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Sadržaj: 0 General Information - 2 About this website - 2 1 Safety first! - 5 2 Introduction - 10 3 Roadside repairs - 13 4 Weekly checks - 23 5 Lubricants, fluids and tyre pressures - 39 1a Routine maintenance and servicing - petrol models - 42 Degrees of difficulty - 42 Servicing specifications - petrol models - 43 Maintenance schedule - petrol models - 46 Component location - petrol models - 51 1 Introduction - 53 2 Regular maintenance - 54 Every 5000 miles (7500 km) or 6 months - 56 3 Engine oil and filter renewal - petrol models - 57 Every 10 000 miles (15 000 km) or 12 month, whichever comes first - 'Oil' on display - 60 4 Brake pad check - 61 5 Resetting the service interval display - petrol models - 63 Every 20 000 miles (30 000 km) or 2 years, whichever comes first - '01' on display - 64 6 Exhaust system check - 65 7 Hose and fluid leak check - 66 8 Auxiliary drivebelt check - 68 9 Antifreeze check - 69 10 Brake hydraulic circuit check - 70 11 Headlight beam adjustment - 71 12 Pollen filter element renewal - 72 13 Manual transmission oil level check - 74 14 Underbody protection check - 76 15 Driveshaft gaiter check - 77 16 Steering and suspension check - 78 17 Batterry check - 80 18 Hinge and lock lubrication - 82 19 Airbag unit check - 83 20 Windscreen/tailgate/headlight washer system check - 84 21 Engine management self-diagnosis memory fault check - 85 22 Sunroof check and lubrication - 86 23 Road test and exhaust emissions check - 87 Every 40 000 miles (60 000 km) or 4 years, whichever comes first - 89 24 Air filter element renewal - petrol models - 90 25 Spark plug renewal - petrol models - 92 26 Auxiliary drivebelt check and renewal - petrol models - 97 27 Power steering hydraulic fluid level check - 100 28 Automatic transmission fluid level check - 102 29 Automatic transmission final drive oil level check - 104 Every 60 000 miles (90 000 km) or 4 years, whichever comes first - 106 30 Timing belt renewal - 107 Every 2 years - 108 31 Brake (and clutch) fluid renewal - petrol models - 109 32 Coolant renewal - petrol models - 111 1b Routine maintenance and servicing - diesel models - 114 Degrees of difficulty - 114 Servicing specifications - diesel models - 115 Maintenance schedule - diesel models - 117 Component location - diesel models - 123 1 Introduction - 125 2 Regular maintenance - 126 Every 5000 miles (7500 km) or 6 months - 128 3 Engine oil and filter renewal - diesel models - 129 Every 10 000 miles (15 000 km) or 12 months, whichever comes first - 'Oil' on display - 133 4 Fuel filter water draining (vehicles using high sulphur fuels) - diesel models - 134 5 Brake pad check - 136 6 Resetting the service interval display - diesel models - 138 Every 20 000 miles (30 000 km) or 2 years, whichever comes first - '01' on display - 139 7 Exhaust system check - 141 8 Hose and fluid leak check - 142 9 Fuel filter water draining (vehicles using standard fuel) - diesel models - 144 10 Fuel filter renewal (vehicles using high sulphur diesel fuel) - 145 11 Auxiliary drivebelt check - 148 12 Antifreeze check - 149 13 Brake hydraulic circuit check - 150 14 Headlight beam adjustment - 151 15 Pollen filter element renewal - 152 16 Manual transmission oil level check - 154 17 Underbody protection check - 157 18 Driveshaft gaiter check - 158 19 Steering and suspension check - 159 20 Batterry check - 161 21 Hinge and lock lubrication - 163 22 Airbag unit check - 164 23 Windscreen/tailgate/headlight washer system check - 165 24 Engine management self-diagnosis memory fault check - 166 25 Sunroof check and lubrication - 167 26 Road test and exhaust emissions check - 168 Every 40 000 miles (60 000 km) or 4 years, whichever comes first - 170 27 Air filter element renewal - diesel models - 171 28 Fuel filter renewal (vehicles using standard diesel fuel) - 173 29 Auxiliary drivebelt check and renewal - diesel models - 174 30 Power steering hydraulic fluid level check - 177 31 Automatic transmission fluid level check - 179 32 Automatic transmission final drive oil level check - 181 Every 60 000 miles (90 000 km) - 183 33 Timing belt and tensioning roller renewal (engines with ‘unit’ injectors) - 184 Every 80 000 miles (120 000 km) - 185 34 Timing belt and tensioning roller renewal ( engines with injection pump) - 186 Every 2 years - 187 35 Brake (and clutch) fluid renewal - diesel models - 188 36 Coolant renewal - diesel models - 190 2a SOHC petrol engine in-car repair procedures - 193 Degrees of difficulty - 193 Specifications - 194 1 General Information - 199 2 Compression test - description and interpretation - 201 3 Engine assembly and valve timing marks - general information and usage - 203 4 Camshaft cover - removal and refitting - 206 5 Crankshaft pulley - removal and refitting - 208 6 Timing belt covers - removal and refitting - 210 7 Timing belt - removal and refitting - 213 8 Timing belt tensioner and sprockets - removal and refitting - 217 9 Camshaft - removal, inspection and refitting - 220 10 Hydraulic tappets/roller rocker fingers - removal, inspection and refitting - 226 11 Camshaft oil seal - renewal - 228 12 Cylinder head - removal, inspection and refitting - 229 13 Sump - removal and refitting - 234 14 Oil pump, drive chain and sprockets - removal, inspection and refitting - 237 15 Flywheel/driveplate - removal, inspection and refitting - 243 16 Crankshaft oil seals - renewal - 246 17 Engine/transmission mountings - inspection and renewal - 249 18 Engine oil cooler - removal and refitting - 255 19 Oil pressure relief valve - removal, inspection and refitting - 258 20 Oil pressure warning light switch - removal and refitting - 259 21 Oil level/temperature sender - removal and refitting - 260 22 Balancer shaft unit (2.0 litre AZJ engine) - removal and refitting - 263 2b DOHC petrol engine in-car repair procedures - 266 Degrees of difficulty - 266 Specifications - 267 1 General Information - 274 2 Compression test - description and interpretation - 277 3 Engine assembly and valve timing marks - general information and usage - 279 4 Camshaft cover (1.8 litre engines) - removal and refitting - 285 5 Crankshaft pulley - removal and refitting - 291 6 Timing belt covers - removal and refitting - 296 7 Timing belt(s) - removal and refitting - 302 8 Timing belt tensioner and sprockets - removal and refitting - 315 9 Inlet camshaft timing components/camshaft adjuster (1.8 litre engines) - 321 10 Camshaft carrier (1.4 and 1.6 litre engines) - removal and refitting - 322 11 Camshafts (1.4 and 1.6 litre engines) - removal, inspection and refitting - 328 12 Rockers and tappets (1.4 and 1.6 litre engines) - removal, inspection and refitting - 331 13 Camshafts and tappets (1.8 litre engines) - removal, inspection and refitting - 333 14 Camshaft oil seals - renewal - 342 15 Cylinder head - removal, inspection and refitting - 345 16 Sump - removal and refitting - 356 17 Oil pump (1.4 and 1.6 litre engines) - removal, inspection and refitting - 357 18 Oil pump and drive chain (1.8 litre engines) - removal, inspection and refitting - 363 19 Flywheel/driveplate - removal, inspection and refitting - 364 20 Crankshaft oil seals - renewal - 365 21 Engine/transmission mountings - inspection and renewal - 370 22 Engine oil cooler - removal and refitting - 371 23 Oil pressure relief valve - removal, inspection and refitting - 372 24 Oil pressure warning light switch - removal and refitting - 373 25 Oil level/temperature sender - removal and refitting - 375 2c Diesel engine in-car repair procedures - 377 Degrees of difficulty - 377 Specifications - 378 1 General Information - 384 2 Compression and leakdown tests - description and interpretation - 386 3 Engine assembly and valve timing marks - general information and usage - 389 4 Camshaft cover - removal and refitting - 395 5 Crankshaft pulley - removal and refitting - 400 6 Timing belt covers - removal and refitting - 402 7 Timing belt - removal, inspection and refitting - 405 8 Timing belt tensioner and sprockets - removal, inspection and refitting - 415 9 Pump injector rocker shaft assembly - removal and refitting - 421 10 Camshaft and hydraulic tappets - removal, inspection and refitting - 423 11 Hydraulic tappets - testing - 427 12 Camshaft oil seals - renewal - 429 13 Cylinder head - removal, inspection and refitting - 430 14 Sump - removal and refitting - 442 15 Oil pump and drive chain - removal, inspection and refitting - 443 16 Flywheel/driveplate/clutch pressure plate - removal, inspection and refitting - 444 17 Crankshaft oil seals - renewal - 445 18 Engine/transmission mountings - inspection and renewal - 449 19 Engine oil cooler - removal and refitting - 450 20 Oil pressure relief valve - removal, inspection and refitting - 453 21 Oil pressure warning light switch - removal and refitting - 454 2d Engine removal and overhaul procedures - 455 Degrees of difficulty - 455 Specifications - 456 1 General Information - 462 2 Engine overhaul - general information - 463 3 Engine/transmission removal - preparation and precautions - 465 4 Engine and transmission (SOHC petrol engines) - removal and refitting - 467 5 Engine and transmission (DOHC petrol engines) - removal and refitting - 473 6 Engine and transmission (diesel engines) - removal and refitting - 493 7 Engine overhaul - preliminary information - 498 8 Cylinder head - dismantling - 500 9 Cylinder head and valves - cleaning and inspection - 505 10 Cylinder head - reassembly - 509 11 Piston/connecting rod assemblies - removal - 515 12 Crankshaft - removal - 519 13 Cylinder block/crankcase - cleaning and inspection - 521 14 Piston/connecting rod assemblies - cleaning and inspection - 524 15 Crankshaft - checking endfloat and inspection - 529 16 Main and big-end bearings - inspection - 532 17 Engine overhaul - reassembly sequence - 535 18 Piston rings - refitting - 536 19 Crankshaft - refitting and main bearing clearance check - 538 20 Piston/connecting rod assemblies - refitting and big-end bearing clearance check - 542 21 Engine - initial start-up after overhaul and reassembly - 546 3 Cooling, heating and air conditioning systems - 548 Degrees of difficulty - 548 Specifications - 549 1 General information and precautions - 551 2 Cooling system hoses - disconnection and renewal - 553 3 Radiator - removal, inspection and refitting - 555 4 Thermostat - removal, testing and refitting - 558 5 Electric cooling fan - testing, removal and refitting - 563 6 Cooling system electrical switches and sensors - testing, removal and refitting - 565 7 Coolant pump - removal and refitting - 569 8 Heating and ventilation system - general information - 572 9 Heating/ventilation system components - removal and refitting - 573 10 Heating/ventilation system vents - removal and refitting - 584 11 Air conditioning system - general information and precautions - 585 12 Air conditioning system components - removal and refitting - 587 13 Climatronic system components - removal and refitting - 588 4a Petrol engine fuel system - 591 Degrees of difficulty - 591 Specifications - 592 1 General information and precautions - 595 2 Air cleaner and inlet system - removal and refitting - 598 3 Inlet air temperature control system - general information - 604 4 Accelerator cable - removal, refitting and adjustment - 605 5 Fuel system components - removal and refitting - 608 6 Fuel filter - renewal - 624 7 Fuel pump and gauge sender unit - removal and refitting - 626 8 Fuel tank - removal and refitting - 632 9 Fuel injection system - depressurisation - 635 10 Inlet manifold and associated components - removal and refitting - 637 11 Fuel injection system - testing and adjustment - 648 12 Unleaded petrol - general information and usage - 649 13 Cruise control system - general information - 650 4b Diesel engine fuel system - 651 Degrees of difficulty - 651 Specifications - 652 1 General information and precautions - 655 2 Air cleaner assembly - removal and refitting - 658 3 Accelerator cable - general information - 661 4 Diesel engine management system - component removal and refitting - 662 5 Injectors - general information, removal and refitting - 670 6 Injection pump - removal and refitting - 678 7 Fuel injection pump timing - checking and adjustment - 683 8 Fuel cut-off solenoid valve - removal and refitting - 684 9 Inlet manifold - removal and refitting - 686 10 Fuel filter - renewal - 691 11 Fuel gauge sender unit - removal and refitting - 692 12 Fuel tank - removal and refitting - 693 13 Tandem fuel pump - removal and refitting - 694 14 Inlet manifold changeover flap and valve - removal and refitting - 697 4c Emission control and exhaust systems - petrol engines - 700 Degrees of difficulty - 700 Specifications - 701 1 General Information - 703 2 Evaporative loss emission control system - information and component renewal - 706 3 Crankcase emission system - general information - 709 4 Exhaust Gas Recirculation (EGR) system - component removal - 710 5 Secondary air injection system - information and component renewal - 716 6 Turbocharger - general information, precautions, removal and refitting - 722 7 Intercooler - general information, removal and refitting - 727 8 Exhaust manifold - removal and refitting - 733 9 Exhaust system - component renewal - 741 10 Catalytic converter - general information and precautions - 747 4d Emission control and exhaust systems - diesel engines - 748 Degrees of difficulty - 748 Specifications - 749 1 General Information - 751 2 Crankcase emission system - general information - 753 3 Exhaust Gas Recirculation (EGR) system - component removal - 754 4 Turbocharger - general information and precautions - 758 5 Turbocharger - removal and refitting - 760 6 Turbocharger boost control system components - removal and refitting - 766 7 Intercooler - general information, removal and refitting - 770 8 Exhaust manifold - removal and refitting - 771 9 Exhaust system - component renewal - 774 10 Catalytic converter - general information and precautions - 777 5a Starting and charging systems - 778 Degrees of difficulty - 778 Specifications - 779 1 General information and precautions - 780 2 Battery - testing and charging - 782 3 Battery - removal and refitting - 785 4 Alternator/charging system - testing in vehicle - 787 5 Alternator - removal and refitting - 788 6 Alternator - brush holder/regulator module renewal - 790 7 Starting system - testing - 792 8 Starter motor - removal and refitting - 794 9 Starter motor - testing and overhaul - 797 5b Ignition system - petrol engines - 798 Degrees of difficulty - 798 Specifications - 799 1 General Information - 801 2 Ignition system - testing - 804 3 HT coil(s) - removal and refitting - 806 4 Ignition timing - checking and adjusting - 809 5 Knock sensor(s) - removal and refitting - 810 5c Preheating system - diesel engines - 812 Degrees of difficulty - 812 Specifications - 813 1 General Information - 814 2 Glow plugs - testing, removal and refitting - 815 6 Clutch - 818 Degrees of difficulty - 818 Specifications - 819 1 General Information - 821 2 Hydraulic system - bleeding - 823 3 Clutch pedal - removal and refitting - 825 4 Master cylinder - removal, overhaul and refitting - 827 5 Slave cylinder - removal, overhaul and refitting - 831 6 Clutch friction disc and pressure plate - removal, inspection and refitting - 834 7 Release bearing and lever - removal, inspection and refitting - 843 7a Manual transmission - 850 Degrees of difficulty - 850 Specifications - 851 1 General Information - 852 2 Gearchange linkage (02J and 02M transmissions) - adjustment - 855 3 Manual transmission - removal and refitting - 858 4 Manual transmission overhaul - general information - 865 5 Reversing light switch - testing, removal and refitting - 866 6 Roadspeed sensor/speedometer drive - removal and refitting - 868 7b Automatic transmission - 870 Degrees of difficulty - 870 Specifications - 871 1 General Information - 873 2 Automatic transmission - removal and refitting - 875 3 Automatic transmission overhaul - general information - 880 4 Selector cable - removal, refitting and adjustment - 881 5 Ignition key Park Lock system - description and cable renewal - 883 8 Driveshafts - 885 Degrees of difficulty - 885 Specifications - 886 1 General Information - 888 2 Driveshafts - removal and refitting - 889 3 Driveshaft rubber gaiters - renewal - 892 4 Driveshaft overhaul - general information - 906 9 Braking system - 907 Degrees of difficulty - 907 Specifications - 908 1 General information and precautions - 910 2 Hydraulic system - bleeding - 911 3 Hydraulic pipes and hoses - renewal - 916 4 Front brake pads - removal, inspection and refitting - 917 5 Front brake caliper - removal, overhaul and refitting - 924 6 Brake disc - inspection, removal and refitting - 927 7 Front brake disc shield - removal and refitting - 931 8 Rear brake pads - removal, inspection and refitting - 932 9 Rear brake caliper - removal, overhaul and refitting - 936 10 Brake pedal - removal and refitting - 939 11 Servo unit - testing, removal and refitting - 943 12 Servo non-return valve - testing, removal and refitting - 945 13 Master cylinder - removal, overhaul and refitting - 947 14 Handbrake - adjustment - 950 15 Handbrake lever - removal and refitting - 952 16 Handbrake cables - removal and refitting - 954 17 Handbrake ‘on’ warning light switch - removal and refitting - 956 18 Brake light switch - removal and refitting - 957 19 Anti-lock braking system (ABS) - general information and precautions - 959 20 Anti-lock braking system (ABS) components - removal and refitting - 961 21 Servo unit mechanical vacuum pump (diesel models) - testing, removal and refitting - 963 22 Servo unit electric vacuum pump (diesel models) - testing, removal and refitting - 966 10 Suspension and steering systems - 967 Degrees of difficulty - 967 Specifications - 968 1 General Information - 972 2 Front wheel bearing housing - removal and refitting - 974 3 Front hub bearings - renewal - 980 4 Front suspension strut - removal, overhaul and refitting - 982 5 Front suspension lower arm - removal, overhaul and refitting - 989 6 Front suspension lower arm balljoint - removal, inspection and refitting - 992 7 Front anti-roll bar - removal and refitting - 995 8 Front anti-roll bar connecting link - removal and refitting - 997 9 Rear hub assembly - removal and refitting - 999 10 Rear stub axle - removal and refitting - 1006 11 Rear suspension shock absorber and coil spring - removal and refitting - 1008 12 Rear anti-roll bar - removal and refitting - 1013 13 Rear axle assembly - removal and refitting - 1014 14 Rear axle rubber mountings - renewal - 1017 15 Vehicle level sender - removal and refitting - 1019 16 Steering wheel - removal and refitting - 1020 17 Steering column - removal, inspection and refitting - 1024 18 Ignition switch and steering column lock - removal and refitting - 1036 19 Steering gear assembly - removal, overhaul and refitting - 1039 20 Steering gear rubber gaiters and track rods - renewal - 1043 21 Power steering system - bleeding - 1045 22 Power steering pump - removal and refitting - 1046 23 Track rod end - removal and refitting - 1049 24 Wheel alignment and steering angles - general information - 1051 11 Bodywork and fittings - 1054 Degrees of difficulty - 1054 Specifications - 1055 1 General Information - 1056 2 Maintenance - bodywork and underframe - 1057 3 Maintenance - upholstery and carpets - 1059 4 Minor body damage - repair - 1060 5 Major body damage - repair - 1064 6 Front bumper - removal and refitting - 1065 7 Rear bumper - removal and refitting - 1069 8 Bonnet - removal, refitting and adjustment - 1072 9 Bonnet release cable - removal and refitting - 1074 10 Bonnet lock - removal and refitting - 1077 11 Door - removal, refitting and adjustment - 1079 12 Door inner trim panel - removal and refitting - 1082 13 Door handle and lock components - removal and refitting - 1086 14 Door window glass and regulator - removal and refitting - 1099 15 Tailgate and support struts - removal and refitting - 1103 16 Tailgate lock components - removal and refitting - 1108 17 Boot lid and support struts - removal and refitting - 1111 18 Boot lid lock components - removal and refitting - 1114 19 Central locking components - removal and refitting - 1117 20 Electric window components - removal and refitting - 1122 21 Exterior mirrors and associated components - removal and refitting - 1124 22 Windscreen, tailgate and fixed rear quarter window glass - general information - 1128 23 Sunroof - general information - 1129 24 Body exterior fittings - removal and refitting - 1130 25 Seats - removal and refitting - 1131 26 Front seat belt tensioning mechanism - general information - 1135 27 Seat belt components - removal and refitting - 1136 28 Interior trim - removal and refitting - 1146 29 Centre console - removal and refitting - 1148 30 Facia panel assembly - removal and refitting - 1153 12 Body electrical system - 1159 Degrees of difficulty - 1159 Specifications - 1160 1 General information and precautions - 1161 2 Electrical fault finding - general information - 1162 3 Fuses and relays - general information - 1165 4 Switches - removal and refitting - 1168 5 Bulbs (exterior lights) - renewal - 1177 6 Bulbs (interior lights) - renewal - 1193 7 Exterior light units - removal and refitting - 1199 8 Headlight beam adjustment components - removal and refitting - 1204 9 Headlight beam alignment - general information - 1207 10 Instrument panel - removal and refitting - 1209 11 Instrument panel components - removal and refitting - 1211 12 Service interval indicator - general information and resetting - 1212 13 Clock - removal and refitting - 1213 14 Cigarette lighter - removal and refitting - 1214 15 Horn - removal and refitting - 1215 16 Speedometer sensor - general information - 1216 17 Wiper arm - removal and refitting - 1217 18 Windscreen wiper motor and linkage - removal and refitting - 1218 19 Rear wiper motor - removal and refitting - 1220 20 Washer system components - removal and refitting - 1221 21 Radio/cassette/CD player/changer - removal and refitting - 1226 22 Loudspeakers - removal and refitting - 1230 23 Radio aerial - removal and refitting - 1232 24 Anti-theft alarm system and engine immobiliser - general information - 1233 25 Airbag system - general information and precautions - 1234 26 Airbag system components - removal and refitting - 1236 24 Parking aid components - general information, removal and refitting - 1240 Wiring Diagrams - 1242 Diagram 1 Key to symbols, earth points and fuses - 1242 Diagram 2 Starting and charging, audio - 1243 Diagram 3 Central locking, electric windows and mirrors - 1244 Diagram 4 Central locking and interior lights, horn, fuel tank release, cigarette lighter, 12V socket, radiator fan, diagnostic connector - 1245 Diagram 5 ABS, heater blower and heated read window, wash/wipe, brake lights, reversing lights - 1246 Diagram 6 Headlights, number plate lights, rear foglights, taillights and sidelights, foglight, hazard warning lights and direction indicators - 1247 Diagram 7 Headlight levelling, lighting rheostat, front foglights, gas discharge headlight range control - 1248 Diagram 8 Instrument panel, glovebox light, interior lights - 1249 13 Reference - 1250 1 Dimensions and weights - 1250 2 Buying spare parts - 1252 3 Vehicle identification numbers - 1254 4 General repair procedures - 1257 5 Jacking and vehicle support - 1260 6 Disconnecting the battery - 1262 7 Tools and working facilities - 1264 8 MOT test checks - 1272 9 Fault finding - 1286 10 Glossary of technical terms - 1307 Download Link 2 Ovaj pdf sam sam napravio tako da sam ručno svaki članak iz online priručnika "isprintao" u PDF i potom spojio u jedan, zbog toga nema sadržaja i zadnje stranice, a videozapisi nisu dostupni. 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