| Content
Foreword
Operating instructions
Devices
Body elements
Structural safety of the body
Lighting devices
Windows, sliding sunroof
Heating, ventilation
Air conditioner
Automatic transmission
Driving advice
Fuels
Catalyst
Exhaust fumes
Chassis, speed control
Braking system
Wheels, tires
Self-help
Maintenance
Maintenance
Overall dimensions, weight and capacity
Identification numbers
Maintenance
Part A: Service procedures - gasoline models
Part B: Maintenance procedures - diesel engines
Introduction
Every 400km
Checking the engine oil level
Checking the coolant level
Every 5000 km
Changing the engine oil and filter
Exhaust quality check
Checking the glow plug warning lamp
Draining water from the fuel filter
Every 7,500 km
Changing the engine oil and filter
Every 10,000
Checking and adjusting the idle speed
Draining water from the fuel filter
Replacing the fuel filter
Replacing the air filter element
Checking the condition of the auxiliary drive belt
Checking the concentration of antifreeze in the coolant
Checking systems for leaks
Every 15,000 km
Checking and adjusting the idle speed
Checking and adjusting the maximum engine speed
Every 30,000 km
Replacing the fuel filter
Every 100,000 km
Replacing glow plugs
Checking the condition of the auxiliary drive belt
Throttle lever rod lubrication
Checking the concentration of antifreeze in the coolant
Every 2 years, regardless of mileage
Replacing the coolant
Gasoline engines
Specifications
General description
Maintenance
Basic operations possible with the engine in the car
Basic operations requiring removal of the engine
Engine removal method
Engine - removal
Disassembly of the engine - general description
Ancillary engine parts - removal
Engine - complete disassembly
Pallet - removal and installation with the engine in the car
Engine mount brackets - replacing
Cylinder head - removal and installation with engine in a car
Toothed belt drive - replacement with engine in car
Engine components - inspect and rebuild
Cylinder head - bulkhead
Engine - final assembly
Engine accessories - installation
Engine - installation
Engine - preparation for start-up after overhaul
Troubleshooting - engine
Diesel engine
Specifications
General description
Compression check - description
Basic actions possible with the engine in the car
Basic steps to remove the engine
Engine removal method
Engine - removal
Disassembly of the engine - general description
Ancillary engine parts - removal
Engine - complete disassembly
Pallet - removal and installation with the engine in the car
Engine mount brackets - replacing
Cylinder head - removal and installation (engine in a car)
Valve clearances - check and adjust
Engine components - inspect and rebuild
Cylinder head - bulkhead
Engine - assembly
Engine accessories - installation
Engine - installation
Preheating system - description and functional check
Engine - preparation for the first start after overhaul
Cooling system
Specifications
General description
Routine maintenance
Cooling system - draining fluid
Cooling system - rinsing
Cooling system - filling
Antifreeze mixture - general description
Radiator - removal and installation
Radiator - inspection and repair
Thermostat - removal and installation
Thermostat - test
Thermo-viscous cooling fan - removing and installing
Water pump - removal and installation
Alternator / fan drive belt - replacement and adjustment
Troubleshooting - cooling system
Expansion tank - removal and installation
Temperature gauge sensor - removal and installation
Fuel and exhaust systems - petrol models
Specifications
General description
Routine maintenance
Plugged adjustment screws - general description
Air filter and element - removal and installation
Fuel pump (carburetor models) - removal, inspection and installation
Fuel pump (fuel injection models) - check, removal and installation
Fuel filter (fuel injection models) - replace
Fuel tank - removal and installation
Fuel level sensor - removal and installation
Diaphragm damper (fuel injection engines) - removal and installation
Accelerator cable - removal, installation and adjustment
Fuel control pedal - removal and installation
Carburetor - description
Carburetor - idle and mixture frequency adjustment
Carburetor - removal and installation
Bulkhead carburetor
Carburetor throttle damper (automatic transmission models) - adjust
Carburetor - adjusting the increased idle speed
Thermal carburetor valve - check.
Intake manifold heater element (carburetor models) - removal, inspection and installation
Fuel injection system - description
Fuel injection system - precautions
Fuel injection system - idle speed and mixture adjustment
Fuel injection throttle switch - check and adjust
Bosch L3 Jetronic fuel injection system components - removal and installation
Bosch Motronic ML4 fuel injection system components - removal and installation
Speed ??control system - general description
Intake manifold - removal and installation
Exhaust manifold - removal and installation
Exhaust system - removal and installation
Troubleshooting - fuel and exhaust systems
Fuel and exhaust systems - diesel models
Specifications
General description
Glow plugs - check
Fuel system - bleeding
Injectors - removal and installation
The moment the injection pump starts - check
Gas turbine supercharger - general description
Exhaust system - removal and installation
Ignition system
Specifications
General description and precautions
Routine maintenance
The cover of the breaker-distributor and the distributor runner - removal and installation
Ignition timing - check
Octane plug - adjustment
Ignition coil - test, removal and installation
Inductive impulse transmitter - test, removal and installation
Ignition control unit (models 1.8) - removal and installation
Spark plugs - removal, service and installation
High voltage wires - general description
Troubleshooting - ignition system
Clutch
Specifications
General description
Routine maintenance
Clutch cable - removal and installation
Clutch pedal - removal and installation
Clutch - removal
Clutch - inspect
Release bearing and lever - removal and installation
Troubleshooting - clutch
Clutch - installation
Mechanical and automatic transmissions
Specifications
General description
Routine maintenance
Manual transmission - removal and installation
Manual transmission - disassembly into main blocks
Manual transmission - inspection
Output shaft of a manual transmission - disassembly and assembly
Manual transmission input shaft - disassembly and assembly
Rear crankcase of a manual transmission - disassembly and assembly
Manual transmission main shroud - disassembly and assembly
Manual transmission - assembly
Manual transmission shift lever - removal, bulkhead and installation
Selector lever mounting bracket - removal and installation
Gear shift rod manual gearbox - adjustment
Automatic transmission - removal and installation
Automatic transmission kickdown cable - replace
Automatic transmission kickdown cable - adjustment
Automatic transmission select lever linkage - adjustment
Automatic transmission selection lever - removal and installation
Inhibitor switch - removal and installation
Troubleshooting - mechanical and automatic transmissions
Cardan shaft
Rear brake pads - inspection and replacement
Front brake caliper - removal, repair and installation
Rear brake caliper - removal, repair and installation
Brake disc - inspection, removal and installation
Hand brake shoes - inspection and replacement
Handbrake cable - removal and installation
Hand brake lever - removal and installation
Nice cylinder - removal, adjustment and installation
Rear brake pressure limiter - removal and installation
Hydraulic system - pumping
Brake pipes and hoses removal and installation
Vacuum booster - test
Amplifier vacuum hose and one-way valve - replace
Vacuum booster - removal and installation
Brake pedal - removal and installation
Anti-lock braking system (ABS) - precautions
Hydraulic ABS modulator - removal and installation
Electronic control unit ABS - removal and installation
ABS wheel speed sensor - removal and installation
ABS relay - replacement
Suspension and steering
Specifications
General description
Maintenance
Front suspension strut - removal and installation
Front suspension strut - bulkhead
Front suspension lower arm - removal and installation
Front suspension lower ball joint - replacement
Front anti-roll bar - removal and installation
Front anti-roll bar - removal and installation
Steering knuckle - removal and installation
Front hub and bearings - removal and installation
Front suspension cross member - removal and installation
Rear shock absorber rod - removal and installation
Rear diagonal arm - removal and installation
Rear coil spring - removal and installation
Rear anti-roll bar - removing and installing
Rear axle (complete) - removal and installation
Rear suspension cross member - removal and installation
Rear suspension crossbar installation - replacement
Rear hub and bearing - removal and installation
Rear suspension leveling system components - removal and installation
Steering wheel - removal and installation
Steering column - removal and installation
Steering column (without height adjustment) - bulkhead
Steering column (height adjustable) bulkhead
Steering gear - removal and installation
Steering gear - on-site adjustment
Steering rods - removal and installation
Intermediate steering gear - removal and installation
Power steering pump - removing and installing
Installing wheels - checking and adjusting
Wheels and tires - care and maintenance
Body
Specifications
General description
Maintenance
Body and subframe - service
Upholstery and rugs - service
Repair of minor damage to the body
Body repair - serious damage
Hood - removal and installation
Trunk lid - removal and installation
Rear door - removal and installation
Rear door trim panel - removing and installing
Radiator grill - removal and installation
Door trim panel - removal and installation
Door speaker - removal and installation
Inner door handle - removal and installation
External door handle - removal and installation
Front door lock cylinder - removal and installation
Door lock - removal and installation
Door - removal and installation
Windshield and rear door window / rear window - removal and installation
Front door window - removal and installation
Rear door window - removal and installation
Outside door mirror - removal and installation
Rear side window - removal and installation
Fixed rear door window - removal and installation
Headrest guides - removing and installing
Seat belts - removal and installation
Bumpers - removal and installation
Seats - removal and installation
Luke - general information
Dashboard - removal and installation
Center console - removal and installation
Heater dashboard - removal and installation
Heater radiator - removal and installation
Heater - removal and installation
Heater fan motor - removal and installation
Central air / heating deflectors - removal, installation and adjustment
Side deflectors of airflow and heating - removal and installation
Air conditioning system - description and warnings
Air conditioning system parts - removal and installation
Electrical system
General description
Maintenance
Electrical system precautions
Battery - removal and installation
Battery - charging
Generator - test in a car
Generator - removal and installation
Alternator brushes and voltage regulator - removal and installation
Starter - general description
Starter - check in the car
Starter - removal and installation
Starter bulkhead - general description
Starter traction relay - removal and installation (starter removal)
Starter brushes - inspection and removal
Starter - disassembly and assembly
Fuses and relays - general description
Steering column combination switches - removal and installation
Panel switches - uninstall and install
Interior lighting switch - removal and installation
Watch - removal and installation
Cigarette lighter lighting - removal and installation
Heater control switch - removal and installation
Ignition lock - removal and installation
Dashboard removal and installation
Speedometer cable - replacement
Sound signal - removal and installation
Lamps - replacement
Front direction indicator lamp - removal and installation
Headlight - removal and installation
Headlight - directional adjustment
Wiper blades and arms - removal and installation
Wiper motor and rod - removal and installation
Windshield washer pump - removal and installation
Rear door wiper motor - removal and installation
Rear door washer pump - removal and installation
Central locking system - general description
On-board computer - general description
Heated seats - general description
Control system - general description
Radio equipment - noise reduction (interference elimination)
Wiring diagrams - general description
Changes and additions to the designs of models of later release years
Introduction
Specifications
Fuel and exhaust systems - 2.0 liter models
Ignition system - 1.8 liter carburetor models
Automatic transmission
Final drive and drive shafts
Braking system
Body
Electrical system
Troubleshooting
Wiring diagrams |
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