Engine Mechanical:
Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, valve train, timing belt/chain, lubrication system, cooling system, fuel injection system (K-Jetronic, KE-Jetronic, CIS-E), turbocharger system.
Engine Electrical:
Ignition system, starting system, charging system, ECU diagnostics and component testing, sensor identification and function.
Transmission:
Manual transmission (5-speed), Automatic transmission (4-speed automatic), clutch system, driveshafts, differential, transmission fluid specifications and changes.
Suspension And Steering:
Front suspension (MacPherson struts), Rear suspension (independent trailing arms), power steering system, steering rack, wheel alignment specifications, shock absorbers, springs.
Brakes:
Front disc brakes, rear disc brakes, ABS system (if equipped), brake fluid specifications, master cylinder, brake lines, parking brake.
Electrical System:
Wiring diagrams for all circuits, lighting system, instruments and gauges, horn, wipers and washers, power windows, central locking, climate control system.
Body And Chassis:
Body panel removal and installation, doors, hood, trunk lid, bumpers, interior trim, glass replacement, rust prevention and repair.
Climate Control:
Air conditioning system (R-134a retrofitting considerations), heater core, blower motor, control panel.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, fuel pressure regulator, fuel injectors.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, exhaust pipes.
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection and tensioning.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, electrical system troubleshooting.
Repair And Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly of all major vehicle systems.
Diagnostics:
On-board diagnostics (OBD) information, fault code interpretation, sensor testing, actuator testing.
Specifications And Tolerances:
Engine component clearances, torque specifications for all fasteners, alignment angles, brake system specifications.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems, component location diagrams.
Illustrations And Diagrams:
High-quality, detailed diagrams and exploded views to visually guide repair procedures.
Engine Rebuilding:
Detailed instructions for complete engine teardown, cleaning, inspection, honing, piston ring replacement, bearing replacement, crankshaft grinding, cylinder head rebuilding.
Transmission Overhaul:
Step-by-step guidance for manual and automatic transmission disassembly, component replacement, and reassembly, including torque converter replacement and valve body servicing.
Brake System Repair:
Procedures for brake caliper rebuilding, rotor and pad replacement, master cylinder replacement, brake line bleeding, and ABS component diagnosis and replacement.
Electrical Component Testing:
Detailed methods for testing alternators, starters, ignition coils, fuel injectors, sensors (e.g., MAF, O2, Crankshaft Position), and control modules.
Interior And Exterior Trim:
Instructions for removing and reinstalling interior panels, door cards, dashboard components, exterior trim pieces, and badging.
Depth:
Complete factory service manual covering all aspects of repair and maintenance, suitable for professional technicians and advanced DIY enthusiasts.
Torque Specifications:
Includes critical torque values for engine, transmission, suspension, and chassis components to ensure proper assembly and prevent damage.
Diagnostic Charts:
Provides troubleshooting flowcharts and symptom-based diagnostics to help identify the root cause of vehicle problems.
Part Number References:
May include references to common part numbers for maintenance items and frequently replaced components.
Engine Type:
Inline 5-cylinder, naturally aspirated and turbocharged.
Displacement Range:
2.1L (2144cc) to 2.3L (2309cc).
Turbocharged Variants:
MC, GTE, 200 20V Turbo models featured turbocharged engines, offering significant performance gains.
Engine Codes:
Examples include: WY, WX (2.2L Turbo), KG, KU, KV (2.2L NA), MC, 3B (2.2L Turbo 20V).
Horsepower Range:
Approximately 115 hp (naturally aspirated) to over 200 hp (turbocharged variants).
Torque Range:
Varies significantly based on engine and aspiration, but turbocharged models offered substantial torque for strong acceleration.
Fuel Delivery:
Bosch K-Jetronic (CIS) and KE-Jetronic (CIS-E) continuous injection systems for most models, with some later models featuring more advanced electronic fuel injection.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil used. Refer to the manual for specific recommendations.
Timing Belt Replacement:
Crucial for 5-cylinder engines. Intervals typically range from 60,000-100,000 miles (96,000-160,000 km). Failure can cause catastrophic engine damage. Manual specifies exact interval.
Engine Oil:
API SG or higher, SAE 10W-40 or 15W-40 typically recommended. Check manual for exact viscosity based on temperature. Capacity approx. 4.5-5.0 liters.
Coolant:
G11 specification (blue or green) antifreeze. Mixture of 50% antifreeze and 50% distilled water is standard. Capacity approx. 7-8 liters.
Brake Fluid:
DOT 3 or DOT 4. Must be flushed and replaced every 2-3 years.
Transmission Fluid:
Manual: GL-4 or GL-5 gear oil (SAE 75W-90 or 80W-90). Automatic: ATF Dexron II or equivalent. Refer to manual for specific type and capacity.
Power Steering Fluid:
G 002 000 or Pentosin CHF 11S or equivalent.
Electrical Gremlins:
Aging wiring insulation and connector corrosion can lead to intermittent electrical issues.
Turbocharger Reliability:
Early turbocharger models can experience wear if maintenance intervals are not strictly followed, particularly oil changes.
Climate Control System:
Heater control valves and AC system components can fail over time, leading to loss of heating or cooling.
Fuel Injection System:
K-Jetronic systems can be sensitive to dirt and aging components, requiring careful maintenance and cleaning of injectors and air flow meter.
Suspension Wear:
Bushings and ball joints are common wear items and may require replacement to restore handling and eliminate clunks.
