| Contents
Foreword
Operating instructions
Adjustment and maintenance
Specifications
Introduction and routine maintenance schedule
Engine adjustment
Tire condition and pressure check
Liquid level checks
Battery check and maintenance
Inspection, adjustment and replacement of the drive belt
Checking the cooling system operation
Checking and replacing hoses in the engine compartment
Inspection and replacement of wiper blades
Lubrication
Exhaust system inspection
Suspension and steering test
Checking the brakes
Checking the carburetor choke operation
Checking and adjusting the frequency and proportion of the idle mixture
Changing the engine oil and filter
Fuel system check
Replacing the fuel filter
Checking and adjusting the throttle rod
Checking the tightness of the carburetor fasteners
Checking the thermostatic air filter
Inspection of transmission output shaft oil seals and drive shaft covers
Rearrangement of wheels
Clutch pedal adjustment
Mechanical transmission oil change
Cooling system maintenance (draining, flushing and refilling)
Rear wheel bearing inspection and maintenance
Change automatic transmission fluid
Replacing the filter element of the air filter and the filter of the crankcase ventilation system
Replacing the oxygen sensor
Checking and replacing the crankcase ventilation system valve
Checking the exhaust gas recirculation (EGR) valve
Checking the fuel vapor recovery system
Checking and adjusting the ignition timing
Inspection and replacement of spark plugs
Checking and replacing spark plug wires, cap and distributor runner
Valve adjustment and checking the cylinder head bolts for tightness
Compression test
Checking the additional air supply system
Engine
Specifications
General information
Camshaft cover - removal and installation
Toothed belt cover - removing and installing
Oil pump housing oil seal - replacement
Toothed drive belt - removal, installation and adjustment
Camshaft sprocket - removal and installation
Crankshaft pulley - removal and installation
Toothed belt sprocket - removal and installation
Camshaft - removal and installation
Rear cover - removing and installing
Rocker arm assembly - removal and installation
Front casing oil seal - replacement
Valves, springs and valve stem seals - removal and installation
Intake manifold - removal and installation
Exhaust manifold - removal and installation
Cylinder head - removal and installation
Front cowl cover - removing and installing
Oil pump - removal and installation
Oil pump - disassembly, inspection and assembly
Flywheel / drive disc and rear cover oil seal - removal and installation
Flywheel ring gear - replacement
Oil cooler - removal and installation
Pallet - removal and installation
Engine mounts - replacement with the engine installed on the vehicle
Engine - removal and installation
Engine and transmission - separation and connection
General engine rebuild procedures
Specifications
General description
Repair operations possible on an engine installed on a vehicle
Engine repair - general description
Engine rebuilding options
Engine removal - methods and precautions
Engine repair - dismantling sequence
Cylinder head - dismantling
Cylinder head - cleaning and inspection
Valve - service
Cylinder head - bulkhead
Piston / connecting rod assembly - removal
Crankshaft - removal
Engine block - cleaning
Engine block - inspection
Camshaft - inspect
Piston / connecting rod assembly - inspect
Crankshaft - inspection
Main and connecting rod bearings - inspection
Piston rings - installation
Crankshaft - setting and checking the main bearing running clearance
Piston / connecting rod assembly - setting and checking bearing working clearance
Rear cover & oil seal - installation
Engine bulkhead - assembly sequence
Startup and break-in after bulkhead
Cooling, heating and ventilation systems
Specifications
General description
Antifreeze - general description
Thermostat - replacement
Thermostat - check operation
Radiator - removal, service and installation
Fan - removal and installation
Electric fan and related components - description, inspection and replacement of components
Water pump - check operation
Water pump - removal and installation
Heater blower motor - removal and installation
Air conditioning system - service
Fuel and exhaust systems
Specifications
General description
Fuel pump - check
Fuel pump - removal and installation
Fuel line - installation and replacement
Fuel tank - removal and installation
Fuel tank - repair
Carburetor - removal and installation
Carburetor - repair and adjustment
Exhaust system components - removal and installation
Cold mode stabilization system stroke - check and adjust
Choke cable - removal, installation and adjustment
Engine electrical system
Specifications
Ignition system - general description and precautions
Battery - removal and installation
Battery - start from external source
Battery connection cables - check and replace
Ignition system - check
Distributor - removal and installation
Slider - replacement
Distributor - removal and bulkhead
Ignition coil - test
Ignition coil - removal and installation
Charging system - general description and precautions
Charging system - check
Generator - removal and installation
Generator - brush replacement
Generator - bulkhead
Engine starting systems - general description
Starter - car test
Starter - removal and installation
Starter traction relay - removal and installation
Starter - changing brushes
Starter - test
Emissions control systems
General description
Contactless ignition system
Air intake system
Coastal leaning system
Positive crankcase ventilation (PCV) system
Intake temperature control system
Deceleration control system
Economy mode indication system
Mechanical transmission
Specifications
General description
Transmission brackets - inspect and replace
Gear lever assembly - removal and installation
Transmission - removal and installation
Transmission - bulkhead
Output shaft assembly - inspection and bulkhead
Input shaft assembly - inspection and bulkhead
Differential - inspection and bulkhead
Transmission - assembly
Transmission oil seals - replacement
Automatic transmission
Specifications
General description
Diagnostics - general information
Vacuum diaphragm - function check and replacement
Kickdown mechanism - operation check and adjustment
Forced reverse shift solenoid (kickdown) - check operation
Blocker - check and replace
Transmission - removal and installation
Transmission seals - replacement
Drive mode switch rod - check and adjust
Oil pan gasket - replace
Clutch and drive shafts
Specifications
Clutch - general description
Clutch - checking operation
Clutch pedal - removal and installation
Clutch cable - removal and installation
Clutch - removal, inspection and installation
Drive shaft - general description
Drive shaft and connecting shaft - removal and installation
Drive shaft cover - replacement
Braking system
Specifications
General description
Disc brake pads - replacement
Disc brake caliper - removal and installation
Disc brake caliper - bulkhead
Brake disc - inspection, removal and installation
Drum brake pads - replacement
Drum brake slave cylinder - removal, bulkhead and installation
Master cylinder - removal, bulkhead and installation
Brake hoses and pipes - inspect and replace
Parking brake - check operation and adjustment
Brake pedal assembly - removal and installation
Parking brake assembly - removal and installation
Parking brake cables - removal and installation
Brake booster - inspection, removal and installation
Hydraulic system - pumping
Brake fluid level sensor - check operation
Double pressure regulator valve - check operation, remove and install
Suspension and steering
Specifications
Wheels and tires - general information
Wheel and tire - removal and installation
Suspension adjustment - general information
Suspension system - general description
Suspension system - inspect
Anti-roll bar - removing and installing
Front lower control arm - removal, repair and installation
A-pillar shock absorber assembly - removal and installation
Rear post assembly - removal, inspection and installation
Rear suspension, side and longitudinal balancers - removal and installation
Three-way damper control switches - check, removal and installation
Steering system - general description
Steering wheel - removal and installation
Steering column - removal and installation
Steering knuckle and hub - removal and installation
End of connecting rod - removal and installation
Rack and pinion cover seals - replacement
Rack and steering gears assembly - removal and installation
Power steering pump - removing and installing
Bleeding the power steering system
Suspension strut / shock absorber assembly - removal and repair
Rear hub bearings - replacement
Rear stub axle fastener - removal and installation
Body
General description
Body - service
Upholstery and rugs - service
Vinyl finishing - service
Hinges and locks - service
Body repair - minor damage
Body repair - serious damage
Hood - removal and installation
Bonnet lock mechanism and release cable - removal and installation
Rear door shock absorber - removal and installation
Rear door - removal, installation and adjustment
Trunk lid - removal and installation
Rear compartment lid lock assembly - removing and installing
Rear compartment lid strike plate - removing and installing
Fuel filler / rear compartment opening lever - removal - refitting
Door trim panel - removal and installation
Trim connectors - removal and installation
Door glass and window regulator - removal and installation
Glass triangular interior vents (coupe models) - removal and installation
Console - removal and installation
Dashboard - removal and installation
Radiator grill - removal and installation
Radiator grille cover - removing and installing
Hood panel - removal and installation
Skirt front panel - removal and installation
Bumpers - removal and installation
Replacing fixed glasses
External door handle - removal and installation
Outside mirror - removal and installation
Central locking - general description
Doors - removal, installation, adjustment
Seats - removal and installation
Seat heaters - item inspection and replacement
Luke - general description
Electrical system
Specifications
General description
Electrical troubleshooting - general description
Fuses - general description
Fusible links - general description
3-Pin adjustable suspension shock actuator - check
Combination switch - removal and installation
Ignition lock / steering wheel lock - removal and installation
Headlight - removal and installation
Headlight adjustment
Replacing a light bulb
Radio and speakers - removal and installation
Dashboard board - removal and installation
Front panel instruments - removal and installation
Dashboard switches - removal and installation
Heater control - removal, installation and adjustment
Windshield wiper motor and linkage assembly - removal and installation
Rear window wiper assembly - removal and installation
Electric radio antenna - removal and installation
Heated rear window (electric type) - check and repair
Audible warning system - general description
Bulb inspection system - precautions
Speed ??control system - general description
Interrupter for direction indicators and alarm - removal and installation
Fuel level and temperature indicators - check
Castle lighting system - general description
Reversing light board - lens replacement
Relay - identification and replacement
Speedometer drive cable - removal and installation
Washer pumps - removal and installation
Wiring diagram information
Appendix: Information about later models
Specifications
View
Adjustments and routine maintenance
Engine
Fuel and exhaust systems
Engine electrical systems
Emission control systems
Brakes
Suspension and steering
Corpus
Chassis electrical system
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Clutch
Mechanical transmission
Automatic transmission
Drive shafts
Braking system
Suspension and steering
Electrical system
Wiring diagrams (wiring diagrams) |
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