Map of all site pages

Ceed 1 (2006-2012)
General information
User manual
Interior equipment of the car
Instrument panel
Engine compartment
Vehicle keys
Remote keyless entry
Anti-theft alarm system
Immobilizer is an electronic blocking system
Door locks
Locking system super class
Emergency door lock release system using a collision sensor
Automatic door locking system when the vehicle is moving
Locking the rear door locks from inside the car
Luggage compartment door
Emergency release lever for the luggage compartment door lock
Luggage compartment light
Power windows with electric drive
Front seat adjustment
Heated front seats
Adjusting the front headrests
Rear seat adjustment
Rear seat headrests
Pre-tensioning seat belts
Seat belts
Warning light and sound signals
Fastening seat belts
Rear seat safety belt
Use of seat belts
Child seats
Supplemental Restraint System (SRS)
Airbag Emergency Warning Light (SRS)
Opening and closing the hood
Fuel tank cap
Exterior rear view mirrors
Day/night position of the interior rearview mirror
Indoor lighting lamps
Salon equipment
Sunroof control
Outdoor antenna
Audio control
Steering wheel remote control
Ignition switch
Starting a gasoline engine
Starting a diesel engine
Starting and stopping a diesel engine with a turbocharger
Manual transmission
Automatic transmission
Brake pad wear indicator for disc brakes
Parking brake
Anti-lock braking system (ABS)
Steering wheel
Steering column tilt adjustment
Constant speed control system (cruise control)
Electronic Stability Program (ESP)
Control devices
Control lamps
On-board computer
Information monitor
Reverse parking system
Battery discharge prevention system
External lighting switch
Direction indicators
Front fog lights
Rear fog lamp
Headlight corrector
Windshield wiper
Windshield washer
Rear window wiper and washer switch
Rear window defroster
Windshield Ice Removal Mode
Emergency light signaling
Manual air conditioning system
Automatic air conditioning system
Air Conditioning System Operation Tips
Cooled/heated glove compartment
Defrosting and defogging the windshield
Operation logic for eliminating windshield fogging
Towing a car
Tire pressure monitoring system
Wheel replacement
Tire storage
Maintenance
Working fluids and lubricants
Periodic maintenance
Maintenance schedule for operating a vehicle with a gasoline engine under normal conditions
Maintenance schedule for operating a vehicle with a gasoline engine in severe conditions
Maintenance schedule for normal operation of a diesel engine vehicle
Maintenance schedule for heavy-duty diesel vehicle operation
Maintenance work
Owner Performed Maintenance
Maintenance Precautions
Vehicle Identification Numbers
Lifting a car
Tightening torques for threaded connections
Basic data for adjustments and control
Power unit
Petrol engines 1.4, 1.6 l
Engine specifications
Compression check
Checking and adjusting valve clearances
Removal and installation of engine and gearbox
Gas distribution mechanism drive chain
Intake manifold
Exhaust manifold
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head — assembly
Cylinder head — installation
Cylinder block — device
Cylinder Block — Disassembly
Cylinder Block — Check
Engine assembly
Lubrication system
Selecting motor oil
Changing engine oil and oil filter
Checking the engine oil level
Oil pan
Oil pressure sensor
Exhaust gas system
Troubleshooting Engines
Petrol engines 2.0 l
Engine specifications
Compression check
Adjusting the timing belt tension
Checking and adjusting valve clearances
Removal and installation of engine and gearbox
Timing belt for gas distribution mechanism drive
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head — assembly
Cylinder head — installation
Cylinder block — device
Cylinder Block — Disassembly
Cylinder Block — Check
Engine assembly
Intake manifold
Exhaust manifold
Lubrication system
Selecting motor oil
Checking the engine oil level
Changing engine oil and oil filter
Oil pump
Oil pressure sensor
Exhaust gas system
Troubleshooting Engines
Diesel engine 1.6 l
Engine specifications
Compression check
Gas distribution mechanism drive chain
Removal and installation of engine and gearbox
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head — assembly
Cylinder head — installation
Cylinder block — device
Cylinder Block — Disassembly
Cylinder Block — Check
Engine assembly
Intake manifold
Exhaust manifold
Intermediate air cooler
Lubrication system
Changing engine oil and oil filter
Checking the engine oil level
Selecting motor oil
Oil pump
Oil pressure sensor
Exhaust gas system
Troubleshooting Engines
Diesel engine 2.0 l
Engine specifications
Compression check
Removal and installation of engine and gearbox
Timing belt for gas distribution mechanism drive
Intake manifold
Exhaust manifold
Intermediate air cooler
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head — assembly
Cylinder head — installation
Cylinder block — device
Cylinder Block — Removal
Cylinder Block — Disassembly
Cylinder Block — Check
Pistons and connecting rods — device
Pistons and connecting rods — removal
Pistons and connecting rods — check
Pistons and connecting rods — assembly
Lubrication system
Selecting motor oil
Checking the engine oil level
Oil pump
Oil pressure sensor
Replacing the oil filter
Exhaust gas system
Troubleshooting Engines
Cooling system
Technical characteristics of the cooling system
Cooling system device
Replacing the coolant and bleeding air
Pressure testing the radiator cap
Checking the radiator for leaks
Water pump for petrol engines 1.4 and 1.6 l
Water pump for 2.0L petrol engine
Water pump diesel engine 1.6 l
Thermostat for petrol engines 1.4 and 1.6 l
Thermostat for 2.0L petrol engine
Thermostat diesel engine 1.6 l
Radiator for cars with 1.4 and 1.6 l petrol engines
Car radiator with 2.0L petrol engine
Radiator of a car with a 1.6 L diesel engine
Coolant temperature control unit for cars with 1.4 and 1.6 l petrol engines
Checking the radiator fan
Emission control system
Device of the system of control and reduction of toxicity of exhaust gases
Crankcase ventilation system (PCV)
Scheme of the exhaust gas toxicity control and reduction system and fuel vapor recovery
Crankcase ventilation valve
Fuel vapor recovery system
Activated carbon canister (absorber)
Solenoid valve for cleaning the absorber
Fuel Tank Air Filter — Replacement
Fuel filler cap
Exhaust system of vehicles with catalytic converter
MFI fuel injection system
Variable Valve Timing (CVVT) system
Troubleshooting issues
Fuel system (gasoline)
Fuel system specifications
Basic Fuel System Checks
Checking the engine management system
Malfunction Indicator Lamp (MIL)
Relationship between fault codes and driving patterns
Diagnostic Trouble Codes
Location of fuel system components
Engine control unit
Manifold Absolute Pressure Sensor (MAPS)
Intake Air Temperature Sensor (IATS)
Coolant Temperature Sensor (ECTS)
Throttle Position Sensor (TPS)
Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor (CKPS)
Heated oxygen concentration sensor
Knock Sensor (KS)
Fuel injectors
Engine idle speed control actuator (ISCA)
CVVT Oil Control Valve (OCV)
Oil Temperature Sensor (OTS) [with CVVT]
Fuel Evaporative Control System Solenoid Valve (PCSV)
Fuel lines and hoses
Fuel pump (including fuel filter and fuel pressure regulator)
Fuel tank
Fuel filler pipe assembly
Fuel system (diesel)
Fuel system specifications
Diesel Engine Management System
Checking diagnostic trouble codes
Location of fuel system components on a vehicle
Engine control unit
Mass Air Flow Meter (MAFS)
Boost Pressure Sensor (BPS)
Intake Air Temperature Sensor (IATS)
Coolant Temperature Sensor (ECTS)
Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor (CKPS)
Accelerator Pedal Position Sensor (APS)
Fuel Pressure Sensor in the High Pressure Rail (RPS)
Fuel Temperature Sensor (FTS)
Fuel pressure regulator
Exhaust Gas Recirculation (EGR) Valve
Vortex change drive
Sensor for detecting the presence of water in the fuel filter
Turbocharger Geometry Change Control Solenoid Valve
Oxygen concentration sensor
Exhaust Gas Temperature Sensor (EGTS) for VGT
Exhaust Gas Temperature Sensor (EGTS) for CPF
Differential Pressure Sensor (DPS)
Catalytic Converter Particulate Filter (CPF)
Throttle control actuator
Common Rail Fuel System
Fuel tank — removal and installation
Low pressure fuel pump
Fuel level sensor
Fuel filter for a car with a 1.6L engine
Fuel filter for a car with a 2.0L engine
High pressure fuel pump for a car with a 1.6L engine
High pressure fuel pump for a car with a 2.0L engine
Fuel rail with high pressure accumulator (Common rail) of a car with a 1.6 l engine
Fuel rail with high pressure accumulator (Common rail) of a car with a 2.0 l engine
Injectors for a car with a 1.6L engine
Injectors for a car with a 2.0L engine
Fuel filler pipe assembly
Accelerator pedal — removal and installation
Ignition system
Technical characteristics of the ignition system
General information about the ignition system
Checking the spark plug
Checking the condition of spark plugs
Checking the ignition coils of the 2.0L engine
Checking ignition coils of 1.4 and 1.6 l engines
Checking high voltage wires
Troubleshooting the ignition system
Diesel engine preheating system
Checking the diesel engine preheating system
Glow plug
Glow Plug Relay
Transmission
Clutch
Clutch specifications
General information about the clutch
Adjusting the position of the clutch pedal
Bleeding the hydraulic clutch drive system
Slave and pressure plates of the clutch
Clutch pedal — removal and installation
Clutch master cylinder
Clutch slave cylinder
Troubleshooting Clutch Problems
Manual gearbox
Technical characteristics of mechanical transmission
General information about mechanical transmission
Checking the oil level
Transmission oil change
Checking the reverse light switch
Checking the neutral position switch
Replacing the drive shaft seal
Removal the M5CF gearbox
Installing the M5CF gearbox
Shafts and gears of the mechanical gearbox M5CF
Removal the M6GF2 gearbox
Installing the M6GF2 gearbox
Shafts and gears of the mechanical gearbox M6GF2
Cables and gear shift lever
Gearbox repair
Troubleshooting Manual Transmissions
Automatic gearbox
Automatic transmission specifications
General information about automatic transmission
Automatic transmission section
Mechanical elements of the gearbox
Checking the fluid level in the automatic transmission
Automatic transmission fluid replacement
Testing the joint operation of an automatic transmission and engine on a stationary vehicle (stall test)
Checking Transmission Fluid Pressure
Reading diagnostic trouble codes
Location of gearbox components
Removal the gearbox
Gearbox installation
Solenoid valve block
Variable Force Solenoid Valve (VFS)
Input shaft speed sensor
Output shaft speed sensor
Transmission Fluid Temperature Sensor
Selector lever position indicator switch
Gear shift cable and lever
Adjusting the gearbox control cable
Drive shafts
Technical characteristics of drive shafts
General information about drive shafts
Drive shaft — removal and installation
Front wheel steering knuckle and hub
Rear axle / rear wheel hub
Troubleshooting Drive Shafts
Chassis
Car suspension
Suspension specifications
General information about the front suspension
Front suspension shock absorber strut
Lower control arm of the front suspension
Front cross stabilizer
General information about the rear suspension
Rear suspension shock absorber
Upper arm rear suspension
Lower arm rear suspension
Additional transverse arm
Rear suspension trailing arm
Rear stabilizer bar
Wheels and tires
Front wheel alignment angles
Adjusting the front wheel alignment
Rear wheel alignment adjustment
Tightening the wheel nuts
Wheel beating
Tire wear
Wheel rotation
Checking the vehicle's drift and directional instability
Tire wear diagnostics
Troubleshooting suspension problems
Steering
Technical characteristics of the steering system
General information about steering
EPS Type Recognition Operation
Troubleshooting steering problems
Steering column and steering shaft
Steering gear — device
Steering gear — removal
Steering gear — disassembly and inspection
Steering gear — assembly
Steering gear — installation
Brake system
Technical characteristics of the brake system
General information about the braking system
Checking the brake booster
Checking the one-way vacuum valve
Checking and adjusting the brake pedal position
Checking the thickness of the front brake pads
Checking the thickness of the rear brake pads
Vacuum brake booster
Brake pipes and hoses
Bleeding the hydraulic brake drive system
Brake pedal — removal and installation
Front Brake Caliper — Removal and Installation
Master brake cylinder
Rear Disc Brakes — Removal and Installation
Front Brake Caliper Components
Parking brake lever
Parking brake mechanism
Parking brake shoes
Adjusting the clearance of the parking brake shoes
Adjusting the travel of the parking brake lever
Anti-lock braking system (ABS)
Hydraulic unit HECU
Checking the wheel speed sensor
Electronic Brakeforce Distribution (EBD)
Electronic Stability Program (ESP/ESC)
Control lamps
Steering Angle Speed Sensor (SAS)
Troubleshooting the brake system
Body
Exterior
Tightening torques for threaded connections
General information about the body
Removal and installation the hood
Replacing the hood sound insulation
Replacing the hood dust and moisture seal
Replacing the hood release handle
Replacing the hood lock
Adjusting the hood position
Gaps between the elements of the front and rear parts of the body
Fuel tank filler flap
Gaps between the elements of the side part of the body
Replacing the front wheel fender and mudguard
Replacing the rear wheel fender and mudguard
Replacement of the decorative panel of the luggage compartment door
Replacing the outside rearview mirror
Ventilation chamber cover
Front bumper — removal and installation
Rear bumper — removal and installation
Dimensions between the main points of the body frame
Troubleshooting the bodywork
Interior
Replacing the interior rearview mirror
Replacing the auto-dimming interior rearview mirror
Center console — device
Replacing the center console
Center console side covers
Replacing the instrument cluster
Replacing the central trim of the instrument panel
Instrument panel — device
Replacing the central storage compartment of the instrument panel console
Replacing the lower trim of the instrument panel
Replacing the audio system
Replacing the glove box
Replacing steering column covers
Replacing the side covers of the instrument panel
Replacing the instrument panel
Replacement of ceiling elements
Interior upholstery
Replacing the door sill trim
Replacing the front pillar trim
Replacing the lower trim of the front pillar
Replacement of the B-pillar trim
Replacing the rear pillar trim
Replacement of side trim of luggage compartment
Front seat — device
Front seat — replacement of elements
Rear seat — replacement of elements
Seat belts
Replacing the front seat belt
Replacing the rear seat belt
Replacing the front seat belt buckle
Replacing the rear seat belt buckle
Replacing the seat belt height adjuster
Doors and windows
Luggage compartment door
Adjusting the position of the luggage compartment door
Replacing the front door trim
Replacing the inside front door lock release handle
Front door glass replacement
Front door speaker replacement
Replacing the front door window lift motor
Front Door Module Replacement
Replacing the front door outer handle
Replacing the front door seal
Adjusting the position of the front door glass
Adjusting the position of the front door
Adjusting the position of the front door lock strike plate
Rear door trim replacement
Replacing the inner rear door lock release handle
Rear door glass replacement
Rear Door Speaker Replacement
Replacing the rear door window lifter motor
Replacing the outer rear door handle
Rear Door Module Replacement
Replacing the rear door seal
Adjusting the position of the rear door glass
Adjusting the position of the rear door
Adjusting the position of the rear door lock strike plate
Roof hatch — device
Roof hatch — replacement of elements
Hatch initialization
Emergency manual opening or closing of the hatch
Air conditioner
Air Conditioner Specifications
General information about the air conditioner
Instructions for use of refrigerant
Notes when replacing air conditioning system components
Connecting the elements of the air conditioning system
Air conditioning system discharge
Pumping atmospheric air out of the air conditioning system
Charging the air conditioning system
Checking the air conditioning system for leaks
Air conditioning compressor lubrication oil
Checking hoses and tubes
Air conditioning compressor
Compressor noise
Capacitor — Checking and Replacing
Pressure sensor — checking and replacement
Air conditioning pipes and hoses
Evaporator temperature sensor
Car interior air temperature sensor
Photo sensor — checking and replacement
Coolant temperature sensor
Ambient temperature sensor
Air Quality Sensor (AQS)
Humidity sensor — checking and replacement
Heater — device
Heater — replacement
RTS heater
Air temperature control flap drive
Air flow distribution flap drive
Heater Fan Block
Heater Fan Motor
Fan Relay — Checking and Replacing
Switch with output MOSFET
Cabin filter — replacement
Fresh or recirculated air supply damper actuator
Air conditioning control panel
Electrical equipment
Engine electrics
Technical characteristics of the engine electrical equipment
General information about electrical equipment
General recommendations for troubleshooting
Battery charging system
Checking the voltage at the battery terminals
Checking the alternator drive belt of 1.4 and 1.6 liter petrol engines
Checking the voltage drop on the wire connecting the battery to the generator
Checking the current generated by the generator
Checking voltage stabilization
Generator for 1.4 and 1.6 liter petrol engines
2.0L Gasoline Engine Generator
Repair of gasoline engine generator
1.6 liter diesel car generator
Repair of a 1.6 liter diesel engine generator
2.0 liter diesel engine generator
Repair of a 2.0 liter diesel engine generator
Checking the generator elements
Battery — General Information
Battery inspection
Checking the specific gravity of the electrolyte
Engine starting system
Checking the elements of the starting system
Checking voltage drop and current consumption
Checking the engine crankshaft speed
Checking the starter traction relay
Idle performance testing
Starter for gasoline engines
Starter for 1.6 liter diesel engine
Repair of starter of petrol and diesel engines 1.6 liters
Starter for 2.0 liter diesel engine
Repair of starter of diesel engine 2.0 liter
Checking the starter components
Starter relay — check
Troubleshooting the charging system
Troubleshooting the Engine Starting System
Equipment and devices
Audio system — removal and installation
Speakers — Removal and Installation
Electrically powered antenna
Remote control of the audio system
Connector for connecting external mobile audio devices (AUX and USB)
Multifunctional switch
Sound signal
Navigation system
Remote control system for locks and anti-theft alarm
Remote control for locking (transmitter)
Relay — location and testing
Fuses — location in the car
Fuse and relay box
Instrument cluster — removal and installation
Outside rear view mirror — check
Power windows with electric drive — check
Windscreen Defroster — Check
Rear Window Defogger — Check
Windscreen wiper and washer
Windshield washer motor
Rear window wiper and washer
Seat Heaters — Check
Sunroof — Check
On-board computer — removal and installation
Ignition Switch — Removal and Installation
Checking the ignition switch
Troubleshooting of control and measuring instruments
Gauges and pointers
Gauges and indicators — location in the car
Checking the speedometer
Checking the vehicle speed sensor
Checking the tachometer
Checking the fuel gauge
Checking the fuel level sensor
Checking the coolant temperature gauge
Checking the coolant temperature sensor
Checking the oil pressure sensor
Checking the Oil Pressure Warning Light
Checking the Low Brake Fluid Level Sensor
Checking the Low Brake Fluid Warning Light
Checking the Parking Brake Position Switch
Lighting system
Lighting lamp specification
Location of lighting lamps in a car
Checking the headlight relay
Headlight adjustment
Lamp Replacement — Warnings
Headlight bulb replacement
Replacing the rear light bulb
Checking the local lighting lamp
Replacing the local lighting lamp
Replacing the interior light bulb
Overhead Console Light Replacement
Replacing the fog light bulb
Replacing the rear fog light bulb
Replacing the license plate light bulb
Replacing the luggage compartment light bulb
Headlight corrector
Troubleshooting the Lighting System
Security systems
Supplemental Restraint System (SRS)
Precautions when working with airbags
Maintenance and storage of airbags
Precautions for servicing SRS wiring
Precautions when servicing electrical connectors
Airbag connector
SRSCM Security System Control Unit
Driver's airbag and coil wire
Front passenger airbag
Side airbag
Curtain Pillows — Removal and Installation
Seat belt pretensioner
Front Impact Sensor (FIS)
Side Impact Sensor (FIS)
Disposal of airbags
Electrical circuits
Electrical diagram of the engine starting system
Electrical diagram of the charging system (G4GC)
Electrical diagram of the charging system (D4EA)
Electrical diagram of the cooling system
Engine Management System G4FC (MFI)
G4GC Engine Management System (MFI)
Engine Management System D4FB (MFI)
Engine Management System D4EA (MFI)
Automatic transmission control system G4FC
EPS (Power Steering Column) — MDPS
Anti-lock braking system (ABS)
Power windows with electric drive
Windscreen heater
Electrically adjustable exterior mirrors
Electrical diagram of headlights
Electrical diagram of fog lights
Direction indicators and hazard warning lights
Reverse light bulbs
Electrical diagram of brake lights
Rear lighting, side lighting and number plate lighting
Automatic air conditioning system
Windshield wiper and washer
Rear window wiper and washer
Arrangement of electrical equipment elements
Cerato 1 (2004-2009)
General information
User manual
Vehicle layout
Car keys
Remote keyless entry
Immobilizer — turning on and off
Door locks
Rear door security lock
Trunk lid
Power windows with electric drive
Driver's seat
Front passenger seat
Headrests — Removal and Installation
Folding the rear seat
Trunk — opening from outside and inside
Hood — opening, closing
Fuel tank cap
Fuel supply switch
Exterior rear view mirrors
Day/night position of the interior rearview mirror
Digital clock (if available)
Hatch — opening and closing
Ignition switch
Manual transmission
Automatic transmission
Disc Brake Pad Wear indicator
Parking brake
Steering column tilt adjustment
Constant speed control system (cruise control)
Control devices
Control lamps
Battery discharge prevention system
External lighting switch
Windscreen cleaner
Windshield washer
Rear window defroster
Emergency light signaling
Manual air conditioning system
Automatic air conditioning system
Air Conditioning System Operation Tips
Defrosting and defogging the windshield
Fuses — General Information
Replacing fuses
Main fuse box
Memory fuse
Location of fuses
Wheel replacement
Identification numbers
Body dimensions
Maintenance
Maintenance — General Information
Maintenance during normal vehicle operation
Maintenance when operating a vehicle in severe conditions
Lifting a car
Basic data for adjustments and control
Power unit
Petrol engine 1.6 l
Technical data
Checking the compression in the cylinders
Adjusting the timing belt tension
Timing belt for gas distribution mechanism drive
Cylinder head
Removal and installation of engine and gearbox
Cylinder block
Lubrication system
Changing engine oil and oil filter
Selecting motor oil
Oil pressure sensor
Oil pump
Exhaust gas system
Troubleshooting issues
Petrol engine 2.0 l
Technical data
Tightening torques for threaded connections
Compression check
Adjusting the timing belt tension
Checking and adjusting valve clearances
Timing belt of the gas distribution mechanism drive — removal
Timing belt of the gas distribution mechanism drive-device
Timing belt of the gas distribution mechanism drive — check
Timing belt of the gas distribution mechanism drive — installation
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head valve timing mechanism (CWT)
Replacing the cylinder head valve guide bushing
Replacing the cylinder head valve seat
Cylinder head — assembly
Cylinder head — installation
Engine and gearbox mounts — device
Engine and gearbox — removal and installation
Cylinder block — device
Cylinder Block — Disassembly
Cylinder Block — Check
Engine assembly
Intake Manifold — Removal
Intake manifold — device
Exhaust manifold — removal
Exhaust manifold — device
Lubrication system
Replacing the engine and oil filter
Selecting motor oil
Oil pressure sensor
Oil pan — removal and installation
Oil pump — device
Oil pump — removal
Oil pump — check
Oil pump — installation
Exhaust gas system
Troubleshooting issues
Diesel engine 2.0 l
Technical data
Compression check
Adjusting the tension of the poly V-belt
Removal and installation of engine and gearbox
Toothed belt — device
Timing belt of the gas distribution mechanism drive — removal
Timing belt of the gas distribution mechanism drive — check
Timing belt of the gas distribution mechanism drive — installation
Intake manifold — device
Intake Manifold — Removal
Exhaust manifold — device
Exhaust manifold — removal and installation
Cylinder head — device
Cylinder head — removal
Cylinder head — disassembly
Cylinder head — check
Cylinder head — assembly
Cylinder head — installation
Cylinder block — device
Cylinder Block — Removal
Cylinder Block — Disassembly
Crankshaft — device
Balancing shafts — device
Balance shafts — disassembly
Balance shafts — checking
Balance shafts — assembly
Pistons and connecting rods — device
Pistons and connecting rods — removal
Pistons and connecting rods — check
Pistons and connecting rods — assembly
Lubrication system — device
Selecting motor oil
Engine oil change
Checking the oil pressure sensor
Replacing the oil filter
Oil pump — removal
Oil pump — disassembly
Oil pump — check
Oil pump — assembly
Exhaust gas system
Troubleshooting issues
Cooling system
Technical data of the cooling system
Radiator and cooling system fans — device
Elements of the cooling system of gasoline engines
General information about the cooling system
Replacing the coolant and bleeding air
Checking the density of the coolant
Pressure testing the radiator cap
Checking the radiator for leaks
Water pump petrol engine 1.6 l (DOHC) — removal and installation
1.6L DOHC Petrol Engine Water Pump — Check
Water pump petrol engine 2.0 l (DOHC) — removal and installation
2.0L DOHC Gasoline Engine Water Pump — Check
Diesel Engine Water Pump — Removal and Installation
Diesel Engine Water Pump — Checking
Gasoline Engine Thermostat — Checking
Gasoline Engine Thermostat — Removal and Installation
Diesel Engine Thermostat — Removal and Installation
Radiator — check
Radiator — removal and installation
Decreased toxicity
Technical data of the exhaust gas control and toxicity reduction system
General information about the exhaust gas control and toxicity reduction system
Crankcase ventilation system (PCV)
Schemes of the system for monitoring and reducing toxicity of exhaust gases and capturing fuel vapors of engines
Crankcase ventilation valve
Fuel vapor recovery system
Activated Carbon Canister — Check
Activated Carbon Canister Cleaning Solenoid Valve — Check
Fuel filler cap
Exhaust system of vehicles with catalytic converter
MFI fuel injection system
Variable Valve Timing (CWT) System — Description
Troubleshooting issues
Fuel system (gasoline)
Technical data of the fuel system of cars with gasoline engines
Basic Fuel System Checks
Checking the Engine Management System — General Information
Malfunction Indicator Lamp (MIL)
Coolant Temperature Sensor (ECTS)
Throttle Position Sensor (TPS)
Knock sensor
Crankshaft Position Sensor (CKPS)
Camshaft Position Sensor (CMPS)
Fuel Evaporative Control System Solenoid Valve (PCSV)
Vehicle Speed Sensor (VSS)
Engine Idle Speed Control Drive (ISCA)
Oil Control Valve (OCV) (2.0L Engine)
Mass Air Flow Meter (MAFS)
Oil Temperature Sensor (OTS) (with CVVT)
Fuel lines and hoses
Fuel injectors
Fuel pump (including fuel filter and fuel pressure regulator)
Fuel tank — device
Fuel tank — removal and installation
Fuel tank — check
Troubleshooting issues
Fuel system (diesel)
Technical data of the fuel system of diesel engines
Basic checks of the fuel system of diesel engines
General information about the Common Rail injection system
Common Rail Fuel System — Device
Reducing toxicity of exhaust gases
Operation of the Common Rail fuel system
High pressure fuel pump — device
High pressure fuel supply
Diesel Engine Management System
Mass Air Flow Meter (MAFS)
Intake Air Temperature Sensor (IATS)
Coolant Temperature Sensor (ECTS)
Accelerator Pedal Position Sensor (APS)
Fuel Temperature Sensor (FTS)
Fuel Pressure Sensor in High Pressure Rail (RPS)
Camshaft Position Sensors (CMPS) and Crankshaft Position Sensors (CKPS)
Fuel pressure regulator
Injectors — removal and installation
Fuel rail with high pressure accumulator (rail)
Removal the high pressure fuel pump
Fuel filter — removal
Fuel filter — device
Fuel pump — removal and installation
Fuel tank
Troubleshooting the Fuel System
Troubleshooting the Engine Starting System
Troubleshooting the Fuel Tank and Fuel Lines
Spark plugs
Ignition and heating system
Technical data of the ignition system
Ignition system — general information
Checking spark plugs
Checking high voltage wires
Checking ignition coils
Ignition coils
Troubleshooting the ignition system
Technical data of diesel engine preheating system
Diesel Engine Preheating Systems — General Information
Checking the diesel engine preheating system
Glow Plug — Checking
Troubleshooting the Diesel Engine Preheating System
Transmission
Clutch
Clutch technical data
Clutch — General Information
Clutch — device
Slave and pressure plates of the clutch — removal
Slave and pressure plates of the clutch — device
Slave and pressure plates of the clutch — installation
Clutch master cylinder — device
Clutch Master Cylinder — Removal and Installation
Clutch Master Cylinder — Check
Clutch Master Cylinder — Disassembly and Assembly
Clutch pedal — device
Clutch pedal — check
Clutch pedal — removal and installation
Clutch slave cylinder — device
Clutch slave cylinder — check
Clutch slave cylinder — removal and installation
Clutch slave cylinder — disassembly and assembly
Troubleshooting issues
Adjusting the position of the clutch pedal
Bleeding the hydraulic clutch drive system
Mechanical gearbox
Technical data of manual transmission
Gearbox M5BF2 — device
Gearbox — General Information
Checking the oil level
Transmission oil change
Gearbox M5GF1 — device
Replacing the drive shaft oil seal
Removal and installation of the M5BF2 gearbox
Removal and installation of the M5GF1 gearbox
Shafts and housings of a mechanical gearbox — device
Gear shift mechanisms and external elements of the manual transmission M5BF2 — device
Disassembly and assembly of the M5BF2 gearbox
Primary shaft of the gearbox — device
Secondary shaft of the gearbox — device
Primary shaft of the M5BF2 gearbox — disassembly and assembly
Secondary shaft of the M5BF2 gearbox — disassembly and assembly
Checking the primary and secondary shaft components of the M5BF2 gearbox
5th gear synchronizer — device
M5BF2 Gearbox 5th Gear Synchronizer — Check
Synchronizer 5th gear M5BF2 gearbox — assembly
Gear shift forks — device
M5GF1 gearbox shafts — device
Disassembly and assembly of the M5GF1 gearbox
Primary shaft of the M5GF1 gearbox — device
Secondary shaft of the M5GF1 gearbox — device
M5GF1 Gearbox Primary Shaft — Check
Primary shaft of the M5GF1 gearbox — disassembly and assembly
Secondary shaft of the gearbox M5GF1 — check
Secondary shaft of the M5GF1 gearbox — disassembly and assembly
Differential is a device
Differential — disassembly and assembly
Speedometer drive
Gear shift lever — device
Gear shift cables — device
Gear shift forks (M5GF1) — device
Gear Shift Cables and Lever — Check
Cables and gear shift lever — removal and installation
Troubleshooting issues
Automatic transmission A4AF3
Technical data of the automatic transmission A4AF3
Location of electronic controls
Reading diagnostic trouble codes
Checking the fluid level in the automatic transmission
Checking the locking cable
Testing the joint operation of an automatic transmission and engine on a stationary vehicle (stall test)
Checking the operation of the selector lever
Adjusting the selector lever position indicator switch
Adjusting the forced downshift switch
Adjusting the pressure in the main line
Checking Transmission Fluid Pressure
Adjusting the pressure drop
Location of seals and o-rings
Replacing the drive shaft seal
Location of gearbox components
Gearbox mounting elements
Removal and installation the gearbox
Identification of bearing gaskets and thrust washers of automatic transmission A4AF3
Disassembling the gearbox
Gearbox assembly
Oil pump — device
Oil pump — removal
Oil pump — check
Oil pump — assembly
Differential is a device
Differential — disassembly and assembly
Valve block — device
Valve block — disassembly
Valve block — assembly
Speedometer drive
Selector lever — device
Selector lever — removal
Selector lever — check
Selector lever — adjustment
Automatic transmission F4A42
Technical data of the automatic transmission F4A42
Automatic transmission F4A42 — general information
Location of electronic controls of automatic transmission F4A42
Checking the fluid level in the automatic transmission
Automatic transmission fluid replacement
Gearbox range switch and control cable adjustment
Automatic Transmission Component Check (F4A42)
Testing the joint operation of an automatic transmission and engine on a stationary vehicle (stall test)
Checking Transmission Fluid Pressure
Diagnostic function
Adjusting the axial clearance of the reaction brake
Adjusting the axial clearance of the second gear brake
Adjusting the axial clearance of the low gear and reverse gear brakes
Adjusting the axial clearance of the downshift sun gear
Adjusting the differential preload
Identifying Automatic Transmission Bearing Gaskets and Thrust Washers
Replacing the drive shaft seal — removal and installation
Replacing the gearbox range switch
Replacing the input shaft speed sensor
Replacing the output shaft speed sensor
Replacing the vehicle speed sensor
Removal and installation the gearbox
Gearbox components
Location of gearbox components
Valve block and gearbox attachments — device
Internal components of the gearbox
Disassembling the gearbox
Gearbox assembly
Replacing the oil pump seal
Oil pump — device
Differential is a device
Differential — disassembly and assembly
Valve block — device
Valve block — disassembly and assembly
Downshift clutch — device
Downshift Clutch — Disassembly and Assembly
Overdrive and reverse clutch — device
Overdrive and reverse clutch — disassembly and assembly
Selector lever — device
Selector lever — removal
Selector lever — checking and adjustment
Drive shafts
Technical data of drive shafts
Drive shafts — general information
Drive shaft — device
Drive shaft — removal and installation
Drive shaft — check
Drive shaft repair
Steering knuckle and front wheel hub — device
Front Wheel Steering Knuckle and Hub — Removal and Installation
Front Wheel Steering Knuckle and Hub — Check
Front Wheel Steering Knuckle and Hub — Disassembly and Assembly
Rear axle/rear wheel hub — device
Rear Axle/Rear Wheel Hub — Check
Rear Axle/Rear Wheel Hub — Removal and Installation
Troubleshooting issues
Chassis
Car suspension
Technical data of suspensions
Front suspension — device
Front suspension — general information
Front suspension shock absorber strut — device
Front Suspension Shock Absorber — Check
Front suspension shock absorber strut — disassembly and assembly
Front suspension shock absorber strut — removal and installation
Lower arm of the front suspension — device
Lower control arm front suspension — removal and installation
Front Lower Suspension Arm — Check
Lower control arm front suspension — disassembly
Front stabilizer bar — device
Front stabilizer bar — check
Front Anti-Roll Bar — Removal and Installation
Rear suspension elements
Rear suspension wishbones — device
Rear suspension wishbones — removal and installation
Rear suspension strut — device
Rear suspension strut — check
Rear suspension strut — disassembly and assembly
Rear suspension strut — removal and installation
Rear suspension trailing arms — device
Rear Suspension Trailing Arms — Removal and Installation
Rear stabilizer bar — device
Rear Anti-Roll Bar — Removal and Installation
Rear stabilizer bar — check
Wheels and tires
Checking the vehicle's drift and directional instability
Wheel rotation
Tire wear
Tightening the wheel nuts
Wheel beating
Tire wear diagnostics
Front wheel alignment angles
Troubleshooting suspension problems
Steering
Technical data of steering
Steering — General Information
Checking the steering wheel free play
Checking the front wheel steering angle
Checking the torque of the ball joint pin of the tie rod end
Checking the steering wheel turning force
Checking the return of the steering wheel to its original position
Checking the tension of the power steering pump drive belt
Checking the fluid level
Replacing the fluid in the hydraulic power steering drive
Bleeding the hydraulic power steering system
Checking the fluid pressure in the hydraulic system
Steering column/steering shaft — device
Steering column/steering shaft — check
Steering column/steering shaft — removal and installation
Steering gear — device
Steering gear — removal and installation
Steering gear — disassembly and assembly
Power Steering Hoses — Device
Power steering hoses
Power steering pump — device
Power Steering Pump — Check
Power Steering Pump — Removal and Installation
Power Steering Pump — Disassembly and Assembly
Troubleshooting steering problems
Brake system
Brake system — technical data
Location of brake system components
Brake system — general information
Checking the brake booster
Checking the one-way vacuum valve
Vacuum brake booster
Vacuum brake booster — removal and installation
Brake pipes and hoses — checking
Brake pipes and hoses — replacement
Bleeding the hydraulic brake drive system
Checking and adjusting the brake pedal position
Brake pedal — device
Brake pedal — check
Brake pedal — removal and installation
Front brake caliper
Checking the thickness of the front brake pads
Front Disc Brake Pads — Device
Replacing Front Brake Pads — Removal and Installation
Checking brake pads
Checking the brake disc
Checking the thickness of the brake disc
Master brake cylinder — device
Master Brake Cylinder — Check
Master Brake Cylinder — Removal and Installation
Master Brake Cylinder — Disassembly and Assembly
Pressure regulator
Rear brake caliper — device
Rear Disc Brake Pads — Device
Rear disc brakes
Replacing rear disc brake pads — checking
Replacing rear disc brake pads — removal and installation
Rear drum brakes — device
Rear Drum Brakes — Checking
Replacing rear drum brake shoes — checking
Replacing rear drum brake pads — removal and installation
Parking brake — checking and adjusting
Parking brake — removal and installation
Parking brake — device
Anti-lock Braking System (ABS) — Device
Anti-lock Braking System (ABS) — General Information
Anti-lock Braking System (ABS) — Warning Lights
Hydraulic unit HECU — device
Bleeding the hydraulic brake drive system
HECU Hydraulic Unit — Removal and Installation
Wheel Speed Sensor — Check
Wheel Speed Sensor — Removal
TCS (Traction Control System)
Troubleshooting issues
Body
Body elements
Body — technical data
Body lubrication
Adjusting the bonnet hinges
Hood — device
Hood lock
Trunk lid — device
Trunk lid — removal and installation
Trunk lid — disassembly
Trunk lid — adjustment
Front door — device
Front door — removal and installation
Rear door — device
Rear door — removal and installation
Outside rear view mirror — device
Outside rear view mirror — removal and installation
Outside rear view mirror — disassembly and assembly
Instrument panel — device
Instrument panel — removal and installation
Instrument panel — disassembly and assembly
Ceiling upholstery — device
Headlining — Removal and Installation
Rear shelf — device
Rear shelf — removal and installation
Trunk lining — device
Interior upholstery — device
Trunk trim — removal and installation
Interior trim — removal and installation
Windshield — Removal and Installation
Front bumper — device
Rear bumper — device
Front bumper — removal and installation
Rear bumper — removal and installation
Seats — device
Front seats — removal and installation
Front seats — disassembly and assembly
Rear seat — removal and installation
Seat belts — device
Seat belts — general information
Seat belts — check
Front seat belt — removal and installation
Rear Seat Belt — Removal and Installation
Troubleshooting the bodywork
Air conditioning and heater
Technical data of the air conditioning system
Air conditioning system — general information
Air conditioning system circuit — device
Instructions for use of refrigerant
Notes when replacing air conditioning system components
Connecting the elements of the air conditioning system
Precautions when working with air conditioning system components
Air conditioning system discharge
Pumping atmospheric air out of the air conditioning system
Charging the air conditioning system
Checking the air conditioning system for leaks
Performance testing
Air Conditioning System Diagnostics Using Pressure Gauges
Checking the electromagnetic clutch clearance
Checking the operation of the electromagnetic clutch
Checking and adjusting the tension of the poly V-belt (petrol engine)
Air conditioning compressor lubrication oil
Checking hoses and tubes
Evaporator air filter
Air conditioning compressor — device
Air conditioning compressor — removal and installation
Compressor noise
Fan and condenser relay — device
Capacitor — check
Capacitor — replacement
Condenser Fan — Replacement
Fan and condenser relay — check
Receiver/dryer — check
Receiver/dryer — replacement
Triple pressure sensor
Thermistor — Check
Air temperature sensor
Photo sensor — checking and replacement
Ambient temperature sensor
Temperature control flap drive
Air Quality Sensor (AQS)
Humidity sensor — checking and replacement
Air flow distribution flap drive
Fresh/recirculated air damper actuator
Heater — replacement
RTS heater — characteristics and operation
Heater Fan Unit — Replacement
Heater Fan Motor — Checking and Replacing
Fan Relay — Checking and Replacing
Power transistor — testing and replacement
Fan Resistor — Checking and Replacing
Air Conditioning Control Panel — Replacement
Electrical equipment
Equipment and devices
Electrical equipment — general information
Checking the specific gravity of the electrolyte
Starting system — general information
Audio system — output locations
Starter relay — check
Audio system — general information
Audio system — removal and installation
Speakers — General Information
Electrically powered antenna — testing
Multifunction Switch — Removal
Multi-function switch — check
Sound signal — device
Sound signal — check
Sound signal — adjustment
Engine Compartment Fuse and Relay Box — Removal
Engine Compartment Fuse and Relay Box — Check
Fuse and Relay Box in the Car Interior — Removal
The fuse and relay box in the car interior — device
Car Interior Fuse and Relay Box — Checking
Fuses — General Information
Gauges and indicators — location
Sensors and indicators — check
Checking the Parking Brake Position Switch
Instrument cluster — removal and installation
Outside rear view mirror — removal
Outside rear view mirror — check
Power windows with electric drive — check
Rear window defroster — device
Rear Window Defogger — Check
Windshield wiper — device
Windscreen wiper — removal and installation
Windshield wiper — check
Seat heaters — device
Windshield Washer Motor — Removal and Installation
Checking the operation of the windshield washer — check
Seat Heaters — Check
Headlights — removal and installation
Lighting is a device
Headlight adjustment
Replacing lamps
Ignition Switch — Removal and Installation
Safety system (SRS)
Additional passive safety system
Curtain Pillows — Removal and Installation
Seat Belt Pretensioner — General Information
Seat Belt Pretensioner — Removal and Installation
Disposal of airbags
Troubleshooting the charging system
Troubleshooting the Engine Starting System
Troubleshooting of control and measuring instruments
Troubleshooting the Lighting System
Power devices
Electrical equipment — technical data
General recommendations for troubleshooting
Generators for cars with different types of engines — device
Charging system
Checking the voltage at the battery terminals
Checking the alternator drive belt
Checking the voltage drop on the wire connecting the battery to the generator
Diesel Engine Generator — Device
Checking the current generated by the generator
Checking the generator elements
Adjusting the alternator drive belt tension (petrol engines)
Rechargeable battery
Battery inspection
Starter — device
Checking the starting system
Starter — removal and installation
Disassembly and assembly of starter of gasoline engines
Starter of gasoline engines — device
Diesel engine starter — device
Disassembly and assembly of a diesel engine starter
Checking the starter components
Electrical circuits
Electrical diagram of the starting and charging system
Engine and gearbox management system (2.0L engine)
Engine and transmission management system (1.6L DOHC engine)
Electrical diagram of the diesel engine control unit
Electrical diagram of the cooling system
Wiring diagram of the instrument cluster and indicator lamps
Rear fog lights and headlight range control
Direction indicators and hazard warning lights
Horn, brake lights, reverse light and ECM
Electrical diagram of electric window lifters
Electrically powered mirror wiring diagram
Anti-lock braking system (ABS) and traction control system (TCS)
Optima 1 (2000-2005)
Power unit
2.0 liter engines DOHC
General information about 2.0 liter engines
Technical data of 2.0 liter engines
Checking the compression in the cylinders
Timing belt — removal and installation
Checking and adjusting the tension of poly V-belts
Adjusting the alternator drive belt tension
Adjusting the tension of the power steering and air conditioning drive belt
Checking hydraulic valve clearance compensators
Cylinder head and valves — removal and installation
Engine Mounts — Removal and Installation
Removal and installation of engine and gearbox
Camshafts and rocker arms — removal and installation
Front cover, oil pump and balance shafts
Piston and connecting rod — removal and installation
Crankshaft and flywheel — removal and installation
Cylinder Block — Checking and Assembly
Air Filter (except V6) — Removal and Installation
Intake manifold — removal and installation
Exhaust manifold — check
Silencers — removal and installation
Troubleshooting issues
2.5 liter engines V6
General information about 2.5 liter engines
Technical data of 2.5 liter engines
Checking the compression in the cylinders
Adjusting valve clearances
Timing belt — removal and installation
Checking and adjusting the tension of poly V-belts
Tightening the cylinder head bolts
Cylinder head, valves and valve springs
Engine Mounts — Removal and Inspection
Removal and installation of engine and gearbox
Camshafts — Removal and Installation
Hydraulic valve clearance compensators
Pistons and connecting rods — removal and installation
Crankshaft — removal and installation
Cylinder block — disassembly and assembly
Air filter — removal and installation
Expansion chamber — removal and installation
Intake manifold — removal and installation
Exhaust manifold — check
Silencers — removal and installation
Troubleshooting issues
Lubrication system
Description of the lubrication system
Technical data of the lubrication system
Selecting motor oil
Checking the engine oil level 2.0L DOHC
Checking the engine oil level V6 2.5L
Engine Oil Change 2.0L DOHC
Engine Oil Change V6 2.5L
Oil Filter Replacement 2.0L DOHC
Front Cover & Oil Pump 2.0L DOHC
Oil Pump and Oil Pan V6 2.5L
Cooling system
Description of the cooling system
Technical data of the cooling system
Cooling liquid
Checking the tightness of the cooling system
Pressure testing the radiator cap
Checking the density of the coolant
Radiator — removal and installation
Radiator Fan — Removal and Installation
DOHC Engine Water Pump — Removal and Installation
V6 Engine Water Pump — Removal and Installation
SOHC Engine Thermostat — Removal and Installation
V6 Engine Thermostat — Removal and Installation
Engine cooling system tubes and hoses
Decreased toxicity
Description of the toxicity control and reduction system
Crankcase ventilation system (PCV)
Checking the PCV valve
Fuel vapor recovery system
Canister with activated carbon
Electromagnetic valve for cleaning activated carbon canister
Fuel filler cap
Exhaust system of vehicles with catalytic converter
MFI fuel injection system
Troubleshooting issues
Fuel system
Technical data of the fuel system
Multi-port fuel injection (MFI) system
MFI injection system checks
Malfunction Indicator Lamp (MIL)
Diagnostic Trouble Codes
Coolant Temperature (ECT) Sensor
Manifold Absolute Pressure (MAF) Sensor with IAT Sensor
Mass Air Flow (MAF) Meter
Engine Intake Air Temperature (IAT) Sensor
Throttle Position (TP) Sensor — Check
Engine idling speed Control Modulator
Heated Oxygen Sensor (HO2S)
Camshaft Position (CMP) Sensor
Crankshaft Position Sensor (CKP)
Fuel injectors — checking
Fuel Evaporative Emission System Solenoid Valve
Knock sensor — check
Idle speed CO adjustment potentiometer (leaded petrol only)
Power Steering (PSP) Sensor [2.0L DOHC]
Throttle Position (TP) Sensor — Adjustment
Fuel Level Sensor Replacement (2.0L DOHC)
Checking the fuel pump (2.0L DOHC)
Checking the activated carbon canister cleaning channel (2.0L DOHC)
Checking the pressure generated by the pump (2.0L DOHC)
Fuel Filter Replacement (2.0L DOHC)
Cleaning the throttle assembly
Checking the cleaning channel of the activated carbon canister (2.5 l V6)
Replacing the fuel level sensor (2.5L V6)
Checking the fuel pump (2.5L V6)
Checking the pressure generated by the pump (2.5L V6)
Fuel Filter Replacement (2.5L V6)
Throttle Position (TP) Sensor Adjustment (2.5L V6)
Accelerator pedal and cable — removal and installation
Fuel line — removal and installation
Fuel lines and fuel vapor recovery system lines
Fuel tank — removal and installation
Troubleshooting Methodology
Troubleshooting issues
Ignition system
Technical data of the ignition system
General information about the ignition system
Ignition coil for 2.5L V6 engine
Ignition coil for 2.0L engine
Ignition switch — removal and inspection
Spark plugs — checking
High voltage wires — checking
Installing High Voltage Wires (V6 Engine)
Checking spark plugs
Troubleshooting the ignition system
Transmission
Clutch
Clutch technical data
Bleeding the hydraulic clutch drive system
Free play of the clutch pedal
Clutch pedal — removal and installation
Master cylinder, pipe and clutch hose
Clutch Master Cylinder — Disassembly and Assembly
Clutch slave cylinder — disassembly and assembly
Clutch housing and discs — removal and installation
Troubleshooting issues
Mechanical gearbox
Technical data of manual transmission
Checking the oil level
Transmission oil change
Replacing the drive shaft oil seal ring
Gear Shift Lever — Removal and Installation
Removal and installation the gearbox
Gearbox shafts — removal and installation
Gearbox Input Shaft — Disassembly and Assembly
Driven shaft of the gearbox — disassembly and assembly
Troubleshooting issues
Automatic gearbox
Technical data of automatic transmission
Checking the fluid level in the automatic transmission
Automatic transmission fluid replacement
Replacing the oil filter
Checking the transmission range switch conductivity
Checking the conductivity of the sport mode switch (F4A42–2 2.0 and 2.5L)
Gearbox range switch and control cable adjustment
Checking Automatic Transmission Components
Testing the joint operation of an automatic transmission and engine on a stationary vehicle (stall test)
Diagnostic Trouble Codes
Automatic transmission diagnostic function
Diagnostic Codes Inspection Chart
Inspection chart for fault detection
Adjusting the axial clearance of the reaction brake
Adjusting the axial clearance of the second gear brake
Adjusting the axial clearance of the low gear and reverse gear brakes
Adjusting the axial clearance of the downshift sun gear
Adjusting the differential preload
Elements of the transmission control system
Removal and installation the gearbox
Gearbox repair
Drive shafts and axles
Description of drive shafts and axles
Technical data of drive shafts and axles
Drive shaft — removal and installation
Drive shaft with ball type and Birfield type CV joints
Drive shaft with Birfield CV joints (B)
Central bearing and inner drive shaft
Front wheel steering knuckle and hub
Rear axle — removal and installation
Troubleshooting issues
Chassis
Car suspension
Technical data of suspension
Front suspension strut — removal and installation
Lower control arm front suspension — removal and installation
Upper control arm front suspension
Rear shock absorber — removal and installation
Replacing the upper arm of the rear suspension
Replacing the rear suspension trailing arm
Replacing the rear suspension support arm
Replacing the rear suspension center arm
Replacing the rear anti-roll bar link
Front wheel alignment angles
Rear wheel alignment adjustment
Rear wheel alignment
Tire wear
Wheel beating
Troubleshooting issues
Steering
Technical data of steering
Checking the steering wheel free play
Checking the front wheel steering angle
Checking the return of the steering wheel to its original position
Checking the torque of the ball joint of the steering rod end
Checking the fluid level
Replacing the fluid in the hydraulic drive of the power steering
Bleeding the hydraulic power steering system
Checking the tension of the power steering pump drive belt
Checking the fluid pressure in the hydraulic system
Steering column / steering shaft — removal and installation
Steering gear for cars with power steering
Power steering pump — removal and installation
Power Steering Hoses — Removal
Electronic power steering system
Troubleshooting steering problems
EPS Steering Troubleshooting
Brake system
Technical data of the brake system
Anti-lock braking system
Checking and adjusting the brake pedal position
Checking the brake booster
Bleeding the hydraulic brake drive system
Bleeding the hydraulic brake system using a scanner
Adjusting the parking brake stroke
Brake pedal — removal and installation
Master Brake Cylinder — Removal and Installation
Vacuum brake booster — removal and installation
Brake pipes and hoses
Pressure regulator
Replacing the front brake pads
Front Brake Caliper — Removal and Installation
Rear Drum Brakes — Removal and Installation
Replacing the working brake cylinder
Rear disc brakes
Support — disassembly and assembly
Hydraulic unit HECU (Hydraulic and Electronic Control Unit)
Wheel speed sensor
Parking brake — removal and installation
Troubleshooting issues
Body
Exterior
Tightening torques for threaded connections
Front bumper — removal and installation
Rear bumper — removal and installation
Hood — removal and installation
Headlight — removal and installation
Front door and locks
Window lifters — removal and installation
Moisture-proof door seal
Door hinges and door lock strike plate
Rear door — removal and installation
Trunk lid — removal and installation
Trunk lid lock — removal and installation
Trunk lid trim — removal and installation
Interior
Instrument cluster — removal and installation
Instrument cluster repair
Switches — removal and installation
Instrument panel — removal and installation
Heating and ventilation control panel
Air ducts — removal and installation
Floor air ducts — removal and installation
Front seats — removal and installation
Front seat back — removal and installation
Front seat cushion — removal and installation
Rear seat — removal and installation
Seat belts — check
Front seat buckle — removal and installation
Front Shoulder Seat Belt — Removal and Installation
Rear seat safety belts
Rear seat belt buckle
Shoulder rear seat belt
Front Pillar Upper Trim — Removal and Installation
Lower B-Pillar Trim — Removal and Installation
Upper B-Pillar Trim — Removal and Installation
Air conditioning system
Technical data of the air conditioning system
Air conditioning system maintenance
Notes when replacing air conditioning system components
Connecting the elements of the air conditioning system
Connecting elements with a guide pin
Installation of pressure gauges to measure pressure
Pumping atmospheric air out of the air conditioning system
Connecting the outlet valve to the refrigerant cylinder
Charging the air conditioning system
Air Conditioning Compressor Lubricant Oil
Checking hoses and tubes
Compressor noise
Checking and adjusting the tension of poly V-belts
Performance testing
Triple pressure sensor
Checking the condenser fan relay
Checking the air conditioner switch
Checking the mode switch
Checking the fresh/recirculated air switch
Air Conditioning Compressor — Removal and Installation
Clutch bushing and air conditioning compressor pulley
Clutch Excitation Coil — Removal and Installation
Fan and condenser — check
Checking the fan motor
Troubleshooting issues
Checking the air conditioning system relay and condenser fan
Checking the heater fan relay
Electrical equipment
Equipment and devices
Antenna — removal and installation
Troubleshooting issues
Installing the transceiver
Removal and installation the remote control
Removal and installation the audio unit
Multifunctional switch
Fuses — Description and Replacement
Instrument cluster — check
Parking brake position switch
Rear Window Defogger — Checking and Repairing
Airbags (SRS)
SRS Element Warning Labels
Driver's airbag and coil wire
Front passenger airbag
Power devices
Technical data of power electrical equipment
Charging system — description
Checking the voltage drop on the wire connecting the battery to the generator (V6 engine)
Checking the current generated by the generator
Checking the generated voltage
Checking the voltage drop on the wire connecting the battery to the generator (2.0L engine)
Checking the current generated by the generator (2.0L engine)
Checking the generated voltage (2.0L engine)
Generator — disassembly, inspection and assembly
Battery — Description
Battery inspection
Launch system — check
Removal and installation the starter
Troubleshooting the charging system
Troubleshooting the Engine Starting System
Lighting and signaling
Sound signal — removal and installation
Audio signal relay
External lighting fixtures
High Brake Light — Removal and Installation
Outer section of rear combination light
Inner section of rear combination light
Replacing headlight bulbs
Replacing the high-mounted brake light bulbs
Replacing license plate light bulbs
Replacing the bulbs of the outer section of the rear combination light
Replacing the inner section bulbs of the rear combination light
Windshield wipers and washers
Windscreen Wiper and Washer — Description
Windshield Washer Hoses
Windshield washer motor
Sprayers — Removal and Installation
Windscreen wiper arm — removal and installation
Replacing windshield wiper blades
Windscreen wiper rods — removal and installation
Windscreen wiper motor — removal and installation
Windshield Wiper and Washer — Removal and Inspection
Electrical circuits
Electrical diagram of the starting system
Electrical diagram of the charging system
Engine Control Unit (ECU) Wiring Diagram
Engine control unit wiring diagram
Electrical diagram of the engine control unit, transmission (ECU/TCU)
Electrical diagram of the cooling system
Wiring diagram of the anti-lock braking system (ABS)
Wiring diagram of windshield wiper and windshield washer
Headlight washer wiring diagram
Headlights Wiring Diagram
Wiring diagram of turn signals and hazard warning lights
Brake and reverse lights wiring diagram
Electrical diagram of ventilation and air conditioning with manual control
Electrical diagram of electric window lifters
Electrical Wiring Diagram for Power Mirrors
Electrical Wiring Diagram for Electric Driver's Seat
Electrical Wiring Diagram for Power Passenger Seat
Cruise control system wiring diagram
Rio 1 (2000-2005)
General information
User manual
Brief introduction to the car
Car keys
Door locks
Electronic immobilizer
Electric windows
Seats — adjustment
Front seat belts
Rear seat belts
Airbags
Components of the airbag system
Airbag warning light
Trunk door (5-door model)
Trunk lid
Luggage compartment lamp
Hood — opening and closing
Fuel filler flap
Steering wheel
Rear view mirrors
Interior lighting
Salon equipment
Digital watch
Trunk curtain
Power socket
Radio receiver antenna
Sunroof
Sunglasses holder
Cargo luggage net
Roof rack
Ignition switch
Starting the engine
Manual transmission
Automatic transmission
Brake system
Parking brake
Hydraulic power steering
Adjustable steering column
Instrument cluster
Headlights on and off
Direction indicators
Headlight corrector
Daytime running light
Rear fog lights
Windscreen wipers and washers
Rear window defroster
Outside rear view mirror heater
Heating and ventilation system
Operation of the heating and ventilation system
Information on signs
Emergency light signaling
Jump starting from another car's battery
Fuses — location and description
Memory fuse
Towing a car
Windscreen wiper blades
Replacing lamps
Car exterior care
Vehicle maintenance
Power unit
Engine repair
Engine technical data
Checking the compression in the cylinders
Removal and installation the engine
Camshafts — Removal, Inspection and Installation
Pistons and connecting rods — removal, inspection and installation
Crankshaft — Removal and Inspection
Checking connecting rod and main bearings
Air Filter (ACL) — Removal and Inspection
Accelerator cable — adjustment
Cylinder head — removal, inspection and installation
Checking the valves
Checking the valve seat
Checking the valve spring
Timing Belt — Removal, Checking and Installation
Exhaust system — removal and installation
Anti-lock braking system (ABS)
Lubrication system
General description of the lubrication system
Technical data of the lubrication system
Checking engine oil pressure
Engine oil change
Replacing the oil filter
Oil pump — removal, inspection and installation
Cooling system
General description of the cooling system
Technical data of the cooling system
Cooling liquid-check
Replacing the coolant
Water Pump — Removal, Checking and Installation
Radiator — removal, inspection and installation
Checking the tightness of the cooling system
Radiator Fan Motor — Removal and Installation
Checking the radiator cap
Back pressure valve
Thermostat — Removal, Checking and Installation
Fuel system
Technical data of the fuel system
Fuel system components
Ignition timing angle
Idle speed
Air flow meter sensor
Knock sensor — removal, testing and installation
Throttle Position Sensor
Checking the main relay
Checking the fuel pump relay
Checking the voltage of the front and rear heated oxygen sensors
Checking the front and rear heated oxygen sensors
Relieving pressure in the fuel system
Fuel lines — disconnection
Fuel system activation
Checking the residual pressure in the fuel system
Checking fuel lines
Checking fuel injectors
Quick release couplings
Fuel pump — check
Fuel tank — removal
Checking the crankcase ventilation system (PCV)
Checking the fuel vapor recovery system
Checking the fuel vapor recovery system valve
Checking the canister closing valve
Ignition system
General description of the ignition system
Technical data of the ignition system
Operation of the ignition system
Ignition System Components
Ignition timing angle
Ignition coil — removal, inspection and installation
Spark plugs — removal, inspection and installation
High voltage wires — checking
Transmission
Clutch
Description and design of the clutch
Clutch technical data
Adjusting the clutch pedal
Clutch pedal installation height
Clutch disc — removal
Checking the clutch housing with pressure plate
Clutch disc — inspection and installation
Clutch housing and pressure plate — removal, inspection and installation
Replacing the center bearing
Clutch pedal — removal and installation
Clutch cable — removal, inspection and installation
Clutch release bearing — removal, inspection and installation
Clutch release fork release lever
Mechanical gearbox
Mechanical gearbox device
Technical data of manual transmission
Checking the oil level
Engine oil change
Replacing the oil seal ring
Removal and installation the gearbox
Disassembly, inspection and assembly of the gearbox
Clutch housing and transmission housing components
Primary shaft of the gearbox
Secondary shaft of the gearbox
Selection of adjustment shims
Differential — removal, inspection and installation
Gear shift mechanism
Automatic gearbox
Automatic transmission device F4E–K
Technical data of the automatic transmission F4E–K
Checking the operation and adjusting the position of the selector lever
Testing the joint operation of an automatic transmission and engine on a stationary vehicle (stall test)
Time delay testing (Lag test)
Checking Transmission Fluid Pressure
Checking the level and replacing the fluid in the automatic transmission
Automatic Transmission Fluid Replacement Procedure
Automatic transmission fluid leaks
Replacing oil seal rings
Removal and installation of automatic transmission
Automatic transmission repair
Automatic transmission fluid cooling radiator
Valve block — removal and installation
Control valve body — removal and installation
Oil pump — disassembly, inspection and assembly
Checking the resistance of the turbine wheel input shaft speed sensor
Checking the resistance of the speed sensor
Gearbox operating mode switch OD
Gearbox range switch
Automatic transmission temperature sensor
Solenoid valves — testing
Linear Solenoid Valve — Check
Selector lever — removal and installation
Selector lever repair
Checking the operation of the selector lever locking mechanism
Drive shafts and axles
The device of axles and drive shafts
Technical data of axles and drive shafts
Checking the condition of the protective cover
Checking the reliability of the spline connection
Replacing the drive shaft
Drive shaft repair
Front axle design
Checking the play of the front wheel bearings
Front wheel steering knuckle and hub
Front wheel hub bearing
Adjusting the tension of the front wheel hub bearings
Rear Axle — Removal, Checking and Installation
Adjusting the tension of the rear wheel bearings
Chassis
Car suspension
The device of the front and rear suspension
Technical data of suspension
Checking the front suspension components
Checking and adjusting wheel alignment angles
Front wheel alignment
Front suspension strut — removal, inspection and installation
Lower Front Suspension Arm — Removal, Inspection and Installation
Front stabilizer bar
Rear suspension beam — removal, inspection and installation
Wheels and tires
General description of wheels and tires
Technical data of wheels and tires
Recommendations for tire replacement
Checking air pressure and tire condition
Wheel beating
Wheel rotation
Wheel balancing
Steering
Technical data of steering
Steering without hydraulic power steering
Checking the steering without hydraulic booster
Steering column without hydraulic booster
Hydraulic power steering
Checking the fluid pressure in the hydraulic system
Checking the steering wheel turning force
Checking the fluid level
Bleeding the hydraulic power steering system
Power steering pump drive belt
Power steering gear
Power Steering Pump — Removal, Checking and Installation
Brake system
The structure of the braking system
Technical data of the brake system
Checking the brake booster using instruments
One-way vacuum valve
Vacuum brake booster — removal and installation
Bleeding the hydraulic brake drive system
Checking brake pipes
Checking and replacing brake hoses
Brake pedal — removal and installation
Brake pedal installation height
Free travel of the brake pedal
Distance of brake pedal from floor
Replacing the front brake pads
Replacing brake pads on rear drum brakes
Front Brake Caliper Repair
Repair of the working brake cylinder
Master Brake Cylinder — Removal and Installation
Pressure limiter — removal, inspection and installation
Parking brake — removal and installation
ABS control unit
Hydraulic Control Unit (HCU) — Removal and Installation
Front wheel speed sensor
Rear wheel speed sensor
Toothed rotor of the wheel speed sensor
Front Wheel Speed Sensor Rotor
Rear rotor wheel speed sensor
Basic inspection of the brake system
Checking the functionality of the brake system
Body
Exterior
Tightening torques for threaded connections
Hood — removal and installation
Trunk lid — removal and installation
Trunk Lid Hinge — Removal and Installation
Tailgate — Removal and Installation
Gas-filled tailgate support strut
Tailgate Lock — Removal and Installation
External handle of the luggage compartment door
Front door — removal, installation and adjustment
Door moisture seal — removal and installation
Rear door — removal and installation
Rear wheel arch trim for four-door vehicles
Rear wheel arch trim for five-door vehicles
Front bumper — removal, inspection and installation
Rear bumper — removal, inspection and installation
Distances for checking distances between individual points of the car body
Actual distances for checking distances between individual points of the car body
Interior
Instrument panel — removal and installation
Ceiling — removal and installation
Side trim of the trunk of five-door cars
Rear Trunk Trim — Removal and Installation
Upper trim of the front pillar — removal and installation
Lower center pillar trim — removal and installation
Upper trim of the central pillar — removal and installation
Rear pillar trim for four-door vehicles
Rear pillar trim for five-door vehicles
Front door trim — removal and installation
Front door sill trim — removal and installation
Rear Door Trim — Removal and Installation
Tailgate Trim — Removal and Installation
Rear door sill trim — removal and installation
Rear shelf — removal and installation
Front seats — removal, inspection and installation
Front Seat Back Upholstery — Removal and Installation
Front Seat Cushion Upholstery — Removal and Installation
Headrest — removal and installation
Front Seat Folding Hinge — Removal and Installation
Rear seat — removal and installation
Seat belts — removal, inspection and installation
Rear Seat Belts — Removal and Installation
Rear seat belt mounting bracket
Air conditioning system
Description of the air conditioning system
Technical data of the air conditioning system
Air conditioning system circuit
Notes when replacing air conditioning system components
Connecting the elements of the air conditioning system
Precautionary measures
Performance testing
Air conditioning system diagnostics using pressure gauges
Checking the air conditioning compressor clutch clearance
Checking the air conditioning compressor clutch
Air Conditioning Compressor Lubricant Oil
Checking the level and adding oil to the air conditioning compressor
Evaporator Air Filter — Removal
Dual pressure sensor
Air Conditioning Compressor — Removal and Installation
Checking the capacitor
Checking the condenser fan
Checking the dryer receiver
Checking the thermostatic sensor (thermistor)
Checking the fan motor
Checking the Fan Motor Resistor Block
Switch for supplying air into the car interior
Air conditioning control panel
Electrical equipment
Equipment and devices
Description of electrical equipment
Technical data of electrical equipment
Description of electrical circuits
Multifunction switch — removal and installation
Sound signal — check
Fuse and relay box installed in the passenger compartment of the vehicle
Checking the door lock actuator relay
Checking the switch for adjusting the position of the outside rearview mirror
Checking the position actuator of the outside rearview mirror
Checking the window lift motor
Checking the rear window defroster
Repair of the heater conductive strip
Windshield wiper motor
Windscreen washers — checking and adjustment
Headlight adjustment
Adjusting the fog lights
Airbags (SRS)
Warning labels for airbags
Driver's airbag and coil wire
Checking the airbag
Checking the spiral wire (spring)
Front passenger airbag
Power devices
General description of the generator
Checking the generator
Alternator Drive Belt — Checking Tension
Removal, repair and installation of the generator
General description of the battery
Normal charging of the battery
Fast charging of the battery
Checking the battery
Checking the electrolyte level in the battery
Checking the density of electrolyte in the battery
Checking battery voltage
Checking battery voltage under load
Checking the current consumed from the battery when the ignition is off
Checking the voltage drop at the battery terminal connections
General description of the starter
Checking by turning the crankshaft of a cold engine
Checking the electrical circuit of the traction relay
Checking the traction relay
Checking the starter brushes and brush holder
Checking the stator coils
Checking the starter rotor
Removal and installation the starter
Starter repair
Electrical circuits
Electrical diagram of the starting and charging system
Engine control unit wiring diagram
Electrical diagram of the cooling system
Wiring diagram of the instrument cluster and indicator lamps
Wiring diagram of windshield wipers and washers
Front Lighting Wiring Diagram (with Airbag)
Rear Light Wiring Diagram
Headlight Wiring Diagram (DRL)
Front fog lights wiring diagram
Electrical diagram of rear fog lights, headlight beam adjuster (HLLD)
Electrical diagram of the sound signal and emergency light signaling unit
Wiring diagram of reverse and brake light lamps
Air conditioning system wiring diagram
Electrical diagram of the ECAT indicator system
Electrical diagram of the ETWIS electronic control unit
Electrical diagram of the receiver, alarm relay and sound signal
Wiring diagram of backlight lamps
Radio receiver electrical circuit
Electrical diagram of window lifters (2 doors)
Electrical diagram of window lifters (4 doors)
Central locking wiring diagram
Electrical Wiring Diagram for Electrically Operated Outside Rearview Mirror
Wiring diagram for interior lighting and sunroof
Wiring diagram of the anti-lock braking system (ABS)
Seat Heater Wiring Diagram
Wiring diagram of airbags (without side airbags)
Wiring diagram of airbags (with side airbags)
Electrical diagram of the rear window heater and luggage compartment lighting
Electrical diagram of the socket, cigarette lighter and immobilizer
Wiring diagram diagnosis connector, OBD-II check connector
Rio 2 (2005-2011)
General information
User manual
Vehicle identification
Engine specifications
Abbreviations and symbols
General repair instructions
Garage jack and lift paw mounting points
Door lock
Anti-theft system (modifications)
Odometer and trip meters
Trip computer (modifications)
Tachometer — General Information
Fuel quantity indicator
Coolant temperature gauge (modifications)
Instrument cluster indicators
Watches — General Information
Window lifters — general information
Light signaling on the car
Adjusting the brightness of the instrument cluster illumination (modifications)
Hood — General Information
Rear door (hatchback)
Trunk lid (sedan)
Fuel tank filler flap
Windscreen wiper and washer control
Adjusting the position of the steering wheel
Mirror control
Rear window defroster
Seats — General Information
Front seat heater
Seat belts
Precautions when operating vehicles equipped with the SRS system
Hatch (modifications)
Heater and air conditioner control
Radio tape recorder — main points of operation
Cigarette lighter — general information
Connector for connecting additional equipment
Parking brake
Driving a car with automatic transmission
Driving a car with a manual transmission
Anti-lock braking system (ABS)
Tips for driving in different conditions
Towing a car
Starting the engine
Engine malfunctions while driving
Spare tire, jack and tools
Jacking up a car
Wheel replacement
Replacement with «dokatka»
Recommendations for choosing tires
Checking tire pressure and condition
Tire replacement
Features of using aluminum wheels
Replacement of wheel disks
Brake pad wear indicators
Catalytic converter and exhaust system
Fuses — General Information
Replacing lamps
Maintenance
Service intervals
Maintenance intervals
Rules for performing work in the engine compartment
Engine oil and filter
Cooling liquid
Checking and replacing the air filter
Replacing the fuel filter
Rechargeable battery
Checking the idle speed
Spark plugs and high-voltage wires
Checking the ignition timing angle
Checking the end of compression stroke pressure (compression check)
Checking and adjusting drive belts of attachments
Timing belt
Power steering working fluid
Checking the brake fluid level
Checking the clutch release fluid level (manual transmission models)
Automatic transmission fluid
Oil in manual transmission
Brake pads
Checking the efficiency of the parking brake
Checking the drive shaft covers
Checking the tie rod end boot
Cabin filter replacement (modifications)
Air conditioning system refill
Checking the fluid level in the windshield washer reservoir
Additional checks
Catalog numbers of original spare parts
Power unit
Engine repair
General information about the mechanical part of the G4EE (1.4 l) and G4ED (1.6 l) engines
Valve clearances for G4EE (1.4 l) and G4ED (1.6 l) engines
Power unit — removal and installation
Timing Belt — Removal
Timing Belt — Check
Timing Belt — Installation
Removal and installation intake and exhaust manifolds
Cylinder head — removal
Cylinder head — installation
Removal and installation the cylinder block
Cylinder block — preliminary disassembly and final assembly
Disassembly and assembly of the cylinder head
Cylinder head — disassembly
Cylinder head — inspection, cleaning and repair
Cylinder Head — CVVT Sprocket Check
Cylinder head — assembly
Cylinder Block — Disassembly
Disassembly and assembly of the cylinder block
Disassembling the piston-connecting rod assembly
Cylinder Block — Check
Checking the condition of the piston and connecting rod
Cylinder boring
Cylinder block — assembly and installation
Cooling system
General information
Removal and installation the thermostat and coolant pump
Checks and adjustments on the car
Coolant pump
Thermostat — removal and installation, inspection
Removal and installation the radiator and fan
Radiator — removal
Radiator — check
Lubrication system
General information about the lubrication system
Oil pan — removal and installation
Oil pump — removal and installation
Oil pump — disassembly and assembly
Oil pump — check
Replacing the front crankshaft oil seal
Fuel injection system
General rules when working with an electronic control system
Fuel injection system diagnostics — general information
Reading fault codes
Explanations on the operation of the system in emergency mode
Checking signals at the terminals of the electronic control unit
Testing with an oscilloscope
Precautions when working with the fuel system
Checking fuel pressure
Injectors — General Information
Fuel pump — removal and installation
Fuel tank — device
Fuel tank — removal
Intake Air Temperature Sensor
Manifold Absolute Pressure Sensor
Coolant temperature sensor
CWT System Valve (G4ED) — Check
Throttle Position Sensor
Location of fuel injection system components
Oxygen sensor of the electronic engine management system
Knock sensor of the electronic engine management system
Ignition system
Starting and charging system
Starting System Technical Data Table
Troubleshooting the starting system by their symptoms
General information about the launch system
Checking and adjusting the starter
Starter — removal and installation
Disassembling and assembling the starter
Cleaning starter parts
Checking the starter
Checking the starter relay
Troubleshooting the charging system by their symptoms
General information about the charging system
Precautions for servicing the charging system
Checking the charging system
Generator — removal and installation
Generator — disassembly and assembly
Generator — check
Transmission
Clutch and drive shafts
Troubleshooting clutch faults by their symptoms
Bleeding the clutch hydraulic drive
Clutch — device
Clutch pedal — checking and adjustment
Clutch pedal — device
Clutch pedal — removal and installation
Clutch master cylinder — removal and installation
Clutch Master Cylinder — Check
Clutch master cylinder — device
Clutch hydraulic slave cylinder — removal and installation
Clutch slave cylinder — check
Clutch housing and driven disc — removal
Clutch hydraulic drive slave cylinder — device
Clutch housing and driven disc — inspection
Clutch housing and driven disc — installation
Main technical data of the clutch
Drive shaft — device
Drive shafts — removal
Drive shafts — check
Drive shafts — device
Main technical data of drive shafts
Mechanical gearbox
Checking and replacing oil in manual transmission
Replacing the manual transmission drive shaft seal
Technical characteristics of manual transmission
Manual gearbox M5CF1, M5CF1-1 — removal and installation
Disassembly and assembly of a manual gearbox
Manual transmission — device
Input and output shafts of manual transmission
Automatic gearbox
General description of automatic transmission
Technical characteristics of automatic transmission
Automatic transmission A4AF3 — device
Preliminary operations for checking the condition of the automatic transmission
Automatic transmission diagnostics
Guidelines for troubleshooting automatic transmission faults based on their symptoms
Troubleshooting automatic transmissions by their signs
Checking the automatic transmission torque converter on a fully braked vehicle (stall test)
Automatic transmission hydraulic test
Automatic transmission road test
Checking automatic transmission components
Automatic transmission control mechanism — removal and installation
Gearbox control mechanism — device
Automatic transmission selector — device
Gearbox assembly — removal
Gearbox assembly — installation
Chassis
Suspension and wheels
Checking tires and wheels
Checking and adjusting the front wheel alignment angles
Checking the rear wheel alignment angles
Front wheel hub — device
Front Wheel Hub — Removal and Installation
Front wheel hub — disassembly
Front Wheel Hub — Check
Front Wheel Hub — Assembly
Front suspension strut — device
Front Suspension Strut — Removal
Front Suspension Strut — Check
Front suspension strut — disassembly and assembly
Front Suspension Strut — Installation
Lower arm of the front suspension — device
Lower control arm front suspension — removal and installation
Anti-roll bar — device
Anti-roll bar — removal and installation
Rear wheel hub — device
Rear wheel hub — removal and installation
Rear shock absorber — device
Rear shock absorber — removal and installation
Rear suspension spring — device
Rear suspension beam — device
Rear suspension spring — removal and installation
Rear suspension beam — removal and installation
Main technical data of the suspension
Tightening torques for threaded connections
Steering
Steering — Preliminary Checks
Steering column
Steering gear — device
Steering gear — removal and installation
Steering gear — check
Replacing steering rods of the steering mechanism
Power steering pump (models with power steering) — removal and installation
Electric Power Steering (EPS)
Brake system
Troubleshooting by their symptoms
Brake system — device
Checking and adjusting the brake pedal position
Checking the brake light switch
Checking the operation of the brake booster
Checking the operation of the brake booster check valve
Checking brake pads
Bleeding the brake system
Brake pedal — device
Brake pedal — removal and installation
General view of the vacuum booster and master brake cylinder for various modifications
Brake booster — removal
Vacuum brake booster — installation
Master Brake Cylinder — Removal
Master Brake Cylinder — Disassembly
Master Brake Cylinder — Check
Master Brake Cylinder — Assembly
Master Brake Cylinder — Installation
Rear brake pressure regulator (models without ABS)
Brake system lines — device
Brake system lines — removal and installation
Removal and installation the front disc brake
Disassembling and assembling the front disc brake
Checking the front disc brake pads
Removal the rear disc brake pads
Disassembling and assembling the rear disc brake
Rear Disc Brakes — Checking
Rear Drum Brakes — Removal
Rear Drum Brakes — Checking
Rear Drum Brakes — Installation
Parking brake — device
Parking brake — checks and adjustments
Parking brake mechanism — removal
Parking brake mechanism — installation
Main technical data of the brake system
Tightening torques for threaded connections
General information about the anti-lock braking system (ABS) and electronic brake-force distribution (EBD)
ABS system — device and hydraulic diagram
Troubleshooting Anti-lock Brake System (ABS)
Electronic ABS control unit and pressure modulator — removal and installation
Front Wheel Speed Sensor — Removal and Installation
Electronic ABS control unit and modulator — device
Wheel speed sensors — device
Rear Wheel Speed Sensor — Removal and Installation
ESP system — device
Hydraulic diagram of ABS/ESP systems
General information about the Electronic Stability Program (ESP)
Troubleshooting Electronic Stability Program (ESP)
ESP system fault codes
Multi-axis acceleration sensor
ESP switch
Brake fluid pressure sensor
ESP electronic control unit connector
Steering wheel position sensor
ESP electronic control unit and modulator
Wheel speed sensors
Body
Exterior
Search for body faults by their signs
Removal and installation the front bumper
Removal and installation the rear bumper
Removal and installation the hood
Adjusting the hood
Removal and installation bonnet sound insulation
Removal and installation the hood seal
Removal and installation the hood lock drive lever
Removal and installation the hood lock
Removal and installation the hood ventilation grille
Front wing — removal and installation
Removal and installation mudguards
Removal and installation side molding
Removal and installation the trunk lid
Adjusting the trunk lid
Removal and installation the trunk lid lock
Removal and installation the trunk lid opening lever
Removal and installation the trunk lid lock cylinder
Removal and installation the trunk lid opening seal
Fuel tank filler flap
Roof Finishing — Removal and Installation
Adjusting the hatch
Removal and installation sunroof glass
Removal and installation the sunroof drive motor and controller
Removal and installation the sunroof assembly
Removal and installation the sunroof curtain and water drainage channel
Removal and installation the sunroof deflector
Removal and installation the guide assembly
Dismantling the hatch
Initialization of the sunroof drive motor
Windshield — Removal
Windshield — installation
Interior
Center console — device
Center console — removal and installation
Instrument panel — device
Removal and installation the instrument cluster
Instrument panel trim
Removal and installation the air conditioning and heating control panel
Removal and installation the radio
Removal and installation the glove box
Removal and installation side deflectors
Removal and installation steering column covers
Removal and installation the instrument panel and instrument panel amplifier
Interior trim — removal and installation
Trunk trim — removal and installation
Rear Shelf Trim — Removal and Installation
Side and interior rear view mirrors — removal and installation
Removal and installation the front seat
Removal and installation the rear seat
Seat belts
Doors and windows
Front door — device
Disassembling the front door
Removal and installation the front door trim panel
Removal and installation front door glass
Removal and installation the internal front door opening handle
Removal and installation the front door speaker
Removal and installation the front door window lift mechanism
Removal and installation the front door lock
Removal and installation the outer front door opening handle
Removal and installation the outer seal of the front door glass
Removal and installation the front door glass guide bracket
Adjusting the position of the front door glass
Adjusting the position of the front door
Adjusting the front door lock bracket
Removal and installation the rear door trim panel
Rear side door window lift mechanism — device
Rear side door — device
Removal and installation rear door glass
Removal and installation the rear door window lift mechanism
Removal and installation the outer rear door opening handle
Removal and installation the rear door lock
Removal and installation the rear door inner opening handle
Removal and installation the outer seal of the rear door glass
Adjusting the position of the rear door glass
Air conditioning and heater
Safety precautions and features of maintenance and repair
Troubleshooting
Connecting the measuring manifold
Pumping out refrigerant from the air conditioning system
Vacuuming the system
Preparing a refrigerant cylinder for the system filling procedure
Refueling the air conditioning system with refrigerant
Locating refrigerant leaks
Procedure for returning compressor oil to the compressor
Checking the amount and adding compressor oil to the system
Removal and installation the compressor
Removal the compressor electromagnetic clutch
Disassembly and assembly of the electromagnetic clutch of the compressor
Capacitor — removal and installation, inspection
Refrigerant pressure switch
Air conditioning system piping
Evaporator Air Temperature Sensor
Humidity sensor and air temperature sensor in the car interior
Sunlight sensor
Heater coolant temperature sensor
Outside air temperature sensor
Heater unit
Heater Electric Fan Unit — Device
Heater Electric Fan Unit — Removal and Installation
Heater Electric Fan Unit — Check
Heater unit — device
Heater unit flap actuators — removal and installation
Heater Block Damper Servos — Checking
Manual air conditioner
Automatic Air Conditioning — General Information
Automatic air conditioner — removal and installation
Automatic air conditioner — self-diagnostic system
Security systems
Restraint System (SRS) — General Information
SRS system — device
Safety measures during operation and repair work
Checking the operation of the SRS indicator
Checking the indicator of the front and side airbag deactivation system of the front passenger
System diagnostics using a tester
Checking a component with a tester
Checking the component circuit
SRS System Error Codes
SRS Electronic Control Unit
Removal and installation the driver airbag module and coil wire
Checking the driver airbag module and coil wire
Passenger airbag module
Side airbag module
Curtain airbag module
Seat belt with pretensioner
Frontal impact sensors
Side impact sensors
Electrical equipment
Equipment and devices
Troubleshooting by their symptoms
Combination switch
Sound signal
Mounting blocks
Central lock
Electric power windows
Audio system — device
Identifying the Radio Receiver Connectors
Removal and installation the radio receiver
Cleaning the magnetic head and tape transport mechanism
Removal and installation speakers
Remote control central locking system and anti-theft system
Body electrical control system
Removal and installation of the body electrical equipment control unit
Checking the functions of the body electrical control system
Windshield wiper motor
Rear Window Wiper Motor (Hatchback)
Windshield wipers and washers — device
Electric washer pump
Seat heaters
Registration of new immobilizer keys
Setting and changing the immobilizer password
Starting the engine with a faulty immobilizer
Initialization of the electronic engine control unit
Reading diagnostic trouble codes of the immobilizer
Removal and installation the electronic immobilizer control unit
Ring antenna of immobilizer
Parking system — device
Precautions and operation of the parking system
Parking system diagnostics
Checking the operation of parking system sensors
Parking system control unit
Removal and installation parking sensors
Parking system buzzer
Ignition switch
Location of sensors, indicators and pointers of the car
Instrument cluster — removal and installation
Instrument cluster — device
Checking gauges and indicators
Electrically adjustable side mirrors
Electric sunroof
Rear window defroster
Headlights and lighting
Lighting system — device
Checking the lamps
Headlights — removal and installation
Checking the hazard warning relay, fog light relay and rear fog light relay
Removal and installation rear combination lights
Interior lighting lamp
Local illumination lamp
Checking the hazard warning switch
Fog lights
Checking the rheostat
Checking the turn signal relay
Removal and installation license plate light
Removal and installation brake lights
Checking the operation of the daytime lighting system (DRL)
Checking the headlight range control switch
Electrical circuits
Explanations for electrical equipment diagrams
Mounting block in the cabin
Mounting block in the engine compartment
Vehicle power supply system
Ground connection chains
Circuits of the mounting block in the cabin
Engine starting system
Battery charging system
Engine management system (models with manual transmission)
Engine management system (models with automatic transmission)
Electric Fan Control System
Body electrical control system
Instrument cluster
Electronic control system of automatic transmission
Headlights and headlight corrector
Front side lights, rear side lights and number plate light
Direction indicators and hazard warning lights
Fog lights and rear fog lights
Brake light wiring diagram
Reversing lights and parking system
Interior lighting lamps
Instrument lighting in the cabin
Daylight Relief Lighting (DRL) System
Windshield wipers and washers
Electric windows (with electric rear side doors)
Electric windows (without electric rear side doors)
Electric sunroof
Electrically adjustable side mirrors
Side mirror folding system
Manual heater and air conditioner
Automatically controlled heater and air conditioner
Rear window defroster and side mirror defrosters
Seat heaters
Central lock
Remote control central locking system and anti-theft system
Vehicle speed detection system
Electronic Stability Program (ESP), Anti-lock Braking System (ABS) and Traction Control System (TCS)
Supplementary Restraint System (SRS)
Immobilizer system
Audio system with amplifier
Audio system without amplifier
Sound signal
Diagnostic and service connector circuits
Clock and cigarette lighter (connector for connecting additional equipment)
Instrument cluster (models from 2009)
Rear window wiper and washer (2009 and later models)
Central locking (models from 2009)
Remote central locking and anti-theft alarm system (models from 2009)
Electric Power Steering (EPS) (2009 and later models)
Sorento 1 (2002-2009)
General information
User manual
Vehicle identification
Engine specifications
Abbreviations and symbols
General repair instructions
Garage jack stop and lift paw installation points
Door lock
Odometer and trip meters
Tachometer — General Information
Fuel quantity indicator
Coolant temperature gauge
Instrument cluster indicators
Watches — General Information
Additional pointer block
Window lifters — general information
Light signaling on the car
Adjusting the brightness of the instrument cluster illumination (modifications)
Interior and luggage compartment lighting
Additional boxes and compartments in the cabin, luggage fasteners
Hood — General Information
Back door
Rear door glass
Filler neck hatch
Windscreen wiper and washer control
Adjusting the position of the steering wheel
Mirror control
Windshield wiper de-icer, rear door glass defroster and side mirror defrosters
Seats — General Information
Front seat heater
Seat belts
Precautions when operating vehicles equipped with the SRS system
Electric sunroof
Constant speed control system
Parking system
Heater and air conditioner control
Radio tape recorder — general information
Connectors for connecting additional equipment
Cigarette lighter — general information
Cellular Remote Control System (Korea Models)
Driving a car with automatic transmission
Driving a car with a manual transmission
Features of the transmission of 4WD models
Anti-lock braking system (ABS)
Traction Control System (TCS)
Electronic Stability Control (ESC)
Tips for driving in different conditions
Towing a car
Starting the engine
Engine malfunctions while driving
Spare tire, jack and tools
Jacking up a car
Wheel replacement
Recommendations for choosing tires
Checking tire pressure and condition
Tire replacement
Features of using aluminum wheels
Replacement of wheel disks
Brake pad wear indicators
Catalytic converter and exhaust system (petrol models)
Fuses — General Information
Replacing lamps
Maintenance
Maintenance intervals
Service intervals
Rules for performing work in the engine compartment
Checking the engine oil level
Changing engine oil and filter
Replacing the coolant
Checking the air filter
Rechargeable battery
Checking and adjusting drive belts of attachments
Checking the condition of the timing belt and balance mechanism (G4JS and G6CU engines)
Checking the fluid level in the power steering hydraulic system reservoir
Checking the brake fluid level
Checking the clutch release fluid level (manual transmission models)
Checking the oil level in a manual transmission and transfer case
Changing oil in manual transmission and transfer case
Checking the condition and level of working fluid in the automatic transmission
Replacing the working fluid in the automatic transmission
Automatic transmission filter replacement
Checking the oil level in the gearbox housing
Checking the windshield washer fluid level
Replacing the cabin filter
Air conditioning system refill
Additional checks
Checking and cleaning spark plugs (petrol engines)
Checking high voltage wires (G6CU engine)
Checking the idle speed (petrol engines)
Checking for increased idle speed when the air conditioner is turned on (petrol engines)
Checking the ignition timing (petrol engines)
Compression test (petrol engines)
Replacing the fuel filter (petrol engines)
Replacing the fuel filter (diesel engines)
Removing water from the fuel filter (diesel engines)
Removing air from fuel lines (diesel engines)
Compression test (diesel engines)
Catalog numbers of original spare parts
Gasoline engines
Repair of G4JS engines
G4JS Engine — General Information
Checking hydraulic compensators
Timing Belt — Removal
Timing Belt — Check
Timing Belt — Installation
Replacing the cylinder head gasket — removal
Cylinder Head Gasket Replacement — Installation
Engine assembly
Camshafts
Valve rocker arms and hydraulic lifters
Cylinder head assembly — disassembly and inspection
Cylinder head assembly — repair and assembly
Piston and connecting rod — removal and disassembly, inspection
Repair, assembly and installation
Crankshaft, Flywheel and Torque Converter Drive Plate — Disassembly and Inspection
Crankshaft, Flywheel and Torque Converter Drive Plate — Assembly
Cylinder block
Troubleshooting by their symptoms
Engine mounts
Transmission support
Repair of G6CU engines
Engine Technical Data Table
G6CU Engine — General Information
Checking hydraulic compensators
Timing Belt — Removal
Timing Belt — Installation
Replacing oil seals
Replacing the cylinder head gasket — removal
Cylinder Head Gasket Replacement — Installation
Engine assembly
Valve Rocker Arms and Camshafts — Removal and Installation
Rocker arms and camshafts — check
Cylinder head and valves — removal and inspection
Cylinder head and valves — repair and installation
Piston and connecting rod — removal and disassembly, inspection
Replacing the piston pin
Piston and connecting rod — assembly and installation
Crankshaft and Torque Converter Drive Plate — Removal and Inspection
Crankshaft and Torque Converter Drive Plate — Installation
Cylinder block
Troubleshooting by their symptoms
Oil Pump Housing and Oil Pan (G6CU Engine) — Installation
Cooling system
Cooling system — general information
Checks and adjustments on the car
Thermostat — removal and installation
Coolant pump (G4JS engine)
Coolant pump (G6CU engine)
Hoses and pipes of the cooling system (engine G4JS)
Cooling system hoses and pipes (G6CU engine)
Radiator — removal and installation
Electric radiator fan
Lubrication system
Lubrication system — general information
Pressure reducing valve
Oil pressure alarm sensor
Oil Pump Housing and Oil Pan (G6CU Engine) — Removal and Inspection
Oil Pump Housing, Oil Pan and Balance Shafts (G4JS Engine) — Removal and Inspection
Replacing the balance shaft bearing
Oil Pump Housing, Oil Pan and Balance Shafts (G4JS Engine) — Installation
Intake and exhaust system
Air filter — removal and installation
Intake manifold (G4JS engine)
Intake manifold (G6CU engine)
Exhaust manifold (G4JS engine)
Exhaust manifold (G6CU engine)
Exhaust pipes and muffler
Troubleshooting by their symptoms
Toxicity Reduction System — General Information
Forced crankcase ventilation system
Fuel vapor recovery system
Fuel injection system
General rules when working with an electronic control system
Fuel injection system diagnostics — general information
Fuel injection system diagnostics — troubleshooting
General diagrams of the fuel injection system
Fuel injection system diagnostics — troubleshooting recommendations by codes
Checking the idle speed
Checking and adjusting the accelerator pedal cable (throttle side)
Checking the operation of the fuel pump
Checking fuel pressure
Replacing the fuel pump assembly
Cleaning the throttle body (throttle area)
Checking and adjusting the throttle position sensor
Adjusting the base idle speed
Checking the vacuum hose nipple for purging the adsorber
Mass Air Flow Sensor
G6CU Engine Multi-Fuel Injection (MFI) Component Locations
Intake Air Temperature Sensor
Manifold Absolute Pressure Sensor
Coolant temperature sensor
Throttle Position Sensor
Camshaft Position Sensor
Crankshaft position sensor
Oxygen sensor
Injectors — checking
Idle speed control servo
Knock sensor
Ignition coils
Evaporative Evaporative Canister Purge Solenoid Valve
Main relay of the injection system
Fuel pump and fuel pump relay
Sensor-switch for fluid pressure in the power steering system
Testing with an oscilloscope
Checks on the engine control unit connector
Fuel manifold
Fuel tank
Accelerator pedal cable and accelerator pedal
Engine electrical equipment
Engine Starting System — Technical Data Sheet
Troubleshooting the starting system by their symptoms
Engine Starting System — General Information
Checking and adjusting the starter
Starter — General Information
Checking the starter relay
Charging system — technical data table
Troubleshooting the charging system by their symptoms
Charging system — general information
Precautions for servicing the charging system
Checking the charging system
Generator — removal and installation
Generator — disassembly and assembly
Ignition system — technical data table
Troubleshooting ignition system faults by their symptoms
Ignition system — general information
Ignition system — checks and adjustments
Ignition coils
Sensors (engine G6CU)
Generator — check
Checking the generator output voltage waveform on a motor tester (oscilloscope)
Diesel engines
Repair of D4CB engines
Engine Technical Data Table
Diesel engine D4CB — general information
Checking hydraulic compensators
Drive chains — removal and inspection
Drive chains — replacing the lower front cover seal
Drive chains — installation
Lower rear cover and balance shafts
Replacing the cylinder head gasket — removal
Cylinder Head Gasket Replacement — Installation
Engine assembly — removal
Engine assembly — installation
Camshafts
Valve rockers and hydraulic compensators
Cylinder head and valves
Piston and connecting rod — removal and disassembly
Piston and connecting rod — check
Replacing the piston pin
Piston and connecting rod — assembly and installation
Crankshaft, Flywheel and Torque Converter Drive Plate — Disassembly
Crankshaft, Flywheel and Torque Converter Drive Plate — Inspection
Crankshaft, Flywheel and Torque Converter Drive Plate — Assembly
Cylinder block
Cooling system
General information about the cooling system
On-car checks
Thermostat — removal and installation
Coolant fan and pump
Radiator — removal and installation
Lubrication system
Lubrication system — general information
Checking the valves
Oil pump and oil pan
Oil cooler — removal and inspection
Turbocharging, intake and exhaust
General Information and Precautions — D4CB Engine (WGT)
Air Filter — D4CB Engine (WGT)
Intake Manifold — D4CB Engine (WGT)
Exhaust manifold and turbocharger — D4CB engine (WGT)
Exhaust pipes and muffler — engine D4CB (WGT)
General Information and Precautions — D4CB Engine (VGT)
On-car checks — D4CB engine (VGT)
Air Filter — D4CB Engine (VGT)
Intake manifold — D4CB engine (VGT)
Exhaust manifold and turbocharger (D4CB engine (VGT)) — removal and installation
Exhaust manifold and turbocharger (D4CB engine (VGT)) — check
Exhaust pipes and muffler — D4CB engine (VGT)
Fuel system
General information about the fuel system
Injectors — removal
Replacing injectors
Injectors — installation
High pressure fuel pump
Fuel accumulator
Fuel filter
WGT control system
General rules when working with the control system
Fuel injection system diagnostics — general information
Features of fuel injection system testing
Recommendations for troubleshooting by codes
Operating principles of the system — general information
Mass Air Flow Sensor and Intake Air Temperature Sensor
Coolant temperature sensor
Accelerator pedal position sensor
Camshaft Position Sensor
Crankshaft position sensor
Fuel pressure sensor
Fuel pressure regulator
Injectors — General Information
Exhaust gas recirculation system solenoid valve
Main relay of the injection system
Low pressure fuel pump
Electronic Engine Control Unit (ECU) Ground Circuit
Checks on the engine control unit connector
VGT control system
General rules when working with the control system
Fuel injection system diagnostics
Operating principles of the system — general information
Mass Air Flow Sensor and Intake Air Temperature Sensor #1
Boost pressure sensor and charge air temperature sensor
Coolant temperature sensor
Accelerator pedal position sensor
Camshaft Position Sensor
Crankshaft position sensor
Oxygen sensor
Fuel pressure sensor
Fuel pressure regulator
Fuel temperature sensor
Fuel pressure regulator valve
Injectors — General Information
Solenoid valve of the blade position change system
Throttle control solenoid valve
Exhaust gas recirculation system solenoid valve
Main relay of the injection system
Low pressure fuel pump
Electronic Engine Control Unit (ECU) Ground Circuit
Checks on the engine control unit connector
Engine electrical equipment
Engine starting system — troubleshooting by their symptoms
Engine Starting System — General Information
Checking and adjusting the starter
Starter — General Information
Starting aid system
Glow plugs
Charging system — troubleshooting by their symptoms
Charging system — general information
Precautions for servicing the charging system
Checking the charging system
Generator — removal
Disassembling the generator and vacuum pump
Checking the generator parts
Generator assembly
Generator installation
Examples of deviations from the normal shape of the generator signal
Checking the generator output voltage waveform on a motor tester (oscilloscope)
Transmission
Clutch
Checking the clutch fluid level
Bleeding the clutch release drive
Clutch pedal
Clutch release master cylinder
Clutch release slave cylinder
Clutch — removal, inspection and installation
Mechanical gearbox
On-car checks
Manual gearbox assembly
Gear shift mechanism of manual transmission
Automatic gearbox 30-40 LEi
General description of the gearbox
General information about the gearbox
Preliminary checks
Automatic transmission diagnostics
Checking mechanical systems of the gearbox
Gearbox control mechanism
Gearbox assembly — removal and installation
Front gearbox — removal and installation
Automatic gearbox A5SR1/2
Checking the level and condition of the working fluid in the automatic transmission
Replacement of filter and working fluid of automatic transmission
Gearbox diagnostics
Checking mechanical systems of automatic transmission
Checking automatic transmission components
Gearbox assembly
Transfer case
Description of the TOD transfer case
TOD system operating modes
TOD Transfer Case Checks on Vehicle
TOD Transfer Case Assembly
Description of the transfer case (EST)
EST system operating modes
Checking the EST transfer case on a vehicle
EST Transfer Case Troubleshooting
Transfer case EST assembly
Cardan and drive shafts
Cardan shafts — checking on the car
Cardan shafts — removal and inspection
Cardan shafts — installation
Front gearbox — disassembly and assembly
Rear gearbox — removal and installation
Limited slip differential
Front wheel hub and steering knuckle
Left and right drive shafts
Intermediate drive shaft
Half shafts — general information
Chassis
Car suspension
Troubleshooting by their symptoms
Checking and adjusting the front wheel alignment angles
Front suspension strut assembly
Lower control arm of the front suspension
Upper control arm front suspension
Front suspension anti-roll bar
Rear shock absorber and spring
Upper arm rear suspension
Lower arm rear suspension
Rear suspension anti-roll bar
Panhard rod
Steering
On-car checks
Steering column and steering shaft
Steering gear — removal and inspection
Steering gear — assembly and installation
Power steering hydraulic system hoses and lines
Power Steering Pump — Removal and Inspection
Power Steering Pump — Assembly and Installation
Brake system
Troubleshooting by their symptoms
On-car checks
Vacuum brake booster
Brake system lines
Brake pedal
Master brake cylinder
Front disc brake mechanism
Rear disc brake mechanism
Parking brake
Anti-lock Braking System (ABS) — General Information
Some phenomena during operation of the ABS system
Checking the ABS indicator
Reading fault codes using a tester
Troubleshooting procedures by codes
Checking the operation of the ABS system
Pressure modulator
Wheel speed sensor
Cruise control system — troubleshooting by their symptoms
Cruise control system — general information
Electronic control unit of the cruise control system — removal and installation
Checking the terminals of the electronic control unit of the constant speed maintenance system
Body
Exterior
Search for body faults by their signs
Hood — General Information
Front side door
Rear side door
Back door
Roof rack
Car roof hatch
Side rear view mirror
Front bumper
Rear bumper
Interior
Instrument panel
Interior trim
Roof finishing
Windshield
Rear door glass
Front seat
Back seat
Removing and installing the front seat belt
Removing and installing rear seat belts
Heating and air conditioning
Safety precautions and features of maintenance and repair
Troubleshooting
Connecting the measuring manifold
Pumping out refrigerant from the air conditioning system
Vacuuming the system
Preparing a refrigerant cylinder for the system filling procedure
Filling the air conditioning system with refrigerant (in gaseous state)
Filling the air conditioning system with refrigerant (in liquid state)
Checking the efficiency of the air conditioner
Procedure for returning compressor oil to the compressor
Checking the amount and adding compressor oil to the system
Locating refrigerant leaks
Checking the system using a measuring manifold
Compressor — General Information
Condenser fan, motor relay and receiver-dryer
Manual air conditioner
Automatic air conditioning
Heater — general information
Electric heater fan
Autonomous heater (models with D4CB engine)
Electrical equipment
Equipment and devices
Troubleshooting by their symptoms
Audio system — general information
Steering column combination switch
Sound signal
Central Locking Delay and Light Warning System (ETACS)
Indicators and pointers
Central lock
Electrically adjustable side mirrors
Electric power windows
Rear door glass defroster
Windshield wiper and washer
Rear window wiper and washer
Front seat heaters
Electric sunroof
Lighting system
Daylight Relief Lighting (DRL) System
Headlight corrector
Immobilizer — general information
Relay blocks, fuses and fuse links
Security systems
General information about the passive restraint system (SRS)
Safety precautions during operation and maintenance
Troubleshooting the Passive Safety System
Driver Airbag Module and SRS Coil Wire
Passenger airbag module
Seat belt with pretensioner
Electrical circuits
Explanations for electrical equipment diagrams
Power Distribution (G6CU Engine, Since 2002)
Grounding points (G6CU engine, since 2002)
Engine starting and charging systems (G6CU, since 2002)
Engine management system (G6CU, since 2002)
Electric fan control system (G6CU engine, since 2002)
Automatic transmission control system (4A/T) (G6CU engine, since 2002)
EST all-wheel drive system (G6CU engine, since 2002)
TOD All-Wheel Drive (ATT) (G6CU engine, since 2002)
Instrument cluster indicators and additional indicator block (G6CU, since 2002)
Windscreen wiper and washer (G6CU engine, since 2002)
Rear door glass wiper and washer (G6CU engine, since 2002)
Headlights (without automatic headlight switching system) (G6CU, since 2002)
Headlights (with automatic switching on of external lighting) (G6CU, since 2002)
Front side lights, rear side lights, number plate lights (G6CU, since 2002)
Fog lights and trailer light (G6CU, since 2002)
Daylight Relief Lighting (DRL) (G6CU, since 2002)
Direction indicators and hazard warning lights (G6CU, since 2002)
Horn, brake lights, reversing lights and Home Link remote control
Manual Heater and Air Conditioner (G6CU, since 2002)
Heater and air conditioner with automatic control (G6CU, since 2002)
ETACS system, key presence sensor, interior light...
Instrument panel lights and glove compartment light
Audio system (models without audio amplifier) (G6CU, since 2002)
Audio system (models with audio amplifier) (G6CU, since 2002)
Steering wheel remote control switches (G6CU, since 2002)
Electric windows (G6CU, since 2002)
Central locking (G6CU, since 2002)
Electrically adjustable side mirrors (G6CU, since 2002)
Electric sunroof (G6CU, since 2002)
Electric Power Steering (EPS) (G6CU, since 2002)
Anti-lock braking system (ABS) (G6CU, since 2002)
Front seat heaters (G6CU, since 2002)
Electric adjustment and driver's seat heater (G6CU, since 2002)
Cruise control system (G6CU, since 2002)
Supplemental Restraint System (SRS) (G6CU, since 2002)
Windscreen and rear door glass defrosters (G6CU, since 2002)
Cigarette lighter, socket for connecting additional equipment and clock
Immobilizer system (G6CU, since 2002)
Diagnostic connector and universal service connector (G6CU, since 2002)
Connecting and closing connectors
Automatic transmission control system (5A/T) (engine G6CB, since 2005)
EST all-wheel drive system (G6CB engine, since 2005)
TOD All-Wheel Drive (ATT) (G6CB engine, since 2005)
Power Distribution (Models with G4JS Engine)
Power Distribution (Models with D4CB Engine)
Grounding points
Engine starting and charging systems (G4JS engine)
Engine starting and charging systems (D4CB engine)
Engine Management System (models with G4JS engine)
Engine Management System (models with D4CB engine)
Electric Fan Control System (D4CB Engine)
Fuel line heater (D4CB engine)
Automatic transmission control system (D4CB and G4JS engines)
Rear fog lights, headlight washers (D4CB and G4JS engines)
Manual heater and air conditioner (D4CB and G4JS engines)
Automatic heater and air conditioner (D4CB and G4JS engines)
Autonomous heater (models with D4CB engine)
Immobilizer system (models with D4CB engine)
Engine management system (models with D4CB (VGT) engine)
Location of vehicle electrical wiring connectors
Location of grounding points for electrical equipment wiring
Sportage 1 (1993-2005)
User manual
Introduction to the guide
A few words about this guide
Abstract for KIA Sportage cars
Identification numbers and information labels
Purchase of spare parts
Jacking up/lifting a car, changing a wheel
Towing a car
Starting the engine from an auxiliary power source
Car fault diagnostics
Kia Sportage Car Specifications
Governing bodies
Car keys
Opening and closing doors
Opening and closing the hood
Fuel tank filler neck
Removable top (Convertible models)
Single lock / anti-theft alarm
Elements of security systems
Seat belts
Transportation of children
Adjusting seats and headrests
Supplemental Restraint System (SRS)
The dangers of carbon monoxide poisoning
Instrument panel and center console
Instrument cluster, gauges, control lamps and indicator lights
Interior controls and equipment
Ventilation, heating and air conditioning systems
Operating techniques
Running in the car for the first 1500 km
Starting the engine and starting the movement
Features of operation of cars with manual transmission (MT)
Features of operation of cars with automatic transmission (AT)
Using the transfer case
Braking a car
Features of driving a car with power steering (PS)
Features of operation of cars with a catalytic converter
Peculiarities of driving in off-road conditions
Tips for Economical Driving
Towing a car trailer
Jacking up and changing a wheel
Maintenance and care
Maintenance Specifications
General information about maintenance
General information about settings and adjustments
Schedule of current maintenance
Checking the level of working fluids
Checking the condition of the tires and their inflation pressure, rotating the wheels
Changing engine oil and oil filter
Replacing manual transmission oil
Replacement of transfer case and differential lubricants
Lubrication of locks and hinges
Checking the condition of the drive shaft boots
Lubrication of universal joints of cardan shafts
Checking brake system components
Checking the functioning of the cooling system and frost resistance of the coolant, replacing the liquid
Replacing the air cleaner filter element
Replacing spark plugs
Replacing glow plugs
Checking the condition and tension of auxiliary drive belts
Checking the condition and reliability of fastening of chassis, suspension and steering components
Checking the condition of the exhaust system components
Checking the condition and replacing engine compartment hoses, localizing leaks
Checking the fuel system, replacing the fuel filter
Checking the idle speed
Automatic Transmission Fluid Replacement (ATF)
Checking the proper functioning of the PCV valve (petrol models)
Checking the condition of the high-voltage wiring (petrol models)
Checking the condition and replacing the timing belt
Checking the air conditioning system
Checking the condition and replacing the windshield wipers
Checking battery condition, care and charging
Power unit
Petrol engines
Petrol Engine Specifications
Checking compression pressure, assessing the condition of the cylinders
Checking the engine with a vacuum gauge
Auxiliary drive belts
Lubrication system — general information, checking engine oil pressure
Removal and installation the engine
Removal and installation of timing drive components
Removal and installation the intake manifold and exhaust manifold
Servicing of cylinder head and valve train components
Disassembly and assembly of the cylinder block, maintenance of components
Removal and installation the oil pan
Removal, installation and maintenance of the oil pump
Removal and installation the flywheel/drive disc
Replacing crankshaft seals
Diesel engines
Diesel Engine Specifications
Lubrication system — general information
Removal and installation the engine
Removal and installation of timing drive components
Checking and adjusting valve clearances
Removal and installation the intake manifold and exhaust manifold
Servicing of cylinder head and valve train components
Disassembly and assembly of the cylinder block, maintenance of components
Removal and installation the oil pan
Removal, installation and maintenance of the oil pump
Removal and installation the oil cooler
Removal and installation oil sprayers
Replacing crankshaft seals
Cooling system
Cooling system specification
General information about the engine cooling system
Coolant — General Information
Coolant Replacement — General Notes
Checking for leaks, replacing cooling system hoses
Checking the Thermostat
Checking the proper functioning of the cooling system fan clutch
Flushing the cooling system tract
Removal and installation the thermostat
Removal, condition check and installation of the cooling system radiator, replacement of radiator hoses
Removal and installation the expansion tank
Removal and installation the bypass pipe of the cooling system of a gasoline engine
Replacing the cooling system fan drive bearing
Removal, installation and maintenance of the water pump
Heating and air conditioning
Heating, ventilation and air conditioning system specification
General information and safety precautions
Diagnostics of faults, testing of air conditioning system components
Blower Fan/Evaporator Assembly Removal and Installation, Component Maintenance
Removal and installation of the heater assembly, maintenance of components
Removal and installation of communication lines of the refrigeration system K/V
Removal, inspection and installation of the air conditioning compressor
Removal, inspection and installation of the condenser fan K/V
Removal, inspection and installation of the K/V capacitor
Removal, checking and installation the receiver-dryer
Power system (gasoline)
Specification of the power supply and engine management system
Safety precautions and general rules adopted when servicing components of fuel systems of internal combustion engines
General information on the fuel system of gasoline engines
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine, filling the fuel path
Power supply system checks
Removal and installation air intake tract components
Removal and installation the gas pedal, adjusting the throttle cable
Removal and installation the fuel tank
Removal and installation the fuel pump
Removal and installation the fuel level sensor
Removal and installation the check valve
Removal and installation of the fuel supply and return lines
Removal and installation the fuel tank filler neck and fuel vapor separator
Removal and installation the fuel pressure regulator
Removal and installation of the fuel distribution line
Removal and installation of fuel injectors
Fuel system (diesel)
Specification of the power supply and engine management system
General information on the fuel system of diesel engines
Power supply system checks
Adjusting the idle speed
Adjustment of valve timing (injection timing)
Removal and installation a turbocharger
Removal and installation the gas pedal, adjusting the gas cable
Removal and installation of fuel injection pump
Removal and installation injectors
Engine management systems
General information about the engine management system
ECM — Checking the health of the condition and replacing
On-Board Diagnostics (OBD) System — General Information
Self-diagnosis system for diesel models
Using an Oscilloscope to Monitor the Performance of a Control System
Checking the proper functioning of engine management/emission control system components
General information about the exhaust system
Checking the condition of the exhaust system components
Removal and installation of exhaust system components
Ignition system
Engine Electrical System Specifications
Ignition system of a gasoline engine
Ignition Control System Tests
Checking the ignition timing angle
Checking ignition coils
Checking the knock sensor
Replacing ignition coils
Spark Plugs — General Information
Removal and installation the camshaft position sensor (CMP)
Removal and installation the crankshaft position sensor (CKP)
Removal and installation the knock sensor (KS)
Diesel cold start assist system
Checking glow plugs
Checking the glow plug relay
Starting and charging system
General information about the charging and starting system
Battery — General information, maintenance recommendations
Charging system — general information and safety precautions
Checking the charging system
Removal and installation the generator
Engine Starting System — General Information and Safety Precautions
Removal and installation the starter
Checking and replacing the starter circuit breaker switch (CPP) on models with manual transmission
Transmission
Clutch
General information about the clutch
Checking and adjusting the hydraulic fluid level
Checking and adjusting the clutch pedal
Removal and installation the clutch pedal
Removal, maintenance and installation of the clutch release master cylinder
Removal, maintenance and installation of the clutch release actuator cylinder
Removal, inspection and installation of clutch components
Mechanical gearbox
Manual Transmission Specifications
General information about manual transmission
Removal and installation the manual transmission shift lever
Removal and installation of manual transmission
Automatic gearbox
Automatic Transmission Specifications
General information about automatic transmission
Troubleshooting — General Information
Reading DTC codes, clearing processor memory
Checks and adjustments of the components of the AT control system
Checks and adjustments of the mechanical and hydraulic parts
Checking and adjusting the AT drive cable
Removal and installation the AT selector lever
Removal and installation of automatic transmission
Transfer case
General information about the transfer case
Removal and installation the transfer case mode shift lever
Removal and installation the speedometer drive assembly
Replacing output shaft seals
Removal and installation the transfer case
Drive shafts and axles
Drive shaft and axle specifications
General information about drive shafts, axles and transmission
Cardan shaft device
Checking the condition of the cardan shaft without removing it from the vehicle
Removal, maintenance and installation of cardan shafts
General information about the front and rear axles
No-dismantling procedures for checking and servicing wheel drive components
Replacing differential seals
Removal, maintenance and installation of components of front and rear axle assemblies
Chassis
Brake system
Brake system specifications
General information about the brake system and safety precautions
Checking and adjusting the foot brake pedal
Checking the parking brake lever
Checking the proper functioning of the brake booster
Checking the differential pressure regulator bypass valve (models without ABS and EBD)
Removal and installation the foot brake pedal
Removal, maintenance and installation of the brake master cylinder
Removal and installation the brake booster assembly
Evaluation of wear level, replacement of front wheel disc brake pads
Disassembling the front wheel brake mechanism, assessing the condition of the disc
Removal and installation of flexible brake hoses of the hydraulic tract of the front wheel brake mechanisms
Servicing rear wheel drum brakes
Removal and installation the parking brake lever, adjusting the drive cable
Bleeding the brakes
Read ABS/EBD fault codes, clear processor memory
Removal and installation of hydraulic and electronic control units ABS / EBD
Removal, check and installation of ABS wheel sensors
Replacing the front wheel ABS sensor rotors
Front suspension
General information about suspension and steering
Assessing the condition of suspension and steering components
General information about the front suspension
Removal and installation of front axle assembly components
Removal, component condition check and installation of anti-roll bar
Removal, maintenance and installation of rack assemblies
Removal, maintenance and installation of upper suspension arms
Removal, maintenance and installation of lower suspension arms
Car Wheel Alignment Angles — General Information
Checking and adjusting the front wheel alignment angles
Suspension and steering specifications
Rear suspension
General information about the rear suspension
Removal and installation of rear axle assembly components
Removal, inspection and installation of shock absorbers and coil springs
Removal, maintenance and installation of trailing arms
Removal, maintenance and installation of the reaction rod
Steering
General information about steering
Removal air from the working circuit of the power steering system
Checking the steering pump pressure
Removal, checking and installation the steering wheel and steering column
Removal and installation tie rod ends
Removal and installation steering components
Removal and installation the steering pump
Body
Exterior
Specifications of the body and its elements
General information about the body
Removal, installation and adjustment of windshield cleaning and washing device components
Removal, installation and adjustment of components of the rear window cleaning and washing devices
Removal and installation the fairing grille
Removal, installation and adjustment of the hood
Removal and installation bumpers
Removal and installation door rear view mirrors
Removal and installation the folding spare wheel mounting bracket
Car body glazing — general information
Disassembly, removal, installation and adjustment of doors
Door window lift drive design
Door lock drive design
Control body dimensions
Interior
Instrument panel — general information, removal and installation of components
Removal and installation the center console
Seats — General information, condition check, removal and installation of components
Design and installation details of seat belt components, removal of deployed emergency tensioners
Layout and installation details of interior trim panels
Electrical equipment
Equipment and devices
On-board electrical equipment specifications
General information and precautions
Search for causes of electrical equipment failures
Fuses — General Information
Circuit Breakers — General Information
Relays — general information and checking the correct functioning
Fuse/Relay Mounting Blocks — Removal, Installation, Replacement of Fuses
Timer and Alarm Gong System (ETWIS) — Control Module Removal and Installation
Checking the proper functioning of the ignition switch
Checking the proper functioning of the steering column switches
Checking the proper functioning of the control switches and electric motors of the window lift drive
Checking the serviceability of the control switch and electric motors for adjusting the rear-view mirrors
Interior lights — replacing lamps, checking for proper functioning
Replacing lamps and checking the proper functioning of outdoor lighting fixtures
Removal, checking the correct functioning and installing the turn signal/hazard warning flasher
Removal, installation and adjustment of headlights
Airbags — General Information and Precautions
Disabling SRS
Reading DTC fault codes
Removal and installation the driver's airbag module
Removal, installation and adjustment of the contact cable drum of the driver's airbag module
Removal and installation the airbag diagnostic module (ADU)
Electrical circuits
Explanations of electrical diagrams
Power distribution electrical diagram
Electrical diagram of grounding distribution
Electrical diagram of the engine management system
Electrical diagram of the starting system
Electrical diagram of the charging system
On-board computer wiring diagram
Computer data line wiring diagram
Instrument cluster wiring diagram
Automatic transmission (AT) wiring diagram
AT shift lock circuit diagram
Wiring diagram of the anti-lock brake system (ABS)
Electrical diagram of the tempostat
Electrical diagram of the condenser fan K/V
Electrical diagram of the heating system
Air conditioning system wiring diagram (A/C)
External lighting wiring diagram (station wagon)
External lighting wiring diagram (convertible)
Headlights Wiring Diagram
Reverse Light Wiring Diagram
Instrument lighting wiring diagram
Horn wiring diagram
Wiring diagram for interior lighting when doors are opened
Windscreen wiper/washer wiring diagram
Rear Window Wiper/Washer Wiring Diagram
Electrical diagram of the electric drive of the door mirrors
Rear window heating wiring diagram
Supplemental Restraint System (SRS) Wiring Diagram
Warning system wiring diagram
Electric window lifter wiring diagram (station wagon)
Electrical diagram of the electric window lifter (convertible)
Radio receiver electrical circuit
Single lock wiring diagram
Electrical diagram of the anti-theft system
Spectra (2000-2009)
General information
Vehicle device
General information about the car
Vehicle Passport Data
Car keys
Instrument panel
Instrument cluster
Heating (air conditioning) and ventilation of the passenger compartment
Car door locks
Electric windows
Seat belts on the front seats
Seat belts in the rear seats
Airbags
Installing a child seat
Adjusting the position of the front seats
Folding the rear seat back
Adjusting the position of the steering wheel
Rear view mirrors
Interior lighting
Sun visors
Opening and closing the hood
Trunk lid
Gearbox control lever
Vehicle operation
Safety regulations
Operating recommendations
Traffic safety recommendations
Tools and spare parts for everyday use
Setting off on a long journey
Running in a car
Operation of the vehicle during the warranty period
Preparing the car for departure
Filling up a car with petrol
Using a jack
Towing a car
How to prepare your car for winter
Recommendations for starting the engine in severe frost
What is useful to buy for winter
Useful winter tips
Faults en route
The engine will not start
Malfunctions in the starting system
Checking the engine ignition system
Checking the engine fuel system
Fuel injection system faults
Idle speed is gone
Engine misfires
Diagnosis of engine condition by the appearance of spark plugs
The car moves in jerks
A jerk at the start of movement
Jerks during acceleration
Jerks during steady motion
The car accelerates poorly
The engine stalled while driving
Oil pressure dropped
Checking the lubrication system
Engine overheating
Checking the cooling system
The battery is not recharging
Checking the electrical equipment of the charging system
Starting the engine from external power sources
Electrical equipment faults
Extraneous knocking sounds appeared in the engine
Extraneous knocks in the suspension and transmission
Possible transmission knocks (noises), their causes and methods of elimination
Vibration and shock on the steering wheel
Possible causes of vibrations and shocks on the steering wheel and ways to eliminate them
Brake problems
Bleeding the brake system
Checking the brake system
Tire puncture
Wheel replacement
Daily care
Checking the wheels
Checking the level and adding coolant
Checking the level and adding oil to the lubrication system
Checking the level and adding brake fluid to the reservoir of the master brake cylinder and the master cylinder of the clutch release drive
Checking the level and topping up oil in a manual gearbox and working fluid in an automatic gearbox
Checking the level and adding working fluid to the power steering reservoir
Checking the level and adding fluid to the washer reservoir
Car body wash
Polishing of paintwork
Body sealing
Engine wash
Car wash
Care of interior trim panels made of polymeric materials
Caring for upholstery and carpets
First maintenance
Vehicle maintenance regulations
Changing engine oil and oil filter
Cleaning the crankcase ventilation system
Adjusting the timing belt tension of the gas distribution mechanism
Replacing the air filter element
Checking the technical condition of the front suspension parts on the car
Checking the technical condition of the rear suspension parts on the car
Inspection and testing of the steering system on the vehicle
Checking the free play (play) of the steering wheel
Checking and adjusting the tension of the air conditioning compressor drive belt and the power steering pump
Checking the tightness of the hydraulic brake drive
Checking and adjusting the brake pedal position
Checking the operation of the brake booster
Checking the degree of wear of brake pads
Checking the parking brake
Checking the efficiency of the braking system
Battery care and testing
Checking and adjusting the tension of the generator and water pump drive belt
Replacing the cabin filter of the heating and air conditioning system
Lubrication of body fittings
Trip to the service station (STO)
Recommendations for preparation for technical inspection
List of faults and conditions under which operation of vehicles is prohibited
Second maintenance
Replacing the coolant
Replacing the fuel filter
Adjusting the throttle cable
Adjusting the clutch release drive
Replacing the working fluid in the clutch release hydraulic drive
Gearbox oil change
Checking and adjusting wheel alignment angles
Replacing brake fluid
Adjusting the parking brake drive
Headlight adjustment
Replacement and maintenance of spark plugs
Cleaning the drainage holes of the body
Technical information
Tightening torques for threaded connections
Fuels and lubricants and operating fluids
Lamps used in the car
Basic data for adjustment and control
Purchase of spare parts
Selecting motor oil
Selection of plastic lubricants
Selecting a Coolant
Selecting brake fluid
Fine fuel filter
Engine lubrication system oil filter
Interchangeability of spark plugs
Power unit
Engine repair
Engine design features
Possible engine malfunctions, their causes and solutions
Helpful Troubleshooting Tips
Checking the compression in the cylinders
Removal and installation the decorative engine cover
Removal and installation engine mudguards
Replacing the powertrain suspension mounts
Replacing the protective beam
Setting the piston of the first cylinder to the TDC position of the compression stroke
Replacing the timing belt
Replacing the tension and support rollers of the timing belt
Removal, defect detection and installation of the flywheel
Replacing the cylinder head cover gasket
Replacing the engine intake manifold gasket
Replacing the cylinder head gasket
Replacing the engine oil pan seal
Replacing the engine exhaust manifold gasket
Replacing the camshaft seal
Replacing valve stem seals
Replacing engine crankshaft seals
Removal, inspection and installation of engine camshafts
Replacing engine hydraulic compensators
Possible malfunctions of hydraulic compensators, their causes and methods of elimination
Disassembly, repair and assembly of the engine cylinder head
Lapping valves
Removal and installation the engine
Cooling and lubrication system
Removal, defect detection and installation of the oil pump
Design features of the cooling system
Possible malfunctions of the cooling system, their causes and methods of elimination
Removal and installation of radiator electric fans
Replacing the cooling system radiator
Replacing the water pump
Replacing the thermostat
Removal and installation the expansion tank
Exhaust system
Design features of the exhaust system
Replacing the exhaust system suspension cushions
Removal and installation the exhaust manifold
Replacing the catalytic converter
Replacing the additional muffler
Replacing the intermediate pipe
Replacing the main muffler
Removal and installation of thermal screens and thermal housings
Fuel system
Features of the power supply system design
Checking the fuel pressure in the fuel system
Reducing pressure in the fuel system
Removal and installation the air filter
Replacing the fuel pump
Replacing the fuel tank and its filler pipe
Removal and installation the throttle assembly
Replacing the idle speed control valve
Removal, installation and testing of injectors and removal of the fuel rail
Checking and replacing the fuel pressure regulator
Replacing the throttle cable
Replacing the fuel vapor recovery system canister
Removal and installation the purge solenoid valve of the adsorber
Transmission
Clutch
Clutch design features
Possible clutch malfunctions, their causes and solutions
Removal and installation the clutch
Removal and installation the clutch release fork and bearing
Replacing the clutch release hydraulic master cylinder
Replacing the clutch release hydraulic drive slave cylinder
Replacing the clutch release hydraulic hose and lines
Bleeding the clutch release hydraulic drive
Car gearbox
Gearbox design features
Possible malfunctions of a manual gearbox, their causes and methods of elimination
Replacing gearbox drive seals
Removal and installation the gearbox
Replacing the transmission control drive rods
Front wheel drives
Design features of front wheel drives
Possible faults of front wheel drives, their causes and methods of elimination
Removal and installation front wheel drives
Replacement of constant velocity joints
Chassis
Front suspension
Features of the front suspension design
Possible faults of the front suspension, their causes and methods of elimination
Removal and installation the front suspension telescopic strut
Repair of the telescopic strut of the front suspension
Replacing the upper support of the telescopic strut of the front suspension
Removal and installation the front suspension arm
Replacing the ball joint
Replacing rubber-metal hinges (silent blocks) of the front suspension arm
Replacing the front suspension stabilizer bar components
Replacing the front hub bearing
Removal and installation the front suspension crossmember
Rear suspension
Features of the rear suspension design
Possible malfunctions of the rear suspension, their causes and methods of elimination
Removal and installation the rear suspension telescopic strut
Repair of the rear suspension telescopic strut
Replacing the upper support of the telescopic strut of the rear suspension
Removal, installation of the longitudinal arm and its repair
Removal, installation of transverse arms and their repair
Replacing the rear suspension stabilizer bar components
Replacing the rear hub
Replacing wheel studs
Steering
Features of the steering design
Possible malfunctions of power steering, their causes and methods of elimination
Removal and installation the steering wheel
Replacing steering shafts
Replacing the outer tie rod end
Replacing the working fluid and bleeding the power steering system
Replacing the drive belt of the power steering pump and air conditioning compressor
Replacing the power steering pump
Replacing the steering gear
Replacing the power steering fluid reservoir
Brake system
Design features of the brake system
Possible malfunctions of the brake system, their causes and methods of elimination
Bleeding the hydraulic brake system
Replacing the brake master cylinder reservoir
Replacing the master brake cylinder
Vacuum brake booster
Replacing the vacuum booster
Replacement of hydraulic brake hoses and tubes
Replacing brake hoses
Replacing brake pipes
Replacing the brake pads of the front wheel brake mechanisms
Replacing the front brake caliper
Replacing the brake disc
Replacing the brake pads of the rear wheel brake mechanism
Replacing the brake drum
Replacing the rear wheel brake slave cylinder
Replacing the parking brake cables
Replacing the parking brake lever
Body
Exterior
Features of the body design
Possible body malfunctions, their causes and methods of elimination
Removal and installation the front bumper and disassembling it
Removal and installation of the rear bumper, its reinforcement and their mounting brackets
Removal and installation the mudguard and front wheel liner
Removal and installation the rear wheel mudguard
Removal and installation the front wing
Removal and installation the hood
Replacing the fuel filler cap
Replacing the fuel tank lid lock and lock drive
Removal and installation the outside mirror
Anti-corrosion protection of the body
Preparation and anti-corrosion treatment of hidden cavities of the body
Interior
Removal and installation the rear trunk trim
Removal and installation the side trims of the trunk
Removal and installation the front seat
Removal and installation the rear seat
Removal and installation upper anchors for child seats
Removal and installation the interior mirror
Removal and installation the glove box
Removal and installation the upper instrument panel trim
Removal and installation the left lower instrument panel trim
Removal and installation the side trims of the instrument panel console
Removal and installation the right lower instrument panel trim
Removal and installation the instrument panel
Features of the heater and air conditioner
Removal and installation the heating and air conditioning control unit
Checking the air conditioning system on a car
Removal and installation door sill trims
Removal and installation of body pillar trims
Replacing handrails
Removal and installation steering column covers
Replacing sun visors
Removal and installation the floor tunnel lining
Doors and windows
Removal and installation the front door trim
Front door glass replacement
Replacing the outer handle of the front door lock
Replacing the front door lock
Removal and installation the front door
Replacing the front door opening limiter
Removal and installation the rear door trim
Rear door glass replacement
Replacing the outer rear door handle
Replacing the rear door lock
Removal and installation the rear door
Replacing the rear door opening limiter
Replacing the trunk lid torsion bar
Replacing the upper part of the trunk lid lock
Replacing the trunk lid lock drive and the lower part of the lock
Replacing the trunk lock and fuel filler flap handle
Windshield replacement
Airbags
Features of the design of airbags
Removal and installation the driver's airbag
Removal and installation the front passenger airbag
Replacing the front seat belt
Replacing the rear seat belt
Removal and installation the electronic control unit of the additional passive restraint system (SRS)
Electrical equipment
Equipment and devices
Features of the design of electrical equipment
Diagnostics of faults of on-board electrical equipment
Location of fuses and relays
Replacing relays, fuses and fuse links
Removal and installation of mounting blocks
Replacing Windshield Wiper Blades
Windshield wiper gear motor replacement
Removal and installation the windshield wiper drive
Removal and installation the windshield washer
Removal and installation of the electric motor of the radiator fan of the engine cooling system
Replacing additional resistance
Removal and installation the heater fan motor
Electrically heated rear window
Removal and installation the cigarette lighter socket
Possible malfunctions of the instrument cluster, their causes and methods of elimination
Removal and installation the instrument cluster
Replacing the control unit for the outside rearview mirrors and the headlight beam adjuster
Replacing the instrument panel switches
Removal and installation the watch
Removal and installation the ETWIS unit
Removal and installation speakers of the acoustic system
Removal and installation the antenna
Replacing the oil pressure warning light sensor
Replacing the fuel level indicator sensor and the low fuel reserve indicator light sensor
Replacing the reverse light switch
Replacement and adjustment of the brake light switch
Replacing the Parking Brake Indicator Light Switch
Replacing the interior light switches
Anti-theft engine start blocking system
Power devices
Battery design features
Possible battery malfunctions, their causes and solutions
Removal and installation the battery
Charging the battery
Design Features of the Generator
Possible generator malfunctions, their causes and methods of elimination
Replacing the alternator and water pump drive belt
Removal and installation the generator
Generator repair
Features of the starter design
Possible starter malfunctions, their causes and solutions
Removal and installation the starter
Starter repair
Engine management
Design features of the ignition switch
Checking and replacing spark plug high-voltage wires
Removal and installation ignition coils
Design features of the engine management system
Removal and installation of the electronic engine control unit
Replacing the sensors of the engine management system
Headlights and lighting
Features of the design of car lighting
Replacing lamps in lighting fixtures
Headlight replacement
Replacing the headlight beam corrector
Front Fog Light Replacement
Replacing the rear light
Replacing the rear fog light
Replacing an additional brake light
Replacing the side turn signal light
Replacing the license plate light
Replacing the front interior light
Replacing the central interior light
Replacement of the trunk light
Replacing steering column switches
Removal and installation the horn
Replacing the ashtray light bulb
Replacing control lamps and instrument cluster illumination lamps
Replacing the instrument panel switch illumination lamps
Electrical circuits
Scheme 1. Headlight connections
Scheme 2. Connections of headlights and front fog lights
Scheme 3. Connections of the control system of electric fans of the radiator of the cooling system and the condenser of the air conditioning system
Diagram 4. Connections of the ETWIS system and interior lighting lamps
Scheme 5. Rear light connections
Scheme 6. DRL system connections
Scheme 7. Connections of the electric headlight corrector and rear fog lights
Diagram 8. Connections of direction indicators and hazard warning lights
Diagram 9. Connections of the horn, brake light and reversing light
Scheme 10. Connections of diagnostic pads (cars equipped with a manual transmission)
Scheme 11. Connections of diagnostic pads (cars equipped with automatic transmission)
Scheme 12. Starting system and generator set
Scheme 13. Windscreen wiper and washer for the windshield and rear door glass (hatchback vehicles)
Scheme 14a. Heating and air conditioning system
Scheme 14b. Heating and air conditioning system
Diagram 15. ECAT system connections
Diagram 16. Connections of the ECAT system and the automatic transmission control system
Diagram 17. Anti-lock braking system (ABS) connections
Diagram 18a. Engine management system connections
Scheme 18b. Engine control system connections
Scheme 18v. Engine management system connections
Scheme 18g. Engine control system connections
Scheme 18d. Engine control system connections
Scheme 18e. Engine management system connections
Diagram 19. Passive Restraint System (SRS) connections
Diagram 20. Front seat heating system connections
Diagram 21. Connections of the electric drive of the roof sunroof
Diagram 22. Connections of the central door locking system
Scheme 23. Electric window connections
Scheme 24. Connections of audio system and clock
Diagram 25a. Interior lighting connections
Scheme 25b. Interior lighting connections
Diagram 26. Connections of the ETWIS unit circuits, cigarette lighter, rear window heating and side rear-view mirrors
Avella (1994-2000)
User manual
Control devices
General view of the hatchback car
General view of the car (4-door sedan)
Instrument panel design
Luggage compartment arrangement
Front and rear door arrangement
Car keys
Door locks: opening and closing
Rear door lock and central locking
Windows with power windows
Front seat adjustment
Rear seats: possible manipulations
Safety harness system
Use of seat belts for special groups of passengers
Correct use of seat belts
How does an airbag work?
Opening and closing the tailgate
Opening the hood
Opening the fuel filler cap
Sound signal
Exterior rear view mirrors
Rear view mirror with Day/Night switch
Interior and trunk lighting
Trunk shelf
Car driving
Fuel requirements
Catalytic converter
Running in a car
Calculating fuel consumption
Recommendations for economical driving
Refueling in the field
Driving in dangerous conditions
«Swinging» the car
Driving in winter
Driving in flooded areas
Ignition switch and anti-theft steering wheel lock
Starting the engine
Manual transmission control
Automatic transmission control
Hydraulic brake booster
Foot brake
Parking brake
Brake system malfunction warning
Anti-lock braking system (ABS)
Power steering
Dashboard
Control and measuring instruments
Warning and signal boards
Lighting
Windscreen wiper and washer
Rear window wiper and washer
Rear window defroster
Cigarette lighter and ashtray
Glove box
Cup holder
Sun visors
Climate control system
Climate control system controls
Operation of the climate control system
Actions in event of breakdown
Emergency alarm button
Starting the engine using an additional battery and wires
Starting the engine by towing or pushing
Electrical circuit fuses
Main fuse box (engine compartment)
Driver's side fuse box
Towing a car
If you have a flat tire
Maintenance
Precautionary measures
Owner's liability
Maintenance periods
Maintenance composition
General view of the engine compartment
Checking the engine oil level
Cooling system
Checking the coolant level
Replacing the coolant
Checking the brake fluid level
Checking the brake pedal
Checking the parking brake
Checking the mechanical brake
Checking the clutch pedal
Checking the fluid level in a manual transmission
Changing the fluid in a manual transmission
Checking the fluid level in the automatic transmission
Checking the power steering fluid level
Checking the washer fluid level
Replacing the air filter
Caring for your windshield wipers
Rechargeable battery
Belt tensioning
Spark plugs
Tire care
Wheel replacement
Lighting lamps
Specification of lubricants and fluids
Recommended SAE viscosity grades
Finding and troubleshooting minor problems
Car exterior care
Cleaning upholstery and car interior care
Power unit
Engine repair
Features of the B3 SOHC engine
Possible malfunctions, their causes and methods of elimination
Engine oil — check
Cooling liquid-check
Attachment drive belts
Hydraulic clearance adjusters: causes of malfunction and ways to eliminate them
Checking the ignition timing setting
Compression pressure (compression)
Removal and installation the engine
Camshaft oil seal
Rear crankshaft oil seal
Front crankshaft oil seal
Coolant pump pulley
Thermostat housing
Crankshaft pulley
Valve timing belt covers
Timing belt tensioner
Timing belt
Camshaft
Camshaft pulley
Crankshaft pulley
Cylinder head cover
Hydraulic valve clearance adjuster
Rocker arms, valve springs and valve stem seals
Exhaust manifold
Intake manifold
Cylinder head
Oil pan
Flywheel — removal and installation
Connecting rod and piston group
Crankshaft main bearing shells
Crankshaft — removal and installation
Cylinder head — disassembly and assembly
Connecting rod and piston — disassembly and assembly
Checking and repair
Cylinder head — inspection and repair
Valve and valve guide — inspection and repair
Replacing the valve guide bushing
Valve seat
Valve spring
Camshaft
Rocker arms and rocker arm axle
Hydraulic valve clearance adjusters
Cylinder Block — Check
Piston rings and piston pins
Connecting rod — check
Crankshaft
Main and connecting rod bearings — check
Engine specifications
Timing belt
Tensioner and its tension roller
Timing Belt Pulley, Camshaft Pulley
Lubrication system
Features of the device
Oil pressure — check
Engine Oil — Checking and Changing
Troubleshooting issues
Lubrication scheme for VZ SOHC and B5 SOHC engines
Oil filter — replacement
Oil pan — removal and installation
Oil pump — removal and installation
Special tool required for maintenance of the lubrication system
Data for maintenance purposes
Recommended SAE viscosity values
Cooling system
Features of the device and operation
Radiator fan
Possible malfunctions, their causes and methods of elimination
Coolant circulation diagram
Engine coolant
Radiator cap
Thermostat — checking operation
Electrical diagram of the fan
Electrical fan system
Radiator — removal and installation
Thermostat — removal and installation
Coolant pump
Coolant temperature sensor
Electric Fan Relay
Fan and housing assembly
Electric fan motor
Technical characteristics of the cooling system
Special tools required for servicing the cooling system
Air intake and exhaust
Features of the device and operation of the air intake system
Throttle valve
Intake manifold
Throttle control pedal
Throttle drive cable
Engine Idle Speed Control System (IAC VPA) — Features of the Design and Operation
Idle air valve
Air valve
Features of the device and operation of the catalytic converter
Exhaust system units
Technical characteristics of exhaust gas intake and exhaust systems
Supply system
Features of the device and operation — electronic fuel injection
Fuel injection synchronization
Pressure Relief — Precautions
Bleeding the fuel system
Power supply system operation
Fuel tank
Fuel filter
Fuel pump — check
Fuel pump relay
Pressure regulator — check
Injector — check
Checking the resistance of the injector valve winding
Special tool required for maintenance of the power supply system
Fuel system specifications
Ignition system
Ignition distributor: design and operation features
Checking and adjusting the ignition timing angle
Electrical diagram of the ignition system
Ignition coil
High voltage wires
Spark plugs
Technical characteristics of the ignition system
Tightening torques
Engine start system
Features of the starter device and operation
Removal the starter — sequence of actions
Ways to troubleshoot starter problems
Disassembling the starter
Checking the starter
Assembling the starter
Starter installation sequence
Special tool required for maintenance of the starting system
Technical specifications
Tightening torque
Battery and alternator
General Battery Maintenance Operations (50D 20L)
Charging the battery
Battery — diagnostics
Battery — Checking, Replacing, Removing
Battery specifications
Features of the generator design and operation
Electrical diagram of the generator
Generator diagnostics
Generator — removal and installation
Generator — disassembly
Generator — check
Generator — assembly
Charging System Specifications — Service Data
Transmission
Clutch
Features of the device and operation
Possible malfunctions, their search and methods of elimination
Clutch adjustment
Clutch cable — removal, inspection, installation
Clutch pedal — removal and installation
Clutch release bearing
Clutch release fork and lever
Clutch pressure and driven discs
Clutch housing
Clutch slave disc
Flywheel — removal, inspection, installation
Thrust bearing — removal and installation
Clutch specifications
Features of the design and operation of the gearbox
Gearbox control drive
Mechanical gearbox B3
Gear selection mechanism
Reverse intermediate gear
Reverse gear lock mechanism
Gear shift lock mechanism
Shift locks
Primary and secondary shafts
Differential — design description
Possible malfunctions, their causes and methods of elimination
Checking the oil level
Checking for oil leaks
Clutch pedal free play — adjustment
Gearbox — removal
Disassembling the gearbox
Installation of bearing rings, adjusting washers, seals
Secondary shaft — disassembly
Primary shaft — disassembly
Differential — disassembly
Speedometer driven gear assembly — removal
Synchronizer — disassembly
Shift rod for 5th gear and reverse gear
Gear Selector Mechanism — Disassembly
Gear Selector Mechanism — Assembly
Shift rod for 5th and reverse gears — assembly
Synchronizer — assembly
Speedometer driven gear assembly — installation
Differential — assembly
Primary shaft assembly
Secondary shaft assembly
Main gear — assembly
Secondary shaft bearing preload — adjustment
Differential Bearing Preload — Adjustment
Checking the differential bearing preload
Differential Bearing — Installation
Gearbox control — description
Gear shift rod — removal
Gear Shift Lever Housing — Removal
Gear Shift Lever Housing — Disassembly and Assembly
Gear Shift Lever Housing — Installation
Gear shift rod — installation
Technical specifications
Tightening torques
Special tools and devices required for maintenance and repair of the gearbox
Mechanical gearbox B5
Possible malfunctions, their causes and methods of elimination
Checking the oil level
Oil change
Gearbox device
Replacing the oil seal
Removal the oil seal
Precautions when disassembling the gearbox
Gear 5, reverse gear and crankcase parts — disassembly
Clutch housing and gearbox housing units
Measuring the axial clearance of the primary shaft assembly
Primary shaft assembly — disassembly
Measuring the axial clearance of the secondary shaft assembly
Secondary shaft assembly — removal
Synchronizer ring — check
Reverse idler gear and reverse gear engagement lever — check
Primary shaft — check
Gears III, IV and V gears, sleeve of gear V gear — check
Secondary shaft bearing
Gears of the 1st and 2nd gears — check
Synchronizer Clutch Hub Assembly — Check
Lubricating radial clearance, mm
Precautions when assembling the gearbox
Clutch Hub Assembly — Assembly
Secondary shaft assembly — assembly
Measuring the axial clearance after installing the secondary shaft assembly
Primary shaft assembly — assembly
Measuring the axial clearance after installing the primary shaft assembly
Precautions when assembling the clutch housing and gearbox housing units
Gear V and reverse gear crankcase parts — assembly
Gearbox installation
Selection of adjustment shims
Primary shaft assembly — installation
Secondary shaft assembly — installation
Differential — installation
Differential Bearing Preload
Disassembling the differential
Differential assembly
Gear shift drive — disassembly and assembly
Technical specifications
Special tools required for gearbox maintenance and repair
Drive shafts and axles
Front wheel drive and chassis components — design features
Wheel bearing axial play
Removal the wheel bearing
Disassembly and assembly of chassis components
Possible malfunctions, their search and methods of elimination
Checking the chassis components
Assembly of chassis components
Adjusting the undercarriage bearing preload
Installation of chassis components
Features of the rear axle design
Rear axle wheel axial play
Rear axle bearing preload
Removal the rear axle
Checking the rear axle
Installing the rear axle
Bearing preload
Features of the front wheel drive device
Front Wheel Drive Maintenance
Removal the front wheel drive
Disassembling the front wheel drive
Front Wheel Drive Assembly
Installing the front wheel drive
Technical specifications
Special tools and accessories required for servicing front wheel drives
Steering wheel free play — checking and adjusting
Steering Wheel Effort — Checking and Adjusting
Chassis
Steering
Checking the front wheel drive
Non-power steering — general information
Tie Rod End — Removal and Installation
Possible malfunctions, their search and methods of elimination
Protective cover — removal and installation
Steering wheel and steering column — removal and installation
Steering column — check
Steering gear and steering linkage — removal
Disassembling the steering mechanism
Steering gear — check
Steering gear — assembly
Steering gear — installation
Features of the power steering device
Checking the pressure in the power steering system
Checking the force on the power steering wheel
Possible malfunctions of power steering, their detection and troubleshooting methods
Checking the fluid level in the power steering reservoir
Bleeding the Power Steering System
Removal the power steering gear
Disassembling the power steering mechanism
Power Steering Gear — Assembly
Power steering gear — installation
Power Steering Pump — Removal
Power Steering Pump — Disassembly and Assembly
Power Steering Pump Assembly Instructions
Power Steering Pump — Check
Power Steering Pump — Installation
Power Steering Pump Drive Belt — Check
Power Steering Pump Drive Belt — Adjustment
Power Steering Pump Drive Belt — Replacement
Tightening torques
Special tools and devices required for removing and installing the steering system
Brake system
Brake system — design and operation features
Bleeding the brake system
Hydraulic circuits of the brake system — inspection
Hydraulic circuits of the brake system — removal and installation
Possible malfunctions, their causes and methods of elimination
Brake drive device
Checking for brake fluid leaks
Checking the brake fluid level
Check valve — check
Brake pedal — inspection without disassembly
Checking the operation of the vacuum booster (simplified method)
Checking the vacuum booster with a measuring device
Pressure limiter — check
Brake pedal — removal and installation
Master Brake Cylinder — Removal and Installation
Disassembly, inspection, assembly of the master brake cylinder
Pressure Limiter — Replacement
Vacuum brake booster — removal and installation
Features of the design and operation of the front disc brake
Replacing the front disc brake pads
Checking the condition of the front disc brake pads
Installing front disc brake pads
Removal and installation the caliper
Support — disassembly and assembly
Front wheel brake mechanism device
Rear Drum Brake — General Information
Rear Drum Brake — Removal and Installation
Wheel Cylinder Brake Hose — Removal and Installation
Wheel cylinder — removal and installation
Wheel cylinder — disassembly and assembly
Parking brake system — design and operation features
Adjusting the parking brake cable
Possible parking brake malfunctions, their causes and troubleshooting methods
Parking brake lever — removal and installation
Parking brake cable — removal and installation
Special tools and devices required for servicing the brake system
Technical specifications
Clarus (1995-2001)
Power unit
Engine repair
Maintenance intervals
Engine technical data
Engine Description
Air filter element
Spark plugs
Oil in the engine crankcase
Coolant level
Drive belt
High voltage wires
Hydraulic valve clearance compensators
Checking the ignition timing angle
Checking the compression in the cylinders
Removal and installation the engine
Removal and installation of auxiliary elements from the engine
Removal and installation the timing belt and pulleys
Cylinder head — removal, inspection and installation
Cylinder Block — Removal, Inspection and Installation
Troubleshooting issues
Lubrication system
Description of the engine lubrication system
Technical data of the lubrication system
Checking the engine oil level
Checking engine oil pressure
Engine oil change
Replacing the oil filter
Oil radiator — removal and installation
Oil pan — removal and installation
Oil pump — removal and installation
Troubleshooting issues
Cooling system
Description of the cooling system
Technical data of the cooling system
Cooling liquid
Checking the tightness of the cooling system
Replacing the coolant
Checking the radiator cap
Radiator — removal and installation
Water pump — removal and installation
Thermostat — removal and installation
Checking the radiator fan
Coolant temperature sensor
Radiator Fan Relay
Troubleshooting issues
Power and exhaust systems
Description of the power supply and exhaust system
Technical data of the fuel and exhaust system
Throttle valve — check
Intake manifold
Adjusting the accelerator cable
Variable Intake Manifold Turbocharging System (VICS) (FE DOHC)
Valve of the idle speed control system
Elements of the exhaust system
Emission control and reduction systems
Description of the design of multi-point fuel injection
Preliminary engine checks
Self-diagnosis function
Error codes
Exhaust gas toxicity reduction system
Crankcase ventilation system (PCV)
Checking the crankcase ventilation system Valve (PCV)
Fuel vapor recovery system
Checking the fuel vapor recovery system
Checking the fuel vapor recovery system valve
Checking the activated carbon filter
Checking the two-way valve
Checking the fuel vapor separator
Checking the fuel vapor valve
Exhaust Gas Recirculation (EGR) System
Checking the exhaust gas recirculation system
Checking the electromagnetic valve (EGR)
Check valve (EGR)
Variable-length turbocharging system (FE–DOHC engine)
Vacuum chamber
One-way shut-off valve
Air flow meter
Coolant temperature sensor
Throttle position sensor
Main Relay — Check
Fuel system
Description of the fuel system
Technical data of the fuel system
Relieving pressure in the fuel system
Filling the fuel system with fuel
Checking the residual pressure in the fuel system
Checking fuel lines
Fuel tank — removal and installation
Fuel filter — removal and installation
Fuel pump — removal and installation
Checking the fuel pump relay
Checking the maximum pressure generated by the pump
Checking for an open circuit in the electrical circuit
Pressure regulator — removal and inspection
Fuel injectors — removal and installation
Ignition system
Description of the ignition system
Technical data of the ignition system
Spark generation check
Spark plugs — removal and installation
Checking spark plugs
High voltage wires — checking
Ignition coil — check
Ignition distributor — removal and installation
Troubleshooting issues
Transmission
Clutch
Clutch Description
Clutch technical data
Checking the fluid level in the clutch hydraulic drive
Adjusting the clutch pedal
Clutch pedal — removal and installation
Bleeding the hydraulic clutch drive system
Clutch Master Cylinder — Removal and Installation
Clutch Master Cylinder Repair
Clutch slave cylinder — removal and installation
Repair of the clutch slave cylinder
Clutch disc — removal and installation
Troubleshooting issues
Mechanical gearbox
Description of the manual gearbox
Technical data of manual transmission
Checking the oil level
Gearbox oil change
Removal the gearbox
Gearbox installation
General recommendations for disassembling the gearbox
Disassembly, inspection of fifth/reverse gear and crankcase
Disassembling the clutch housing and gearbox housing units
Replacing the differential oil seal on a car
Disassembling the primary shaft of the gearbox
Disassembling the secondary shaft of the gearbox
Checking the primary and secondary shaft parts
General recommendations for gearbox assembly
Secondary shaft assembly
Assembling the primary shaft
Assembly, inspection of fifth/reverse gear and crankcase
Selection of adjustment shims
Differential Bearing Preload
Adjusting the bearing preload
Gearbox Assembly Notes
Differential — disassembly, inspection and assembly
Gear shift mechanism — removal and installation
Troubleshooting issues
Automatic gearbox G4A-EL
Description of automatic transmission G4A–EL
Technical data of automatic transmission G4A–EL
Troubleshooting
Quick diagnostic table
Self-diagnosis system
Error codes
Diagnostic connector
Post-repair operation
Testing the joint operation of an automatic transmission and engine on a stationary vehicle
Testing for lag time
Transmission Fluid Pressure Testing
Valve Reducing Pressure Testing
Checking the level and condition of the liquid
Automatic transmission fluid leaks
Throttle drive cable
Mode switch
Brake light switch
ATF Transmission Fluid Temperature Sensor
Checking the resistance of the pulse generator
Solenoid valves — testing
Removal the automatic transmission
General recommendations for disassembling the gearbox
Disassembling an automatic transmission
Checking and adjusting bearing preload
Automatic transmission assembly
Installation of automatic transmission
Oil radiator — removal and installation
Drive Disc — Removal and Installation
Checking the operation and adjusting the position of the selector lever
Selector lever — removal and installation
Selector lever repair
Automatic gearbox 50-40 LE
Description of automatic transmission AKP 50–40 LE
Technical data of the automatic transmission 50–40 LE
Friction mechanisms
Troubleshooting
Error codes
Testing for lag time
Testing the joint operation of an automatic transmission and engine on a stationary vehicle
Transmission Fluid Pressure Testing
Valve Reducing Pressure Testing
Checking the level and condition of the liquid
Position sensor — checking and adjustment
Gear hold switch
Mode Switch — Check
ATF Transmission Fluid Temperature Sensor
Checking the resistance of the speed sensor (output)
Checking the resistance of the speed sensor (input)
Solenoid valves — testing
Replacing the transmission fluid temperature sensor sealing ring
Gearbox side cover
Speed sensor (input and output)
Gear shift valves (No. 1, No. 2)
Oil cooler tubes
Disassembly and assembly of the gearbox
Note on disassembly and assembly
Drive shafts and axles
Description of axles and drive shafts
Technical data of drive shafts
Front wheel steering knuckle and hub
Steering knuckle repair
Rear suspension — general information
Rear axle — removal and installation
Drive shafts — general information
Right drive and intermediate shafts
Disassembly and assembly of the intermediate shaft
Left Drive Shaft — Removal and Installation
Drive shaft with tripod type CV joints
Troubleshooting issues
Chassis
Steering
Steering Description
Technical data of steering
Checking the steering wheel free play
Checking the steering wheel turning force
Power steering pump drive belt
Checking the fluid pressure in the hydraulic system
Replacing the steering rod protective boot
Steering shaft — removal and installation
Steering gear — removal and installation
Power Steering Pump (FE DOHC)
Disassembling and assembling the power steering pump (FE DOHC)
Troubleshooting issues
Brake system
Description of the brake system
Technical data of the brake system
Bleeding the hydraulic brake drive system
Checking brake pipes and hoses
Replacing brake hoses
Brake pedal installation height
Free travel of the brake pedal
Distance of brake pedal from floor
Brake pedal — removal and installation
Checking the brake light switch
Master Brake Cylinder — Removal and Installation
Checking the brake booster
Front Disc Brake — Removal and Installation
Rear Disc Brake — Removal and Installation
Pressure regulator — check
Parking brake — removal, installation and adjustment
Anti-lock braking system (ABS)
List of brake system fault codes
Precautions when carrying out repairs
Hydraulic Control Unit (HCV)
ABS control unit — removal and installation
Wheel Speed Sensors — Removal and Installation
Front sensor rotor
Basic inspection of the brake system
Checking functionality
Troubleshooting issues
Car suspension
Description of front and rear suspension
Technical data of suspension
Adjusting the front wheel alignment angles
Adjusting the rear wheel alignment angles
Front shock absorber strut with spring
Repair of the front suspension shock absorber
Lower control arm of the front suspension
Front stabilizer bar
Thrust of the front stabilizer bar
Crossbar — removal and installation
Rear shock absorber strut — removal and installation
Repair of rear shock absorber strut
Rear stabilizer bar
Rear stabilizer bar pull
Transverse and longitudinal traction
Rear crossmember — removal and installation
Troubleshooting issues
Wheels and tires
Technical data of wheels and tires
General recommendations for wheels and tires
Recommendations for tire replacement
Checking air pressure and tire condition
Wheel beating
Types and causes of tire tread wear
Removal and installation wheels
Wheel rotation
Wheel balancing
Troubleshooting issues
Body
Exterior
Main external and internal elements of the body
Hood — removal and installation
Trunk lid — removal and installation
Front bumper — removal and installation
Rear bumper — removal and installation
Front door — removal and installation
Rear door — removal and installation
Windscreen wiper and washer
Windscreen washer reservoir — removal and installation
Windshield — Removal and Installation
Rear window — removal and installation
Outside rear view mirror — removal and installation
Electrically adjustable outside rear view mirror
Interior
Instrument panel — removal and installation
Front seats — removal and installation
Rear seat — removal and installation
Backrest tilt mechanism
Seat belts — removal and installation
Air conditioner
Description of the air conditioning system
Technical data of the air conditioning system
Checking the air conditioning system drives
Connection of pipelines
Quick release couplings
Checking the air conditioning system components located in the vehicle interior
Removal and installation the compressor
Mode control drive
Mixing Drive — Check
Air intake drive — check
Channel sensor
Compressor — Description of Work
Magnetic clutch — description of work
Dual-mode pressure switch
Refrigerant (R–134A) — Description and Precautions
Basic information about cooling system maintenance
Troubleshooting issues
Electrical equipment
Equipment and devices
Description of electrical equipment
Technical data of electrical equipment
Devices for testing electrical equipment elements and electrical circuits
Electrical Connectors — Checking and Replacing
Wires — Type Description
Replacing the fuse
Main and fuses
Main fuse box
Fuse — Removal and Installation
Battery — Checking and Charging
Generator — removal and installation
Checking the sound signal
Checking the rear window defroster
Rear Window Defogger Switch
Rear Window Defogger Relay
Instrument cluster — checking sensors and lamps
Airbag System (SRS)
Car locking system
Electrical circuits
Starting and charging system
Engine management system
Windscreen wiper and washer (front, rear)
Headlights, side lights, rear lights and number plate lights
Fog lights and rear fog lights
Cargo area lights, tail lights and number plate lights
Sound signal and emergency light signaling
Horn, brake lights and reversing lights
Heating and air conditioning system
Electrical diagram of the audio system
Power windows with electric drive
Central lock
Electrically adjustable rear view mirrors
Cooling system
Shuma 1 (1997-2001)
Power unit
Engine repair
Frequency of vehicle maintenance
Engine technical data
Timing Belt — Removal, Checking and Installation
Hydraulic valve clearance compensators
Cylinder head — removal, inspection and installation
Front Oil Seal Ring — Removal and Installation
Rear Oil Seal Ring — Removal and Installation
Removal and installation the engine
Disassembly and assembly of the engine
Checking the engine
Lubrication system
Description of the engine lubrication system
Technical data of the engine lubrication system
Checking the engine oil level
Engine oil change
Replacing the oil filter
Checking oil pressure
Oil pan — removal and installation
Oil pump — removal and installation
Oil pump repair
Cooling system
Description of the cooling system
Technical data of the cooling system
Cooling liquid-warnings
Checking the coolant level
Coolant quality
Checking the tightness of the cooling system
Replacing the coolant
Checking the radiator cap
Back pressure valve
Thermostat — Removal, Checking and Installation
Radiator Fan Relay — Removal, Checking and Installation
Radiator Fan Motor — Removal, Checking and Installation
Radiator — removal, inspection and installation
Water Pump — Removal, Checking and Installation
Power and exhaust systems
Description of the power supply and exhaust systems
Adjusting the accelerator cable
Checking the air filter element
Elements of the exhaust system
Air filter element — removal and installation
Checking the ignition timing and idle speed
Electronic Engine Control Module (ECM)
Checking the crankcase ventilation system (PCV)
Checking the fuel vapor recovery system
Checking the fuel vapor recovery system valve
Checking the fuel vapor separator
Checking the two-way control valve
Checking the activated carbon canister
Checking the fuel vapor valve
Air Flow Sensor (TED) — Check
Vacuum check
Air flow sensor (TED) — removal and installation
Coolant Temperature Sensor — Removal and Installation
Throttle position sensor
Heated oxygen sensor
Checking the front and rear heated oxygen sensors
Main Relay — Removal and Installation
Fuel system
Description of the fuel system
Technical data of the fuel system
Relieving pressure in the fuel system
Fuel system activation
Checking the residual pressure in the fuel system
Checking fuel lines
Fuel pump — check
Checking the maximum pressure generated by the pump
Checking the fuel pump relay
Checking fuel injectors
Checking the tightness of fuel injectors
Checking the performance of fuel injectors
Checking the resistance of fuel injectors
Fuel tank — removal and installation
Fuel Supply Unit — Removal and Installation
Pressure regulator — removal and installation
Fuel lines — removal and installation
Fuel filler pipe — removal and installation
Fuel filter — removal and installation
Quick release couplings
Fuel line — removal and installation
Fuel injectors — removal and installation
Ignition system
Description of the ignition system
Technical data of the ignition system
Ignition coil — removal, inspection and installation
Spark plugs — removal, inspection and installation
High voltage wires — checking
Ignition timing angle
Camshaft Position Sensor — Removal and Installation
Crankshaft Angle Sensor — Removal and Installation
Transmission
Clutch
General description of the clutch
Clutch technical data
Bleeding the hydraulic clutch drive system
Adjusting the clutch pedal
Clutch pedal — removal and installation
Clutch Master Cylinder — Removal and Installation
Clutch slave cylinder — removal and installation
Clutch disc — removal
Checking the clutch release bearing
Checking the clutch housing with pressure plate
Checking the clutch disc
Checking the center bearing
Flywheel Check — Checking and Installing
Clutch Master Cylinder Repair
Repair of the clutch slave cylinder
Mechanical gearbox
Mechanical gearbox device
Technical data of manual transmission
Checking the BF DOHC Oil Level
Checking the TE DOHC Oil Level
Changing oil in manual transmission
Replacing the oil seal ring
Removal and installation the gearbox
Disassembly, inspection and assembly of fifth/reverse gear and rear cover BF DOHC
Disassembly, inspection and assembly of 5th/reverse gear and rear cover TE DOHC
BF DOHC Clutch Housing and Transmission Housing Components
TE DOHC Clutch Housing and Transmission Housing Components
Primary shaft of the BF DOHC gearbox
Primary shaft of the TE DOHC transmission
Secondary shaft of the BF DOHC gearbox
Secondary shaft of the TE DOHC gearbox
Selection of adjustment shims
Differential — removal, inspection and installation
Gear shift mechanism — removal and installation
Automatic gearbox
Automatic transmission device
Checking the operation and adjusting the position of the selector lever
Checking the level and replacing the fluid in the automatic transmission
Automatic Transmission Fluid Replacement Procedure
Automatic transmission fluid leaks
Replacing oil seal rings
Control Valve Block — Checking and Installing
Automatic transmission fluid cooling radiator
Removal and installation of automatic transmission
Automatic transmission repair
Oil pump — disassembly, inspection and assembly
Control valve body — removal and installation
O/D Switch — Checking, Disassembling and Assembling
Gearbox range switch
Automatic transmission temperature sensor
Inlet/Turbine Speed Sensor
Speed Sensor — Voltage Check
Solenoid valves — removal and inspection
Linear Solenoid Valve — Resistance Test
Selector lever — removal and installation
Selector lever repair
Drive shafts and axles
Description of axles and drive shafts
Technical data of axles and drive shafts
Checking the play of the front wheel bearings
Checking the condition of the drive shaft
Front wheel steering knuckle and hub
Rear axle — removal and installation
Drive shaft — removal and installation
Steering knuckle repair
Tripod type CV joint
Chassis
Steering
Steering Description
Technical data of steering
Checking the non-power steering
Checking the hydraulic power steering
Power steering pump drive belt
Replacing the steering rod protective boot
Steering shaft — removal and installation
Steering gear — removal and installation
Power Steering Pump — Removal and Installation
Steering shaft repair
Steering gear repair
Power Steering Pump Repair
Wheels and tires
General description of wheels and tires
Technical data of wheels and tires
Recommendations for tire replacement
Checking air pressure and tire condition
Wheel beating
Wheel rotation
Wheel balancing
Brake system
Description of the brake system
Technical data of the brake system
Bleeding the hydraulic brake drive system
Checking brake pipes and hoses
Replacing brake hoses
Brake pedal installation height
Free travel of the brake pedal
Distance of brake pedal from floor
Checking the brake booster
Parking brake — checking and adjusting
Brake pedal — removal and installation
Master Brake Cylinder — Removal and Installation
Vacuum brake booster — removal and installation
Replacing the front brake pads
Replacing brake pads on rear drum brakes
Replacing brake pads on rear disc brakes
Parking brake — removal and installation
Hydraulic Control Unit (HCU) — Removal and Installation
Front wheel speed sensor
Rear wheel speed sensor
Toothed rotor of the wheel speed sensor
Repair of the working brake cylinder
Basic inspection of the brake system
Checking the functionality of the brake system
List of brake system fault codes
Car suspension
General description of car suspension
Technical data of suspension
Checking and adjusting wheel alignment angles
Lower control arm front suspension — removal and installation
Front stabilizer bar
Transverse rods and trailing arm of the rear suspension
Rear stabilizer bar
Rear suspension cross beam — removal and installation
Repair of the front suspension shock absorber
Repair of the rear suspension shock absorber
Body
Exterior
General description of body and interior elements
Tightening torques for threaded connections
Front bumper — removal, inspection and installation
Rear bumper — removal, inspection and installation
Headlight — removal and installation
High Brake Light — Removal and Installation
Rear combination light — removal and installation
Hood — removal and installation
Sound signal — removal and installation
Replacing the glass of the outside rearview mirror
Trunk lid — removal and installation
Trunk Lid Hinge — Removal and Installation
Distances between body points
Interior
Ceiling — removal and installation
Instrument cluster — removal and installation
Instrument cluster repair
Replacing the instrument cluster bulbs
Printed circuit board — removal and installation
Upper decorative trim for the instrument panel
Switches — removal and installation
Central panel — removal and installation
Center console trim — removal and installation
Center console — removal and installation
Instrument cluster backlight regulator — removal and installation
Left and right windshield heater grilles
Left and right side heater grilles
Air ducts for heating and ventilation systems
Floor air ducts — removal and installation
Glove box — removal and installation
Hood Lock Release Cable — Removal and Installation
Bonnet Lock Release Handle — Removal and Installation
Instrument panel — removal and installation
Heating and ventilation control panel
Outside rear view mirror — removal and installation
Front seats — removal and installation
Front Seat Back Upholstery — Removal and Installation
Front Seat Cushion Upholstery — Removal and Installation
Front seat folding hinge
Rear seat — removal and installation
Seat belts — check
Front seat retainer — removal and installation
Front Shoulder Seat Belt — Removal and Installation
Rear Seat Belts — Check
Rear seat belt mounting bracket
Shoulder rear seat belt — removal and installation
Front Pillar Upper Trim — Removal and Installation
Lower B-Pillar Trim — Removal and Installation
Upper B-Pillar Trim — Removal and Installation
Rear pillar trim — removal and installation
Footrest Trim — Removal and Installation
Doors and windows
Front door — removal and installation
Door moisture seal — removal and installation
Door hinges and door lock strike plate
Door lock — removal and installation
Internal door opening handle — removal and installation
External door handle — removal and installation
Door Lock Cylinder — Removal and Installation
Window lift switches — removal and installation
Electric window lift
Door glass — removal and installation
Rear door — removal and installation
Front door trim — removal and installation
Rear Door Trim — Removal and Installation
Air conditioner
Description of the air conditioning system
Technical data of the air conditioning system
Checking the air conditioner compressor relay
Checking the air conditioner switch
Checking the air conditioner thermal contact
Fan/evaporator — removal and installation
Checking the fan motor
Checking the Fan Motor Resistor Block
Air Conditioning Compressor — Removal and Installation
Checking the Fan Switch
Air conditioning compressor drive belt
Condenser — removal and installation
Condenser Fan — Removal, Checking and Installation
Checking the condenser fan relay
Heater unit — removal and installation
Heating and ventilation control unit
Electrical equipment
Equipment and devices
General description of electrical equipment
Description of electrical circuits
General description of fuses
Checking the rear window defroster
Driver's airbag — removal and installation
Front passenger airbag
Spiral wire — removal and installation
Power devices
Technical data of power electrical equipment
Rechargeable battery
Checking the level and density of electrolyte and charging
Maintenance free batteries
Battery wires and terminals
Charging standard batteries
Starter — General Description
Starter Interlock Switch — Check
Removal and installation the starter
Starter repair
Checking the traction relay
Checking the starter brushes and brush holder
Checking the stator coils
Checking the starter rotor
General description of the generator
Generator Drive Belt — Checking and Replacing
Removal and installation the generator
Generator repair
Diagnostics of starting system malfunctions and methods of their elimination
Windshield wipers and washers
Windshield Washer Hoses — Removal and Installation
Windshield Washer Motor — Removal and Installation
Windscreen wiper arm — removal and installation
Sprayers — Removal, Installation and Adjustment
Replacing Windscreen Wiper Blades — Removal and Installation
Windscreen wiper rods — removal and installation
Windscreen wiper motor — removal, inspection and installation
Electrical circuits
Electrical diagram of the cooling system
Electrical diagram of the exhaust gas control and toxicity reduction system (TED engines)
Electrical diagram of the exhaust gas control and toxicity reduction system (BDD engines)
Electrical diagram of the engine starting system
Electrical diagram of the charging system
Automatic transmission control circuit diagram
Electrical diagram of the brake system
Airbag Wiring Diagram
Air conditioning system wiring diagram

4934