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Details procedures for the engine's cylinder head and valve drive systems.
Outlines procedures for the engine's lubrication system maintenance and repair.
Covers procedures for the engine's cooling system maintenance and repair.
Details the L-Jetronic fuel injection system's testing and adjustment procedures.
Detailed specifications for the engine, including bore, stroke, power, and torque.
Detailed steps for the initial removal of the engine, including disconnecting components and lifting.
Procedures for disconnecting electrical harnesses, fuel lines, and vacuum hoses.
Steps for disconnecting the air cleaner assembly and fuel lines.
Procedures for disconnecting the starter and clutch slave cylinder.
Detailed instructions for disconnecting coolant hoses and removing the radiator.
Steps for removing the stabilizer, engine mounts, and front axle cross member.
Procedures for lowering and removing the engine from the vehicle.
Initial steps for installing the engine, securing the radiator, and tightening bolts.
Final procedures for filling and bleeding the cooling system after engine installation.
Procedures for disconnecting battery, splash guard, stabilizers, and shields.
Steps to unscrew hydraulic engine mounts from the front axle cross member.
Identifies symptoms indicating a defective or damaged engine mount.
Details visual inspection criteria and height measurements for hydraulic engine mounts.
Steps for fitting new mounts, bolt usage, and torque specifications.
Procedure for checking the polyrib belt tension using a special tool.
Steps for adjusting the polyrib belt tension for both 5-rib and 6-rib belts.
Procedure for aligning balance shaft sprockets with drive belt cover marks.
Method for checking drive belt tightness using thumb pressure and deflection.
Steps for adjusting the drive belt tension using mounting bolts and pressure rod.
Instructions for checking belt tightness on a cold engine, including splash shield and belt cover removal.
Steps to align crankshaft and camshaft sprockets with drive belt cover marks.
Procedure for checking the alignment of balance shaft sprockets with drive belt cover marks.
Steps for using a special tool to measure drive belt tension and its specifications.
Steps for adjusting the tensioner roller, idler pulley, and final tightening.
Steps for checking radial clearance, including removing crankcase, oil, placing Plastigage, and measuring.
Procedure for checking axial clearance using a special tool and specifying wear limits.
Steps for performing honing and lapping, including oil feed and silicium mixture usage.
Instructions for setting up the machine, adjusting cylinder diameter, and the cylinder machining process.
Steps for aligning TDC marks and checking belt wear/damage while turning.
Using a special tool to measure belt tension and adjusting it if necessary.
Initial steps for cylinder head removal, including battery disconnect, coolant drain, and belt removal.
Steps for relaxing belt tension, removing drive belt cover, and unscrewing fuel lines.
Steps for unscrewing the intake brace, intake distributor, and exhaust manifold bolts.
Procedures for removing aluminum plugs, coolant lines, camshaft housing, and the air cleaner assembly.
Instructions for unscrewing cylinder head nuts, noting the crosswise order.
Procedures for installing the cylinder head gasket and mounting the cylinder head.
Steps for mounting the camshaft housing and installing/adjusting the drive belt.
Torque specifications for cylinder head bolts for models from 82 onwards, including stages and angles.
Torque specifications for cylinder head bolts for models from 89 onwards, including stages and rotation angles.
Details the tightening sequence (3 steps) and torque for cylinder head nuts, with notes on washer reuse.
Method for checking head distortion with a feeler gauge and straight edge, and permissible limits.
Guidance on grinding the sealing surface and notes on wear limits and gasket thickness.
Steps for cleaning the head, grinding guides, and pressing them out using special tools.
Procedures for measuring cylinder head bores and correcting valve guides.
Steps for grinding service valve guides and the required press fit for intake and exhaust guides.
Procedure for correcting valve guides to the specified size using a broach.
Steps for reaming valve guides, including lubrication and checking the bore.
Notes that valve seat inserts must also be machined after valve guide replacement.
Steps for removing valve stem seals with a special tool and installing new ones using a pressure pad.
Notes on checking dimension "A" before refacing and the wear limit for valve seats.
Steps for checking valve guides using a cleaning reamer, new valve, and dial gauge.
Procedure for turning crankshaft to TDC and checking belt tension on a cold engine.
Steps for undoing nuts and screws, and adjusting belt tension.
Checking the mobility of the tensioning roller lever and tightening nuts.
Procedures for draining oil, removing the filter, and replacing the seal.
Procedures for installing the oil pump assembly, including shaft seals and plugs with torque.
Instructions for replacing shaft seals, installing toothed sleeve, and using a tool for driving.
Procedures for applying Loctite to housing insert, lubricating rotors, and installing oil pump housing.
Steps for installing the oil pressure transmitter with a new seal and specified torque.
Procedures for running the engine to operating temperature and checking oil pressure at idle and 4000 rpm.
Steps for draining coolant and installing drain plugs with torque values.
Instructions for adding coolant, running engine, and checking/correcting coolant level.
Instructions for removing radiator, including expansion tank cap, air cleaner, splash guard, and coolant drain.
Steps for removing the fan housing, disconnecting coolant hoses, and ATF hoses for automatic transmissions.
Steps for installing the radiator in rubber mounts, installing clamps, and pouring coolant.
Procedures for removing the temperature switch, including air cleaner and fan housing removal.
Specifies installation torques for temperature switches with plastic and brass threads.
Steps for cleaning the system using cleaning agent and water, including draining and warm-up.
Procedures for rinsing with water until clear and filling the system with coolant and antifreeze.
Procedures for pinching fuel lines, removing the old filter, and installing the new one.
Steps for setting up the test, including disconnecting hoses and relays, and bridging terminals.
Procedure for running the fuel pump and measuring fuel volume in a measuring glass.
Procedures for removing the fuel pump, including disconnecting battery, cover, hoses, and pipes.
Instructions for installing the fuel pump, using new seals, and checking for leaks.
Initial steps for fuel tank removal, including battery disconnect, fuel draw-out, and exhaust flange removal.
Further steps for fuel tank removal, including muffler shield, fuel pump cover, and transmission removal.
Steps for removing trunk floor cover, fuel level transmitter cover, and fuel filler neck hoses.
Ensuring perfect hose connections and routing before installing the fuel tank.
Procedures for removing the expansion tank, including disconnecting battery, trim panels, and hoses.
Instructions for checking hose seating, sealing the filler neck cover, and installing the expansion tank.
Procedures for removing the sender, including floor covering, panel, hoses, and electrical connections.
Instructions for installing the sender with a new seal, coating the nut, and tightening to specified torque.
Procedures for removing the housing cover, filter cartridge, and cleaning the housing.
Specifications for electric fuel pump delivery rate, fuel pressure, and leak test.
Specifications for idle speed (rpm) and CO content for various regions and vehicle types.
Specifications for idle setting, idle speed, CO content, and HC value.
Specifications for fuel pump delivery rate, fuel pressure, and idle speed control value.
Specifications for idle speed and CO content for models from 85/2, with catalytic converter notes.
Steps for connecting the pressure tester, bridging terminals, and checking fuel pump operation.
Specifies control values for engine stopped and engine running at idle speed.
Procedure for checking CO level and correcting it by adjusting the air flow sensor.
Steps for removing the air flow sensor and drilling a plug for mixture adjustment.
Steps for applying oil to the lower seal and pressing injectors into the intake manifold.
Procedures for removing the sensor, including loosening hose clamps and unscrewing mounting screws.
Steps for cleaning threads, coating with Loctite, and tightening screws for the air flow sensor.
Steps for adjusting idle speed and CO level using a throttle housing screw.
Procedure for turning the control screw on the throttle housing to achieve specified engine speed.
Conditions for adjusting idle speed, including engine condition and ambient temperature.
Steps for connecting the exhaust testing line and CO tester.
CO level specification and adjustment on the air flow sensor if limits are not met.
Steps for connecting CO tester, tachometer, and bridging plugs for idle speed adjustment.
Procedures for removing the control unit, including switching off ignition and removing circlips.
Steps for pulling off multiple pin plugs after slightly pulling out the control unit.
Steps for removing the steering column switch, including battery disconnect and cover removal.
Steps for unscrewing casing screws, pulling off the plug, and disconnecting the instrument panel plug.
Procedures for removing the drive, including switching off ignition and disconnecting plugs.
Steps for pressing off cable retaining clips, unscrewing nuts, and removing mounts.
Steps for pressing off cables from operating and control levers and disconnecting them.
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