Engine:
M40B18 engine (1.8L 4-cylinder), including disassembly, assembly, diagnostics, and tuning.
Fuel System:
Bosch LE-Jetronic fuel injection system, fuel pump, injectors, pressure regulator, fuel filter, and tank.
Ignition System:
Electronic ignition system (distributor, coil, spark plugs, ignition control module).
Cooling System:
Radiator, water pump, thermostat, coolant hoses, fan, and coolant specifications.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, and emissions control components.
Transmission Manual:
Getrag 240 5-speed manual transmission: removal, installation, clutch service, and internal repairs.
Transmission Automatic:
ZF 4HP22 4-speed automatic transmission (if applicable to specific models): removal, installation, and basic service.
Drivetrain:
Driveshafts, universal joints, rear differential, axles, and wheel bearings.
Suspension Front:
MacPherson struts, control arms, ball joints, anti-roll bar, bushings, and shock absorber replacement.
Suspension Rear:
Semi-trailing arms, shock absorbers, springs, bushings, and wheel alignment specifications.
Steering System:
Power steering system, steering rack, tie rods, and steering column components.
Brakes Front:
Ventilated disc brakes, brake calipers, pads, rotors, and brake fluid specifications.
Brakes Rear:
Solid disc brakes (or drum brakes on some early models), brake calipers/wheel cylinders, pads/shoes, rotors/drums, and parking brake system.
Electrical System:
12V electrical system, battery, alternator, starter motor, fuses, relays, and wiring diagrams.
Lighting System:
Headlights, taillights, interior lights, fog lights, and bulb specifications.
HVAC System:
Heating, ventilation, and air conditioning (if equipped) system: blower motor, heater core, A/C compressor, refrigerant, and controls.
Bodywork Exterior:
Body panel removal and installation, door mechanisms, trunk, hood, bumpers, and trim.
Bodywork Interior:
Dashboard, seats, carpets, headliner, door panels, and interior trim components.
Diagnostics:
Troubleshooting guides for common issues, symptom-based diagnostics, and basic electrical testing procedures.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, fluid checks, and belt inspections.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components.
Overhaul:
Complete engine and transmission overhaul procedures, including specifications for machining and rebuilding.
Troubleshooting:
Diagnostic flowcharts and fault finding for engine, electrical, and mechanical systems.
Adjustment:
Valve adjustments, idle speed adjustments, timing adjustments, and brake adjustments.
Replacement:
Component replacement procedures for all parts of the vehicle.
Depth:
Comprehensive workshop level detail, suitable for professional technicians and advanced DIY enthusiasts.
Diagrams:
Detailed step-by-step diagrams, exploded views, and schematic illustrations.
Specifications:
Includes torque specifications, clearances, fluid capacities, and electrical resistance values.
Oil Change Interval:
Every 10,000-15,000 km (6,000-9,000 miles) or annually.
Air Filter Replacement:
Every 30,000 km (18,000 miles) or as needed.
Spark Plug Replacement:
Every 30,000-40,000 km (18,000-25,000 miles) depending on spark plug type.
Timing Belt Replacement:
Every 60,000 km (37,000 miles) or 4 years for M40 engine (critical preventative maintenance).
Brake Fluid:
DOT 4 recommended
Power Steering Fluid:
ATF Dexron II/III or Pentosin CHF 11S (confirm specific application)
Common Issues:
Timing belt failure (M40), fuel distributor leaks, rear axle bushings wear, heater core leaks, rust (especially around wheel arches and sills), sagging headliner.
