Content

Abbreviations

Conventions

Identification

Jacking points

Operation manual

• Instrumentation and controls
• Keys (models with immobilizer)
• Electric sunroof
• Additional door lock
• Folding the seats
• Seat transformation
• Transmission features
• Anti-lock braking system (ABS)
• Driving tips for different conditions
• Car towing
• Starting the engine
• Engine malfunctions while driving
• Wheel replacement
• Catalytic converter and exhaust system
• Car maintenance

Engine - mechanical

• Coolant check
• Checking engine oil
• Battery test
• Checking and cleaning the air filter
• Checking high voltage wires and spark plugs
• Checking the alternator drive belt
• Checking and adjusting the valve clearance
• Checking and adjusting the ignition timing
• Checking the idle speed
• Checking CO / CH at idle (models with a catalytic converter)
• Checking and adjusting the CO concentration at idle (models without a catalytic converter)
• Compression pressure test
• Timing Belt
• Cylinder head
• Removing the cylinder head
• Dismantling the cylinder head
• Checking, cleaning and repairing cylinder head parts
• Cylinder head assembly
• Installing the cylinder head
• Cylinder block
• Pre-disassembly operations
• Dismantling the cylinder block
• Checking the cylinder block
• Dismantling the piston-connecting rod assembly
• Checking the condition of the piston and connecting rod
• Cylinder boring
• Checking and repairing the crankshaft
• Replacing the crankshaft oil seals
• Piston-connecting rod assembly
• Cylinder block assembly
• Final assembly

Cooling system

• Checking and replacing the coolant
• Coolant pump
• Thermostat
• Radiator
• Cooling system fan
• Checking sensors and relays
• Sensor - coolant temperature switch
• Main motor relay
• Relay No. 1 of the electric fan
• Relay No. 2 of the electric fan
• Relay No. 3 electric fan

Lubrication system

• Checking engine oil level and pressure
• Oil and filter change
• Oil pump
• Oil cooler

Fuel injection system

• Description
• Fuel system
• Air supply system
• Electronic control system
• Precautions
• Maintenance precautions
• Precautions when using a mobile radio system
• Air supply system
• Electronic control system
• Fuel system
• Diagnostic system
• Diagnosing faults with a road test
• Electronic fuel injection system test procedure
• Fuel pump
• Fuel pressure regulator
• Injectors
• Throttle body
• Idle speed ??control valve
• Fuel injection main relay
• Fuel pump relay switch
• Exhaust gas recirculation electro-pneumatic valve
• Valve system for increasing idle speed when the air conditioner is turned on
• Coolant temperature sensor
• Intake air temperature sensor
• Manifold MAP sensor
• Variable resistor (models without catalytic converter)
• Knock sensor
• Oxygen sensor
• Electronic control unit
• Fuel cut-off system in forced idle modes

Ignition system

• Description of the ignition system
• Warnings
• Vehicle checks
• Spark test
• Checking high voltage wires and spark plugs
• Examination of distributor
• Switch test
• Dispenser
• Ignition coils (models with electronic ignition system without distributor)

Launch system

• How it works
• Starter
• Starter relay

Charging system

• How it works
• Precautions
• Vehicle checks
• Generator

Clutch

• Clutch pedal
• Checking the pedal height
• Checking and adjusting the clutch pedal travel
• Clutch master cylinder
• Clutch slave cylinder
• Clutch

Manual gearbox and transfer case

• Removing the manual transmission and transfer case
• Disassembly of the gearbox
• Checking transmission parts
• Gearbox input shaft
• Gearbox output shaft
• Gearbox oil pump
• Shaft of the gear selector
• Differentials
• Center differential locking system
• Oil cooler
• Disassembling the transfer case
• Transfer case driven gear bearing holder
• Transfer case final drive pinion
• Transfer case assembly
• Gear Lever

Automatic transmission

• Driving with automatic transmission
• General information
• Preliminary checks
• Checking the transmission fluid
• Checking the transfer case oil
• Changing the transmission fluid
• Changing the oil in the transfer case
• Checking and adjusting the control cable
• Automatic transmission control rod adjustment
• Checking and adjusting the engine start inhibit switch
• Idle speed check (N range)
• Gearbox diagnostics
• Self-diagnosis system
• Checking mechanical gearbox systems
• Filter replacement
• Engine start inhibit switch
• Throttle valve control cable
• Replacing the speed sensor (models with a speedometer drive)
• Replacing the gearbox front output shaft speed sensor
• Replacing the output shaft seals (front wheel drive)
• Replacing the output shaft seal (rear wheel drive)
• Gearbox assembly

Cardan shaft

Suspension

• General check
• Front wheel alignment
• Rear wheel alignment
• Front axle hub
• Front drive shaft
• Front suspension strut
• Front suspension lower arm
• Lower ball joint
• Anti-roll bar
• Rear wheel hub
• Rear drive shaft
• Differential
• Rear shock absorber
• Rear suspension arm and spring

Braking system

• Checks and adjustments
• Checking and adjusting the brake pedal position
• Checking the operation of the vacuum brake booster
• Bleeding the brake system
• Checking and adjusting the parking brake
• Brake master cylinder
• Vacuum brake booster
• Front disc brakes
• Rear drum brakes
• Pressure regulator
• Anti-lock braking system (ABS)
• Self-diagnosis system description
• Self-diagnosis system check
• Resetting trouble codes
• Troubleshooting
• Speed ??sensor and deceleration sensor diagnostics
• Checking the operation of the deceleration sensor
• Removing and installing pressure modulator
• Checking the pressure modulator
• Control relay test
• Checking the front wheel speed sensors
• Removing the front wheel speed sensor
• Checking the rear wheel speed sensors
• Removing the rear wheel speed sensor
• Checking the anti-lock brake system circuit (models up to 1997)
• Checking the anti-lock braking system circuit (models from 1997)

Steering

• Car check
• Checking the steering wheel play
• Checking the power steering pump drive belt
• Checking the idle speed increase system
• Checking the power steering fluid level
• Replacing the hydraulic fluid
• Bleeding the power steering system
• Checking the pressure of the working fluid
• Checking the effort on the steering wheel
• Removing the steering column
• Steering column (option without tilt adjustment)
• Checking steering column parts
• Steering column (tilt-adjustable version)
• Installing the steering column
• Power steering pump
• Steering gear

Body

• Precautions during work
• Bonnet adjustment
• Bumpers
• Front door
• Back door
• Tail door
• Windshield
• Rear side window glass (3-door models)
• Rear side window glass (5-door models)
• Tailgate glass
• Washers and wipers
• Dashboard

Air conditioning, heating and ventilation

• Air conditioning system
• Air conditioning piping
• Compressor
• Receiver
• Capacitor
• Cooling unit
• Heater block
• Heater fan block
• Expansion valve
• Electro-pneumatic valve system for increasing idle speed
• Condenser fan
• Heater fan
• Heater blower resistor
• Thermistor
• Speed ??sensor
• Pressure switch
• Repeat
• Air conditioner amplifier
• Air conditioner control panel

Body electrical equipment

• General information
• Precautions
• Conducting inspections
• Replacing fuses
• Connector identification
• Switching circuit breaker (thermal fuse)
• Location of relays and fuses (except for modifications)
• Location of fuses (modifications)
• Ignition lock and forgotten key warning system
• Headlight and taillight system
• Rear fog lamp system
• Direction indicator and hazard warning system
• Indoor lighting system
• Reversing light system
• Brake light system
• Headlight washer system
• Wiper and Washer System
• Instrument cluster
• Tailgate glass heater system
• Electric windows
• Central locking
• Seat heaters
• Exterior mirror adjustment system
• Electric sunroof
• Airbag and seat belt pretensioner (SRS) system
• Location of relay blocks and junction boxes
• Component and connector locations

Wiring diagrams

• Explanations for the electrical circuits
• Power system
• Launch system
• Charging system
• Cigarette lighter and clock
• Ignition system
• Engine management (models with automatic transmission)
• Engine management (models with manual transmission)
• Electronic control system of automatic transmission
• Headlights (with daytime running lights)
• Key left in ignition warning system
• Headlights (without daytime running lights)
• Headlamp leveling (headlight range control)
• Dimensions and lighting
• Interior lighting system
• Lighting warning buzzer
• Direction indicators and hazard warning lights
• Rear fog lamp
• Center differential locking system (models with manual transmission)
• Reversing lights
• Stop signals
• Headlight cleaner (LHD for Europe)
• Tailgate glass heater
• Tailgate lock control
• Electric drive mirrors
• Seat heater (LHD, Europe)
• Central locking
• Power windows
• Anti-lock braking system (ABS)
• Windscreen wiper and washer
• Sound signal
• Radio
• Instrument cluster
• Cooling fan and air conditioner condenser fan
• Air conditioning system (Europe)
• Air conditioning system (except Europe)
• Wiring Diagrams - Supplement for Models from 1995
• Power system
• Engine management (models with automatic transmission)
• Immobilizer (models with automatic transmission)
• Engine management (models with manual transmission)
• Immobilizer (models with manual transmission)
• Dimensions and lighting
• Central locking (left hand drive)
• Central locking (right hand drive)
• Power windows (left hand drive)
• Power windows (right hand drive)
• Electric sunroof
• Instrument cluster