| Contents
Operating instructions
Maintenance
Dimensions and weight
Lubricants and fluids
Service specifications
Vehicle identification numbers
Weekly checks
Check points under the hood
Engine oil level
Coolant level
Brake (and clutch) fluid level
Power steering fluid level
Battery
Electrical equipment
Condition and pressure of tires
Examples of typical tire tread wear
Washer fluid level
Wiper blades
Maintenance procedures
Maintenance plan
Introduction
Regular maintenance
Every 15,000 km
Changing the engine oil and filter
Checking the thickness of the front brake pads
Checking the condition and tension of the auxiliary drive belt
Every 12 months
Checking the functioning of the windscreen / rear window / headlight washer system
Check tire wear
Checking the condition of the toothed drive belt
Lubrication of hinges and locks
Checking the electrolyte level in the battery
Initializing the service interval display
Reading fault codes from the memory of the electronic engine control module
Checking the tightness of hoses and other components in the engine compartment / underbody
Checking the concentration of antifreeze in the cooling system
Checking the condition of the brake hoses and pipes
Checking the thickness of the rear brake pad
Checking the condition of the exhaust system and its attachments
Checking the condition / tightness of the steering and suspension components
Running trials
Every 30,000 km
Replacing the fuel filter
Replacing the dust filter of the ventilation system
Checking the underbody protection
Checking the oil level in the manual transmission
Adjusting the direction of the headlamp beam
Every 60,000 km
Replacing the air filter element
Replacing spark plugs
Checking oil level in final drive (automatic transmission)
Changing transmission fluid
Every 120,000 km
Replacing the auxiliary drive belt
Every 2 years (regardless of mileage)
Replacing the brake fluid
Coolant replacement
Replacing the timing belt
Checking emission control systems
Engine repair in the engine compartment
Specifications
General description
Camshaft timing marks - general description and use
Checking the compression in the engine cylinder
Toothed drive belt - removal, inspection and installation
Toothed belt tensioner and sprockets - removal, inspection and installation
Accessory drive belts - removal and installation
Valve cover - removal and installation
Camshaft oil seal - replacement
Intermediate shaft oil seal - replacement
Crankshaft oil seals - replacement
Cylinder head - removal and installation
Hydraulic slack adjuster - functional check
Flywheel / drive disc - removal, inspection and installation
Engine mounts - inspection and replacement
Pallet - removal and installation
Oil pump and suction tube - removal, inspection and installation
Engine removal and rebuilding procedures
Specifications
General description
Engine bulkhead - general description
Engine removal - methods and precautions
Engine - removal and installation
Engine overhaul - preliminary information
Cylinder head - disassembly, cleaning, inspection and assembly
Connecting rod and piston assemblies - removal and inspection
Crankshaft - removal and inspection
Intermediate shaft - removal and installation
Cylinder block / crankcase - cleaning and inspection
Piston and connecting rod assemblies - condition check and selection
Engine assembly procedure after overhaul
Crankshaft - installing and checking main bearing clearances
Pistons and piston rings - assembly
Connecting rod-piston assemblies - installing and checking the clearances in connecting rod bearings
Starting the engine after overhaul
Cooling, heating and ventilation systems
Specifications
General description and precautions
Coolant hoses - disconnecting and replacing
Radiator - removal, inspection and installation
Thermostat - removal, service check and installation
Fans - serviceability check, removal and installation
Electrical switches and sensors of the cooling system - serviceability check, removal and installation
Water pump - removal and installation
Heating and ventilation system - general description
Heating / ventilation system components - removal and installation
Air conditioning system - general description and precautions
Air conditioning components - removal and installation
Fuel system - multipoint petrol injection
Specifications
General description and precautions
Air filter and intake ducts - removal and installation
Gas pedal cable - removal, installation and adjustment
Bosch motronic engine management system - removing and installing components
Simos engine management system - component removal and installation
Fuel filter - change
Fuel pump / fuel level sensor - removal and installation
Fuel tank - removal and installation
Fuel injection system - depressurization
Intake manifold - removal and installation
Fuel injection system - health check and adjustment
Turbine generator - general description, removal and installation
Air cooler - removal and installation
Exhaust gas aftertreatment and exhaust system
Specifications
General description
Fuel vapor retaining system - information and component replacement
Blow-by gas venting system - general description
Exhaust manifold - removal and installation
Exhaust system - component replacement
Catalytic converter - general description and precautions
Starting and charging systems
Specifications
General description and precautions
Battery - health check and charging
Battery - disconnect, remove and install
Alternator / charging system - vehicle functional check
Generator - removal and installation
Alternator brush holder / voltage regulator - replace
Launch system - health check
Starter - removal and installation
Starter - health check and bulkhead
Ignition system
Specifications
General description
Ignition system - health check
High voltage ignition coil - removal, service check and installation
Distributor - removal, inspection and installation
Ignition timing - check and adjust
Ignition system sensors - removal and installation
Distributor slider - removal and installation
Clutch
Specifications
General description
Hydraulic system - pumping
Clutch pedal - removal and installation
Master cylinder - removal, bulkhead and installation
Slave cylinder - removal, bulkhead and installation
Friction and pressure plates of clutch - removal, inspection and installation
Release bearing and clutch release lever - removal, inspection and installation
Mechanical transmission
Specifications
General description
Shift rod - adjustment
Mechanical transmission - removal and installation
Mechanical transmission bulkhead - general description
Multifunction switch - removal and installation
Speedometer converter - removal and installation
Oil seals - replacement
Automatic transmission
Specifications
General description
Automatic transmission - removal and installation
Bulkhead automatic transmission - general description
Drive mode selection cable - removal, installation and adjustment
Drive shafts
Specifications
General description
Drive shafts - removal and installation
Drive shafts - bulkhead
Drive shaft overhaul - general description
Braking system
Specifications
General description
Hydraulic brake system - bleeding
Brake 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
Brake pedal - removal and installation
Vacuum booster unit - serviceability check, removal and installation
Vacuum booster check valve - removal, serviceability check and installation
Hand brake - adjustment
Hand brake lever - removal and installation
Handbrake cables - removal and installation
Brake light switch - removal, installation and adjustment
Anti-lock braking system (ABS) - general description
ABS system components - removal and installation
Suspension and steering gear
Specifications
General description
Front wheel hub bearings - replacement
Front suspension strut - removal and installation
Front suspension strut - bulkhead
Front suspension arms - removal, bulkhead and installation
Anti-roll bar front suspension - removal and installation
Sub-frame - removal and installation
Rear wheel bearings - adjustment
Rear wheel bearings - replacement
Rear steering knuckle - removal and installation
Rear suspension strut - removal and installation
Rear suspension strut - bulkhead
Rear axle assembly - removal and installation
Steering wheel - removal and installation
Steering column shaft - removal, inspection and installation
Ignition switch / steering column lock - removal and installation
Assembly of the steering gear, removal, bulkhead and installation
Rubber steering covers - replacement
Hydraulic power steering - bleeding
Power steering pump - removal and installation
Tie rod ball joint - removal and installation
Tie rod - removal and installation
Steering gear - adjustment
Wheel alignment - general description
Body and trim
Specifications
General description
Body and underbody - service
Upholstery and rugs - care
Minor damage to the body - restoration
Significant damage to the body - restoration
Door vibration - troubleshooting
The hood and its pillar - removal, installation and position adjustment
Bonnet lock and its cable - removal and installation
Bumpers - removal and installation
Radiator frame upper cross member / subframe - removal and installation
Front wheel arch liners - removal and installation
Trunk lid - removal and installation
Trunk lock and its cylinder - removal and installation
Luggage compartment door (Station wagon models) - removal and installation
Rear lid support - removal and installation
Luggage compartment door lock and its cylinder (Station wagon models) - removal and installation
Side door trim panel - removal and installation
Central gaze - general description
Door lock - removal and installation
Door handles and lock cylinder - removal and installation
Door glass and window regulator mechanism - removal and installation
Electric windows - general description and replacement of the motor
Doors - removal and installation
Windshield, rear window and non-retractable side window - general description
Luke - general description
Outside mirror components - removal and installation
Central control panel - removal and installation
Dashboard and related panels - removal and installation
Glove box - removal and installation
Interior mirror - removal and installation
Seats - removal and installation
Interior trim - removal and installation
Belt tensioner - general description
Seat belts - general description
Onboard electrical equipment
Specifications
General description and precautions
Troubleshooting - general description
Fuses and relays - general description
Ignition switch steering column lock / lock - removal and installation
Steering column combination switch - removal and installation
Switches - removal and installation
External lighting fixtures and lamps - removal and installation
Interior lights - replacement
Headlights - removal, installation and beam adjustment
Instrument panel - removal and installation
Electric discharge headlights system - removal and installation of components
Anti-icing system - removing and installing components
Wiper components - removal and installation
Washer system - general description
Rear door wiper motor - removing and installing
Sunroof motor - removal and installation
Central locking system - general description and replacement of components
Airbag system - general description and precautions
Airbag system components - removal and installation
Anti-theft alarm system - general description
Radio tape recorder - removal and installation
Radio antenna - removal and installation
Troubleshooting
Introduction
Engine
Cooling system
Fuel and exhaust systems
Clutch
Mechanical transmission
Automatic transmission
Braking system
Suspension and steering
Electrical system
Wiring diagrams (electrical equipment diagrams) |
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