Content

Operating instructions

Maintenance

• Dimensions and weight
• Lubricants and fluids
• Tire pressure
• Service specifications
• Vehicle identification numbers

Introduction

• Every 15,000 km or annually - "OIL" or "IN01" on the display
• Every 30,000 km or 2 years (diesel models only)
• Every 2 years (regardless of mileage)
• Every 45,000 km or 3 years - "IN02" on display
• Every 60,000 km or 4 years
• Every 90,000 km (diesel only - models)
• Every 120,000 km

Engine compartment repair operations - Ford engines

• Specifications
• General description
• Camshaft timing marks - general description and use
• Checking the compression in the engine cylinder
• Drive chain, sprockets and tensioner - removal, inspection and installation
• Balance shaft / oil pump drive chain - removing and installing
• Accessory drive belt - removal and installation
• Valve cover - removal and installation
• Drive chain covers - removal and installation
• Camshafts and hydraulic slack adjusters - removal, inspection and installation
• Crankshaft oil seals - replacement
• Cylinder head - removal and installation
• Flywheel / drive disc - removal, inspection and installation
• Engine mounts - inspection and replacement
• Pallet - removal and installation
• Balancing shafts and their covers - removal, inspection and installation
• Oil pump - removal, inspection and installation 82 Oil pressure switch - removal and installation

Engine compartment repairs - VW engines

• Specifications
• General description
• Camshaft timing marks - general description and use
• Checking the compression in the engine cylinders
• Toothed drive belt - removal, inspection and installation
• Tensioner and sprockets - removal, inspection and installation
• Accessory drive belts - removing, installing and tensioning
• Camshaft cover - removal and installation
• Camshaft oil seal - replacement
• Intermediate shaft oil seal - replacement
• Crankshaft oil seals - replacement
• Cylinder head - removal and installation
• Hydraulic pushers - health check
• Flywheel / drive disc - removal, inspection and installation
• Engine mounts - inspect
• Pallet - removal and installation
• Oil pump and suction tube - removal, inspection and installation

Engine compartment repair operations - diesel engines

• Specifications
• General description
• Installing the piston of cylinder No. 1 at TDC
• Compression check - description
• Timing belt - removal, inspection and installation
• Timing belt tensioner and sprocket - removal and installation
• Accessory drive belts - removing, installing and tensioning
• Valve cover - removal and installation
• Camshaft oil seal - replacement
• Intermediate shaft oil seal - replacement
• Crankshaft oil seals - replacement
• Cylinder head - removal and installation
• Hydraulic pushers - checking operation
• Camshaft and hydraulic tappets - removal and installation
• Flywheel / drive disc - removal, inspection and installation
• Engine mounts - inspection and replacement
• Pallet - removal, inspection and installation
• Oil pump and its suction tube - removal, inspection and installation
• Oil pressure sensors - removal and installation

Engine removal and rebuilding procedures

• Specifications
• General description
• Engine bulkhead - general description
• Removing the engine - preparation and precautions
• Engine - removal and installation
• Engine overhaul - preliminary information
• Cylinder head - dismantling, cleaning, inspection and assembly
• Piston / connecting rod assemblies - removal and inspection
• Crankshaft - removal and inspection
• Intermediate shaft - removal and installation
• Crankcase - cleaning and inspection
• Main and connecting rod bearings - inspection and set
• Engine overhaul - assembly sequence
• Crankshaft - installation
• Pistons and piston rings - assembly
• Connecting rod and piston groups - installation
• Starting the engine after overhaul

Cooling, heating and ventilation systems

• Specifications
• General description and precautions
• Coolant hoses - disconnecting and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, serviceability check and installation
• Fan - serviceability check, removal and installation
• Electrical switches and sensors of the cooling system - check, removal and installation
• Water pump - removal and installation
• Interior heating and ventilation system - general description
• Interior heating / ventilation system components - removal and installation
• Air conditioning system - general description and precautions
• Air conditioning components - removal and installation

Fuel system - petrol models

• Specifications
• General description and precautions
• Air filter assembly and air intake components - removal and installation
• Throttle cable - removal, installation and adjustment
• Engine management system components - removal and installation
• Fuel filter - change
• Fuel pump / fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel injection system - depressurization
• Intake manifold - removal and installation
• Fuel injection system - check and adjust
• Inertial fuel supply switch - removal, installation and adjustment

Fuel system - diesel models

• Specifications
• General description and precautions
• Air filter and intake ports - removing and installing
• Gas pedal position sensor - removal and installation
• Fuel level sensor - removal and installation
• Fuel tank - removal and installation
• Fuel pump - removal, installation and adjustment
• Injectors - general description, removal and installation
• Engine management system components - removal and installation
• Turbocharger - general description, removal and installation
• Intercooler - removal and installation
• Intake manifold - removal and installation

Exhaust gas aftertreatment system and exhaust system

• Specifications
• General description
• Fuel vapor retaining system - information and component replacement
• Blow-by-blow system - general description
• Exhaust gas recirculation - component removal
• Exhaust manifold - removal and installation
• Exhaust system - component replacement
• Catalytic converter - general description and precautions
• Auxiliary air system - information and component replacement

Starting and charging systems

• Specifications
• General description and precautions
• Battery - check and charge
• Battery - disconnect, remove and install
• Battery compartment panels - removal and installation
• Alternator / charging system - vehicle functional check
• Generator - removal and installation
• Alternator brush holder / voltage regulator - replace
• Launch system - health check
• Starter - removal and installation
• Starter - health check and bulkhead

Ignition system - petrol models

• Specifications
• General description
• Ignition system - diagnostics
• High voltage ignition coil - removal and installation
• Ignition timing - check and adjust
• Ignition control unit - removal and installation

Preheating systems - diesel models

• Specifications
• General description
• Glow plugs - serviceability check, removal and installation

Clutch

• Specifications
• General description
• Hydraulic system - bleeding
• Clutch pedal - removal and installation
• Master cylinder - removal, bulkhead and installation
• Slave cylinder / release bearing - removal, bulkhead and installation
• Friction and pressure plates of clutch - removal, inspection and installation
• Clutch pedal switch - removal, installation and adjustment

Mechanical transmission

• Specifications
• General description
• Transmission oil - draining and filling
• Gear shift mechanism - adjustment
• Gear shift mechanism - removal and installation
• Oil seals - replacement
• Reversing light switch - serviceability check, removal and installation
• Transmission - removal and installation
• Transmission bulkhead - general description
• Checking the transmission oil level
• Vehicle speed sensor - removal and installation

Automatic transmission

• Specifications
• General description
• Automatic transmission - removal and installation
• Bulkhead automatic transmission - general description
• Drive mode switch cable - removal, installation and adjustment
• Transmission fluid - replacement
• Transmission operating mode sensor - removal and installation
• Starter blocker - removal and installation
• Drive shaft oil seals - replacement
• Control unit - removal and installation
• Four-wheel drive models - general description

Drive shafts

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

Drive shaft support bearing - replacement

Braking system

• Specifications
• General description
• Hydraulic brake system - bleeding
• Front brake pads - replacement
• Rear disc brake pads - replacement
• Front brake disc - inspection, removal and installation
• Rear brake disc - inspection, removal and installation
• Front brake caliper - removal, bulkhead and installation
• Rear brake caliper - removal, bulkhead and installation
• Master cylinder - removal, bulkhead and installation
• Brake pedal - removal and installation
• Vacuum booster unit - serviceability check, removal and installation
• Check valve of the vacuum booster unit - removal, check and installation
• Handbrake - adjustment
• Hand brake lever - removal and installation
• Handbrake cables - removal and installation
• Brake switches - removal and installation
• ABS system - general description
• ABS system components - removal and installation
• Vacuum pump (diesel models) - removal and installation

Suspension and steering gear

• Specifications
• General description
• Front suspension strut - removal, bulkhead and installation
• Front suspension lower arm - removal, bulkhead and installation
• Front suspension lower arm ball joint - replacement
• Front wheel bearing - replacement
• Front anti-roll bar bushings - replacement
• Front anti-roll bar vertical link - removal and installation
• Front anti-roll bar - removal and installation
• Sub-frame - removal and installation
• Rear suspension shock absorber - removal, inspection and installation
• Rear suspension spring - removal and installation
• Rear anti-roll bar and its bushings - removal and installation
• Diagonal arms of the rear suspension and their bushings - removal and installation
• Rear wheel bearing - replacement
• Rear cross member - removal and installation
• Steering wheel - removal and installation
• Ignition lock, its cylinder and steering column lock - removal and installation
• Steering column - removal and installation
• Steering rack - removal and installation
• Steering rack cover - replacement
• Power steering pump - removal and installation
• Power steering hydraulic system - bleeding
• Tie rod end ball joint - removal and installation
• Tie rods - removal and installation
• Wheel alignment - general description

Body and trim

• Specifications
• General description
• Service - body and bottom
• Upholstery and rugs - care
• Minor damage to the body - restoration
• Significant damage to the body - restoration
• Door rattling - finding the cause and eliminating it
• Hood - removing, installing and adjusting position
• Hood lock and cable - removal and installation
• Bumpers - removal and installation
• Radiator grill - removal and installation
• Front wheel arch liners - removal and installation
• Luggage compartment door and its inner lining - removal and installation
• Tailgate strut - removing and installing
• Luggage compartment door lock, handle of its drive and lock cylinder - removal and installation
• Door trim panel - removal and installation
• Door lock - removal and installation
• Door lock drive handles and lock cylinder - removal and installation
• Door glass and window regulator - removal and installation
• Electric windows - general description and motor parts
• Rear side glass - removing and installing
• Car front window glass - removal and installation
• Doors - removal and installation
• Windshield and tailgate glass - general description
• Luke - general description
• Exterior mirror - replacement
• Central control panel - removal and installation
• Dashboard and related panels - removal and installation
• Glove box and its lock - removal and installation
• Interior mirror - removal and installation
• Seats - removal and installation
• Internal lining - general description, removal and installation
• Belt tensioner - general description
• Safety belts general description
• Protective visors - removal and installation
• Handrails - removal and installation

Onboard electrical equipment

• Specifications
• General description and precautions
• Troubleshooting - general description
• Fuses and relays - general description
• Ignition / steering column lock - removal and installation
• Steering column combination switch - removal and installation
• Switches - removal and installation
• Blocks of headlights and lanterns, lamps - removal and installation
• Interior lights - replacement
• Headlights - removal, installation and beam adjustment
• Instrument panel - removal and installation
• Front wiper components - removal - refitting
• Washers - general description
• Rear wiper motor - removing and installing
• Sound signals - removal and installation
• Lamp health monitoring module - removal and installation
• Sunroof motor - removal and installation
• Central locking - general description
• Car radio - removal and installation
• Amplifier - removal and installation
• CD-changer - removal and installation
• Radio antenna - removal and installation
• Speakers removal and installation
• Air bags - general description and precautions
• Airbag components - removal and installation
• Anti-theft alarm system - general description
• Watch - removal and installation
• Outside air temperature sensor - removal and installation
• Fuel filler flap lock motor - removal and installation
• Speed ??control system - general description and component replacement

Troubleshooting

• Fault codes read from the memory of the engine management system
• Engine
• Cooling system
• Fuel and exhaust systems
• Clutch
• Mechanical transmission
• Automatic transmission
• Drive shafts
• Braking system
• Steering and suspension
• Electrical system

Wiring diagrams