Contents

Foreword

Operating instructions

Maintenance

• Overall dimensions, weights and capacities
• Identification numbers
• Maintenance
• Recommended lubricants and fluids

Engine

• Specifications
• Part A - 4-cylinder engines
• General description
• Maintenance
• Basic actions possible with the engine in the car
• Basic actions possible only after removing the engine from the car
• Engine removal method
• Engine - removal and installation
• Disassembly of the engine - general description
• Optional components - removal and installation
• Cylinder head and camshaft removal
• Camshaft and tappets - removal
• Valves - removal and reconstruction
• Cylinder head - research and reconstruction
• Camshaft and bearings - research and reconstruction
• Valves - installation
• Camshaft and tappets - installation
• Cylinder head and camshaft - installation
• Valve clearances - check and adjust
• Toothed belt and sprockets - removal and installation
• Flywheel / drive disc - removal and installation
• Intermediate shaft - removal and installation
• Pallet - removal and installation
• Crankshaft oil seals - replacement
• Oil pump - removal, research and installation
• Pistons and connecting rods - removal and disassembly
• Pistons and cylinder bores - study
• Pistons and connecting rods - assembly and installation
• Crankshaft - removal, research and installation
• Oil filter and casing - removal and installation
• Engine mounting bracket - removing and installing
• Part B - 5 cylinder engines
• General description
• Maintenance
• Basic actions possible with the engine in the car
• Basic actions possible only after removing the engine from the car
• Engine removal method
• Engine - removal and installation
• Dismantling the engine
• Optional components - removal and installation
• Camshaft and tappets - removal
• Cylinder head removal
• Valves - removal and reconstruction
• Cylinder head - research and reconstruction
• Camshaft and bearings - research and reconstruction
• Valves - installation
• Cylinder head - installation
• Camshaft and tappets - installation
• Valve clearances - check and adjust
• Toothed belt and sprockets - removal and installation
• Flywheel / drive disc - removal and installation
• Pallet - removal
• Crankshaft oil seals - replacement
• Oil pump - removal, check and installation
• Pistons and connecting rods - removal and disassembly
• Pistons and cylinder bores - check
• Pistons and connecting rods - assembly and installation
• Crankshaft - removal, inspection and installation
• Oil filter - removal and installation
• Engine mounting brackets - removal and installation
• Troubleshooting - engine

Cooling system

• Specifications
• General description and service
• Cooling system - draining fluid
• Cooling system - flushing
• Cooling system - filling
• Antifreeze mixture
• Radiator - removal, inspection, cleaning and installation
• Thermostat - removal, testing and installation
• Water pump - removal and installation
• Cooling fan thermal switch - test, removal and installation
• Cooling temperature sensor liquids - removal and installation
• Heater valve - removal and installation
• Troubleshooting - cooling system

Fuel and exhaust systems

• Specifications
• Part A: Carburetor and related fuel system components
• General description
• Maintenance
• Air filter element - replacement and cleaning
• Air filter - removal and installation
• Automatic air temperature control - general description
• Mechanical fuel pump - test, removal and installation
• Fuel line filter - replacement
• Fuel tank - removal and installation
• Fuel tank - removal, service and installation
• Fuel level sensor and gravity valve - removed tie and installation
• Accelerator cable - removal, installation and adjustment
• Carburetor - removal and installation
• Carburetor - disassembly, maintenance and assembly
• Carburetor adjustment
• Intake and exhaust manifolds - removal and installation
• Exhaust system - removal and installation
• Part B: Fuel injection system
• Fuel injection system - general description
• Service, adjustment and precautions - fuel injection system
• Air filter element (injection system) - removing, cleaning / replacing and installing
• Air filter (injection system) - removal and installation
• Thermostat of the air intake of the air filter (injection system) - removal, testing and installation
• Intake manifold (injection system) - removal and installation
• Fuel pump (injection system) - removal, testing and installation
• Idling speed (injection system) - adjustment
• Idle mixture (injection system) - adjustment
• Fuel filter (injection system) - removal and installation
• Fuel accumulator (injection system) - removal and installation
• Fuel rail - removal and installation
• Air flow meter - removal and installation
• Unloader valve - removal, service and installation
• Start fuel switch - check
• Cold start valve - check
• Warm-up control - check
• Airflow sensor lever and control plunger - check
• Auxiliary air valve - check
• Part C: Troubleshooting
• Troubleshooting - fuel system (carburetor models)
• Troubleshooting - fuel system (fuel injection models)

Ignition system

• Specifications
• General description
• Maintenance
• Distributor - removal and installation
• Distributor - disassembly, inspection and assembly
• Thermo-pneumoclanan and control valve - check
• Transistor ignition system - precautions
• Transistor ignition system - test
• Ignition timing - basic setting
• Ignition timing - dynamic setting
• Ignition coil - test
• Spark plugs and high voltage wires - general description
• Troubleshooting - ignition system

Clutch

• Specifications
• General description
• Clutch - adjustment
• Clutch cable - replacement
• Clutch pedal - removal and installation
• Coupling - removal, inspection and installation
• Release bearing and mechanism - removal and installation
• Troubleshooting - clutch

Mechanical transmission and final drive

• Specifications
• General description
• Maintenance
• Gearbox - removal and installation
• Gearbox (014) - disassembly into main blocks
• Input shaft (014) - bulkhead
• Output shaft (014) - bulkhead
• Gearbox / final drive cover (014) - service
• Bearing housing / gears (014) - service
• Switch cover (014) - service
• Gearbox (014) - assembly
• Gear lever (014) - removal, installation and adjustment
• Gear shift rod (014) - bulkhead
• Gearbox (013 and 093) - disassembly into main blocks
• Input shaft (013 and 093) - bulkhead
• Output shaft (013 and 093) bulkhead
• Gearbox / final drive cover (013 and 093) - service
• Bearing / gear carrier (013 and 093) - service
• Switch cover (013 and 093) - service
• 5th gear components (013 and 093) - service
• Gearbox (013 and 093) - assembly
• Gear lever (013 and 093) - removal, installation and adjustment
• Troubleshooting - manual transmission and final drive

Automatic transmission and final drive

• Specifications
• General description
• Automatic transmission - precautions and maintenance
• Transmission fluid - draining and filling
• Automatic transmission 089 - removal and installation
• Automatic transmission 087 - removal and installation
• Torque converter - check and drain fluid
• Automatic transmission - disassembly and assembly
• Final drive cover - service
• Regulator - removal, configuration and installation
• Accelerator pedal and traction - adjustment
• Lever and cable selection - removal, installation and adjustment
• Inhibitor switch - removal, installation and adjustment

Drive shafts

• Specifications
• General description and service
• Drive shafts - removal and installation
• Drive shafts - bulkhead
• Troubleshooting - drive shafts

Braking system

• Specifications
• General description
• Maintenance
• Brake disc pads - inspection and replacement
• Disc support - removal and installation
• Disc support - bulkhead
• Brake disc - inspection, removal and installation
• Rear brake shoes - inspect and replace
• Rear working brake cylinder - removal, bulkhead and installation
• Brake drum - inspection and restoration
• Master cylinder - removal and installation
• Master cylinder - bulkhead
• Brake pressure regulator - test and adjustment
• Brake pipes and hoses - removal and installation
• Hydraulic system - pumping
• Brake pedal - removal and installation
• Hand brake lever - removal and installation
• Handbrake - adjustment
• Vacuum booster - description and test
• Vacuum booster - removal and installation
• Troubleshooting - brake system

Electrical equipment

• Specifications
• General description
• Maintenance
• Battery - removal and installation
• Battery - service
• Battery - electrolyte replenishment
• Battery - charging
• Generator - maintenance and special precautions
• Generator - removal and installation
• Alternator drive belt - replacement and adjustment
• Generator - service
• Starter - test in the car
• Starter - removal and installation
• Starter - bulkhead
• Automatic stop / start system (ASS) - general information
• Parts of the automatic stop / start system (models up to 1983) - removal and installation
• Parts of the automatic stop / start system (models since 1983) - removal and installation
• Fuses and relays - general description
• Ignition socket / steering column lock - removal and installation
• Dashboard block - removal and installation
• Dashboard unit - removal, testing and assembly
• Steering column switches - removal and installation
• Valve switches - removal and installation
• Door and trunk lighting switches - removal and installation
• Lighter - removal and installation
• Speedometer cable - removal and installation
• Headlights and headlights - removal and installation
• Headlights - adjustment
• Incandescent bulbs - replacement
• Sound signal - removal and installation
• Wiper blades - replacing
• Wiper motor - removal and installation
• Wiper holders and rod - removal and installation
• Rear window wiper blade - replace
• Rear window wiper motor - removing and installing
• Rear wiper holder and rod - removing and installing
• Washer system for windshield, rear window and headlights
• Speed control system - description and action
• Speed control system - removal and installation
• Heater motor block - removal and installation
• Heater control switch - removal and installation
• Heated rear window - care and repair
• Wiring diagrams - description
• Troubleshooting - electrical equipment

Suspension and steering

• Specifications
• General description
• Maintenance
• Front suspension strut - removal and installation
• Front suspension strut - bulkhead
• Front hub and bearing - removal and installation
• Anti-roll bar - removing and installing
• Front wishbone - removal, repair and installation
• Rear axle - removal and installation
• Rear suspension strut / shock absorber - removal and installation
• Rear wheel bearings - removal, installation and adjustment
• Rear stub axle - removal and installation
• Steeringe wheel - removal and installation
• Steering column - removal, bulkhead and installation
• Tie rod - removal and installation
• Steering gear unit - removal and installation
• Steering damper - test, removal and installation
• Steering covers - replacement
• Direct acting steering gear - adjustment
• Power steering - filter change
• Power steering - draining and filling fluid
• Power steering - check leaks
• Power steering pump - removal, installation and adjustment
• Installing wheels - checking and adjusting
• Wheels and tires
• Troubleshooting - suspension and steering

Body

• General description
• Body and subframe - service
• Upholstery and rugs - service
• Repair of minor damage to the body
• Body repair - serious damage
• Door bounce - find and repair
• Front door trim panel - removal and installation
• Front and rear door locks - removal and installation
• External door handles - removal and installation
• Front door - removal and disassembly
• Rear door trim panel - removing and installing
• Back door - removal and repair
• Doors - removal and installation
• Door strike plate - adjustment
• Front grill - removal and installation
• Hood - removal, installation and adjustment
• Bonnet release cable - removal and installation
• Trunk lid - removal, installation and adjustment
• Trunk lid lock - removal, installation and adjustment
• Rear door (Hatchback) - removal, installation and adjustment
• Rear door lock (Hatchback) - removal and installation
• Rear door (Station wagon) - removal and installation
• Rear door lock (Universal) - removal and installation
• Rear door support pillars - removal and installation
• Exterior mirror - removal and installation
• Bumpers - removal and installation
• Windshield and rear window glass - removal and installation
• Dashboard - removal and installation
• Center console - removal and installation
• Seats - removal and installation
• Roof hatch - general information
• Roof hatch - adjustment only
• Roof hatch - removal, installation and adjustment
• Central locking - general information
• Electric windows - general information
• Heater - removal and installation
• Heater control cables - adjustment
• Air conditioner

Appendix: Changes and information on later models

• Introduction
• Specifications
• Engine
• Cooling system
• Fuel and exhaust systems
• Ignition system
• Clutch
• Mechanical transmission and final drive
• Automatic transmission and final drive
• Electrical system
• Suspension and steering

Appendix: Diesel models

• Part A. Diesel engine
• Specifications
• General description
• Basic actions possible with the engine in the car
• Basic actions possible only after removing the engine from the car
• Engine removal method
• Engine - removal and installation
• Engine / gearbox - decoupling and assembly
• Disassembly of the engine - general description
• Ancillary engine components - removal
• Toothed belt and sprockets - removal
• Camshaft - removal, inspection and installation
• Cylinder head removal
• Cylinder head disassembly
• Sump and oil pump - removal and installation
• Pistons and connecting rods - removal
• Crankshaft and main bearings - removal
• Intermediate shaft - removal
• Oil filter - change
• Oil cooler - removal and installation
• Oil filter bracket - removing and installing
• Oil seals - replacement
• Inspection and maintenance - general description
• Crankshaft and bearings - inspection and maintenance
• Cylinder block / crankcase - inspection and maintenance
• Pistons and connecting rods - inspection and maintenance
• Oil pump - inspection and service
• Intermediate shaft - inspection and service
• Flywheel / drive disc - inspection and service
• Toothed belt and sprockets - inspection and service
• Engine - general description
• Crankshaft and main bearings - installation
• Intermediate Shaft - Installation
• Pistons and connecting rods - installation
• Valve clearances - check and adjust (models produced in August 1985)
• Cylinder head - installation
• Timing belt and sprockets - installation
• Ancillary engine components - installation
• Engine - installation
• Part B. Fuel system for diesel models
• Fuel system - general description
• Hydraulic pushers - check free run (models from august 1985)
• Winter operation
• Engine - adjustment after complete bulkhead
• Fuel injection system repair
• Removing water / replacing fuel filter
• Throttle draft adjustment
• Checking and adjusting the maximum engine speed
• Cold start actuator adjustment
• Checking and adjusting idle speed
• Cleaning / replacing replacement air filter element
• Glow plugs
• Checking the preheating plugs
• Removing and installing injectors
• Checking the start of fuel delivery by the pump
• Checking / adjusting motor control
• Removing and installing fuel level indicator sensor with gravity valve
• Removing and installing fuel tank
• Exhaust system
• Turbocharger

Wiring diagrams