechanical transmission oil change
Differential oil change
Checking the fuel vapor recovery system
Reset service indicator data
Every 90,000 km
Replacing the engine timing belt
Repair of a gasoline engine in a car
Specifications
General description
Repair operations performed without removing the engine from the car
Installing the piston of cylinder No. 1 at top dead center (TDC)
Valve cover - removal and installation
Intake manifold - removal and installation
Exhaust manifold - removal and installation
Drive chain covers - removal and installation
Drive chain and sprockets - removal, inspection and installation
Toothed belt covers - removing and installing
Toothed belt and sprockets - removal, inspection and installation
Front oil seals - replacement
Cylinder head - removal and installation
Pallet - removal and installation
Oil pump - removal, inspection and installation
Flywheel / drive disc - removal and installation
Rear crankshaft oil seal - replacement
Engine mount brackets - inspect and replace
Bulkhead gasoline engine
Specifications
General information
Engine overhaul - general information
Compression test
Engine removal - methods and precautions
Engine - removal and installation
Engine bulkhead - ways
Engine bulkhead - sequence
Cylinder head disassembly
Cylinder head and its components - cleaning and inspection
Valves - service
Cylinder head - assembly
Pistons / connecting rods - removal
Crankshaft - removal
Intermediate shaft - removal and inspection
Engine block - cleaning
Engine block - inspection
Honing a cylinder
Pistons / connecting rods - inspect
Crankshaft - inspection
Main and connecting rod bearings - inspection
Engine overhaul - assembly sequence
Piston rings - installation
Intermediate shaft - installation
Crankshaft - installing and checking the main bearing running clearance
Rear crankshaft oil seal - installation
Pistons / connecting rods - installing and checking connecting rod bearing running clearance
Initial engine start after bulkhead
Diesel engines
Specifications
Diesel engine management system - general description
Clearance between rocker arms and camshaft cams - adjustment
Fuel system - bleeding
Fuel filter - sediment drain
Fuel filter - change
High pressure fuel pump - removal and installation
Initial fuel injection timing - adjustment
Idling frequency - check
Turbine generator - removal and installation
Pressure reducing valve - check and adjust
Toothed drive belt - replacing and adjusting tension
Cylinder head - removal and installation
Cylinder head - bulkhead
Engine - removal and installation
Engine disassembly
Crankshaft & main bearings - installation
Pistons and connecting rods - assembly and installation
Engine - final assembly and installation
Oil pump - removal and installation
Oil pump - check
Water pump - replacement
Coolant - replacement
Cooling, heating and air conditioning systems
Specifications
General description
Antifreeze - general description
Thermostat - check and replace
Radiator - removal and installation
Fans - serviceability check, removal and installation
Water pump - functional check
Water pump - removal and installation
Coolant temperature gauge sensor - check and replace
Heater and air conditioner blower motor - removal, service check and installation
Heater / air conditioner control panel assembly - removal and installation
Heater matrix - removal and installation
Air conditioning system - precautions and service
Air conditioner compressor - removal and installation
Air conditioner condenser - removal and installation
Filter accumulator - removal and installation
Evaporator matrix - removal and installation
Fuel and exhaust systems - petrol models
Specifications
General information
Fuel injection system - depressurization
Fuel priming pump / fuel pressure - check
Fuel pump, priming pump and fuel level sensor - removal and installation
Fuel lines and connections - repair and replacement
Fuel tank - removal and installation
Fuel tank cleaning and repair - general information
Air filter - removal and installation
Gas pedal cable - check, adjustment and replacement
Fuel injection system - general information
Fuel injection systems
Fuel injection system - check
Air flow meter - check, removal and installation
Throttle body - check, removal and installation
Fuel pressure regulator - check and replace
Cold start injector and start fuel mode switch - check and replace
Fuel injectors - check and replace
Idle air stabilizer valve - check
Exhaust system maintenance - general information
Engine electrical systems
Specifications
General information
Battery - start from external source
Battery - removal and installation
Battery wires - check and replace
Ignition system - general information and precautions
Ignition system - check
Ignition timing (TCI system) -check and adjust
Distributor - removal and installation
Ignition coil - check and replace
Pulse generator and ignition control unit - check and replace (TCI system)
Air gap (TCI system) - check and adjust
Ignition sensors (Motronic system) - check and replace
Charging system - general information and precautions
Charging system - check
Generator - removal and installation
Voltage regulator - replacement
Alternator brushes - check and replace
Launch systems - general information and precautions
Starter - check in the car
Starter - removal and installation
Starter traction relay - removal and installation
Engine management and exhaust gas treatment systems
General description
Self-diagnosis of the Motronic engine management system - general description
Electronic control unit (ECU) - removal and installation
Information sensors
Positive crankcase ventilation (PCV)
Fuel vapor emission control system (EVAP)
Catalytic converter
Mechanical transmission
Specifications
General description
Gear lever - removal and installation
Oil seals - replacement
Transmission brackets - inspect and replace
Transmission - removal and installation
Transmission bulkhead - general description
Automatic transmission
Specifications
General description
Troubleshooting - general information
Gear lever linkage - adjustment
Kickdown cable adjustment
Starter lock / reversing light switch - check and replace
Automatic transmission - removal and installation
Seals - replacement
Clutch and drive
Specifications
General description
Clutch - general description and inspection
Clutch master cylinder - removal and installation
Clutch pedal - adjustment
Launcher (where installed) - health check and replacement
Clutch slave cylinder - removal and installation
Clutch hydraulic system - bleeding
Clutch components - removal, inspection and installation
Cardan shaft - removal and installation
Elastic coupling - inspection and replacement
Center bearing - check and replace
Universal joints - inspection and replacement
Front center rail - inspect and replace
CV joint for propeller shaft - replacement
Drive shafts - removal and installation
CV joints and their covers - inspection and replacement
Differential housing side oil seals - replacement
Differential housing - removal and installation
Main drive pinion shaft oil seal - replacement
Braking system
Specifications
General description
Anti-lock braking system (ABS) - general description
Disc brake pads - replacement
Disc brake caliper - removal, bulkhead and installation
Brake disc - inspection, removal and installation
Master cylinder - removal and installation
Vacuum brake booster - serviceability check, removal and installation
Handbrake cable - replacement
Hand brake - adjustment
Hand brake assembly - inspection, removal and installation
Brake pedal - adjustment
Brake light switch -check operation and adjust position
Brake hoses and pipes - inspection and replacement
Hydraulic brake system - bleeding
Suspension and steering gear
Specifications
General description
Front anti-roll bar - removal and installation
Lower and thrust arms - inspection, removal and installation, bushing replacement
A-pillar assembly - removal and installation
Front suspension struts and shock absorber / spring blocks - replace
Ball joints - inspection and replacement
Front wheel hub and bearing assembly - removal and installation
Rear shock absorber / spring spring assembly - removal and installation
Rear anti-roll bar - removal and installation
Rear suspension trailing arms - removal and installation
Rear wheel bearings - replacement
Steering - general description
Tie rod ends - removal and installation
Steering rods - inspection, removal and installation
Steering gear unit - removal and installation
Power steering pump - removing and installing
Hydraulic power steering - bleeding
Steering wheel - removal and installation
Wheels and tires - general description
Wheel alignment - general description
Body
General description
Body and sub-frame - service
Interior finishing - service
Upholstery and rugs - service
Body repair - minor damage
Body repair - serious damage
Hinges and locks - service
Installed glass - replacement
Radiator grill - removal and installation
Hood - removal, installation and adjustment
Bumpers - removal and installation
Door trim panel - removal and installation
Door - removal, installation and adjustment
Trunk lid / tailgate - removal, installation and adjustment
Latch, lock cylinder and handles - removal, installation and adjustment
Door window glass - removal and installation
Door window opening regulator - removal and installation
Outside mirror - removal and installation
Steering column covers - removal and installation
Seats - removal and installation
Seat belt check
Electrical system
General description
Electrical fault detection - general description
Fuses - general description
Relays - general description
Direction indicator / hazard warning light - check and replace
Steering column switches - removal and installation
Ignition lock - removal and installation
Radio - removal and installation
Antenna - removal and installation
Instrument panel - removal and installation
Service signal panel (SI) - general description
Headlights - changing bulbs
Headlights - adjustment
Headlamp housing - removal and installation
Replacing lamps
Windshield / rear door wiper motor - removing and installing
Heated rear window - check and repair
Supplemental security system (SRS.) - general description
Speed ??control system - description and check
Central locking - description and check
Electric windows - description and check
Wiring diagrams - general description
Troubleshooting
Engine
Engine electrical system
Fuel system
Fuel injection system
Cooling system
Clutch
Mechanical transmission
Automatic transmission
Braking system
Suspension and steering
Wiring diagrams |
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