Contents

Foreword

Operating instructions

Maintenance

• Dimensions and weight
• Specifications
• Capacities
• Identification numbers
• Tire pressure

Service procedures - gasoline models

• Weekly Checks
• Every 400 km or weekly
• Every 15,000 km
• Every 30,000 km
• Every 2 years

Service procedures - diesel engines

• Every 400km
• Every 5000 km
• Every 7,500 km
• Every 10,000 km
• Every 15,000 km
• Every 30,000 km
• Every 45,000 km
• Every 60,000 km
• Every 90,000 km
• Every 100,000 km
• Every 2 years, regardless of mileage

Undercamshaft engine

• Specifications
• General description
• Compression check - description
• Actions possible with the engine in the car
• Actions requiring engine removal
• Disassembly and assembly of the engine - general description
• Optional components - removal and installation
• Valve clearances - adjustment
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Cylinder head and pistons - carbon removal
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pump - bulkhead
• Timing sprocket components - removal and installation
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Engine / transmission mounts - removing and installing
• Camshaft and tappets - removal and installation
• Rear crankshaft oil seal - removing and installing
• Crankshaft and main bearings - removal and installation
• Engine lubrication system - general description
• Engine - removal and installation
• Engine - starting after bulkhead

Overhead camshaft engines

• Specifications
• General description
• Compression check - description
• Actions requiring engine removal
• Disassembly and assembly of the engine - general description
• Optional components - removal and installation
• Oil pressure regulator valve - removing and installing
• Camshaft timing belt - removal, installation and adjustment
• Cylinder head - removal and installation
• Camshaft - removal and installation
• Cylinder head - bulkhead
• Cylinder head and pistons - carbon removal
• Pallet - removal and installation
• Oil pump - removal and installation
• Oil pump - bulkhead
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Front crankshaft oil seal - removing and installing
• Engine / transmission brackets - removal and installation
• Rear crankshaft oil seal - removing and installing
• Crankshaft and main bearings - removal and installation
• Engine components - inspection and service
• Lubrication and crankcase ventilation systems - general description
• Engine - removal and installation
• Engine - starting after bulkhead

Engine with two overhead camshafts (16-valve)

• Specifications
• General description
• Compression check - description
• Actions requiring engine removal
• Disassembly and assembly of the engine - general description
• Optional components - removal and installation
• Oil pressure regulating valve - removal and installation
• Camshaft timing belt - removing and installing
• Belt tensioner and idler rollers - removal and installation
• Camshaft sprocket oil seals - replacement
• Camshafts - removal and installation
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Oil catch pan and plate - removal and installation
• Oil pump - removal and installation
• Oil pump - bulkhead
• Thermal valve for oil cooler - removal and installation
• Front crankshaft oil seal - replacement
• Pistons and connecting rods - removal and installation
• Disassembly and assembly of pistons and connecting rods
• Flywheel - removal and installation
• Rear crankshaft oil seal - replacement
• Engine / transmission brackets - removal and installation
• Crankshaft and main bearings - removing and installing
• Engine components - inspection and service
• Engine - removal and installation
• Engine - starting after bulkhead

Diesel engine

• Specifications
• General description
• Basic operations performed without removing the engine from the car
• Engine oil and oil filter - change
• Camshaft drive belt - inspection, removal, installation 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
• Coolant pump - removal and installation
• Thermostat - removal, check and installation
• Pistons and connecting rods - removal and installation
• Flywheel - removal and installation
• Oil seals - replacement
• Engine / transmission mounting brackets - replacing
• Engine / transmission removal methods
• Engine / transmission - removal
• Engine / transmission - split
• Disassembly of the engine - general description
• Ancillary components - removal
• Engine - complete 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 - transmission connection
• Engine / transmission - installation
• 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, operation check and installation
• Coolant pump - removal and installation
• Radiator fan - operation check, removal and installation
• Electrical switches and sensors for the cooling system - operation check, removal and installation
• Interior heating / ventilation system - general description
• Heater components - removal and installation

Fuel and exhaust systems - carburetor models

• Specifications
• General description
• Non-gallon gasoline - general description and use
• Air filter cover - removal and installation
• Air temperature control system - general description
• Fuel pump - check, removal and installation
• Fuel tank sensor - removal and installation
• Fuel tank - removal and installation
• Accelerator cable - removal, installation and adjustment
• Gas pedal - removal and installation
• Choke cable - removal, installation and adjustment
• Carburetor - description
• Carburetor 32TL - adjustments
• Carburetor 35 PDS1- adjustments
• Carburetor 1В1- adjustment
• Carburetor 2EZ - adjustments
• Carburetor Varajet 11- adjustments
• Idling cutoff - description and check
• Carburetor - removal and installation
• Carburetor 32Tl - bulkhead
• Carburetor 35 PDS1 - bulkhead
• Carburetor 1В1 - bulkhead
• Carburetor 2EZ - bulkhead
• Carburetor Varajet 11- bulkhead
• Exhaust manifold - removal and installation
• Exhaust manifold - removal and installation
• Intake manifold heater (1.6 l models with automatic transmission) - general description, removal and installation
• Exhaust system - inspection, removal and installation

Fuel and exhaust systems - fuel injection models

• Specifications
• General description and precautions
• Air filter cover - removal and installation
• Accelerator cable - removal, installation and adjustment
• Unleaded gasoline - general description and use
• Fuel injection system - general description
• Fuel system - decompression
• Fuel pump - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - check and adjust
• Single-point fuel injection system components (1.4 and 1.6 liter models) - removal and installation
• Components of the multiport fuel injection system (models 1.8 and 2.0 liters) - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - inspection, removal and installation

Fuel and exhaust systems - diesel models

• Specifications
• General description and precautions
• Fuel system - pollution
• Air filter - element replacement
• Fuel filter - element replacement
• Fuel filter - sludge drain
• Heated fuel filter - location and service
• Idle speed - check and adjust
• Maximum engine speed - check and adjust
• Injection timing - checking and adjusting
• 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
• Fuel tank - removal and installation
• Collectors - removal and installation

Starting and charging systems

• Specifications
• General description and precautions
• Troubleshooting electrical systems - general description
• Battery - test and charge
• Battery - removal and installation
• Charging system - check
• Alternator drive belt - removing, installing and tensioning
• Generator - removal and installation
• Generator - test and bulkhead
• Engine starting system - check
• Starter - removal and installation
• Starter - check and bulkhead
• Ignition lock - removal and installation
• Oil pressure warning lamp switch - removing and installing
• Oil level sensor (16 valve models) - removal and installation
• Preheating system (diesel engines) - description and functional check
• Oil pressure warning lamp sensor - removing and installing

Ignition system with interrupter

• Specifications
• General description
• Ignition system - check
• Breaker contacts - adjusting the gap and the angle of rotation of the distributor cam
• Breaker contacts - removal and installation
• Capacitor - test, removal and installation
• Distributor - removal and installation
• Distributor - bulkhead
• Ignition timing - adjustment
• Ignition coil - removal, testing and installation

Electronic ignition system (without interrupter)

• Specifications
• General description
• Ignition system - check
• Distributor - removal and installation
• Distributor - bulkhead
• Ignition timing - adjustment
• Ignition coil - removal, testing and installation
• Ignition module (control unit) - removal and installation

Clutch

• Specifications
• General description
• Clutch - initial adjust
• Clutch cable - removal and installation
• Clutch pedal - removal and installation
• Coupling - removal, inspection and installation
• Release bearing, lever, bushings and oil seal - removal and installation

Mechanical transmission

• Specifications
• General description
• Transmission - oil drain and fill
• Lever - gear shifting - removal and installation
• Reverse lock cable - removal and installation
• Rod of the gearshift mechanism - removal, installation and adjustment
• 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
• K1ckdown function activation cable - removal, installation and adjustment
• Gear selection cable - removal, installation and adjustment
• Starter lock / reversing light switch - removal and installation
• Automatic transmission - removal and installation

Drive shafts

• Specifications
• General description
• Drive shaft - removal and installation
• SHRUS protective covers - replacement

Braking system

• Specifications
• General description
• BrakesI hydraulic system - bleeding
• Hydraulic tubes and hoses - replacement
• Front brake pads - replacement
• Rear brake pads - replacement
• Rear brake pads - replacement
• Front brake disc - inspection, removal and installation
• Rear brake disc - inspection, removal and installation
• Rear brake drum - removal, inspection and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake caliper - removal, bulkhead and installation
• Rear brake slave cylinder - removal, bulkhead and installation
• Master cylinder - removal and installation
• Pressure control valves - operation check, removal and installation
• Vacuum hose and unidirectional brake booster valve - replace
• Vacuum booster unit - operation check, removal and installation
• Brake pedal - removal and installation
• Handbrake cable - removal and installation
• Hand brake lever - removal and installation
• Hand brake pads (models with rear disc brakes) - replacement
• Anti-lock braking system (ABS) - general description
• Anti-lock braking system (ABS) components - removal and installation

Suspension and steering

• Specifications
• General description
• Front suspension strut - removal and installation
• Front wheel hub bearings - replacement
• Front suspension strut - bulkhead
• Front suspension lower arm - removal and installation
• Lower arm bushings - replacement
• Lower arm ball joint - replacement
• Front anti-roll bar - removal and installation
• Rear wheel hub bearings - adjustment
• Rear wheel hub - removal and installation
• Rear wheel hub bearings - replacement
• Rear shock absorbers - removal and installation
• Rear anti-roll bar - removing and installing
• Rear spring springs - removal and installation
• Rear axle assembly - removal and installation
• Rear axle mounting bushings - replacement
• Leaf spring rear suspension components (pickup) - removal and installation
• Suspension control system - description and service
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering column - bulkhead
• Elastic steering column coupling - removal and installation
• Steering column lock cylinder and ignition lock wiring block - removal and installation
• Tie rod ball joints - removal and installation
• Steering rack guard - removing and installing
• Steering damper - removal and installation
• Steering gear - removal and installation
• Steering gear - bulkhead
• Power steering - pumping
• Power steering pump - removing and installing
• Power steering hydraulic reservoir - removal and installation
• Wheel alignment and kingpin tilt - general description

Body

• Specifications
• General description
• Hood - removal and installation
• Bonnet cable - removal and installation
• Front panel - removal and installation
• Rear panel - removal and installation
• Front wing - removal and installation
• Fairing - removal and installation
• Door trim panel - removal and installation
• Door - removal and installation
• Door lock - removal and installation
• External door handle - removal and installation
• Inner handle of a door lock - removal and installation
• Front door lock cylinder - removal and installation
• Window regulator - removal and installation
• Door glass - removal and installation
• Rear door - removal and installation
• Rear door hinges - removal and installation
• Rear door support - removal and installation
• Rear door lock - removal and installation
• Rear door lock cylinder - removal and installation
• Trunk lock components - removal and installation
• Side rear slightly opening windows - removal and installation
• Rear side opening windows - seal replacement
• Outside mirror components - removal and installation
• Front seat - removal and installation
• Headrests - removal and installation
• Rear seat - removal and installation
• Removing the trunk trim panel - general description
• Central control panel - removal and installation
• Glove box - removal and installation
• Hatch - operation and maintenance

Body electrical system (wiring diagrams)

• Specifications
• General description
• Electrical troubleshooting - general description
• Fuses and relays - general description
• Switches - removal and installation
• Sound signal (s) - removal and installation
• Watch - removal and installation
• Cigarette lighter lighting - removal and installation
• Dashboard - removal and installation
• Dashboard - dismantling and assembly
• Speedometer cable - removal and installation
• Lamps - replacement
• Headlight / turn signal assembly - removal and installation
• Headlight adjustment - general description
• Dim Light incidence system - general description
• On-board computer - general description
• Central locking system - general description
• Heated seats - general description
• Pins and rear door plate, hinged upwards - removal and installation
• Wiper blades and levers - removal and installation
• Wiper motor and rod - removal and installation
• Rear wiper motor - removing and installing
• Windshield / rear window washer system - general description

Troubleshooting

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

Wiring diagrams