Contents

Routine maintenance

• Dimensions and weight
• Lubricants and fluids
• Tire pressure
• Service Specifications
• Vehicle identification
• Weekly checks
• Check points in the engine compartment
• Engine oil level
• Coolant level
• Fluid level in the brake system (clutch hydraulic system)
• Washer fluid level
• Wiper blades
• Power steering fluid level
• Condition and pressure of tires
• The main types of tire wear
• Lamps and fuses
• Battery
• Maintenance intervals and intervals
• Engine compartment - early model with automatic transmission
• Engine compartment - model X2 GSi
• Front bottom view - early automatic transmission
• Bottom view of the front part of the body - model X2 GSi
• Service procedures
• General description
• Intensive service
• Rear bottom view - model X2 GSi
• Every 9,500 km or every 6 months
• Changing engine oil and filter
• Checking and replacing auxiliary drive belts
• Checking and cleaning the air filter element
• Reading fault codes
• Checking leaks and condition of hoses
• Checking the refrigerant level in the air conditioner
• Every 18,000 km or 12 months
• Checking and adjusting valve clearances
• Checking and adjusting the ignition timing
• Checking the fuel filter (carburetor models only)
• Checking and cleaning spark plugs
• Checking the fuel vapor recovery system
• Checking the speed and quality of the idle mixture
• Checking the oil level in the manual transmission
• Checking fluid level in automatic transmission
• Checking the pads, calipers and front brake discs
• Checking the pads and drums of the rear brakes
• Checking the parking brake operation
• Checking the steering and suspension
• Checking the exhaust system
• Checking and lubricating the rear wheel bearings
• Checking drive shafts and rubber gaiters
• Checking the free play of the clutch and brake pedals
• Every 38,000 km or 2 years
• Replacing the fuel filter
• Replacing the air filter element
• Replacing spark plugs and checking the ignition system
• Checking the crankcase ventilation system valve
• Changing the oil in a manual transmission
• Change transmission fluid
• Every 48,000 km or 30 months
• Checking the timing belt
• Every 76,000 km or 48 months
• Replacing the auxiliary drive belt
• Every 2 years, regardless of mileage
• Coolant replacement
• Checking the crankcase ventilation hose
• Replacing the timing belt
• Checking fuel hoses and fuel vapor emission hose
• Check exhaust gas recirculation
• Replacing the brake fluid

Engine - repair operations in the car

• Specifications
• General description
• Compression - checking and analyzing results
• Top dead center (TDC) of piston # 1 - location
• Valve cover - removal and installation
• Rocker arm assembly - removal, inspection and installation
• Toothed drive belt - removal, inspection and installation
• Toothed belt sprockets and tensioner pulley - removal, inspection, and installation
• Camshaft oil seal - replacement
• Camshaft - removal, inspection and installation
• Cylinder head - removal and installation
• Oil pan - removal and installation
• Oil pump and suction tube / sieve oil receiver - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel / drive disc - removal, inspection and installation
• Engine / transmission mounts - inspect and replace

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Engine removal - methods and precautions
• Engine and transmission - removal, separation and installation
• Engine bulkhead - work sequence
• Cylinder head disassembly
• Cylinder head and valves - cleaning and inspection
• Cylinder head - assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Cylinder block, crankcase - cleaning and inspection
• Piston / connecting rod assemblies - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine assembly sequence
• Crankshaft - installing and checking the main bearing running clearance
• Piston rings - installation
• Piston / connecting rod assemblies - installing and checking connecting rod bearing running clearance
• Engine - starting after bulkhead

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - disconnecting and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, serviceability check and installation
• Radiator fan - removal and installation
• Fan switch - serviceability check, removal and installation
• Water pump - removal, inspection and installation
• Coolant temperature gauge sensor - serviceability check, removal and installation
• Heating / ventilation system components - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel and exhaust systems - carburetor models

• Specifications
• General description and precautions
• Air filter assembly - removal and installation
• Air filter temperature control system - general description
• Distributor - removal and installation
• Ignition timing - check and adjust
• Charging system - functional check
• Generator - removal and installation
• Generator - check and repair
• Launch system - health check
• Starter - removal and installation
• Starter - health check and repair
• Ignition lock - removal and installation
• Oil pressure warning lamp switch - removal and installation

Clutch

• Specifications
• General description
• Clutch - check and adjust
• Clutch cable - removal and installation
• Clutch master cylinder - removal, bulkhead and installation
• Clutch slave cylinder - removal, bulkhead and installation
• Hose and pipes of the hydraulic system of the clutch - removal and installation
• Clutch hydraulic system - bleeding
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation
• Clutch release mechanism - removal, inspection and installation

Mechanical transmission

• Specifications
• General description
• Gear shift mechanism - check and adjust
• Rigid shift rod assembly - removal, bulkhead and installation
• Gear shift cables - removal, inspection and installation
• Gear lever assembly - removal, bulkhead and installation
• Oil seals - replacement
• Reversing light switch - serviceability check, removal and installation
• Speedometer drive - removal and installation
• Transmission - removal and installation
• Transmission bulkhead - general description

Automatic transmission

• Specifications
• General description
• Drive mode switch cable - adjustment
• Drive mode switch cable - removal and installation
• Assembling the drive mode selection lever - removal and installation
• Kickdown cable - adjustment
• Kickdown cable - removal and installation
• Speedometer drive - removal and installation
• Oil seals - replacement
• Transmission fluid cooler - general description
• Starter lock / reversing light switch - general description, removal, installation and adjustment
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description

Drive shafts

• Specifications
• General description
• Drive shafts - removal and installation
• Drive shaft rubber boots - replacement
• 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 drum - removal, inspection and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake cylinder - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Brake pedal - adjustment
• Vacuum booster unit - serviceability check, removal and installation
• Control valve of the vacuum booster unit - removal, service check and installation
• Hand brake - adjustment
• Hand brake lever - removal and installation
• Handbrake cables - removal and installation
• Pressure control valve in the rear brake assemblies - serviceability check, removal and installation
• Brake light switch - removal, installation and adjustment

Suspension and steering gear

• Specifications
• General description
• Front steering knuckle assembly - removal and installation
• Front wheel hub bearings - replacement
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front suspension lower arm - removal / bulkhead and installation
• Front suspension lower arm ball joint - removing and installing
• Front suspension push rod (early models) - removing and installing
• Anti-roll bar front suspension - removal and installation
• Rear wheel hub - removal and installation
• Rear wheel hub bearings - replacement
• Rear suspension shock absorber - removal, service check and installation
• Rear suspension spring - removal and installation
• Rear axle assembly - removal, bulkhead and installation
• Steering wheel - removal and installation
• Steering column - removal, inspection and installation
• Steering column intermediate shaft - removal, inspection and installation
• Ignition / steering column lock - removal and installation
• Steering gear assembly - removal, bulkhead and installation
• Rubber steering covers - replacement
• Power steering hydraulic system - bleeding
• Power steering pump - removal and installation
• Tie rod ball joint - removal and installation
• Tie rod - removal and installation
• Wheel alignment - general description

Body and trim

• Specifications
• General description
• Body and subframe - service
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Serious damage to the body - refurbishment
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation and adjustment
• Bonnet cable - removal and installation
• Bonnet lock - removal and installation
• Radiator grill - removal and installation
• Door - removal, installation and adjustment
• Door trim panel - removal and installation
• Latch, lock cylinder and door handle components - removal and installation
• Door glass and window regulator mechanism - removal and installation
• Trunk lid (Sedan models) - removal, installation and adjustment
• Luggage compartment door and support leg (Hatchback models) - removal, installation and adjustment
• Trunk lid lock components (Sedan models) - removal and installation
• Components of the lock and handle of the tailgate (Hatchback models) - removal and installation
• Central locking system components - removal and installation
• Outside mirror - removal and installation
• Luke - general description
• Seats and seat belts - removal and installation
• Center console - removal and installation
• Panel and glove compartment - removal and installation

Body electrical equipment

• Specifications
• General description and precautions
• Troubleshooting electrical circuits - general description
• Fuses and relays - general description
• Switches, clock and cigarette lighter - removal and installation
• Lamps (external lighting) - replacement
• Lamps (interior lighting) - replacement
• External lighting units - removal and installation
• Adjusting the direction of the light beam - general description
• Instrument panel - removal and installation
• Sound signal - removal and installation
• Speedometer drive cable - removal and installation
• Wiper arm - removing and installing
• Wiper motor and rod - removal and installation
• Rear door wiper motor - removing and installing
• Windshield / rear window washer system components - removal and installation
• Car radio and antenna - removal and installation
• Speakers - removal and installation

Troubleshooting

• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Suspension and steering
• Electrical system

Wiring diagrams