Engine Mechanical:
Complete disassembly, assembly, timing, valve adjustment, cylinder head, crankshaft, pistons, connecting rods
Engine Lubrication System:
Oil pump, oil cooler, oil filter, lubrication passages, pressure testing
Engine Cooling System:
Radiator, fan, water pump, thermostat, coolant passages, system pressure testing
Engine Control System:
Ignition system, fuel injection system (Bosch K-Jetronic), timing, sensors, actuators
Fuel System:
Fuel pumps, fuel accumulator, fuel lines, injectors, pressure regulators
Exhaust System:
Exhaust manifolds, pipes, mufflers, catalytic converters (if applicable), mounting
Accelerator Control System:
Throttle linkage, cables, pedal assembly
Clutch:
Clutch disc, pressure plate, release bearing, hydraulic system, adjustment
Manual Transmission:
Disassembly, assembly, gear ratios, synchromesh, bearings, seals, lubrication
Automatic Transmission:
Repair and overhaul procedures for models equipped with automatic transmission
Propeller Shaft:
Universal joints, balancing, mounting
Rear Final Drive:
Differential, gears, bearings, seals, lubrication, backlash adjustment
Front Axle:
Steering knuckle, bearings, hubs, wheel alignment specifications
Rear Axle:
Half shafts, CV joints, wheel bearings, hub assembly
Front Suspension:
Wishbones, coil springs, shock absorbers, anti-roll bar, bushings, geometry
Rear Suspension:
Wishbones, trailing arms, coil springs, shock absorbers, anti-roll bar, bushings, geometry
Brake System:
Hydraulic system, master cylinder, brake lines, calipers, pads, rotors, bleeding procedures
Parking Brake System:
Mechanism, cables, adjustment
Brake Control System:
ABS components (if applicable), brake proportioning valves
Steering Control System:
Steering rack, tie rods, power steering pump, hoses, fluid, alignment
Seat Belts:
Installation, adjustment, retractors, maintenance
Supplemental Restraint System Srs:
Airbag system components, diagnosis, safety precautions
Body Lock Security System:
Door locks, latches, key mechanisms, central locking (if equipped)
Glasses Window System Mirrors:
Window regulators, door glass, seals, mirrors, windshield installation
Exterior Interior:
Trim, body panels, bumpers, upholstery, headliner, carpeting
Instrument Panel:
Gauges, warning lights, speedometer, tachometer, fuel gauge, temperature gauge, oil pressure gauge, electrical diagnostics
Seat:
Adjustment mechanisms, upholstery repair, seat frame
Automatic Air Conditioner:
System components, diagnosis, refrigerant, maintenance
Starting Charging System:
Battery, alternator, starter motor, wiring, voltage regulation
Lighting System:
Headlights, taillights, turn signals, interior lights, wiring diagrams
Driver Information System:
Onboard computer functions (if equipped), warning indicators
Wiper Washer Horn:
Wiper motor, blades, washer pump, nozzles, horn operation
Body Control System:
Power windows, power locks, mirrors, basic body electronic modules
Lan System:
Onboard diagnostic network (if applicable, though basic for this era)
Audio Visual Navigation Telephone System:
Radio, speakers, antenna, wiring (pre-modern systems)
Auto Cruise Control System:
Components, operation, troubleshooting (if equipped)
Power Supply Ground Circuit Elements:
Fuse boxes, relays, grounding points, wiring harness diagrams
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Troubleshooting:
Diagnostic procedures, symptom-based fault finding, electrical troubleshooting charts
Repair:
Step-by-step instructions for component replacement and repair
Diagnostics:
Specific testing procedures for engine, transmission, electrical, and chassis systems
Rebuilds:
Detailed instructions for engine, transmission, and differential rebuilds
Adjustments:
Valve lash, ignition timing, carburetor/fuel injection settings, clutch, parking brake
Specifications And Data:
Torque values, clearances, fluid capacities, electrical resistance values
Alphabetical Index:
Included for quick reference to specific topics.
Depth:
Factory-level, covering all aspects from routine maintenance to complete engine and gearbox overhauls.
Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or annually, whichever comes first.
Timing Belt Interval:
Every 2-3 years or 30,000-50,000 km (20,000-30,000 miles), critical due to interference engine design.
Spark Plug Replacement:
Every 20,000-30,000 km (12,000-18,000 miles)
Engine Oil:
SAE 20W-50 or 10W-40 API SG/SH or equivalent (e.g., Castrol Classic XL 20W-50)
Coolant:
50/50 mix of ethylene glycol coolant and distilled water
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 hypoid gear oil
Differential Fluid:
API GL-5 SAE 90 hypoid gear oil
Carburetor Tuning Challenges:
Downtuning of European spec K-Jetronic can be complex; requires specialized knowledge.
Cooling System Maintenance:
Regular flushing and inspection of radiator and hoses is crucial to prevent overheating.
Rust Prone Areas:
Wheel arches, sills, door bottoms, and rear valance.
Electrical Gremlins:
Aging wiring and connections can lead to intermittent electrical issues.