Systems Covered:
Engine mechanical, engine control, fuel system, exhaust system, cooling system, ignition system, starting system, charging system, transmission (manual & automatic), clutch system, drive shafts, suspension (front & rear), steering system, brake system, wheel and tire system, electrical system, lighting system, climate control (heater & air conditioner), body repair, interior components, safety systems (SRS, ABS), and more.
Emission Control:
Coverage for Emission Control Systems, including components like Charcoal Canister, and diagnostics related to emissions compliance.
Estimated Page Count:
Extensive (implied by comprehensive nature and list of topics). Specific page count not provided, but typical factory service manuals for this era are often 800-1500+ pages.
Manual Type:
Factory Service Repair Manual
Language:
English (implied by product description and sales context)
Engine Mechanical:
Detailed procedures for engine assembly, disassembly, cylinder head, cylinder block, pistons, connecting rods, crankshaft, camshafts, valve clearance adjustment, timing belt replacement, oil pump, oil filter, and more.
Fuel System:
Components like fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, and fuel system diagnostics.
Transmission:
Coverage for both Manual Transaxle System and Automatic Transaxle Assy, including operation, components, maintenance, and repair procedures.
Suspension And Steering:
Front and rear suspension systems, steering system components, steering column, power steering, and wheel alignment (front and rear).
Brake System:
Comprehensive brake system coverage including brake fluid, master cylinder, booster, calipers, discs, pads, parking brake, and hydraulic lines.
Electrical System:
Wiring diagrams, wire harness repair, lighting system, starting system, charging system, ignition system, power windows, power locks, and interior electronics.
Body And Interior:
Body repair, exterior panels (hood, doors, bumpers), glass, seals, interior trim, seats, and sunroof system.
Safety Systems:
Supplemental Restraint System (SRS), airbags (front, side, curtain), seat belts, and potentially Anti-lock Braking System (ABS) if equipped.
Climate Control:
Heater and Air Conditioner system, including controls, refrigerant, blower, and heating radiator.
Wiper And Washer System:
Detailed information on wiper motors, washer systems, and rubber blade replacement.
Lighting System:
Headlamps, tail lamps, interior lighting, and associated switches and wiring.
Maintenance Procedures:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt adjustments, and general upkeep.
Repair Procedures:
Detailed step-by-step instructions for repairing/replacing virtually all mechanical and electrical components.
Troubleshooting Diagnostics:
Diagnostic charts, common fault finding, and systematic approaches to diagnosing issues within various systems.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data for accurate repairs.
Engine Rebuild:
Detailed procedures for cylinder head removal/installation, piston and rod assembly, crankshaft installation, and all related engine component overhauls.
Electrical Diagnostics:
Includes wiring diagrams and diagnostic procedures for identifying faults in starting, charging, lighting, and accessory circuits.
Body Repair:
Information on body panel replacement, frame straightening (if applicable), and repair of structural components.
Depth:
Comprehensive. Covers everything from basic maintenance to full engine and transmission rebuilds, electrical system diagnostics, and bodywork.
Diagnostic Codes:
Likely includes diagnostic procedures for engine control systems (e.g., early EFI systems) but may not cover OBD-II style codes as this was pre-OBD-II era for most of its production.
Oil Change Interval:
Typically 5,000-7,500 miles or 6-12 months, whichever comes first. Refer to manual for specific engine/oil type.
Timing Belt Interval:
Critical component for Boxer engines. Typically recommended every 30,000-50,000 miles or 4-5 years. Failure can cause catastrophic engine damage.
Spark Plug Replacement:
Recommended replacement interval typically every 20,000-30,000 miles, depending on plug type and condition.
Engine Oil Spec:
Viscosity typically 10W-40 or 15W-50 (API SG/SH or higher). Consult manual for exact specification.
Coolant Spec:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Color may vary (often green or blue). Refer to manual for specific type.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid (depending on year and ABS presence).
Transmission Fluid Spec:
Manual: API GL-4 gear oil, typically 75W-80 or 80W-90. Automatic: DEXRON II or equivalent.
Common Problems:
Rust (especially sills, wheel arches, floor pans), aging electrical components, carburetor/fuel injection issues, wear on suspension bushings, timing belt degradation, thermostat failure, and cooling system leaks.
Engine Specific Notes:
Boxer engine requires careful timing belt replacement. Valve adjustments are periodic maintenance. Oil leaks can be common due to engine design and age of seals.