Content

Operating instructions

Maintenance

• Foreword
• Engine oil and oil filter
• Periodic maintenance
• Front wheel brake pads
• Dust filter - replacement
• Light bulbs and sound signal - functional check
• Automatic transmission fluid level - check
• Airbag unit
• Washer (s) - check
• Check hoses for leaks
• Battery electrolyte level - check
• Hinges and locks - lubrication
• Suspension and steering
• CV Joints and driveshaft shrouds - check
• Brake system - check
• Exhaust system
• Rear brake pads - check (models with rear disc brakes)
• Rear brake pads - check (models with rear drum brakes)
• Automatic transmission fault codes - read
• Adjusting the direction of the headlamp beam - check
• Test drive
• accessory drive belts - inspect and replace
• Spark plugs - replacement
• Air filter - replacement
• Checking the condition and tension of the toothed belt of the drive
• Manual transmission oil level - check
• Transmission - general maintenance procedures
• Automatic transmission fluid and filter - change
• Fuel filter - change
• Coolant - replacement
• Anti-corrosion coating on the underside of the car - check the condition
• Toothed belt - replacement
• Brake fluid - replacement
• Exhaust gas content

Maintenance - diesel models

• Specifications
• Foreword
• Engine oil and oil filter
• Periodic maintenance
• Front wheel brake pads
• Dust filter - replacement
• Removing condensation from the fuel filter
• Light bulbs and sound signal - functional check
• Airbag unit
• Washer (s) - check
• Check hoses for leaks
• Battery electrolyte level - check
• Hinges and Locks - Lubrication
• Suspension and steering
• CV Joints and driveshaft shrouds - check
• Brake system - check
• Exhaust system
• Rear wheel brake pads
• Idling speed
• Adjusting the direction of the headlamp beam - check
• Test drive
• Accessory drive belts - inspect and replace
• Air filter - replacement
• Checking the condition and tension of the toothed belt of the drive
• Fuel filter - change
• Transmission oil level - check
• Toothed belt and tensioner
• Coolant - replacement
• Transmission
• Anti-corrosion coating on the underside of the car - check the condition
• Brake fluid
• Exhaust gas content - check

Gasoline engine - repair without removing the engine from the car

• Specifications
• General information
• Engine and timing labels - general information and usage
• Compression in engine cylinders
• Toothed belt of the timing mechanism and its outer covers - removal and installation
• Timing belt sprockets and tensioner - removal, inspection and installation
• Accessory Drive Belts - Removing, Installing and Tensioning
• Cylinder head cover
• Camshaft oil seal - replacement
• Intermediate shaft oil seal - replacement
• Crankshaft oil seals - replacement
• Cylinder head and manifolds
• Hydraulic pushers - check
• Flywheel / drive faceplate
• Engine mounts - inspect and replace
• Pallet - removal and installation
• Oil pump and oil intake pipe - removal, inspection and installation

Diesel engine - repair without removing the engine from the car

• Specifications
• General information
• Top dead center (TDC) for the piston of cylinder № 1 - location
• Compression in cylinders - check
• Toothed belt of the timing mechanism and its outer covers - removal and installation
• Timing belt tensioner and sprocket - removal and installation
• Accessory drive belts - removing, installing and tensioning
• Cylinder head cover
• Camshaft oil seal
• Intermediate shaft oil seal
• Crankshaft oil seals
• Cylinder head, intake and exhaust manifolds
• Hydraulic pushers - check
• Flywheel / drive faceplate
• Engine mounts - inspect and replace
• Pallet - removal, inspection and installation
• Oil pump and oil intake pipe
• Top cover of the engine (engines of the AFN brand) - removal and installation

Removal and general engine rebuild procedures

• Specifications
• Powertrain (engine and transmission) removal - preparation and precautions
• Engine and transmission
• Engine bulkhead
• Cylinder head
• Pistons and connecting rods - removal and inspection
• Engine crankshaft
• Intermediate shaft
• Cylinder block / crankcase
• Main and connecting rod bearings
• Engine bulkhead
• Crankshaft - setting and checking the main bearing clearance
• Pistons and piston rings - assembly
• Pistons / connecting rods - installing and checking connecting rod bearing running clearance
• Engine - first start after bulkhead

Cooling, heating and ventilation systems

• Specifications
• Basic information
• Coolant hoses
• Radiator - removal and installation
• Thermostat - removal, check and installation
• Water pump - removal and installation
• Cooling fan and electric motor
• Fan thermal switch
• Coolant temperature sensor - check, removal and installation
• Thermo switches and coolant temperature sensors associated with the fuel system
• Corks - replacement
• Interior ventilation and heating system
• Interior ventilation and heating system components - removal and installation
• Body parts and deflectors
• Air conditioning system
• Air conditioning components - removal and installation

Fuel system - single fuel injection (petrol engines)

• Specifications
• Basic information and precautions
• Air filter and air intake system - removal and installation
• Intake air temperature regulator - check, removal and installation
• Accelerator cable
• Fuel injection system components
• Fuel pump and fuel level sensor
• Fuel tank - removal and installation
• Fuel injection system - pressure relief
• Intake manifold - removal and installation
• Fuel injection system
• Unleaded gasoline

Fuel system - multipoint fuel injection (petrol engines)

• Specifications
• Basic information and precautions
• Removing and installing air filter and air intake system
• Intake air temperature control system
• Accelerator cable
• Digifant system
• Digifant system components
• Simos system components
• Fuel pump and fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - pressure relief
• Intake manifold - removal and installation
• Fuel injection system
• Unleaded gasoline

Fuel system - diesel models

• Specifications
• Basic information and precautions
• Air filter - removal and installation
• Accelerator cable (engines with code AAZ) - removal, installation and adjustment
• Cold cranking accelerator (CSA) cable (Code AAZ) - removing, installing
• Fuel tank level sensor
• Fuel tank - removal and installation
• High pressure fuel pump (TNVD) - removal and installation
• Maximum engine speed (engine code AAZ)
• High idle speed (engine code AAZ)
• Fuel injection start point (engines with code AAZ)
• Injectors
• Fuel cutoff solenoid valve - removal and installation
• Diesel engine management system - component removal and installation
• Intercooler

Exhaust systems and emission control

• Specifications
• Basic information
• Fuel vapor recovery system
• Positive crankcase ventilation system - general information
• Exhaust gas recirculation (EGR) system (Diesel Engines) component replacement
• Exhaust manifold - removal and installation
• Turbocharger - removal and installation
• Exhaust system
• Catalytic converter

Battery starting and charging systems

• Specifications
• General information and precautions
• Battery
• Generator / battery charging system
• Generator - removal and installation
• Alternator - brush holder / voltage regulator unit replacement
• Launch system - check
• Starter - removal and installation
• Starter - check and repair

Ignition system - models with petrol engines

• Specifications
• Basic information
• Ignition system - check
• High voltage ignition coil
• Ignition distributor
• Ignition timing
• Ignition Sensors

Preheating system - diesel models

• Specifications
• Basic information
• Glow plug control unit
• Glow plugs

Clutch

• Specifications
• General information
• Clutch pedal removal and installation
• Clutch hydraulic system - bleeding
• Clutch slave cylinder
• Clutch master cylinder
• Clutch cable
• Coupling - removal, inspection and installation
• Release bearing and clutch release lever - removal and installation

Mechanical transmission

• Specifications
• General information
• Gear lever and cables
• Mechanical transmission
• Bulkhead mechanical transmission
• Reversing light switch
• Speedometer drive

Automatic transmission

• Specifications
• General information
• Automatic transmission
• Bulkhead automatic transmission
• Selector cable

Drive shafts

• Specifications
• General information
• Drive shafts - removal and installation
• Protective covers (anthers) of drive shafts - replacement
• Overhaul of drive shafts

Braking system

• Specifications
• General information
• Hydraulic brake system - bleeding
• Brake pipes and hoses - replacement
• Front brake pads - replacement
• Rear brake pads (with disc brakes) - replacement
• Rear brake pads (with drum brakes) - replacement
• Front brake disc
• Rear brake disc
• Rear brake drum
• Front brake caliper
• Rear brake caliper
• Rear wheel slave cylinder
• Brake master cylinder
• Brake pedal - removal and installation
• Vacuum brake booster
• Vacuum brake booster check valve - removal, check and installation
• Parking brake - adjustment
• Parking brake lever
• Parking brake cables
• Brake force regulator
• Brake light switch
• Anti-lock braking system (ABS) - general information
• Anti-lock braking system (ABS) components - removal and installation
• Vacuum pump (diesel models)

Suspension and steering

• Specifications
• General information
• Front suspension strut
• Front suspension strut and coil spring
• Front steering knuckle
• Front wheel bearing
• Wishbone / lower suspension arm
• Anti-roll bar
• Rear wheel hub bearings
• Rear stub axle
• Coiled coil spring and rear suspension strut - removal and installation
• Coiled coil spring and rear suspension strut
• Rear axle beam
• Pneumatic suspension
• Pneumatic suspension
• Steering wheel - removal and installation
• Steering column - removal and installation
• Steering column height adjustment mechanism - removal and installation
• Corrugated Steering Covers - Replacement
• Steering gear - removal and installation
• Steering gear - adjustment
• Ball joints of the ends of the steering rods - removal and installation
• General information, draining and filling of working fluid into the power steering
• Power steering pump - removal and installation
• Wheel alignment angles

Body and its equipment

• Specifications
• General description
• Body and underbody - service
• Upholstery and rugs - care
• Minor damage to the body
• Serious damage to the body - repair
• Doors rattle
• Hood - removal, installation and adjustment
• Bonnet lock and cable
• Bumpers - removal and installation
• Front body cladding
• Front wheel arch liners
• Trunk lid - removal and installation
• Trunk lid lock and lock cylinder - removal and installation
• Tail door - removal and installation
• Tailgate stop (s)
• Tailgate lock and cylinder
• Door trim panel
• Central locking - general information
• Door lock - removal and installation
• Outside door handle and lock cylinder - removal and installation
• Glass and window regulators of doors
• Power windows
• Doors - removal and installation
• Windshield, rear and rear side windows - removal and installation
• Luke - general information
• Outside rearview mirror
• Center Console
• Dashboard and related panels - removal and installation
• Glove box
• Rear-view mirror installed in the passenger compartment
• Seats - removal and installation
• Interior trim - removal and installation
• Front seat belt tensioner - general information
• Seat belts - general information
• Radiator grille (late models) - removing and installing

Body electrical equipment

• Specifications
• Basic information and precautions
• Troubleshooting electrical circuits - general information
• Fuses, fuses and relays
• Ignition / steering column lock
• Steering column combination switch - removal and installation
• Switches - removal and installation
• Lamps in external lighting devices
• Indoor lamps
• Headlights - removing, installing and adjusting the direction of the headlamp beam
• Instrument panel - removal and installation
• Devices - removal and installation
• Cigarette lighter - removal and installation
• Windshield wiper components - removal and installation
• Washer - general information
• Tailgate wiper motor - removal and installation
• Sound signals - removal and installation
• Sunroof motor
• Central locking
• Car radio - removal and installation
• Car radio antenna
• Speakers - removal and installation
• Inflatable airbags
• Airbag system components - removal and installation
• Anti-theft alarm system
• Heated front seat components - removing and refitting

Troubleshooting

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

Wiring diagrams