Content

Operating instructions

Maintenance

• Car care
• Starting the engine using a booster battery
• Car towing
• Jacking up the car
• Maintenance plan
• Maintenance - works
• Fuel filter - condensation removal / replacement
• Ribbed belt - check
• Timing belt - check
• Coolant - check
• Coolant - concentration check
• Exhaust system - visual check for leaks
• Replaceable air filter element - replace
• Spark plugs - removal, inspection and installation
• Gearbox and final drive
• Brakes. Tires. Wheels
• Brake fluid - check level
• Brake fluid - replacement
• Wheels and tires
• Front axle and steering
• Body. Salon equipment

Petrol 4-cylinder engines

• Specifications
• General description
• Compression check - description
• Installing the piston of cylinder No. 1 at top dead center (TDC)
• Camshaft cover - removal and installation
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - removing and installing
• Sprockets, tensioner and toothed belt idler pulleys - removal and installation
• Camshaft oil seals - replacement
• Camshafts and hydraulic tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, bulkhead and installation
• Crankshaft balancer block - removal, installation and adjustment
• Flywheel / drive disc - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine / transmission mounts - inspect and replace

Gasoline 6-cylinder engines

• Specifications
• General description
• Compression check - description
• Installing the piston of cylinder No. 1 at top dead center (TDC)
• Valve covers - removal and installation
• Crankshaft pulley - removal and installation
• Toothed belt covers - removing and installing
• Toothed drive belt - removing and installing
• Sprockets, tensioner and timing belt pulleys - removal and installation
• Camshaft oil seals - replacement
• Camshafts and hydraulic tappets - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, bulkhead and installation
• Engine oil cooler - removal and installation
• Flywheel / drive disc - removal, inspection and installation
• Crankshaft oil seals - replacement
• Engine / transmission mounts - inspect and replace

General engine rebuild procedures

• General description
• Engine bulkhead - general description
• Removing the engine - methods and precautions
• Engine - removal and installation
• Engine overhaul - disassembly sequence
• Cylinder head - removal
• Cylinder head and valves - cleaning and inspection
• Cylinder head assembly
• Piston / connecting rod assembly - removal
• Crankshaft - removal
• Cylinder block - cleaning and inspection
• Piston / connecting rod assembly - inspect
• Crankshaft - inspection
• Main and connecting rod bearings - inspection
• Engine - assembly sequence
• Piston rings - installation
• Crankshaft - installing and checking main bearing running clearance
• Piston / connecting rod assemblies - installing and checking connecting rod bearing running clearance
• Engine - preparing to start after bulkhead

Diesel engines of 2.0 and 2.2 liters

• Specifications
• Engine - removal and installation
• Cylinder head cover - removing and installing
• TDC of the cylinder № 1 piston - installation
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Camshaft - removal and installation
• Vacuum pump - removal and installation
• Casing of the gas distribution mechanism - removal and installation
• Oil pump - removal and installation
• Crankshaft - removal and installation
• Crankshaft - checks
• Connecting rod-piston group - removal and installation
• Flywheel - removal and installation
• Rear crankshaft oil seal - removing and installing
• Torsional vibration damping unit - removing and installing
• Ribbed belt of accessory drive - removal and installation
• Oil pan - removal and installation
• Compression - check

Diesel engines of 2.5 l

• Specifications
• Engine - removal and installation
• Cylinder head cover - removing and installing
• TDC of the cylinder № 1 piston - installation
• Cylinder head - removal and installation
• Cylinder head - bulkhead
• Vacuum pump - removal and installation
• Crankshaft - removal and installation
• Connecting rod-piston group - removal and installation
• Flywheel - removal and installation
• Front crankshaft oil seal - replacement
• Rear crankshaft oil seal - replacement
• Ribbed belt of accessory drive - removal and installation
• Oil pan - removal and installation
• Oil pump - removal and installation
• Compression - check

Cooling, heating and ventilation system

• General information and device
• Coolant - draining, filling and checking concentration
• Thermostat - removal and installation
• Radiator - removal and installation
• Radiator fan thermal switch - check
• Radiator blower motor - removal and installation
• Viscous coupling - removal and installation
• Water pump - removal and installation
• Heating and air conditioning system
• Heater switch block - removal and installation
• Additional fan resistances - removal and installation
• Air distribution flap actuator diaphragm valve - removal and installation
• Interior blower motor - removal and installation
• Air conditioner

Fuel injection system - petrol engines

• General information
• Fuel injectors - check, removal and installation
• Lambda probe - removal and installation

Power system - diesel engines

• The principle of operation of a diesel engine
• Preheating unit - checking, removing and installing glow plugs
• Preheating unit relay - removal and installation
• Fuel cut-off valve - check, removal and installation
• High pressure fuel lines and injectors - removal and installation
• Start of injection pump feed - check and adjustment
• Intake manifold - removal and installation

Fuel system

• General description
• Fuel pump - removal and installation
• Fuel gauge - removal and installation
• Accelerator cable - removal, installation and adjustment
• Air filter - removal and installation
• Intake air accumulation chamber - removal and installation
• Intake manifold - removal and installation

Exhaust system

• General information
• Exhaust system - removal and installation
• Rear muffler - replacement
• Catalyst

Ignition system

• Specifications
• Ignition system - general description
• Ignition system - check
• Ignition module - removal and installation
• Ignition timing - check and adjust

Clutch

• Specifications
• General description
• Clutch hydraulic system - bleeding
• Master cylinder - removal and installation
• Release cylinder - removal and installation
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation

Mechanical transmission

• Specifications
• General description
• Transmission oil - draining, filling the unit and measuring level
• Shift rod - adjustment
• Gear shift rod - removal and installation
• Oil seals - replacement
• Reversing light switch - serviceability check, removal and installation
• Transmission - removal and installation
• Transmission bulkhead - general description

Automatic transmission

• Specifications
• General description
• Transmission fluid - block draining and filling
• Drive mode switching rod - adjustment
• Drive mode switching rod - removal and installation
• Assembling the drive mode selection lever - removal and installation
• Oil seals - replacement
• Transmission fluid cooler - general description
• Electrical components of the transmission control system - removal and installation
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description

Main gear, drive and cardan shafts

• Specifications
• General description
• Final drive block - removal and installation
• Final drive unit - filling and checking oil level
• Damper bushings for final drive unit - replacement
• Final drive unit rear cover gasket - replacement
• Final drive pinion oil seal - replacement
• Differential bearing oil seal - replacement
• Drive shaft - removal and installation
• Rubber protective covers of the drive shaft and its outer CV joint - replacement
• Cardan shaft - removal and installation
• Propshaft center bearing - replacement
• Elastic joints of the propeller shaft - replacement

Braking system

• Specifications
• General description
• Front wheel brake pads - check, remove and install
• Rear wheel brake pads - check and replace
• Front brake caliper - removal, bulkhead and installation
• Rear wheel brake caliper - removal, bulkhead and installation
• Brake disc - check, removal and installation
• Parking brake pads - inspection, removal and installation
• Parking brake lever and cables - removal and installation
• The main brake cylinder - removal and installation
• Expansion tank and brake fluid level sensor - removal and installation
• Brake system - bleeding
• Brake hoses - removal and installation
• Vacuum brake booster - check, removal and installation
• Vacuum booster hose and its one-way valve - replacement
• Brake pedal - removal and installation
• ABS and traction control - general description
• ABS and Traction Control - Component Removal and Installation

Suspension and steering

• Specifications
• General description
• Front suspension strut - removal and installation
• Camber front wheels - adjustment
• Lower suspension arm - removal and installation
• Front suspension lower ball joint - replacement
• Front anti-roll bar - removal and installation
• Front stabilizer bar - removal and installation
• Steering knuckle - removal and installation
• Front wheel hub and bearings - removal and installation
• Sub-frame - removal and installation
• Rear shock absorber - removal and installation
• Rear diagonal arm - removal and installation
• Rear leaf spring - removal and installation
• Rear anti-roll bar - removal and installation
• Rear suspension jet rod - removal and installation
• Rear suspension control system - component removal and installation
• Rear suspension assembly - removal and installation
• Rear suspension cross member - removal and installation
• Rear cross member mountings - replacing
• Rear wheel hub and bearing - removal and installation
• Steering wheel - removal and installation
• Steering column - removal and installation
• Ignition / steering column lock - removal and installation
• Steering gear - removal and installation
• Steering rods - removal and installation
• Pendulum arm - removal and installation
• Power steering pump - removal and installation
• Wheel alignment - check and adjust

Body and interior trim

• General description
• Front bumper - removal and installation
• Front bumper cover - removal and installation
• Front cross member - removal and installation
• Rear bumper - removal and installation
• Fairing - removal and installation
• Front fenders - removal and installation
• Hood - removal and installation
• Door - removal, fit settings
• Door trim - removal and installation
• Door glass - removal, installation and adjustment
• Door handles - removal and installation
• Door lock - removal and installation
• Center console - removal and installation
• Rear hinged door - removal and installation

Electrical system

• Checking bulbs
• Checking electric motors
• Light and motor switches - check
• Switch sensors - check
• Relay - check
• Turn signal interrupter - check
• Wiper motor - check
• Heated rear window - check
• Stop signal - check
• Central locking
• Battery - removal and installation
• Generator
• Starter - removal and installation
• Lighting devices
• Instrument panel - removal and installation
• Indicator lights on the instrument panel - replacement

Troubleshooting

• Identification of engine faults and their elimination
• Identification of malfunctions of the engine lubrication system and their elimination
• Identification of engine cooling system malfunctions and their elimination
• Determination of malfunctions of the petrol injection system and their elimination
• Determination of malfunctions of the diesel engine power system and their elimination
• Determination of malfunctions of the brake system and their elimination
• Clutch troubleshooting
• Battery troubleshooting
• List of starter malfunctions and their elimination
• Identify and troubleshoot generator faults
• Identifying and fixing wiper faults

Basic electrical diagrams (wiring diagrams)