Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair procedures for all engine variants.
Engine Electrical:
Ignition system, fuel injection system (Bosch CIS-Jetronic/KE-Jetronic), starting system, charging system, sensors, and ECU diagnostics.
Transmission Manual:
Repair and overhaul of 4-speed and 5-speed manual transmissions.
Transmission Automatic:
Repair and overhaul of ZF 3-speed and 4-speed automatic transmissions (e.g., 4HP22).
Drivetrain And Axles:
Front-wheel drive system, rear differential, driveshafts, CV joints, and wheel bearings.
Suspension System:
Front MacPherson struts, rear semi-independent trailing arm suspension, shock absorbers, springs, bushings, and alignment procedures.
Steering System:
Power steering system, steering rack, tie rods, and steering column.
Braking System:
Hydraulic system, brake fluid, master cylinder, brake boosters (vacuum), front disc brakes (solid/ventilated), rear drum/disc brakes, and parking brake.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, and Bosch K-Jetronic/KE-Jetronic fuel injection components.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan, and heater core.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable for market), mufflers, and exhaust pipe replacement.
Climate Control:
Heating and ventilation system (HVAC), air conditioning system (if equipped), controls, blower motor, and refrigerant handling.
Electrical System Chassis:
Lighting system (headlights, taillights, interior), horn, wipers, washer system, central locking, power windows, and instrument cluster.
Body And Chassis:
Corrosion protection and basic structural repair guidelines.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-offs, belt inspections.
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, including symptom-based troubleshooting charts.
Component Overhaul:
Detailed step-by-step instructions for rebuilding engines, transmissions, steering racks, and brake calipers.
Alignment And Suspension:
Wheel alignment specifications and procedures, suspension component replacement.
Electrical Diagnostics:
Wiring diagrams, component testing, and troubleshooting logic for the entire electrical system.
Fuel Injection Tuning:
Adjustment and recalibration procedures for K-Jetronic/KE-Jetronic systems, including idle speed, CO mixture (where adjustable), and idle stability.
Body Repair Minor:
Removal and installation of trim, panels, and glass; minor dent repair guidance.
Diagnostic Capabilities:
Comprehensive diagnostic trees and fault code interpretation (for ECUs present in '84 models).
Repair Complexity:
Suitable for professional mechanics and skilled DIY enthusiasts, covering everything from basic tune-ups to complete engine and transmission rebuilds.
Torque Specifications:
Extensive list of torque specifications for all critical fasteners.
Tolerances And Clearances:
Detailed specifications for engine component clearances, bearing tolerances, and other critical measurements.
Engine Codes Gasoline:
JN, KX, NP, RU (5-cylinder 2.2L); WC (4-cylinder 1.8L, less common in some markets).
Engine Type Gasoline:
Inline-5 cylinder, naturally aspirated and turbocharged (e.g., 2.2L Turbocharged).
Displacement:
1781cc (1.8L), 2144cc (2.2L).
Horsepower 2.2L Na:
Approximately 136 PS (134 hp) @ 5700 rpm.
Horsepower 2.2L Turbo:
Approximately 165 PS (163 hp) @ 5500 rpm.
Torque 2.2L Na:
Approximately 18.8 kg⋅m (185 Nm / 136 lb-ft) @ 3500 rpm.
Torque 2.2L Turbo:
Approximately 24.0 kg⋅m (235 Nm / 174 lb-ft) @ 3500 rpm.
Fuel Delivery:
Bosch K-Jetronic or KE-Jetronic (CIS-E) continuous injection system.
Fuel Type:
Unleaded gasoline (Octane rating varies by market, typically 95 RON).
Engine Oil Change:
Typically every 7,500 - 15,000 km (4,500 - 9,000 miles) or 6-12 months, depending on driving conditions and oil specification used.
Air Filter Replacement:
Every 15,000 - 30,000 km (9,000 - 18,000 miles).
Spark Plug Replacement:
Every 20,000 - 40,000 km (12,000 - 24,000 miles), depending on plug type.
Timing Belt Replacement:
Critical for 5-cylinder engines. Typically every 60,000 - 90,000 km (37,000 - 56,000 miles) or 4-5 years. Failure leads to catastrophic engine damage.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 often recommended. Check manual for specific viscosity based on ambient temperature.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Specific OAT or HOAT coolant not typically required for this era.
Brake Fluid Type:
DOT 3 or DOT 4 (check cap/reservoir for specification).
Transmission Fluid Manual:
GL-4 gear oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron II or equivalent ATF (Automatic Transmission Fluid).
Electrical Gremlins:
Common issues include corroded ground points, failing relays, intermittent dashboard warnings, and faulty door lock actuators due to age and wiring degradation.
Fuel System K Jetronic:
Air flow sensor plate issues, failing warm-up regulator (WUR), clogged injectors, and vacuum leaks can cause rough idle, stalling, and poor performance.
Suspension Wear:
Worn control arm bushings, ball joints, and tie rod ends are common due to mileage and age, leading to vague steering and alignment issues.
Cooling System Leaks:
Degradation of rubber hoses, radiator core leaks, and water pump seal failure are prevalent.
Rust And Corrosion:
Areas like wheel arches, sills, and the underbody can be susceptible to rust, especially in regions with harsh winters and road salt.
