| Content
Foreword
Operating instructions
Maintenance
Dimensions, weight and capacity
Vehicle identification number
General information
Every 400 km or weekly
Every 15,000 km or annually
Every 20,000 km or annually
Recommended lubricants and fluids
Every 40,000 km or 24 months
Every 60,000 km or 24 months
Every 24 months - regardless of mileage
Every 100,000 km
Engine
Specifications
Gasoline engines
General description
Maintenance
Engine oil and oil filter - change
Valve clearances - check and adjust
Crankcase ventilation system - description and service
Basic operations that can be carried out without removing the engine from the car
Basic operations that can only be performed on a removed engine
Engine removal method
Engine - removal without transmission
Engine / manual transmission assembly - removal and separation
Engine - installation (manual transmission in the car)
Engine / manual transmission assembly - connection and installation
Engine / transmission mounts - replacement
Disassembly of the engine - general description
Toothed belt and sprockets - removal and installation
Timing belt tension - check and adjust
Toothed belt covers - removing and installing
Front camshaft oil seal - replacement
Camshaft cover, camshaft and tappets - removal and installation
Camshaft cover, camshaft and tappets - disassembly, inspection and assembly
Cylinder head - removal and installation (engine in a car)
Cylinder head - removal and installation (engine removed)
Cylinder head - bulkhead
Cylinder head - inspection and service
Intermediate shaft - removal, inspection and installation
Flywheel - removal, inspection and installation
Front crankshaft oil seal - replacement
Rear crankshaft oil seal - replacement
Pallet - removal and installation
Oil pump - removal and installation
Oil pump - disassembly, inspection and assembly
Pistons and connecting rods - removal and installation
Pistons and connecting rods - inspection and maintenance
Crankshaft and main bearings - removal and installation
Crankshaft and bearings - inspection and maintenance
Cylinder block and cylinder bores - inspection and maintenance
Inspection and maintenance - general description
Engine assembly - general description
First start-up after a bulkhead or major overhaul
Part B: Diesel engines
General description
Engine - removal and installation
Engine - disassembly and assembly
Cylinder head - removal and installation
Toothed belt - installation
High pressure fuel pump - installation
Cylinder head - repair
Connecting rods and pistons
Connecting rods - replacement
Pistons - check and replace
Flywheel - repair
Cylinder block
Lubrication system
Oil pump - repair
Gas distribution system
Gas distribution system - adjustment
Power system
Heating starter
Cooling system
Specifications
General description
Maintenance
Cooling system - draining fluid
Cooling system - flushing
Cooling system - filling
Coolant - main characteristics
Radiator - removal and installation
Radiator - inspect and clean
Thermostat - removal and installation
Thermostat - check
Water pump - removal and installation
Water pump / generator drive belt - check, replace and tension
Fan - removal and installation
Coolant temperature gauge sensor - removing and installing
Cooling fan thermal switch - removal and installation
Fuel and exhaust systems
Specifications
General description
Fuel system precautions
Maintenance
Air filter element - replace
Air filter - removal and installation
Air filter temperature control - description and test
Fuel filter - change
Fuel priming pump - test
Fuel priming pump - removal and installation
Fuel tank - removal and installation
Fuel level sensor - removal and installation
Gas pedal - removal and installation
Gas pedal cable - removal, installation and adjustment
Choke cable - removal, installation and adjustment
Carburetor (Weber TIDE type) - description
Carburetor - removal and installation
Carburetor - idle and mixture frequency adjustment
Carburetor - cleaning
Float regulator needle and float - removal, installation and adjustment
Valve diaphragm - carburetor economizer - replacement
Diaphragm of the accelerator pump of the carburetor - replacement
Thermocontrolled diaphragm of the carburetor accelerator pump - replacement
Vacuum diaphragm of the carburetor accelerated idling device - replacement and adjustment
Pull-down block vacuum diaphragm damper - replacement
Carburetor damper - adjustment
Vacuum valve with thermal control - removal and installation
Intake manifold blower components - description, removal and installation
Collectors - removal and installation
Exhaust system - check, removal and installation
Part B: Injection systems
General information
Bosch central injection system
Weber IAW multi-position injection system - general description
Ignition system
Specifications
General description
Ignition system - precautions
Maintenance
Spark plugs - inspection and replacement
Ignition coil - health check
Ignition coil - removal and installation
Breaker cover, slider and high voltage wires - remove, check and install
Ignition distributor - removal and installation
Distributor - disassembly, inspection and assembly
Ignition timing - check and adjust
Ignition timing - trim for unleaded fuel
Electronic blocks - removal and installation
Crankshaft speed / position sensor (Diyiplex 2 system) - removal and installation
Fuel cut system components - check, remove and install
Troubleshooting - ignition system
Troubleshooting - Digiplex 2 system
Clutch
Specifications
General description
Maintenance
Clutch cable adjustment
Clutch cable - removal and installation
Clutch pedal - removal and installation
Clutch - removal
Clutch - inspect
Clutch - installation
Release bearing and lever - removal, inspection and installation
Manual transmission
Specifications
General description
Maintenance
Gear selector rods - removal, bulkhead and installation
Gear lever - removal and installation
Gearbox - removal and installation (engine remains in the car)
Transmission bulkhead - main features
Gearbox - dismantling for basic consideration
Input shaft - bulkhead
Output shaft - bulkhead
Synchronizer bulkhead
Differential - bulkhead
Input shaft oil seal - replacement
Selector lever assembly bulkhead
Overhaul of the gearbox housing
Gearbox assembly
Drive shafts
Specifications
General description
Maintenance
Drive shaft - removal and installation
Protective cover for inner CV joint - replacement
Protective cover for inner CV joint - replacement
Trioid CV joint - inspection, removal and installation
SHRUS - inspection, removal and installation
Internal CV joint cover bearing - inspection, removal and installation
Drive shaft vibration damper - removal and installation
Braking system
Specifications
General description
Maintenance
Hydraulic brake system - bleeding
Front brake pads - inspection and replacement
Rear brake pads - inspection and replacement
Front brake caliper - removal, bulkhead and installation
Brake disc - inspection, removal and installation
Brake drum - removal, inspection and installation
Rear wheel cylinder - removal, bulkhead and installation
Rear brake shield - removal and installation
Front brake disc guard - removal and installation
Master cylinder - removal and installation
Master cylinder - bulkhead
Vacuum booster - description and functional check
Vacuum booster - removal and installation
Brake pipes and hoses - removal and installation
Handbrake - adjustment
Handbrake cable - removal and installation
Hand brake lever - removal and installation
Brake pedal - removal and installation
Suspension and steering
Specifications
General description
Maintenance
Front wheel bearing - replacement
Front wheel hub - removal and installation
Steering knuckle - removal and installation
Front suspension strut - removal and installation
Front suspension strut - bulkhead
Front suspension lower arm - removal and installation
Front lower arm bushings - replacing
Sub-frame - removal and installation
Front anti-roll bar - removal and installation
Front anti-roll bar bushings - replacement
Rear wheel bearing - replacement
Rear wheel hub - removal and installation
Rear shock absorber - removal and installation
Rear leaf spring - removal and installation
Trailing arm suspension - removal and installation
Rear suspension assembly - removal and installation
Rear anti-roll bar - removal and installation
Steering wheel - removal and installation
Steering column - removal and installation
Steering covers - replacement
Steering gear without amplifier - removal and installation
Steering gear without power - bulkhead
Power steering - removal and installation
Power steering - bulkhead
Hydraulic power steering - bleeding
Power steering pump drive belt - inspect, replace and tension
Power steering pump - removal and installation
Power steering hydraulic reservoir - removal and installation
Tie rod end - removal and installation
Tie rod - removal and installation
Front wheel alignment - check and adjust
Wheels and tires - service
Body
Specifications
General description
Body and frame maintenance
Upholstery and rugs - service
Repair of minor damage to the body
Repair of serious damage to the body
Hood - removal and installation
Bonnet release cable - removal and installation
Bonnet lock - removal and installation
Rear doors - removal and installation
Tailgate lock - removal and installation
Tailgate lock core - removal and installation
Rear door pillars - removal and installation
Door - removal and installation
Door trim - removal and installation
Lower door frame - removal and installation
Inner door handle - removal and installation
External door handle - removal and installation
Door lock - removal and installation
Windshield, rear window and rear wall windows - removal and installation
Door window - removal and installation
Door window lifter - removal and installation
Side mirror - removal and installation
Bumper - removal and installation
Radiator grille panel - removing and installing
Windshield side hood trim - removal and installation
Wheel arch liners - removal and installation
Engine and transmission mud flaps - removal and installation
Fuel filler flap - removal and installation
Luke - removal and installation
Interior trim panels - general description
Interior trim panels - removal and installation
Dashboard - removal and installation
Center console - removal and installation
Ceiling - removal and installation
Seats - removal and installation
Seat belts - removal and installation
Heater control panel - removal and installation
Heater controls - adjustment
Heater matrix - removal and installation
Temperature control flap - removal and installation
Heater blower motor - removal and installation
Electrical system
Specifications
General description
Electrical system precautions
Maintenance
Battery - check and charge
Battery - removal and installation
Generator - description
Alternator drive belt - check, replace and tension
Generator - removal and installation
Alternator - troubleshooting and testing
Alternator brushes - removal, inspection and installation
Starter - general description
Starter - check in the car
Starter - removal and installation
Starter - bulkhead
Fuses and relays - basic description
Ignition lock and lock cylinder - removal and installation
Multifunction switch - removal and installation
Dashboard switches - removal and installation
Hazard switch - removal and installation
Electric external mirror regulator - removal and installation
Electric exterior mirror motor - removal and installation
Interior lighting switch - removal and installation
card reading light switch - removal and installation
Sunroof control switch - removal and installation
Brake light switch - removal and installation
Hand brake warning lamp switch - removal and installation
Reversing light switch - removal and installation
Oil pressure warning lamp switch - removing and installing
Cigarette lighter - removal and installation
Dashboard - removal and installation
Dashboard components - removal and installation
Control system components - removal and installation
Sound signal - removal and installation
Interior lighting - removal and installation
Luggage compartment light - removal and installation
Flashlight for reading the map - removal and installation
Interior lamps - replacement
headlight - removal and installation
Headlights - adjustment
Front direction indicator lamp - removal and installation
Side repeater front turn signal - removal and installation
Rear light assembly - removal and installation
License plate light - removal and installation
Ambient light bulbs - replacement
Wiper blades - replacing
Wiper arms - removal and installation
Washer jets - removal and installation
Wiper motor and bracket - removing and installing
Rear door wiper motor - removal and installation
Headlamp wiper motor - removing and installing
Washer fluid reservoir - removal and installation
Washer pump - removal and installation
Power window components - removal and installation
Central door locking components - removal and installation
Radio antenna - removal and installation
Speakers - removal and installation
Radio tape recorder - removal and installation
Sunroof engine - removal and installation
Speedometer cable - removal and installation
Digital speedometer sensor - removal and installation
Economizer pointer sensor - removal and installation
Wiring diagrams - explanatory notes
Troubleshooting
Engine
Cooling system
Fuel and exhaust systems
Clutch
Manual transmission
Drive shafts
Brake hydraulics
Suspension and steering
Electrical system
Malfunctions of individual electrical components
Wiring diagrams |
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