Engine Manual
General, Technical Data
- Instructions for use of service manual
- Engine and vehicle identification
- Vehicle identification number location
- Technical data
Crank Case and Cylinder Head
- Opening hood, setting vertical warnings
- Checking compression pressure
- Checking cylinders for leaks
- Removal and installation of engine
- Replacing freeze plug in engine block
Crankshaft Assembly
- Checking, removing and tightening of control bolts
- Renewing front crankshaft radial seal
- Renewing rear crankshaft radial seal
- Removing, installing belt pulley, flywheel dumper and hub
- Removing, installing flywheel or driven plate
- Machining flywheel
Engine Timing and Valves
- Removal and installation of camshaft
- Removal and installation of valve springs
- Renewing valve stem seals
- Removal and installation of chain tensioner
- Renewing timing chain
- Removing and installation of tensioning rail
- Removing and installation of guide rail
- Removal and installation of crankshaft gear
Injection System
- Checking Idling Speed, readjusting or emission test
- Testing, regulating engine
- Performing cylinder comparison test with engine tester
- Testing electronic idling speed control
- Testing engine output and emissions on drum dynamometer
- Determining fuel consumption by driving on road
- Checking fuel pressures and internal leaks
- Testing electrical components of CIS-E injection system
- Testing throttle (orifice) in fuel distributor for unobstructed passage
- Testing starting unit
- Testing starting valve activation
- Performing cold start
- Electric wiring diagrams
- Testing fuel pump
- Testing injection valves
- Testing, replacing throttle valve switch
- Performing fuel quantity comparison measurement
- Testing relay fuel pump
- Removal and installation of mixture control unit
- Replacing fuel distributor
- Replacing sealing ring for control piston
- Removal and installation of injection valves
- Replacing air volume meter
- Removal and installation of mixture control unit with air guide housing
- Removal and installation of throttle valve housing
- Replacing, centering air flow sensor plate, testing and adjusting for zero
- Removal and installation of control unit
- Replacing electrohydraulic actuator (EHA)
- Removal and installation of fuel accumulator
- Removal and installation of fuel filter
- Removal and installation of fuel pump
Air Cleaner
- Removal and installation of air cleaner
- Renewing or intake scoop
Belt Drives
- Checking condition of poly V-belt and renewing
- Removing, installing tensioning device
Intake manifold – exhaust manifold (Emission Control Systems)
- Identification of vehicles
- Function of emission control system
- Checking oxygen sensor failure indication
- Removal and installation of intake manifold
- Renewal of intake manifold, (intake manifold removed)
- Removal and installation of exhaust manifold
- Renewal of oxygen sensor
Electrical System – engine
- Notes regarding jobs on breakerless transistorized ignitions
- Electronic ignition system with variable characteristics (EZL)
- Check ignition timing
- Evaluation of oscilloscope image
- Renewing spark plugs
- Removal and installation of high voltage distributor
- Checking the electronic ignition system with variable characteristics
Engine Lubrication
- Engine oil and filter change
- Removal and installation of oil filter
- Removal and installation of oil pump
- Renewing oil pump chain
- Removal and installation of oil pressure relief valve in oil pump
- Removal and installation of oil level sensor
- Renewing oil level return lock
Engine Cooling
- Draining, pouring in coolant – antifreeze protection table
- Testing coolant system for leaks
- Removing, installing coolant
- Removal and installation of coolant pump
- Removal and installation of viscous fan clutch
- Removal and installation of radiator
- Removal and installation of overflow tank
Engine Suspension
- Removal and installation of front engine mounts
- Removal and installation or rear engine mounts
Throttle Control
- Adjusting control linkage
- Removal and installation of accelerator pedal with front wall mounting
- Removal, installation and adjustment of Bowden cable
- Removal and installation of accelerator pedal
- Lubricating control linkage and control shaft
Fuel System
- Operation of fuel tank with surge bowl
- Operation of fuel gauge pickup
- Operation of fuel tank positive and negative ventilation
- Removal and installation of fuel tank
- Removal and installation of fuel gauge pickup
- Function of fuel evaporation system
- Checking the fuel evaporation system
- Function of fuel cooler
Exhaust System
- Removal and installation of exhaust system
Electrical Troubleshooting Manual –Wiring Diagrams
WIRING DIAGRAMS LIST
Air Injection Management
Anti-Lock Brake System
Anti-Theft Alarm System
Automatic Antenna
Automatic Climate Control
Auxiliary Fan
Central Locking System
Charging System
Cigar Lighter
Clock
Component Locations
Cruise Control
Diagnostic Socket
Electronic Engine Controls
Fuel Delivery
Fuse/Relay Box
Fuse-Circuit List
Gauges
Ground Distribution
Ground Distribution ACC
Heated Seats
Horns
Idle Speed Stabilization
Ignition
Lamps (Backup/Center Console/Courtesy/Fog Lamps/Glove Box/
Hazard/Headlamps/Instrument Cluster/License/Marker/Park/
Stop/Tail/Trunk/Turn Signal/ Vanity)
Outside Heated Mirrors
Outside Temperature Display
Power Distribution
Power Distribution ACC
Power Windows
Radio
Rear Defogger
Start
Supplemental Restraint System
Tachometer
Transmission Kick-Down
Warning Indicators
Warning System
Wiper Washer
Maintenance Manual
A-MAINTENANCE SYSTEM SHEETS
B-MAINTENANCE MANUAL INDEX
- Inspecting component condition
- Inspecting condition of lines and hoses
- Inspecting components, lines and hoses
- Suspension and body structure inspection
- Water leakage and corrosion inspection
- Engine oil and filter change
- Adjusting valve clearance
- Checking valve clearance
- Checking and adjusting idle speed – Engine 601
- Checking and adjusting idle speed – Engine 110
- Checking injection timing
- Adjusting injection timing
- Replacing fuel filter
- Replacing fuel prefilter
- Cleaning metal-reinforced air filter element
- Replacing air-filter element
- Replacing air filter
- Replacing air filter elements – Eng 116, 117
- Checking conditions and tensions of V-belts
- Inspecting poly-V-belt
- Checking intake/exhaust manifold seating
- Replacing oxygen sensor
- Check spark plugs, replace if necessary
- Replacing spark plugs
- Checking coolant level, antifreeze protection
- Checking coolant level
- Checking coolant and heating system
- Replacing coolant
- Adjust engine stop, retorque engine mount bolts
- Adjust engine stop
- Checking clutch disk for wear
- Manual transmission oil change
- Manual transmission, checking, correcting oil level
- Automatic transmission fluid and filter change
- Automatic transmission, checking, correcting fluid level
- Transfer case fluid change
- Transfer case, checking, correcting fluid level
- Clutch system, checking, correcting fluid level
- Clutch system inspect
- Inspecting, lubricating throttle linkage
- Checking and adjusting idle speed adjuster
- Level control, ADS, ASD, 4MATIC, fluid level
- Inspecting self-leveling suspension
- Front axle, checking correcting oil level
- Checking front axle ball joints
- Checking ball joints using special tool
- Rear axle oil change
- Rear axle, checking, correcting oil level
- Rear axle mount, adjusting limiting stop
- Inspecting/rotating wheels
- Checking tires
- Correcting tire pressure
- Tightening wheel bolts
- Inspecting drive shaft flexible coupling
- Checking break fluid level
- Inspecting break lines for damage
- Checking break pad/disk thickness
- Inspecting, cleaning break disks
- Inspecting parking break cable
- Adjusting parking break
- Replacing break fluid
- Brake test, parking break check
- Checking power steering fluid level
- Checking steering play
- Retightening steering bolts
- Checking fluid system condition
- Retightening exhaust flange
- Retightening exhaust system connections
- Checking and correcting battery fluid level
- Checking warning and indicator lamps
- Cleaning water drains
- Removing and installing engine compartment lower panel
- Lubricating door hinges
- Lubricating door locks
- Hydraulic top, checking and connecting fluid levels
- Sun roof, clean and grease rails
- Soft top, checking locking tabs
- Checking, correcting windshield washer fluid level
- Cleaning cassette deck tone head
- Cleaning antenna mast
- Headlamp and exterior lamp inspection
- Windshield and headlamp wiper/washer inspection
- Replacing windshield wiper blade
- Checking, correcting A/C refrigerant charge
- Replacing dust filter for heating/ventilation
- Replacing active charcoal filter
- Replacing recirculating air filter
- Lubricating folding side mirror
- Lubricating hood
- Inspecting safety belts for damage
- Backrest lock – check operation
- Removing and installing lower noise encapsulation panels
- Checking body for paint damage
Climate Control Manual –
GENERAL, TECHNICAL DATA
- Instructions for use of service manual
- Model and system identification
- Vehicle identification number locations
SECTION I – Heating / Ventilation and air conditioning I
- Removing and installation of heat exchanger
- Checking oil level in A/C compressor
- Removing and installation of A/C compressor
- Removing and installation of speed sensor on A/C compressor
- Replacing of shaft seal on A/C compressor
- Removing and installation of electromagnetic clutch
- Removing and installation and checking of solenoid coil
- Removing and installation of series resistor for auxiliary fans
- Removing and installation of condenser
- Removing and installation of fluid reservoir
- Checking or removing and installation of pressure switch for A/C compressor in fluid reservoir
- Removing and installation of pressure for auxiliary fans in fluid reservoir
- Removing and installing and checking evaporator temperature sensor
- Removing and installing and checking of outside air temperature sensor
- Removal and installation of expansion valve
- Removal and installation of evaporator
- Removal and installation of blower motor
- Removal and installation of control unit for air conditioner/automatic temperature control
- Removal and installation of auxiliary fan
- Removal and installation of switch for air conditioner / automatic temperature control
- Removal and installation of switch for fresh air / recirculated air
- Removal and installation of switch-over valve or 4-point connection valve block for fresh air / recirculated air flap
- Removal and installation of vacuum elements
- Removal and installation and checking of speed sensor on starter ring gear
SECTION II – AIR CONDITIONING II
- Description of function of the automatic climate control
- Checking function of automatic climate control
- Testing regulating quality and heat output
- Testing automatic climate control with impulse counter
- Testing electrical components of the automatic climate control
- Testing compressor cutoff and remedial measures
- Electrical circuit diagrams
- Checking refrigerating capacity (short test)
- Checking refrigerating capacity and suction/high pressure
- Checking flap control vacuum system for leaks
- Removal and installation of heat exchanger
- Removal and installation of mono valve
- Removal and installation of circulating pump
- Pushbutton control unit
- Removal and installation of ventilation blower for temperature sensor interior air
- Removal and installation, testing of temperature sensor interior air
- Removal and installation, testing of temperature sensor heat exchanger
- Removal and installation, testing of temperature sensor evaporator
- Removal and installation, testing of temperature sensor outside air
- Removal and installation, testing of fresh/recirculating air switch
- Removal and installation of switchover valve block
- Removal and installation of vacuum elements
- Removal and installation of electric blower regulator
- Removal and installation of Hall-sensor
Chassis and Body Manual
coverage is, more or less the same, for all models and years
General, technical data
- Instructions for use of service manual
- Engine and vehicle identification
- Technical data
- Vehicle identification number location
- Vehicle data card
- Body plate