Workshop Manual for Engine 4G93.pdf

This manual contains service/maintenance/overhaul procedures of 4G93 Engine (Mitsubishi Lancer). Each procedure is described comprehensive along with pictures, bolt torque tightening values, exploded diagrams and sequences. Should be very concise procedures for ones who want to overhaul their Lancer.Inside this manual:CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL AND DRIVE PLATECYLINDER HEAD AND

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Mercedes Benz W124 Owner's Manual

Applies to:
200
200E
230E
260E
300E
230CE
300CE
260E4MATIC
300E4MATIC

Contains:
Instruments and control
Starting the engine
Vehicle Maintenance
Practical Tips
Technical Data
Service Products

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Honda Civic 1996-1998 Service Manual

This manual contains information for the 1996-1998 Civic. It is divided into 24 sections. Each section includes:
- a table of contents
- disassembly/assembly procedures and tools
- inspection
- testing and troubleshooting
- repair
- adjustments

Main sections:
General information
Special tools
Specifications
Maintenance
Engine
Cooling
Fuel and emissions
Transaxle
Steering
Suspensions
Brakes (including ABS)
Body
Heather and AC
Electrical
SRS

Models covered:
U.S. 1996 Model (2 door Hatchback)
U.S. 1996 Model (4 door Sedan)
U.S. 1996 Model (2 door Coupe)
Canada 1996 Model (2 door Hatchback)
Canada 1996 Model (4 door Sedan)
Canada 1996 Model (2 door Coupe)
U.S. 1997 Model (2 door Hatchback)
U.S. 1997 Model (4 door Sedan)
U.S. 1997 Model (2 door Coupe)
Canada 1997 Model (2 door Hatchback)
Canada 1997 Model (4 door Sedan)
Canada 1997 Model (2 door Coupe)
U.S. 1998 Model (2 door Hatchback)
U.S. 1998 Model (4 door Sedan)
U.S. 1998 Model (2 door Coupe)
Canada 1998 Model (2 door Hatchback)
Canada 1998 Model (4 door Sedan)
Canada 1998 Model (2 door Coupe)

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BMW 3 & 5 Series (1983-1991) - Service and Repair Manual

Models covered:

3-Series (E30)
316 (83 to 88), 316i (88 to 91), 318i (83 to 91), 320i (87 to 91), 325i (87 to 91).
5-Series (E28)
518 (81 to 85), 518i (85 to 88), 525i (81 to 88), 528i (81 to 88), 535i (85 to 88), M535i (85 to 88)
5-Series (E34)
518i (90 to 91), 520i (88 to 91), 525i (88 to 91), 530i (88 to 91), 535i (88 to 91)
Engines covered
1596 cc, 1766 cc, 1795 cc, 1990 cc, 2494 cc, 2788 cc, 2986 cc & 3430 cc

Does not cover Diesel, dohc or V8 engines, or four-wheel-drive models

The E30 3-Series range first became available in the UK in March 1983, and
continued in production until April 1991, when the revised E36 3-Series range
(not covered by this manual) was introduced. Convertible and Touring (Estate)
models were introduced for 1988, and these models have continued in E30 form
to date.
The E28 5-Series models were introduced in October 1981, and were superseded
in June 1988 by the revised E34 5-Series range, Touring versions of which
became available from March 1992.
Throughout this manual, E28 models are also referred to as “oldshape”, while
E34 models are designated “new-shape”.
The models covered by this manual are equipped with single overhead cam
in-line four- and six-cylinder engines. Early 316 and 518 models are fitted
with carburettors, but all other models are fitted with fuel injection systems. Transmissions are a five-speed manual, or three- or four-speed automatic.
The transmission is mounted to the back of the engine, and power is transmitted
to the fully-independent rear axle through a twopiece propeller shaft. The final drive unit is bolted solidly to a frame crossmember, and drives the rear wheels through driveshafts equipped with inner and outer constant velocity joints.
The front suspension is of MacPherson strut type, with the coil spring/shock
absorber unit making up the upper suspension link. The rear suspension is
made up of coil springover-shock absorber struts, or coil springs and conventional shock absorbers, depending on model.
The brakes are disc type at the front, with either drums or discs at the rear, depending on model. Servo assistance is standard on all models. Some later
models are equipped with an Anti-lock Braking System (ABS).
All models are manufactured to fine limits, and live up to the BMW reputation
of quality workmanship. Although many of the models covered by this manual appear complex at first sight, they should present no problems to the home mechanic.

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2000 Toyota Celica Service & repair manual

Vol 1

- Maintenance
- Preparation
- Specifications
- Diagnostics

Vol 2

- Engine
- Chassis
- Body
- Electrical

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Ford Granada Service and Repair Manual

Contains:

Routine maintenance and servicing
Air cleaner filter element renewal
Air conditioner condenser check
Air conditioner refrigerant charge check
Automatic choke check
Automatic transmission brake band adjustment
Automatic transmission fluid level check
Automatic transmission selector lubrication
Auxiliary drivebelt check
Battery electrolyte level check
Battery terminal check
Brake fluid renewal
Brake pipe and hose check
Brake system seal and hose renewal
Camshaft drivebelt renewal
Crankcase ventilation vent valve renewal
Driveshaft check
Electrical system check
Engine coolant renewal
Engine inlet manifold security check
Engine oil and filter renewal
Engine valve clearance check
Exhaust system check
Final drive oil level check
Fluid leak check
Fluid level checks
Front and rear brake pad check
Fuel filter renewal
Hinge and lock check and lubrication
Hot starting check
Idle mixture check
Idle speed check
Idle speed linkage clean
Ignition system component check
Intensive maintenance
Introduction
Manual gearbox oil level check
Oil filler cap check
Power steering fluid level check
Road test
Roadwheel security check
Seat belt check
Spark plug renewal
Specifications
Steering and suspension security check
Tyre checks
Underbody inspection
Wiper blade check

1.8 & 2.0 litre SOHC engines

2.0 litre DOHC engine

2.4, 2.8 and 2.9 litre V6 engines

Cooling, heating and ventilation systems

Fuel and exhaust systems

Engine electrical systems
Air charge temperature sensor - removal and refitting
Alternator - brush renewal
Alternator - removal and refitting
Alternator - testing on the vehicle
Battery - charging
Battery - removal and refitting
Carburettor stepper motor (2.0 litre models) - removal, refitting and
adjustment
Coolant temperature sensor - removal and refitting
Crankshaft speed/position sensor - removal and refitting
Distributor - removal and refitting
Electrical fault-finding - general information
Engine management control module - removal and refitting
Engine management system relays - testing
Fuel temperature sensor - removal and refitting
Fuel trap (carburettor models) - removal and refitting
General information and precautions
HT leads, distributor cap and rotor arm - removal, inspection and
refitting
Ignition coil - testing, removal and refitting
Ignition module (fuel-injection models) - removal and refitting
Ignition timing - checking
Ignition timing and idle speed adjustments
Manifold absolute pressure (MAP) sensor - removal and refitting
Manifold heater (carburettor models) - removal and refitting
Spark plugs - removal, inspection and refitting
Starter motor - brush renewal
Starter motor - removal and refitting
Starter motor - testing on the vehicle
Vehicle speed sensor - removal and refitting

Braking system
ABS module - removal and refitting
Brake discs - inspection
Brake hydraulic system - bleeding
Brake hydraulic system - fluid renewal
Brake pedal - removal and refitting
Brake pipes and hoses - inspection, removal and refitting
Control module (April 1992 on) - removal and refitting
Front brake disc - removal and refitting
Front brake pads - inspection and renewal
Front caliper - overhaul
Front caliper - removal and refitting
G (gravity) switch (April 1992 on) - removal and refitting
General information
Handbrake cable - adjustment
Handbrake cable - removal and refitting
Handbrake control lever - removal and refitting
Hydraulic unit - removal and refitting
Hydraulic unit accumulator - removal and refitting
Hydraulic unit fluid reservoir - removal and refitting
Hydraulic unit hoses - removal and refitting
Hydraulic unit pressure switch - removal and refitting
Hydraulic unit pump and motor - removal and refitting
Master cylinder (April 1992 on) - removal and refitting
Pedal Travel Sensor (PTS) (April 1992 on) - removal and refitting
Rear brake disc - removal and refitting
Rear brake pads - inspection and renewal
Rear caliper - overhaul
Rear caliper - removal and refitting
Rear disc splash shield - removal and refitting
Vacuum servo unit (April 1992 on) - testing, removal and refitting
Vacuum servo unit check valve (April 1992 on) - removal, testing and refitting
Valve block and pump assembly (April 1992 on) - removal and refitting
Wheel sensors - removal and refitting

Applies to:
Engine oil
SOHC with filter
DOHC with filter
DOHC without filter
V6 with filter

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Daewoo Leganza MY2000 Service Manual

This manual contains procedures for maintenance, adjustment, service operations and removal and installation of components of Leganza vehicle.

Contains:

General information
Engine
Suspension
Driveline/Axle
Brakes
Transmission/Transaxle
Steering
Heating/Ventilation/Air Conditioning
Restraints
Body and Accessories

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Ford Sierra Service and Repair Manual

Models covered:
Saloon (Sapphire and Hatchback), Estate and P100 Pick-up models, including special/limited editions, with four-cylinder SOHC, DOHC & CVH petrol engines and two-wheel-drive.
Does not cover:
V6 or Diesel engine models, four-wheel-drive models, or RS Cosworth

The Ford Sierra was first introduced in late 1982 with the option of seven different engines and four different trim levels. This manual covers the four cylinder in-line petrol engines, but other models in the range are fitted with V6 or diesel engines.
The Sierra was introduced by Ford as the successor to the Cortina and initially received a mixed reception as it was one of the first vehicles to make use of the “aeroback” body style designed to reduce the air drag coefficient to a minimum in the interests of fuel economy.
Mechanically the Sierra is similar to the Cortina with the exception of all-round independent suspension.
Initially, 1.3, 1.6 and 2.0 litre SOHC carburettor engines were available, with Hatchback and Estate body styles. In late 1984, a 1.8 litre SOHC engine became available and in 1985, a performance orientated 2.0 litre SOHC fuel injection engine was introduced.
Towards the end of 1986, the 1.3 litre engine was phased out. In order to fill a gap in the range, a Saloon body style, designated the Sapphire, was introduced in early 1987 and shortly afterwards, a 1.8 litre CVH engine replaced the previously used 1.8 litre SOHC engine throughout the model range.
A 1.6 litre CVH engine was introduced in September 1991 to replace the 1.6 litre SOHC engine used previously, this engine being broadly similar to the original 1.8 litre CVH engine which was in turn uprated in March, 1992.
A 2.0 litre DOHC (Double OverHead Camshaft) engine was introduced in August 1989 to replace the 2.0 litre SOHC engine.
In early 1988, a Sierra-based P100 pick-up model became available to replace the previous Cortina-based design. The P100 consists of a Sierra-type “cab” and front suspension, and a Ford Transit-type rear suspension and 2.0 litre engine.
A wide range of standard and optional equipment is available within the Sierra
range to suit most tastes, including an anti-lock braking system.
For the home mechanic, the Sierra is a straightforward vehicle to maintain and
repair since design features have been incorporated to reduce the actual cost of
ownership to a minimum, and most of the items requiring frequent attention are
easily accessible.

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Chrysler Voyager 1998 Service Manual

Contains:

Lubrication and Maintenance
Suspension
Brakes
Clutch
Cooling System
Battery
Starting System
Instrument Panel and Systems
Vehicle Speed Control System
Wiper and Washer Systems
Lamps
Vehicle Theft/Security Systems
Chime Warning/Reminder System
Wiring Diagrams
Engine
Frame and Bumpers
Fuel System—2.5L Diesel Engine/2.0L Gas Engine
Steering
A—598 Manual Transaxle
Body
Heating and Air Conditioning
Emission Control System

The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components.

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Daewoo Korando Service Manual

Contains:

Engine
Suspension
Drive line / Axle
Brake
Transmission
Steering
HVAC (Heating, Ventilation & Air conditioning)
Restraints
Body and Accessories

This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.

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Volkswagen Golf & Jetta Mk2 petrol repair manual

VW Golf & Jetta Mk 2 models with petrol engines, including fuel injection, catalytic converter, Formel E, 16-valve and special/limited edition models 1043 cc, 1272 cc, 1595 cc & 1781 cc

The Mk. II Volkswagen Golf and Jetta range of models was introduced in March 1984, revised body and trim features being the main visual difference to the earlier range of models.
The engine/transmission is mounted transversely at the front of the vehicle, drive being to the front wheels. Detailed improvements have been made throughout the years of manufacture to improve power output and economy. These include the introduction of hydraulic bucket tappets, the Digifant, Digijet and Mono-Jetronic fuel injection systems, the 16-valve engine fitted to the GTi variant, the fully electronic ignition system (FEI), the 085 5-speed gearbox and several other minor modifications and revisions.
As with earlier models the new range is proving popular, giving economy, reliability, comfort and, if previous models can be used as a yardstick, long life.

The aim of this Manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur.
However, it is hoped that you will use the Manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads.
The Manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence.

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Ford Scorpio Service and Repair Manual 1.8 SOHC, 2.0 SOHC, 2.0 DOHC, 2.4, 2.8 and 2.9 liter V6 engines

Contains:

Routine maintenance and servicing
1.8 & 2.0 liter SOHC engines
2.0 liter DOHC engine
2.4, 2.8 and 2.9 liter V6 engines
Cooling, heating and ventilation systems
Fuel and exhaust systems
Engine electrical systems
Braking system
Steering and suspension
Bodywork and fittings
Body electrical system

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Fiat Uno Service and Repair Manual

Models covered:
Fiat Uno 45, 55, 60, 70, 1.1 and 1.4, including Turbo ie and special/limited editions 903 cc, 999 cc, 1108 cc, 1116 cc, 1299 cc, 1301 cc and 1372 cc petrol engines with manual transmissions

Contains:

Roadside Repairs
Jump starting
Jacking, towing and wheel changing
Identifying leaks
Routine Maintenance and Servicing
Maintenance schedule (also see Chapter 13)
Recommended Lubricants and Fluids
Conversion factors
Engine and Associated Systems
Engine
Cooling and heating systems
Fuel system
Ignition system
Transmission
Clutch
Transmission
Drive shafts, hubs, road wheels and tyres
Brakes
Braking system
Electrical
Electrical system
Steering and suspension
Steering
Suspension
Bodywork
Revisions and information on later models
Wiring Diagrams

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Citroen BX Service Manual

Contains:

150 engine
Cylinder head - dismantling, decarbonising, inspection and
reassembly
Cylinder head - removal and refitting
Cylinder liners - checking protrusion
Engine - complete dismantling
Engine - complete reassembly
Engine dismantling - ancillary items
Engine dismantling - general information
Engine - examination and renovation
Engine - initial start-up after overhaul
Engine - preparation for reassembly
Engine reassembly - general information
Engine - reconnection to transmission
Engine - separation from transmission
Engine/transmission - removal and refitting
General information and precautions
Major operations possible with engine in vehicle
Major operations requiring engine removal
Oil filter - removal and refitting
Valve rocker clearances - checking and adjustment


171 and 159 engines (Including engine variants B1A/A, B2C, BDY, D2A, D2E, D2F, D6A, D6D and DKZ)
Camshaft - removal and refitting
Camshaft drive belt - removal and refitting
Cylinder head - dismantling, decarbonsing, inspection and
reassembly
Cylinder head - removal and refitting
Cylinder liners - checking protrusion
Engine - complete dismantling
Engine - complete reassembly
Engine dismantling - ancillary items
Engine dismantling - general information
Engine - examination and renovation
Engine - initial start-up after overhaul
Engine - preparation for reassembly
Engine reassembly - general information
Engine - reconnection to transmission
Engine - separation from transmission
Engine/transmission - refitting
Engine/transmission - removal
General information and precautions
Major operations possible with engine in vehicle
Major operations requiring engine removal
Oil filter - removal and refitting
Valve clearances - checking and adjustment

K1G engine
Camshaft drivebelt - removal and refitting
Cylinder head - dismantling, decarbonising, inspection and reassembly
Cylinder head - removal and refitting
Cylinder liners - checking protrusion
Engine - complete dismantling
Engine - complete reassembly
Engine dismantling - ancillary items
Engine dismantling - general information
Engine - examination and renovation
Engine - initial start-up after overhaul
Engine - preparation for reassembly
Engine reassembly - general information
Engine - reconnection to transmission
Engine - separation from transmission
Engine/transmission - removal and refitting
General information and precautions
Major operations possible with engine in vehicle
Major operations requiring engine removal
Oil filter - removal and refitting
Valve rocker clearances - checking and adjustment

D6C engine
Cylinder head - removal, overhaul and refitting
Cylinder liners - checking protrusion
Engine - complete dismantling
Engine - complete reassembly
Engine dismantling - ancillary items
Engine dismantling - general information
Engine - examination and renovation
Engine - initial start-up after overhaul
Engine - preparation for reassembly
Engine reassembly - general information
Engine - reconnection to transmission
Engine - separation from transmission
Engine/transmission - refitting
Engine/transmission - removal
General information and precautions
Major operations possible with engine in vehicle
Major operations requiring engine removal
Oil filter - removal and refitting
Timing belt - removal and refitting

Cooling, heating and air conditioning systems

Air conditioning system - maintenance
Coolant low level warning switch - removal and refitting
Coolant pump (BX and BX 14) - removal and refitting
Coolant pump (BX 16 and BX 19) - removal and refitting
Coolant temperature switch - removal and refitting
Cooling fan - removal and refitting
Cooling fan thermal switch - removal and refitting
Cooling system - draining, flushing and filling
General information and precautions
Heater blower motor - removal and refitting
Heater control panel (later models) - removal and refitting
Heater matrix - removal and refitting
Heater unit (air conditioned models) - removal and refitting
Heater unit (non air conditioned models) - removal and refitting
Radiator - removal, inspection, cleaning and refitting
Thermostat - removal, testing and refitting

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Nissan Titan 2004

This manual contains maintenance and repair procedures for the 2004 NISSAN TITAN.
In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

Quick index:

General Information

Engine Mechanical
Engine Lubrication System
Engine Cooling System
Engine Control System
Fuel System
Exhaust System
Accelerator Control System

Transmission
Automatic Transmission

Transfer
Propeller Shaft
Front Final Drive
Rear Final Drive
Front Axle
Rear Axle

Front Suspension
Rear Suspension
Road Wheels & Tires

Brake System
Parking Brake System
Brake Control System

Power Steering System

Seat Belts
Supplemental Restraint System

Body, Lock & Security System
Glasses, Window System & Mirrors
Roof
Exterior & Interior
Instrument Panel
Seat
Adjustable Pedal

Air Conditioner

Starting & Charging System
Lighting System
Driver Information System
Wiper, Washer & Horn
Body Control System
LAN System
Audio Visual, Navigation & Telephone System
Auto Cruise Control System
Power Supply, Ground & Circuit Elements

Maintenance

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Jeep Cherokee Service Manual 2000

Contains:

Lubrication & Maintenance
Suspension
Differential & Drive line
Brakes
Clutch
Cooling System
Battery
Starting Systems
Charging System
Ignition System
Instrument Panel Systems
Audio Systems
Horn Systems
Speed Control System
Turn Signal & Hazard Warning Systems
Wiper & Washer Systems
Lamps
Passive Restraint Systems
Electrically Heated Systems
Power Distribution Systems
Power Lock Systems
Vehicle Theft/Security Systems
Power Seat Systems
Power Window Systems
Power Mirror Systems
Chime/Buzzer Warning Systems
Overhead Console Systems
Wiring Diagrams
Engine
Exhaust System
Exhaust System & Turbocharger
Frame & Bumpers
Fuel System
Fuel System - 2.5L Diesel Engine
Steering
Transmission & Transfer Case
Tires & Wheels
Body
Heating & Air Conditioning
Emission Control Systems

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Ford Fiesta Service and Repair Manual

Applies to:

1.0 and 1.1 OHV with filter
1.3, 1.4 and 1.6 CVH with filter
1.0 and 1.1 OHV without filter
1.3, 1.4 and 1.6 CVH without filter

Contains:

Air cleaner element renewal
Air cleaner temperature control check
Auxiliary drive belt check
Battery electrolyte level check
Battery terminal check
Brake hydraulic fluid renewal
Brake hydraulic system seal and hose renewal
Brake pipe and hose check
Choke adjustment check
Contact breaker point renewal and distributor lubrication
- OHV engines
Crankcase ventilation system check
Emission control filter element renewal - CVH engines
Engine coolant renewal
Engine idle speed check
Engine oil and filter renewal
Engine valve clearance check - OHV engines
Exhaust system check
Fluid leak check
Fluid level checks
Front and rear brake pad/shoe check
Front wheel alignment check
Gearbox oil level check
Handbrake check
Hinge and lock check and lubrication
HT lead, distributor cap and ignition circuit check
Ignition timing and contact breaker gap (dwell angle) check
- OHV engines
Intensive maintenance
Mixture adjustment check
Road test
Road wheel security check
Seat belt check
Spark plug check
Spark plug renewal
Steering and suspension security check
Throttle damper operation check
Timing belt renewal - CVH engines
Tyre checks
Underbody inspection
Wiper blade check

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Peugeot 205 Service and Repair Manual

Contains:

Air cleaner filter element renewal
Air conditioning system check
Automatic transmission fluid level check
Automatic transmission fluid renewal
Auxiliary drive belt check and renewal
Bodywork, paint and exterior trim check
Brake fluid renewal
Clutch pedal stroke adjustment
Coolant renewal
Drive shaft bellows check
Engine oil and filter renewal
Exhaust system check
Emissions control systems check
Front brake pad check
Fuel filter renewal - fuel injection models
Handbrake check and adjustment
Headlight beam alignment check
Idle speed and mixture check and adjustment
Ignition system check
Intensive maintenance
Lock and hinge check and lubrication
Manual transmission oil level check
Manual transmission oil renewal
Rear brake pad condition check - models with rear disc brakes
Rear brake shoe check - models with rear drum brakes
Road test
Seat belt check
Spark plug renewal
Steering and suspension check
Throttle and choke cable lubrication and adjustment
Timing belt renewal
Under body and fuel/brake line check
Under bonnet check for fluid leaks and hose condition


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Opel Kadett Sevice and Repair Manual

Contains:

Routine maintenance and servicing
OHV engine
OHC engines
DOHC (16-valve) engine
Cooling, heating and ventilation systems
Fuel and exhaust systems - carburettor models
Fuel and exhaust systems - fuel-injected models
Starting and charging systems
Contact breaker ignition system
Electronic (breakerless) ignition systems
Braking system
Suspension and steering
Bodywork and fittings
Body electrical system

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Volkswagen Passat (1995, 1996, 1997) Factory Repair Manual

Gasoline,Turbo Diesel, TDI, 4-cylinder and WR6 including wagon



Suspension, Wheels, Brakes, Steering



General, Technical data

Suspension, Wheels, Brakes, Steering

Technical data

Steering

Brakes

Wheels, tires



Front suspension

Front Wheel Suspension, Shafts and Axle

Front suspension, servicing (Base suspension)

Sub-frame, stabilizer bar and control arm (Base suspension)

Ball joint, checking (Base and Plus suspension)

Reworking cap nut in side member (Base and Plus suspension)

Wheel bearing, suspension strut and drive shaft, removing and installing (Base

running gear)

Front suspension strut, servicing (Base and Plus suspension)

Front suspension, servicing (Plus suspension)

Sub-frame, stabilizer bar and control arm, removing and installing (Plus

suspension)

Ball joint, removing and installing (Plus running gear)

Wheel bearing and suspension strut, removing and installing (Plus suspension)

Drive shaft, removing and installing (Plus running gear)

Drive shaft, repairing

Outer constant velocity joint, checking

Inner constant velocity joint, checking

Drive shaft with tripod joint, repairing

Drive axle with triple-rotor joint, removing and installing

Drive axle with triple-rotor joint, servicing

Triple-rotor joint, disassembling

Triple-rotor joint, assembling



Rear suspension

Rear Wheel Suspension, Shafts and Axle

Rear axle, servicing (vehicles with front wheel drive)

Reworking cap nut in side member (front wheel drive vehicles)

Suspension strut, disassembling and assembling (front wheel drive vehicles)

Wheel bearings, servicing

Drum brakes (front wheel drive vehicles), wheel bearings, servicing

Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

Rear axle, servicing (four wheel drive vehicles)

Rear drive shafts, servicing

Reworking cap nut in side member (four wheel drive vehicles)

Suspension strut, disassembling and assembling (four wheel drive

vehicles)

Wheel bearings, servicing - disc brakes (four wheel drive vehicles)



Wheels, Tires, Wheel alignment

Vehicle alignment

Test requirements:

Vehicle alignment specifications (front wheel drive vehicles)

Vehicle alignment specifications (four wheel drive vehicles)

Front wheel camber, adjusting



Anti-lock brake system

Anti-locking Brake System (ABS) and Anti-locking Brake System with

Electronic Differential Lock (ABS/EDL) Teves 04

Notes for repair work on ABS, ABS/EDL

Control module, removing and installing

Wheel speed sensor and rotor for speed sensor, removing and installing

Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock

(ABS/EDL), Teves 20 GI

Safety precautions

ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master

cylinder (Teves 20 GI), servicing

ABS hydraulic unit and ABS control module (Teves 20 GI), removing and

installing

Brake hydraulic system, bleeding and filling

Assembly overview - hydraulic unit, brake servo/brake master cylinder

Hydraulic unit, removing and installing

Brake Pedal Position Sensor, removing and installing



Brakes - Mechanical components

Front brakes, servicing (Girling caliper)

Brake pads, removing and installing

Front brakes, servicing (Teves/Ate)

Brake pads, removing and installing

Rear wheel brakes, servicing (drum brakes)

Brake shoe adjustment, releasing

Rear wheel brakes, servicing

Brake shoes, removing and installing

Parking brake, adjusting (drum brakes)

Rear wheel brakes, servicing (disc brakes)

Girling rear wheel disc brakes (front and four wheel drive vehicles)

Brake pads, removing and installing

Parking brake, adjusting (disc brakes)

Parking brake lever assembly overview

Brake pedal/brake servo, removing and installing

Brake pedal, removing and installing

Brake Light Switch, adjusting



Brakes - Hydraulic components

Assembly overview: brake master cylinder/brake servo

Girling front brake caliper, servicing

Front brake caliper pistons, removing and installing

Front brake caliper, servicing (Teves/Ate)

Rear brake caliper, servicing

Rear brake caliper piston, removing and installing

Pre-bleeding brake caliper

Brake pressure regulator, checking and adjusting

Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04

Load dependent brake pressure regulator specifications

Adjusting regulator

Brake system, bleeding

Brake system, bleeding (vehicles with and without ABS, ABS/EDL)

Brake system, bleeding (with pressure bleeder VAS 5234)

Brake system, bleeding (without pressure bleeder)



Steering

Steering

Assembly overview: steering column, column tube, steering wheel and airbag

steering wheel

Airbag unit, removing and installing

Airbag steering wheel, removing and installing

Airbag Spiral Spring, removing and installing

Column tube for height adjustable steering wheel, removing and installing

Pump delivery pressure, checking

Power steering gear, removing and installing

Assembly overview: power assisted steering box (TRW)

Power steering gear, adjusting (TRW)

Power steering gear, disassembling and reassembling (TRW)

Power steering gear, disassembling

Inner sealing ring for toothed rod, pulling out

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Sealing rings, installing on toothed rod piston

Power steering gear, assembling

Inner sealing ring for toothed rod, installing

Toothed rod, installing in housing

Adhesive tape, applying

Power steering gear, adjusting with new toothed rod

Assembly overview: power steering gear (ZF)

Power steering gear, adjusting (ZF)

Power steering gear, disassembling and reassembling (ZF)

Power steering gear, disassembling

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Power steering gear, assembling

Tie rods, removing and installing (power steering gear - TRW and ZF)

Left-hand tie rod length, checking and adjusting

Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4-

Cyl. engines)

Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)

Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)

V-belts, tensioning (4-Cyl. engines)

Assembly overview: Pressure and cooling lines (vehicles with VR6 engine)

Power steering vane pump, removing and installing (vehicles with VR6 engine]





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