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
- Handling components
- Handling nuts and bolts
- Cleaning and maintenance of vehicle paint finish
- Cleaning vehicle interior
- Cleaning engine compartment
- Towing of vehicle
- Catalytic converters
- Positioning jack stands
- Lifting vehicle with on board jack
- Lifting vehicle with floor jack
- Lifting vehicle on hoist
Charging system starter
- Testing alternator and regulator in vehicle
- Replacing fan assembly
- Removal and installation of starter
Pedal assembly
- Removal and installation of pedals
- Disassembling and assembling pedals
Suspension
- Springs – Shock Absorbers
- Survey of springs – shock absorbers / spring struts
- Removal and installation of front shock absorbers
- Removal and installation of rear shock absorbers
- Checking shock absorbers
- Checking alignment of front shock absorbers
- Checking alignment of rear shock absorbers
- Removal and installation of front springs
- Adjustments of front springs
- Removal and installation of rear springs
- Adjustment of rear springs
- Test specification of springs
- Removal and installation of front stabilizer bar
- Removal and installation of rear stabilizer bar
- Removal and installation of rear stabilizer bar (w/anti squat)
- Removal and installation of carrier support on stabilizer bar
- Functional description
- Checking spring struts
- Checking pressure reservoir
- Checking pressure oil pump and level controller
- Removal and installation of spring struts
- Removal and installation of pressure reservoir
- Draining and filling hydraulic system
- Removal and installation of pressure oil pump
- Replacement of pressure oil pump seal
- Removal and installation of level controller link
- Removal and installation of level controller
Front Axle
- Removal and installation of front axle half
- Adjustment of wheel bearing end play
- Removal and installation of wheel hub
- Disassembly, inspection, repair and assembly of front wheel hub
- Removal and installation of steering knuckle
- Checking the steering knuckle
- Removal and installation of steering knuckle arm
- Checking upper and lower ball joints
- Replacing ball joints bolts
- Replacing lower ball joint
- Removal and installation of upper control arm
- Removal, disassembly, assembly and installation of lower c.arm
- Removal and installation of lower control arm bushing
- Checking breaking support link and ball joint
- Checking and repairing upper control arm bearing
- Checking upper control arm
- Checking lower control arm
- Removal and installation of breaking support link ball joint carrier
- Removal and installation of ball joint carrier
- Removal and installation of breaking support link ball joint
Rear Axle
- Removal and installation of complete rear axle
- Removal and installation of rear axle subframe front bushings
- Removal and installation of rear axle subframe rear bushings
- Removal and installation of semi-trailing arm
- Removal and installation of rear axle shaft flange
- Removal and installation of coupled seni-trailer arm
- Removal and installation of link btw. Coupled semi-trailer arm and caliper carrier
- Removal, installation, and adjustment of wheel carrier
- Removal and installation of caliper carrier and hub, adjust wheel bearing
- Inspection of rear axel assembly
- Checking semi-trailing arms
- Checking of rear axle subframe
Wheels, tires, and alignment
- Survey wheels and tires
- Wheels
- Tires
- Tire inflation pressure labels
- Snow chains
- Removal and installation of wheel covers
- Removal and installation of cover retaining clip and springs
- Removal and installation of center cap on light alloy wheels
- Removal and installation of wheels
- Replacing tires
- Balancing wheels
- Checking wheel runout
- General checks and preliminary jobs for wheel alignment
- Positioning of wheels
- Aligning vehicle over measuring pit or hoist
- Attachment of wheel mirrors
- Checking chassis alignment measuring instruments
- Checking vehicle level on front and rear axle
- Checking vehicle level on rear axle of vehicle with level control
- Front axle wheel alignment
- Rear axle wheel alignment
- Checking collusion damaged vehicles
- Checking inclination of lower control arm bushing
Drive shaft
- Removal and installation of drive shaft
- Removal and installation of center bearing
- Removal and installation of centering sleeve
Brakes, hydraulic and mechanical
- Bleeding the break system or renewing the break fluid
- Checking brake lines and break hoses
- Replacing break hoses
- Pressure testing the break system
- Checking warning device in expansion tank
- Inspection or adjustment of mechanical break light switch
- Cleaning the break discs with cleaning pads
- Removal and installation of master cylinder
- Reconditioning master cylinder
- Removal and installation of parking break pedal system
- Removal and installation of front break cable control
- Removal and installation of rear break cable control
- Removal and installation of parking break shoes
- Adjustment of parking break
- Layout and operation of ABS (anti-lacking break system)
- Important information during repair jobs
- Removal and installation of hydraulic unit
- Removal and installation of ABS control module
- Removal and installation of motor and valve relays
- Removal and installation of front axle VSS sensors
- Removal and installation of rear axle VSS sensors
- Electrical testing
- Function/test of overvoltage protection relays
- Notes on towing, test and repair work
- Removal and installation of ABS/ASR hydraulic unit
- Removal and installation of ASR charging pump
- Removal and installation of accumulator
- Removal and installation of left/right rear axle VSS sensors
- Removal and installation of ASR control module
- Electrical test program – ASR II
- Hydraulic test program – ASR II
Brakes, pneumatic system
- Testing of check valve
- Testing break booster
- Removal and installation of brake booster
- Removal and installation of vacuum pump
- Removal and installation of piston vacuum pump
- Removal and installation of vacuum pump piston seal and plate valves
- Replacement of piston vacuum pump swing arm
- Checking piston vacuum pump
Steering
- Technical data
- Checking steering play
- Checking power steering pump oil pressure
- Replacing steering following an accident
- Removal and installation of power steering
- Adjusting power steering in vehicle
- Removal and installation of pitman arm and lower housing cover seal
- Checking idler arm play, remove and reinstall idler arm bushing
- Removal and installation of tie rod ends
- Removal and installation of center link
- Removal and installation of center link and tie rod end boots
- Removal and installation of steering wheel
- Removal and installation of steering wheel slip ring
- Removal and installation of steering column
- Steering column disassembly/assembly
- Removal and installation of steering wheel lock
- Power steering pump identification
- Removal and installation of power steering pump seal
- Removal and installation of power steering pump
- Filling and bleeding power steering pump
- Disassembly and assembly of power steering pump
Electrical equipment and instruments
- Filling battery with overfill protection
- Testing and charging battery
- Designations and locations of ground points
- Connector and terminal block locations
- Electrical connections for special equipment
- Bulb failure indicator
- Removal and installation of instrument cluster
- Testing electronic speedometer
- Testing economy vacuum gauge
- Removal and installation of speedometer
- Removal and installation of rotary light switch
- Removal and installation of combination switch
- Removal and installation of upper center console switches
- Relay and control module locations
- Wiring diagrams
- Renewing bulb for ashtray light
- Sun visor with illuminated mirror
- Warning device for seatbelt, ignition key, light
- Cruise control operation
- Testing cruise control adapter
- Testing coding plug
- Removal and installation of actuator
- Removal and installation of switch
- Adjustment of connecting rod
- Removal and installation of control module
- Removal and installation of control module coding plug
- Connector location
Windows, windshield
- Removal and installation of windshield
- Removal and installation of windshield molding
- Removal and installation of rear window
- Removal and installation of rear window molding
- Removal and installation of rear side glass (coupe)
- Removal and installation of rear side glass power window motor
- Adjusting rear side glass
Instrument panel, interior trim
- Removal and installation of instrument panel
- Removal and installation of cover for loudspeaker L/R
- Removal and installation of trimstrip of instrument panel
- Glove box cover
- Removal and installation of glove compartment lid lock
- Removal and installation of glove compartment
- Removal and installation of cover under instrument panel
- Removal and installation of center console
- Removal and installation of cover at selector lever
- Removal and installation of reveal molding on windshield
- Removal and installation of A-pillar moldings
- Removal and installation of headliner
- Removal and installation of rear roof frame paneling
- Removal and installation of C-pillar trim
- Removal and installation of rear side panel
- Removal and installation of rear shelf
- Removal and installation of B-pillar molding
- Removal and installation of trunk liner
- Removal and installation of rear center trunk panel
- Removal and installation of firewall sound deadening
- Removal and installation of fuel tank trunk panel
Doors
- Removal and installation of front door
- Dismantling front door
- Removal and installation of rear door
- Dismantling rear door
- Removal and installation of front door inner trim panel
- Removal and installation of rear door inner trim panel
- Removal and installation of window frame inner trim
- Removal and installation of door inner trim panel
- Removal and installation of arm rest
- Removal and installation of inner sealing strip
- Removal and installation of outer sealing strip
- Removal and installation of front door power window mechanism
- Removal and installation of rear door fixed glass
- Removal and installation of flexible window rum channel
- Removal and installation of guide holder with guide rail
- Removal and installation of door holder
- Removal and installation of rear door sealing frame
- Removal and installation of front door inside handle
- Removal and installation of rear door inside handle
- Removal and installation of front/rear outside handles
- Removal and installation of front/rear door latches
Central Locking System
Too long to list – send email if you need it
Electrical System of Body
Too long to list – send email if you need it
Detachable Body Components
Too long to list – send email if you need it
Seats and Restraint Systems
Too long to list – send email if you need it
Sliding Roof
Too long to list – send email if you need it