| Introduction | page0003.tif |
| Specifications | page0004.tif page0005.tif |
| Power Unit | page0006.tif page0007.tif |
| Dismounting and Mounting | page0008.tif page0009.tif page0010.tif |
| Engine | page0011.tif |
| Checking the Technical Condition | 11 |
| Test Conditions and Car Preparation | page0012.tif |
| Performance Test | 12 |
| Economy Test | page0013.tif page0014.tif |
| Compression Test | page0015.tif |
| Check of Noise of Running Engine | page0016.tif page0017.tif page0018.tif |
| Condition of Individual Parts | page0019.tif |
| Design | 19 |
| Crank Gear | page0020.tif page0021.tif page0022.tif page0023.tif page0024.tif page0025.tif page0026.tif page0027.tif page0028.tif page0029.tif page0030.tif page0031.tif page0032.tif page0033.tif |
| Valve Gear | page0034.tif page0035.tif page0036.tif page0037.tif page0038.tif |
| Lubricating System | page0039.tif page0040.tif page0041.tif page0042.tif page0043.tif page0044.tif |
| Cooling System | page0045.tif |
| Fuel System | page0046.tif page0047.tif page0048.tif page0049.tif page0050.tif page0051.tif page0052.tif page0053.tif page0054.tif page0055.tif |
| Dismantling and Assembling | page0056.tif |
| General Dismantling | page0057.tif page0058.tif page0059.tif |
| Assembling | page0060.tif page0061.tif page0062.tif page0063.tif |
| Removal and Installation of Assemblies and Parts | page0064.tif |
| Cylinder Heads (Engine not Removed) | page0065.tif |
| Timing Gear Cover (Engine Removed) | page0066.tif page0067.tif |
| Timing Gear Cover (Engine not Removed) | 68 |
| Camshaft and Balancing Mechanism (Engine Re-moved) | page0068.tif |
| Camshaft and Balancing Mechanism (without Full Dismantling of Engine) | page0069.tif |
| Cylinders and Piston-Connecting Rod Assemblies (Engine Removed) | page0070.tif page0071.tif |
| Cylinders, Piston Rings, Pistons, Connecting Rods, and Connecting Rod Bearing Shells (Engine not Removed) | page0072.tif page0073.tif |
| Troubleshooting | page0074.tif page0075.tif page0076.tif page0077.tif page0078.tif page0079.tif page0080.tif |
| Repair | page0081.tif |
| Crank Gear | 81 |
| Crankcase | page0082.tif |
| Cylinders | page0083.tif page0084.tif |
| Pistons | page0085.tif page0086.tif |
| Piston Rings | page0087.tif |
| Piston Pins | page0088.tif |
| Connecting Rods | page0089.tif |
| Crankshaft | page0090.tif |
| Flywheel | page0091.tif |
| Crankshaft Seals | 92 |
| Main and Connecting Rod Bearing Shells | page0092.tif |
| Valve Gear and Balancing Mechanism | page0093.tif |
| Removal and Installation of Valves | page0094.tif |
| Inspection of Valve Stems and Valve Guides | page0095.tif |
| Replacement of Valve Guides | page0096.tif |
| Refacing Valve Heads | page0097.tif |
| Regrinding Valve Seat Faces | page0098.tif |
| Valve Seat Replacement | 98 |
| Valve Lapping | page0099.tif |
| Inspection of Valve Springs | page0100.tif |
| Inspection of Valve Caps | 101 |
| Inspection of Rockers and Their Shafts | page0101.tif |
| Inspection of Tappets and Push Rods | 102 |
| Inspection of Push Rod Cover Seals and Drain | page0102.tif |
| Pipe Seals | 102 |
| Inspection of Camshaft | page0103.tif |
| Inspection of Balancing Mechanism | 103 |
| Lubricating System | 103 |
| Eliminating Leaks in Lubricating System | 103 |
| Locating and Eliminating Causes of Oil Pressure Drop | page0104.tif |
| Dismantling and Assembling of Oil Pump | page0105.tif |
| Inspection of Relief Valve | page0106.tif |
| Inspection of Ignition Distributor and Oil Pump Drive | 106 |
| Inspection of Oil Cooler | 106 |
| Inspection of Centrifugal Oil Cleaner | page0107.tif |
| Cooling System | page0108.tif |
| Inspection of Fan | 108 |
| Adjusting Belt Tension | 109 |
| Fuel System | page0109.tif |
| Removal and Installation of Fuel Tank | 109 |
| Repair of Fuel Tank | page0110.tif |
| Removal and Installation of Fuel Pump | 110 |
| Dismantling and Assembling of Fuel Pump Check of Fuel Level in Carburettor | page0111.tif page0112.tif |
| Float Chamber | page0113.tif |
| Removal and Installation of Carburettor | 114 |
| Dismantling and Assembling of Carburettor | page0114.tif |
| Carburettor Adjustments | page0115.tif |
| Carburettor Adjustment for Low Idle Speed | page0116.tif |
| Removal and Installation of Throttle Control Cable and Its Sheath | page0117.tif |
| Removal and installation of air choke control rod and Sheath | 117 |
| Adjustment of Throttle and Air Choke Control Linkages | 117 |
| Running-In the Engine after Repair | page0118.tif |
| Clutch | 118 |
| Design | page0119.tif page0120.tif |
| Clutch Control Gear | page0121.tif page0122.tif page0123.tif |
| Troubleshooting | page0124.tif page0125.tif |
| Repair | 126 |
| Dismantling and Assembling | page0126.tif |
| Inspection of Parts | page0127.tif page0128.tif page0129.tif |
| Assembling | page0130.tif |
| Installation and Final Adjustment | 130 |
| Adjustment of Clearance between Clutch Release Bearing and Collar | page0131.tif page0132.tif |
| Clutch Control Master Cylinder | page0133.tif |
| Clutch Control Slave Cylinder | page0134.tif |
| Clutch Pedal | 134 |
| Gearbox, Final Drive, and Differential | page0135.tif |
| Design | page0136.tif page0137.tif page0138.tif page0139.tif page0140.tif page0141.tif page0142.tif page0143.tif |
| Troubleshooting | page0144.tif page0145.tif page0146.tif |
| Repair | page0147.tif |
| Dismantling | page0148.tif page0149.tif page0150.tif |
| Inspection of Parts | page0151.tif page0152.tif page0153.tif page0154.tif page0155.tif page0156.tif page0157.tif page0158.tif page0159.tif page0160.tif |
| Assembling the Gearbox and Differential | page0161.tif page0162.tif page0163.tif page0164.tif page0165.tif page0166.tif page0167.tif page0168.tif |
| Check and Adjustment of Backlash in Final Drive Gearing | page0169.tif |
| Rear Axle Speed Reducer Drive Shaft | page0170.tif |
| Design | 170 |
| Troubleshooting | 170 |
| Repair | page0171.tif |
| Dismounting | 171 |
| Dismantling | page0172.tif |
| Assembling | page0173.tif |
| Installation on the Car | 174 |
| Axle Shaft | page0174.tif |
| Design | 174 |
| Troubleshooting | page0175.tif |
| Repair | page0176.tif |
| Removal | 176 |
| Dismantling | page0177.tif page0178.tif |
| Assembling | page0179.tif |
| Installation | 180 |
| Wheel Speed Reducer | page0180.tif |
| Design | page0181.tif |
| Troubleshooting | page0182.tif |
| Repair | page0183.tif |
| Dismounting | 183 |
| Dismantling of Speed Reducer | 183 |
| Dismantling of Universal Joint | page0184.tif |
| Inspection of Parts | page0185.tif page0186.tif |
| Assembling of Speed Reducer | page0187.tif page0188.tif |
| Installation of Speed Reducer | page0189.tif |
| Assembling of Universal Joint | page0190.tif |
| Rear Axle Speed Reducer | page0191.tif |
| Design | 191 |
| Troubleshooting | page0192.tif |
| Repair | 192 |
| Removal and Installation | 192 |
| Dismantling | page0193.tif |
| Inspection of Parts | page0194.tif page0195.tif |
| Assembling | page0196.tif |
| Suspension, Shock Absorbers, Wheels, and Tires | page0197.tif |
| Specifications | 197 |
| Design | page0198.tif |
| Suspension | page0199.tif page0200.tif |
| Shock Absorbers | page0201.tif page0202.tif |
| Troubleshooting | page0203.tif page0204.tif |
| Repair | 205 |
| Suspension | page0205.tif |
| Removal | 205 |
| Installation | page0206.tif |
| Torsion Bar Replacement | 206 |
| Torsion Bar Rearrangement | page0207.tif |
| Removal of Suspension Arm | page0208.tif |
| Installation of Suspension Arm | 208 |
| Replacement of Steering Knuckle Pivot Bushing Casings in Assembly with Bushings and ot Pivots | page0209.tif page0210.tif |
| Taking Up the Axial Play in the Pivotal Joints of Steering Knuckle | page0211.tif |
| Replacement of Worn Suspension Arm Bushings with Repair Ones | page0212.tif |
| Suspension Axle Repair | page0213.tif |
| Check and Adjustment of Play in Wheel Speed Reducer Driven Shaft Bearings | 213 |
| Toe-In | page0214.tif |
| Setting the Maximum Front Wheel Turning Angles | 215 |
| Shock Absorbers | page0215.tif |
| Removal of Front Suspension Shock Absorber | 215 |
| Removal of Rear Suspension Shock Absorber | 215 |
| Shock Absorber Check | 215 |
| Disassembly, Repair, and Assembly | page0216.tif page0217.tif |
| Wheel Balancing | 218 |
| Wheel Rotation | 218 |
| Tire Inflation | 218 |
| Steering | page0218.tif |
| Design | page0219.tif page0220.tif page0221.tif page0222.tif |
| Troubleshooting | page0223.tif |
| Repair | page0224.tif |
| Removal and Installation of Steering Gear (without Shaft, Shaft Support, and Steering Wheel) | page0225.tif |
| Dismantling of Steering Gear | page0226.tif |
| Assembling | page0227.tif page0228.tif |
| Replacement of Steering Arm Shaft Bushings in Case and Cover | page0229.tif |
| Removal and Installation of Steering Wheel | 229 |
| Removal and Installation of Steering Shaft | page0230.tif |
| Removal and Installation of Steering Shaft Sup-' port | 230 |
| Removal and Installation of Combination Levers and Steering Rods | 231 |
| Repair of Ball Joint | page0231.tif |
| Removal and Installation of Combination Lever Pivot Pin Bracket | page0232.tif |
| Replacement of Bushings in Combination Lever Bracket | page0233.tif |
| Adjustment of Play in Worm Bearings | 233 |
| Adjustment of Backlash between the Worm and Roller | 233 |
| Adjustment of Steering Wheel Play | page0234.tif |
| Brakes | page0235.tif |
| Specifications | 235 |
| Design | page0236.tif page0237.tif page0238.tif page0239.tif page0240.tif page0241.tif |
| Troubleshooting | page0242.tif |
| Repair | page0243.tif |
| Removal and Installation of Brake Drum | 243 |
| Removal and Installation of Brake Shoes | page0244.tif |
| Replacement of Wheel Brake Cylinder | page0245.tif |
| Dismantling and Assembling of Wheel Cylinder | page0246.tif |
| Replacement of Brake Master Cylinders | page0247.tif |
| Dismantling and Assembling of Brake Master Cylinder | page0248.tif |
| Removal and Installation of Brake Pedal | page0249.tif |
| Replacement of Tubes | 250 |
| Replacement of Flexible Hoses | page0250.tif |
| Filling the Hydraulic System with Working Fluid, Bleeding, and Tightness Test | 250 |
| Bleeding of Circuit | page0251.tif |
| Replacement of Parking Brake Control Cable | page0252.tif |
| Adjustment of Parking Brake Control Cable Tension | 252 |
| Adjustment of Parking Brake Control Gear by Cam Screw | 252 |
| Vacuum-Hydraulic Booster | page0253.tif page0254.tif page0255.tif |
| Removal and Installation of Vacuum-Hydraulic Booster | page0256.tif |
| Replacement of Cups, Diaphragms, Valves of Vacuum-Hydraulic Booster | page0257.tif |
| Electrical Equipment | page0258.tif |
| Generator | 258 |
| Specifications | 258 |
| Design | page0259.tif |
| Troubleshooting | page0260.tif page0261.tif page0262.tif |
| Generator Test on Car | page0263.tif |
| Bench Test of Generator | page0264.tif |
| Location of Faults | page0265.tif |
| Repair Dismantling and Assembling | page0266.tif |
| Inspection of Parts | 266 |
| Voltage Regulator | page0267.tif |
| Specifications | 267 |
| Troubleshooting | page0268.tif |
| Check and Adjustment | page0269.tif |
| Interlock Relay RB 1-10 | page0270.tif |
| Specifications | 270 |
| Operation | 270 |
| Troubleshooting | page0271.tif |
| Test on Car | 271 |
| Test and Adjustment on Test Bench | 272 |
| Storage Battery | page0272.tif |
| Specifications | 272 |
| Troubleshooting | page0273.tif |
| Bringing Dry-Charged Battery into Working State | page0274.tif |
| Battery Check for State of Charge | page0275.tif |
| Ignition System | page0276.tif |
| Ignition Lock with Anti-Theft Device | 276 |
| Ignition Coil | page0277.tif |
| Ignition Distributor | page0278.tif page0279.tif |
| Adjustment of Breaker Point Gap | page0280.tif |
| Adjustment of Ignition Timing | 281 |
| Setting the Ignition Timing | page0281.tif |
| Removal of Distributor | page0282.tif |
| Installation | 282 |
| Bench Test | page0283.tif |
| Dismantling and Assembling | page0284.tif |
| Spark Plugs | 285 |
| Bench Test | page0285.tif |
| Plastic Nipples | 286 |
| High-Tension Wires | 286 |
| Starter | page0286.tif |
| Specifications | 286 |
| Design | page0287.tif page0288.tif page0289.tif |
| Troubleshooting | page0290.tif |
| Location of Faults | page0291.tif |
| Bench Test | 291 |
| Idle Running Test | 291 |
| Full Lock Test | 292 |
| Test of Solenoid Relay | page0292.tif |
| Removal and Installation of Starter | 292 |
| Dismantling | page0293.tif |
| Inspection of Parts | 293 |
| Assembling | page0294.tif |
| Auxiliary Starter Relay PC534 | page0295.tif |
| Specifications | page0296.tif |
| Test and Adjustment | 296 |
| Master Lighting Switch | 296 |
| Three-Lever Switch | page0297.tif |
| Switch of Rear Axle Differential Locking Pilot Lamp | page0298.tif |
| Headlamps | 298 |
| Aiming the Headlamps | page0299.tif |
| Front Lamps | 300 |
| Rear Lamps | page0300.tif |
| Reversing Lamp and Its Switch | page0301.tif |
| Number-Plate Lamps | 302 |
| Brake Failure Signalling System Switches | 302 |
| Stop Light Switch | 302 |
| Horn | page0302.tif |
| Specifications | 302 |
| Design | page0303.tif |
| Troublesliooting | page0304.tif |
| Fuses and Cutouts | page0305.tif |
| Turn Indicator Breaker | page0306.tif |
| Emergency Signalling Switch | 307 |
| Brake Serviceability Signalling Relay | page0307.tif |
| Specifications | 307 |
| Instrumentation | page0308.tif |
| General | 308 |
| Speedometer | page0309.tif |
| Design | 309 |
| Troubleshooting | 309 |
| Installation | 310 |
| Oil Pressure Gauge | page0310.tif |
| Design | 310 |
| Troubleshooting | page0311.tif |
| Oil Temperature Gauge | page0312.tif |
| Design | 312 |
| Troubleshooting | page0313.tif |
| Fuel-Level Gauge | 313 |
| Ammeter | page0314.tif |
| Body | page0315.tif |
| General | 315 |
| Dismantling, Assembling, and Repair | 315 |
| Windshield | 315 |
| Removal | 315 |
| Installation | page0316.tif |
| Windshield Wiper | 316 |
| Removal | 316 |
| Installation | 316 |
| Removal and Installation of Electric Motor | page0317.tif |
| Windshield Washer | 317 |
| Windshield Frame | page0318.tif |
| Removal | 318 |
| Installation | 319 |
| Canopy | page0319.tif |
| Removal | 319 |
| Installation | 320 |
| Door | page0320.tif |
| Design | page0321.tif |
| Removal and Installation of Lock, Outside Han-dle, Button | page0322.tif |
| Removal and Installation of Inside Handle | page0323.tif |
| Door Removal | page0324.tif |
| Door Installation | 324 |
| Removal and Installation of Glasses | 324 |
| Hood | page0325.tif |
| Design | 325 |
| Removal | page0326.tif |
| Installation | 326 |
| Heater | 326 |
| Specifications | 326 |
| Design | page0327.tif page0328.tif page0329.tif page0330.tif page0331.tif |
| Operation | page0332.tif page0333.tif |
| Troubleshooting | 334 |
| Repair | page0334.tif |
| Replacement of Quartz Rod of Switch Adjustment | 334 |
| Disassembly and Assembly of Heater | page0335.tif |
| Removal and Installation of Motor and Heat Exchan-ger | page0336.tif |
| Solenoid-Driven Gasoline Pump | page0337.tif |
| Removal and Installation | 337 |
| Troubleshooting | page0338.tif |
| Appendices | page0339.tif page0340.tif page0341.tif page0342.tif page0343.tif page0344.tif page0345.tif page0346.tif page0347.tif page0348.tif page0349.tif page0350.tif page0351.tif |
