Contents

Operating instructions

Maintenance

Single overhead camshaft (SOHC) engine

• Specifications
• Engine - general description
• Compression check - description
• Top dead center (TDC) - general description
• Camshaft cover - removal and installation
• Crankshaft pulley - removal and installation
• Top outer toothed belt cover - removing and installing
• Lower outer toothed belt cover - removing and installing
• Sponge belt rear cover - removing and installing
• Toothed drive belt (1.4 and 1.6 l models) - removal, installation and adjustment
• Toothed drive belt (C 18 NZ and C 20 NE engines, models up to 1993) - removal, installation and adjustment
• Toothed drive belt (engines C 18 NZ and C 20 NE, models since 1993) - removal, installation and adjustment
• Camshaft sprocket - removal and installation
• Crankshaft sprocket - removal and installation
• Timing Belt Tensioner (1.4 and 1.6 l models) - removing and installing
• Camshaft oil seals - replacement
• Camshaft - removal, inspection and installation
• Cylinder head - removal and installation
• Oil pump pan and receiver pipe - removal and installation
• Oil pump - removal and installation
• Oil pump - disassembly, inspection and assembly
• Crankshaft oil seals - replacement
• Flywheel / drive disc - removal, inspection and installation
• Engine / transmission mounts - inspect and replace
• Engine bulkhead - general description
• Removing the engine, methods and precautions - general description
• Engine - removal and installation (transmission remains in the car)
• Assembly engine / manual transmission - removal and installation
• Engine - removal and installation (automatic transmission remains in the car)
• Assembly engine / automatic transmission - removal and installation
• Engine bulkhead - disassembly
• Cylinder head - disassembly, inspection and assembly
• Pistons and connecting rods - removal and installation
• Pistons and connecting rods - inspection and maintenance
• Crankshaft and bearings - removal and installation
• Crankshaft and bearings - inspect
• Cylinder block and cylinder bores - inspection
• Inspection and maintenance - general description
• Preparing to launch after major overhaul

Engine with two overhead camshafts (DOHC)

• Specifications
• General description
• Toothed belt covers (X 16 XEL) - removing and installing
• Toothed belt covers (except X 16 XEL) - removal and installation
• Toothed drive belt (X 16 XEL) - removal, installation and adjustment
• Toothed drive belt (except X 16 XEL) - removal, installation and adjustment
• Camshaft cover - removal and installation
• Camshaft sprockets (X 16 XEL) - removal and installation
• Camshaft sprockets (except X 16 XEL) - removal and installation
• Front camshaft oil seals - replacement
• Rear camshaft oil seal - general information
• Toothed belt tensioner and idler pulley removal and installation
• Camshafts - removal and installation
• Cylinder head (X 16 XEL) - removing and installing
• Cylinder head (except X 16 XE) - removal and installation
• Cylinder head - bulkhead
• Valve pushers - general description
• Pallet (X 16 XEL) - general description
• Crankshaft gear - removal and installation
• Oil pump - removal and installation
• Crankshaft oil seals - replacement
• Engine with transmission - removal and installation
• Engine oil cooler - removal and installation

Bulkhead diesel engine 17D

• Specifications
• General description
• Basic operations performed without removing the engine from the car
• Engine oil and oil filter - change
• Toothed drive belt - inspect, remove, install and tension
• Gas distribution - check and adjustment
• Cylinder head - removal and installation
• Camshaft - removal and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil bypass valve - change
• Water pump - removal and installation
• Thermostat - removal, check and installation
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Oil seals - replacement
• Bracket engine / transmission mounts - replacement
• Engine / transmission removal methods
• Engine - removal
• Disassembly of the engine - general description
• Ancillary components - removal
• Engine disassembly
• Oil pump - bulkhead
• Cylinder head disassembly and assembly
• Cylinder head - inspect and overhaul
• Cylinder head and pistons - carbon removal
• Inspection and maintenance - general description
• Engine components - inspection and service
• Engine assembly - general description
• Engine - assembly
• Engine - installation
• Engine - starting after bulkhead

Bulkhead diesel engine 17DT

• Specifications
• General description
• Basic operations performed without removing the engine from the car
• Engine oil and oil filter - change
• Toothed drive belt - inspect, remove, install and tension
• Camshaft timing - check and adjust
• Valve clearances - check and adjust
• Cylinder head - removal and installation
• Camshaft - removal and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pressure regulating valve - removing, checking and installing
• Engine oil cooler - removal and installation
• Engine oil cooler thermostat - removal, check and installation
• Water pump - removal and installation
• Cooling system thermostat - removal, check and installation
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Oil seals - replacement
• Engine / transmission mounts - replacement
• Engine / transmission removal methods
• Engine / transmission - removal
• Engine / transmission - split
• Disassembly of the engine - general description
• External components - removal
• Engine disassembly
• Oil pump - bulkhead
• Cylinder head - bulkhead
• Cylinder head - inspect and overhaul
• Cylinder head and pistons - carbon removal
• Inspection and maintenance - general description
• Engine components - inspection and service
• Engine assembly - general description
• Engine - assembly
• Engine / transmission - connection
• Engine / transmission - installation
• Engine - preparing to start after bulkhead

Cooling, heating and ventilation systems

• Specifications
• Cooling system - main features
• Precautions - warnings
• Cooling system - draining, flushing and filling
• Coolant hoses - description
• Radiator - removal, inspection and installation
• Expansion tank - removal and installation
• Thermostat - removal, check and installation
• Fan - check, removal and installation
• Fan thermal switch - check, removal and installation
• Coolant temperature sensor - check, removal and installation
• Coolant level sensor - check, remove and install
• Water pump - removal and installation
• Heating and ventilation system - description
• Control unit, heater and ventilation - removal and installation
• Heating and ventilation control cables - removal and installation
• Heater blower motor - removal and installation
• Heater blower motor resistor - removal and installation
• Heater matrix - removal and installation
• Vacuum air recirculation chamber - removal and installation
• Heating / ventilation deflectors - removal and installation
• Heated front seat components - removing and refitting
• Heater blower and rear window heating switches - removal and installation

Fuel system - carburetor models

• Specifications
• General information and precautions
• Unleaded gasoline - description and application
• Intake air temperature control system - check
• Air filter cover - removal and installation
• Fuel priming pump - check, removal and installation
• Fuel level sensor - removal and installation
• Fuel vapor separator - removal and installation
• Fuel filter - removal and installation
• Fuel tank - removal and installation
• Throttle cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Carburetor - general description
• Carburetor - removal and installation
• Carburetor - identifying faulty topics, bulkhead and adjustment
• Needle and float - removal, inspection and installation
• Secondary flap vacuum diaphragm - removal and installation
• Economizer valve diaphragm - removal and installation
• Accelerator pump diaphragm - removal and installation
• Automatic air damper unit - removal, installation and adjustment
• Automatic air damper pull-down vacuum units - removal, installation and adjustment

Fuel system - fuel injection models

• Specifications
• Precautions and warnings
• System descriptions
• Fuel injection system components - check
• Unleaded petrol - general description
• Electronic control module - removal and installation
• Air box - removal and installation
• Air filter assembly - removal and installation
• Resonator, air filter - removal and installation
• Fuel injection system unit (Multec CFi) - removal and installation
• Throttle body (Multec MPi) - removal and installation
• Throttle body (Multec-S) - removal and installation
• Throttle body (Motronic M1.5) - removal and installation
• Throttle body (Motronic M 2.5 and M 2.8) - removal and installation
• Throttle body (Simtec) - removal and installation
• Fuel injector (Multec CFi) - removal and installation
• Fuel injectors (Multec MPi) - removal and installation
• Fuel injectors (Multec-S) - removal and installation
• Fuel injectors (Motronic M1.5) - removal and installation
• Fuel injectors (Motronic M2.5 and M2.8) - removal and installation
• Fuel injectors (Simtec) - removal and installation
• Fuel pressure regulator - removal and installation
• Throttle position sensor - removal and installation
• Throttle potentiometer - removal and installation
• Idling drive motor - removal and installation
• Idle speed control valve - removing and installing
• Stepper motor removal and installation
• Manifold pressure sensor - removal and installation
• Inductive pulsator - removal and installation
• Coolant temperature sensor - removal and installation
• Oxygen sensor - removal and installation
• Intake air temperature sensor - removing and installing
• Air flow meter - removal and installation
• Knock sensor - removal and installation
• Camshaft sensor - removal and installation
• Charcoal canister cleaning valve - removing and installing
• Fuel priming pump - check, removal and installation
• Fuel filter - removal and installation
• Throttle cable - removal, installation and adjustment

Emission neutralization and exhaust system

• Specifications
• General description
• Crankcase emission control system - general description
• Exhaust gas aftertreatment system - general description
• Catalytic converter - general description and precautions
• Fuel vapor recirculation system - general description
• Exhaust gas recirculation - general description
• Additional air injection system - general description
• Emissions management system - check
• Fuel vapor recirculation system - check
• Coal canister - removal and installation
• Fuel tank vent valve (Multec CFi and MPi models) - removal and installation
• Fuel tank ventilation valve (Motronic M1.5 models) - removing and installing
• Fuel tank ventilation valve (Motronic M2.5 models) - removing and installing
• Exhaust gas recirculation system - functional check
• Exhaust gas recirculation valve removal and installation
• Air blower - removal and installation
• Additional air valve - removal and installation
• Air duct and combination valve - removal and installation
• Intake manifold (14 NV models) - removal and installation
• Intake manifold (Multec CFi models) - removal and installation
• Intake manifold (Multec MPi models) - removal and installation
• Intake manifold, top (Multec-S models) - removal and installation
• Intake manifold, lower part (Multec-S models) - removal and installation
• Intake manifold (Motronic Ml.5 models) - removal and installation
• Intake manifold (Motronic M2.5 and M2.8 models) - removal and installation
• Intake manifold (vogue whether Simtec) - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general description
• Exhaust system - removal and installation
• Front section (DOHC models) - removal and installation

Fuel and exhaust systems - 17D engine

• Specifications
• General description and precautions
• Fuel system - contamination
• Air filter - element replacement
• Fuel filter - element replacement
• Fuel filter - element replacement
• Fuel filter - draining fluid
• Heated fuel filter - location and service
• Idle speed - check and adjust
• Maximum engine speed - check and adjust
• Injection timing - check and adjust
• High pressure fuel pump - removal, bulkhead and installation
• Fuel cut-off valve - removal and installation
• Fuel injectors - removal, bulkhead and installation
• Gas pedal cable - removal and installation
• Cold crank lever cable - removal and installation
• Vacuum controlled cold start - removal and installation
• Fuel tank - removal and installation
• Collectors - removal and installation
• Exhaust system - inspection
• Catalytic converter - removal and installation
• Exhaust gas recirculation - service

Fuel and exhaust systems - 17DT engine

• Specifications
• General description and precautions
• Fuel system - pollution
• Air filter - element replacement
• Air filter cover - removal and installation
• Fuel filter - element replacement
• Fuel filter - draining fluid
• Fuel filter heating element - location and replacement
• Idle speed - check and adjust
• Maximum engine speed - check and adjust
• Cold start acceleration - check and adjust
• Injection timing - check and adjust
• High pressure fuel pump - removal, bulkhead and installation
• Fuel cut-off valve - removal and installation
• Fuel injectors - removal, bulkhead and installation
• Gas pedal cable - removal and installation
• Fuel tank - removal and installation
• Turbine generator - removal and installation
• Charge air cooler (intercooler) - removal and installation
• Pressure relief valve - removal and installation
• Collectors - removal and installation
• Exhaust system - inspection
• Catalytic converter - removal and installation

Engine electrical systems

• Specifications
• Electrical system - general description
• Precautions
• Ignition system - general description
• Ignition system (14 NV) - check
• Ignition system (except 14 NV) - check
• Battery - check and charge
• Battery - removal and installation
• Charging system - functional check
• V-belt - removing, installing and tensioning
• V-belt - removing and installing
• Generator - removal and installation
• Alternator brushes and regulator (Delco-Remy) - removal and installation
• Alternator brushes and regulator (Bosch) - removal and installation
• Launch system - check
• Starter - removal and installation
• Starter bulkhead - general description
• Distributor (14 NV) - removal, bulkhead and installation
• Distributor- (14 SE, C 14 NZ and C 16 NZ) - removal, bulkhead and installation
• Distributor (C 18 NZ and C 20 NE) - removal, bulkhead and installation
• Distributor (early models C 20 XE) - removal, bulkhead and installation
• Ignition coil - removal, check and installation
• Ignition control unit - removal, check and installation
• Ignition amplifier module - removal and installation
• Oil pressure warning lamp sensor - removing and installing
• Oil level sensor - removal and installation

Preheating system

• Specifications
• Preheating system - description and check
• Oil pressure warning lamp switch - removing and installing
• Fan thermal switch check, remove and install
• Fan - check
• Coolant temperature gauge sensor - removing and installing
• Fuel filter temperature sensor - locations and check

Clutch

Mechanical transmission

Automatic transmission

Drive shafts

Braking system

• Specifications
• System description
• Anti-lock braking system (ABS) - general description
• Anti-skid system (TC) - general description
• Hydraulic brake system - bleeding
• Brake pipes and hoses - inspection, removal and installation
• Front brake pads - removal and installation
• Front brake caliper - removal, bulkhead and installation
• Brake disc - inspection, removal and installation
• Front brake disc guard - removal and installation
• Rear brake pads - removal and installation
• Rear brake drum - removal, inspection and installation
• Rear brake cylinder - removal, bulkhead and installation
• Rear brake pads (models with rear disc brakes) - removal and installation
• Rear brake caliper (models with rear disc brakes) - removal, bulkhead and installation
• Hand brake pads (models with disc rear brakes) - removal and installation
• Rear brake shield - removal and installation
• Brake pedal - removal and installation
• Vacuum booster - check, removal and installation
• Unidirectional valve - check, remove and install
• Master cylinder - removal, bulkhead and installation
• Handbrake - adjustment
• Hand brake lever - removal, bulkhead and installation
• Handbrake cables - removal and installation
• Pressure regulating valve in the rear brake assemblies - removal, installation and adjustment

Suspension and steering gear

• Specifications
• General description
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front wheel hub bearing - crushing and installing
• Front suspension lower arm - removal and installation
• Front lower arm bushings - removal and installation
• Ball joint of the lower arm of the front suspension - removal and installation
• Front anti-roll bar - removal and installation
• Front anti-roll bar bushings - removal and installation
• Sub-frame - removal and installation
• Rear hub - removal and installation
• Rear shock absorber - removal, inspection and installation
• Rear shock absorber rubber pads - removal and installation
• Rear suspension spring - removal and installation
• Rear anti-roll bar (s) - removing and installing
• Rear suspension torsion beam / trailing arms - removal and installation
• Rear suspension trailing arm bushings - removal and installation
• Rear suspension control system - general description
• Rear suspension control system components - removal and installation
• Steering wheel - removal and installation
• Steering wheel alignment
• Steering column lock - removal and installation
• Steering column - removal and installation
• Steering column - bulkhead
• Elastic coupling of a shaft of a steering column - removal and installation
• Steering gear rubber covers - removal and installation
• Steering gear - removal and installation
• Steering gear - bulkhead
• Power steering hydraulic system - bleeding
• Power steering pump - removal and installation
• Power steering hydraulic reservoir - removal and installation
• Power steering hydraulic fluid cooling pipes - removal and installation
• Ball joint / tie rod end - removal and installation
• Tie rod - removal and installation
• Front wheel alignment - general description

Body

• Specifications
• Body - general description
• Body and underbody service - general description
• Upholstery and rugs - care and maintenance
• Minor damage to the body - basic description
• Significant damage to the body - restoration
• Front and rear bumpers - removal and installation
• Radiator grill - removal and installation
• Windscreen fairing panel - removal and installation
• Hood - removal and installation
• Bonnet hinges - removal and installation
• Bonnet lock components - removing and installing
• Bonnet cable - removal and installation
• Doors - removal, installation and adjustment
• Inner door handle - removal and installation
• External door handle - removal and installation
• Door locks - removal and installation
• Front door lock cylinder - removal and installation
• Strike plate of the lock - removal and installation
• Door glass - removal and installation
• Window regulator - removal and installation
• Trunk lid (Sedan models) - removal and installation
• Trunk lid hinge - removing and installing
• Trunk lid components - removal and installation
• Luggage compartment door - removal and installation
• Tailgate hinge - removing and installing
• Tailgate components - removal and installation
• Central locking components - removal and installation
• Power window components - removal and installation
• Exterior mirror - removal and installation
• Outside mirror glass - removal and installation
• Electrically adjustable mirror components - removal and installation
• Interior mirror - removal and installation
• Windshield and rear windows - general description
• Rear side door triangular glass - removal and installation
• Glass sunroof panel - removal and installation
• Sunroof components - removal and installation
• Wheel arch liners - main features
• Lower engine shield (depending on model) - removal and installation
• Fuel filler flap - removal and installation
• Rear spoilers - removal and installation
• External body components - removal and installation
• Side skirts and additional spoilers - general description
• Front seats - removal and installation
• Rear seats - removal and installation
• Front seat belt tensioner system - general description
• Seat belts - removal and installation
• Seat belt height adjusters - removal and installation
• Interior trim panels - general description
• Carpet - general description
• Ceiling - general description

Body electrical system

• Specifications
• Electrical troubleshooting - general description
• Fuse box - removal and installation
• Fuses - checking, removing and installing
• Relays - general description
• Ignition lock - removal and installation
• Steering column combination switches - removal and installation
• Combined headlight switch - removal and installation
• Dashboard pushbutton switches - removal and installation
• Emergency stop switch - removal and installation
• Horn switch - general description
• Brake light switch - removal and installation
• Interior lighting switches - removal and installation
• Trunk light switch - general description
• Glove compartment light switch - general description
• Lamps (external lighting fixtures) - general description and replacement
• Lamps (interior lighting) - description and replacement
• External lighting devices - removal and installation
• Adjusting the direction of the light beam - general description
• Motor for adjusting the direction of the light beam - removing and installing
• Instrument cluster - removal and installation
• Instrument cluster components - general description, removal and installation
• Clock / multifunction display - removal and installation
• Additional control system - general description
• Additional control system components - removal and installation
• On-board computer - general description
• Cigarette lighter - removal and installation
• Sound signal - removal and installation
• Speedometer cable - removal and installation
• Wiper arms - removal and installation
• Wiper motor and rod - removal and installation
• Tailgate wiper motor and rod - removal and installation
• Windshield / tailgate washer system components - removal and installation
• Headlamp washer system components - removal and installation

Troubleshooting

Wiring diagrams