Manual Coverage
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Systems Covered
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Engine Service Repair:
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Comprehensive coverage including disassembly, assembly, inspection, and repair of all engine components.
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Transmission Service Repair:
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Detailed procedures for manual and potentially automatic transmission (if applicable) servicing, repair, and clutch service.
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Brake System:
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Diagnosis, repair, and maintenance of hydraulic and mechanical brake components, including master cylinder, calipers, drums, and lines.
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Wiring Diagram:
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Complete electrical wiring diagrams for all vehicle systems, crucial for troubleshooting electrical issues.
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Electrical System:
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Detailed troubleshooting and repair procedures for lighting, ignition, charging system, starting system, accessories, and ECUs.
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Suspension:
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Service and repair of front and rear suspension components, including shock absorbers, springs, control arms, and bushings.
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Steering:
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Repair and adjustment of the steering system, including steering rack, linkages, and power steering components (if equipped).
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Cooling System:
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Maintenance, diagnosis, and repair of the radiator, water pump, thermostat, hoses, and cooling fan.
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Fuel Injection Fuel System:
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Detailed coverage of fuel pump, fuel filter, injectors, fuel lines, and diagnosis of fuel delivery issues, including L-Jetronic or similar systems.
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Emission System:
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Information on emission control devices, diagnosis, and repair procedures to meet regulatory standards.
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Engine Control System:
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Troubleshooting and repair of the Engine Control Unit (ECU), sensors, and actuators for optimal engine management.
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Chassis Body:
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Repair and maintenance of the vehicle's body structure, panels, doors, glass, and chassis components.
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Restraint System:
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Information on seat belts, and potentially early airbag systems if equipped, including inspection and repair.
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Axle:
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Service and repair of front and rear axles, including CV joints and differential (if applicable).
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Procedures Included
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General Maintenance:
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Routine maintenance tasks such as oil changes, filter replacements, fluid checks, and general inspections.
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Troubleshooting:
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Systematic diagnostic procedures for identifying and resolving common and complex vehicle issues.
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Periodic Lubrication:
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Specific lubrication points, recommended lubricants, and service intervals for various chassis components.
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Disassembly Reassembly:
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Step-by-step instructions for taking apart and putting back together major vehicle components.
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Refurbish Renovate Mend Fix:
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Guidance on restoring, repairing, and fixing various mechanical and electrical parts and systems.
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Technical Depth
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Depth:
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Covers basic maintenance to complete engine and transmission overhauls, complex electrical diagnostics, and chassis repair.
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Engine Specifications
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Primary Engine
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Engine Type:
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Naturally Aspirated Boxer (Flat) Engine
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Displacement:
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Commonly 1.3L (1351 cc) and 1.5L (1490 cc) for the 1987 model year. Later models saw 1.7L variants.
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Cylinders:
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4 Cylinders, Boxer Configuration
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Bore X Stroke:
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Varies by specific engine variant (e.g., 1.5L: 80.0 mm x 74.0 mm approx.).
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Performance
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Horsepower:
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Typically ranges from 70-95 HP (DIN) depending on engine displacement and state of tune (e.g., 1.5L often around 85-90 HP).
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Torque:
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Varies by engine variant, typically in the range of 110-130 Nm.
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Fuel System
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Fuel Delivery:
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Carburetor (e.g., Weber twin-choke) or Bosch L-Jetronic Fuel Injection for higher performance variants.
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Engine Control System
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Ignition System:
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Distributor-based electronic ignition (e.g., Marelli).
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Maintenance
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Service Intervals
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Oil Change:
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Typically every 5,000-7,500 km or 6-12 months, depending on driving conditions and oil type used.
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Spark Plug Replacement:
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Recommended every 20,000-30,000 km, depending on spark plug type.
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Timing Belt Replacement:
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Crucial for boxer engines. Typically every 40,000-60,000 km or 4-5 years. Failure can cause catastrophic engine damage.
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Fluid Specifications
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Engine Oil:
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Refer to manual. Typically API SG or higher rated multi-viscosity oil, e.g., 10W-40 or 15W-40 depending on climate.
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Coolant:
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Ethylene glycol-based antifreeze mixed with distilled water. Consult manual for specific mix ratio and type.
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Brake Fluid:
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DOT 3 or DOT 4 brake fluid.
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Known Issues
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Rust Corrosion:
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Common for vehicles of this era, particularly the Alfasud-derived chassis components and bodywork. Rust in sills, wheel arches, and floor pans is frequent.
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Carburetor Tuning:
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Carbureted engines require regular tuning and adjustment to maintain optimal performance and emissions.
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Electrical Gremlins:
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Aging wiring harnesses and connectors can lead to intermittent electrical faults.
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Suspension Wear:
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Worn bushings, ball joints, and tie rod ends are common due to age and mileage, affecting handling and steering feel.
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