Content

General information

• Technical description
• Vehicle data sheet

Safety precautions for maintenance and repair

Maintenance

• Location of the main components and assemblies of the car
• Checking the car
• Checking the condition of wheels and tires
• Checking fluid levels in the windshield washer and tailgate reservoirs
• Replacing the windshield wiper blades and the tailgate wipers
• Checking the oil level in the oil pan
• Changing engine oil and oil filter
• Checking the level and adding coolant
• Coolant replacement
• Checking the gearbox oil level
• Gearbox oil change
• Checking the oil level in the transfer case
• Changing the oil in the transfer case
• Checking the oil level in the front axle gearbox
• Changing the oil in the front axle gearbox
• Checking the oil level in the rear axle gearbox
• Changing the oil in the rear axle gearbox
• Checking the fluid level in the brake reservoir
• bleeding the hydraulic brake system, fluid replacement
• Checking the fluid level in the clutch reservoir
• clutch hydraulic bleeding, fluid replacement
• Checking the fluid level in the power steering reservoir
• Checking the performance of the vacuum brake booster
• Checking the condition of the front wheel brakes
• Checking and adjusting the clearance in the front wheel hub bearings
• Checking the condition of the rear wheel brakes
• Parking brake adjustment
• Functional check and adjustment of the rear brake pressure regulator actuator
• Checking the condition and replacing the auxiliary drive belt
• Checking the condition and replacing the drive belt for the power steering pump
• Checking condition and replacing spark plugs
• Replacing the fuel filter
• Replacing the air filter element
• Checking the condition of the transmission and suspensions
• greasing of bearings of crosspieces and splined joints of driveshafts
• Checking steering status
• Battery maintenance
• Headlight beam adjustment

Diagnostics of malfunctions

• Engine
• Transmission, chassis, steering and braking system
• Electrical equipment
• Body
• Heating and ventilation system

Engine

• Design Description
• Removing the cylinder head cover
• Removing the hydraulic timing chain tensioner
• Removing the timing chain damper
• Replacing the low oil pressure warning lamp sensor
• Removing the oil supply pipe to the hydraulic timing chain tensioner
• Removing the oil supply ramp to the hydraulic support of the valve levers
• Removing the camshaft and valve drive levers
• Replacing the hydraulic support for the valve drive levers
• Replacing valve stem seals
• Replacing the front crankshaft oil seal
• Replacing the crankshaft rear oil seal
• Removing gear for oil pump drive
• Timing chain and chain sprockets
• Removing the oil pump drive roller
• Removing the receiver
• Removing the intake pipe and exhaust manifold
• Removing the cylinder head
• Dismantling and assembling the cylinder head
• Removing the oil separator for the crankcase ventilation system
• Powertrain support replacement
• Crankcase gasket replacement
• Removing the oil pump
• Dismantling and assembling the oil pump
• dismantling the connecting rod and piston group by car
• Removing and installing the engine
• Dismantling and assembling the engine

Engine management system

• Design description
• Operation of the management system
• Removing the controller
• Removing the crankshaft position sensor
• Removing the phase sensor
• Removing the coolant temperature sensor
• Removing the mass air flow sensor
• Removing the accelerator pedal sensor
• Removing the knock sensor
• Replacing oxygen concentration sensors
• Removing the clutch pedal position sensor
• Removing the brake pedal position sensor
• Removing the speed sensor
• Ignition coil removal
• Removing the control unit and the status indicator of the automobile anti-theft system (APS)

Power system

• Design description
• Removing and disassembling the fuel module
• Removing the fuel pressure regulator
• Removing the fuel rail and injectors
• Throttle removal
• Removing the fuel tank
• Removing the separator for the fuel vapor recovery system and gravity valve
• Removing the adsorber of the vapor recovery system
• Removing the canister purge solenoid valve
• Removing the air filter

Cooling system

• Design description
• Coolant temperature sensor sensor replacement
• Removing and checking the thermostat
• Removing the expansion tank
• Removing the radiator
• Removing fans, replacing the motor
• Removing the coolant pump

Exhaust system

• Design description
• Front pipe removal
• Removing the optional silencer
• Removing the main silencer

Grip

• Design description
• Removing the clutch reservoir tank
• Removing the clutch master cylinder
• Removing the clutch slave cylinder
• Removing the clutch hydraulic hose
• Replacing the clutch cover and clutch plate
• Removing the clutch release mechanism

Gearbox

• Design description
• Replacing the stuffing box seal
• Replacement of an epiploon of a secondary shaft
• Removing gearbox input shaft front bearing
• Gearbox removal
• Gearbox disassembly and assembly

Intermediate shaft

• Design description
• Removing the intermediate shaft
• Dismantling the countershaft

Transfer box

• Design description
• Determining the causes of vibration and centering the transfer case
• Replacing oil seal shaft seals
• Removing the speed sensor drive housing
• Removing the transfer case suspension brackets
• Replacing the differential lock warning lamp switch
• Removing the transfer case
• Disassembling the transfer case

Cardan transmission

• Design description
• Removing the propeller shaft
• Dismantling the universal joint
• Replacing oil seal for sliding fork

Front axle

• Design description
• Replacing oil seal for pinion gear
• Replacing the bearing and the oil seal of the housing of the inner wheel drive joint
• Removing the front axle gearbox
• Dismantling the front axle gearbox
• Front wheel drive
• Design description
• Removing front wheel drives
• Removing the outer joint
• Removing and disassembling the inner joint

Rear axle

• Design description
• Removing the axle shaft and replacing the oil seal
• Replacing wheel studs
• Replacing the oil seal for the driving gear of the final drive
• Removing the rear axle gearbox
• Dismantling and assembling the rear axle gearbox

Front suspension

• Design description
• Shock absorber removal
• Removing the upper ball joint
• Removing the lower ball joint
• Spring removal
• Removing the upper arm
• Removing the lower arm
• Removing the anti-roll bar
• Stretch remover
• Crossbeam removal
• Replacing the hub bearings

Rear suspension

• Design description
• Shock absorber replacement
• Spring replacement
• Removing the upper longitudinal bar
• Removing the lower longitudinal bar
• Crossbar removal
• Removing the rear axle beam

Steering

• Design description
• Side link removal
• Medium traction
• Replacing mudguards and tie rods
• Removing and disassembling the swingarm arm
• Steering wheel removal
• Steering column removal
• Steering gear removal
• power steering system bleeding
• Removing the power steering reservoir
• Power steering pump removal

Brake system

• Design description
• Replacing the front brake pads
• Replacing the rear brake pads
• Removing the brake master cylinder reservoir
• Removing the brake master cylinder
• Removing the brake servo and adjusting the brake pedal free play
• Dismantling the front brake mechanism
• Replacing the front brake hose
• Replacing the rear brake hose
• Replacing brake tubes and rear axle beam tee
• Replacing the rear wheel cylinder
• Removing the rear brake pressure regulator and its drive
• Removing the parking brake assemblies

Electrical equipment

• Design description
• Replacing fuses and relays
• Removing the ignition switch
• Removing the battery
• Generator test
• Removing the generator
• Generator disassembly
• Removing and checking starter
• Dismantling the starter
• Headlight removal, lamp replacement
• Replacing the lamps in the front lamp, removing the lamp
• Replacing the side direction indicator lamp, removing the indicator
• Replacing lamps in the rear light, removing the light
• Removing the reversing light switch
• Removing the license plate light, replacing the lamp
• Removing an additional brake signal, replacing lamps
• Removing interior lights and door switches
• Removing the direction indicator relay and alarm
• Removing the alarm switch
• Removing the steering column switch
• Beeping
• Removing the windshield wiper
• Removing the windshield washer pump
• Removing the tailgate wiper
• Removing the tailgate glass washer pump
• Removing the dimmer
• Removing instrument cluster, replacing lamps
• Replacing the outdoor temperature sensor

Body

• Design description
• Removing the radiator lining
• Removing the hood lock and traction drive lock
• Removing the hood
• Removing the mudguards of the engine compartment
• Removing the pipe and the spare wheel support
• Removing the front and rear bumpers and towing eyes
• Removing and installing the windshield
• Removing the exterior rearview mirror
• Removing the door trim
• Removing the door lock
• Removing the outer door handle
• Replacing the door glass
• Removing the door window lifter
• Removing the door open stop
• Removing the door
• Removing the outer trim for the tailgate
• Removing the luggage compartment door trim
• Removing the tailgate lock
• Removing the tailgate
• Removing the gas-filled stops for the tailgate
• Removing the tailgate
• Removing the floor tunnel lining
• Removing the storage shelf
• Removing the radio mount panel
• Removing the front seat
• Removing the rear seat
• Interior upholstery removal
• Removing the dashboard
• Removing the fuel filler flap

Heating and ventilation system

• Design description
• Heater tap removal
• Heater fan removal
• Removing additional heater fan resistor
• Removing heater radiator with faucet
• Removing the air intake box, radiator cover, heater rods and heater control arm bracket
• Removing central nozzles and air ducts for glass heating

Applications

• Repair tools
• Tightening torques for critical threaded connections
• Applicable fuels, lubricants and operating fluids
• Lamps used in the car
• Characteristics of spark plugs

Electrical diagrams

• Front wiring harness wiring diagram
• Engine management system wiring harness wiring diagram
• Instrument panel wiring harness wiring diagram
• Rear wiring harness wiring diagram