1962-1977 BMW 1502 1602 1802 2002 2002A 2002 Ti 2002 Tii Service Manual

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  • Covers 1962-1977 BMW 1502 1602 1802 2002 2002A 2002ti 2002tii
  • 742 pages
  • Instant PDF Download
  • 403mb
  • Bookmarked, searchable, printable
  • Compatible with Windows/Mac/Tablet

This manual covers service, maintenance and troubleshooting procedures for the 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969, 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977 BMW 1502 1602 1802 2002 2002A 2002 Ti 2002 Tii Service Manual. It includes detailed OEM BMW specifications, illustrations and step-by-step procedures to aid the mechanic with correctly repairing and troubleshooting the car. This manual is offered in a convenient PDF format viewable on your computer.

1962-1977 BMW 1502 1602 1802 2002 2002A 2002 Ti 2002 Tii Service Manual Contents:

  • Introduction
  • Torque Specifications
  • Manual and Automatic Transmission
  • Gear selector
  • Clutch
  • Body panels and equipment
  • Bodywork
  • Brakes
  • Engine Electrical
  • Electrical (General)
  • Engine Mechanical
  • Exhaust system
  • Foot pedals
  • Front and Rear Seats
  • Front and Rear Axle
  • Fuel lines and tank
  • Fuel system
  • Heater and Air Conditioning (HVAC)
  • Radiator
  • Radio
  • Wheels and Tires
  • Wiring Diagrams

Automatic transmission Technical data . . . . . . . . . . . . . . . . . . . . .
24 00 004 Selector lever, accelerator linkage and cable: adjusting
009 Hydraulic pressure: checking . . . .
020 Transmission: removing and installing .
040 Exchange transmission: installing
24 11 000 Oil sump: removing and installing
020 Oil filler pipe: removing and installing .
030 Converter dome: removing and installing.
050 Transmission cover: removing and installing
101 Starter lock and reversing lamp switch: renewing
24 12 011 Radial seal for output flange: renewing . . .
031 0-ring for speedometer bushing: renewing . .
051 0-ring for transmission selector lever: renewing
501 Radial seal for torque convertor: renewing . .
24 2? 500 Output shaft: removing and installing . . . .
511 Grooved ball bearing for output shaft: renewing .
/ 24 22 550 Planetary gear set: dismantling and assembling
551 Grooved ball bearing in transmission extension: renewing
633 Planetary gear set: dismantling and assembling
24 23 703 Plate clutches and brakes: dismantling and assembling
24 30 000 Control unit: removing and installing .
001 Control unit: renewing. . . . . . . . . . . .
24 31 510 Primary pump: removing and installing . . . . .
650 Oil strainer at control unit: removing and installing.
24 32 000 Centrifugal governor and governor boss: removing and installing.
503 Centrifugal governor: dismantling and assembling
24 34 001 Pawl for parking lock: renewing . .
101 Accelerator cable: renewing . . . . . . .
690 Index pawl: removing and installing
701 Shaft spring for accelerator cable: renewing
24 40 000 Torque convertor: removing and installing .
001 Torque convertor: renewing . . . . . .
24 51 000 Transmission selector lever: removing and installing
24 71 001 Rubber bush for transmission mounting: renewing
Automatic transmission: fault finding . . . .
51 11 000 Complete f ron t bumper – remov1ng aOO 1nstalhng . . . . . • , . • . . . • . 11 /1
0 11 Bumper – front c&ntre sect1on: ronowmg . • . . . . . . . . . . . . • . • . . . . 1 1 I 1
121 Bumper – front wrap·round sechon: renewing • . , .•.•.• , • • • • 11 / 1
201 Bumper overrider: renew1ng , • . . . • . . 11 /2
5 1 12 000 Bumper – com:plete rear: remov1ng and 1nstalllng t 2/ 1
011 Bum pet re¥ c:entre sec bOO: renew.ng . • • • 12/ 1
201 Bumper – rNr wrap-round MCll()ft: renewWlg . . ..•. 12/ 2
30 1 Bumper f()lnt cover – rear renew.ng • • . . . . 12/ 2
51 13 000 Rad1ator gnlle -centre sec:11on remov•ng and •nstalli.ng , , • , • 13/1
040 Aad•ator gnlle – end sections: remov1ng and •nstalling . . •• , • , . . . 131 1
51 16 000 Roar minor- door: remov•ng ond mstalling . . . . • . . . . . . . . • . • . . . . . . 1611
060 Rear mnor – interior: removing and installmg ………•.. • , • . 16/ t
200 StoraQe compartment – remOVtnQ and ‘”-Stalling . . • • • . • . • . • . • . . 16/ 1
360 Glove compartment removtnQ and 1nstaU.ng • . . • • • 16/ 3
51 21 00 I Door 1101>. renewing . . • • • • • • .. . .. 2 I II
090 Door lock removmg and onstoAng .. .. .. .. 2 1/ 1
120 lock – remote actuator removtng and l’lstaling . . 2 1 I 2
170 Door outer handle~ removWlg and M’lstelhog . . . . . . . 21 / 3
230 Door interior handle: remov1ng 8n<t Installing . . • . . . • • • • • • • • • 2 1/3
280 Door brake removing and installing
300 Door window-well seal .ng stnp-outor: removing and installing
Rubber contact for c:e11tng light renew.ng . . . . . . • . • • • . • . • . • . 21 I 4
EtlQ•n• compartment ild adtutt•ng • • • • . . . . • . • • 23/ 1
Ltv« W11h brac;ke1 ror hood retW* catch: removing .•••
and onsrallong • .. .. .. . .. • .. .. • .. • .. • 23/ 1
Cable tor hood retainer catch· remov~ng and instaiiWlQ 23/ 2
Luggag• compDrtmefi t reta1ner catch. removmg and insralli:ng 24 /1
Luggag• compartment la<:k: removmg and mstall1ng …•..• . … . 24/ 2
Loc,<lng brac.l<et for luggage compar tment retainer catch • .. • • • .•• 2412
Gas spnng – replacing . . . . . . . . . . . . . . • . • . . . • . . . • . • • 24/2
341 TorsiOn bar spnngs for luggagt compartment .••.. , • . • . 2413
5 1 31 000 Wind-lt’Meld . complete rem()YW’IQ and install.ng • . . . . • . • • • 3 1/ 1
001 WtndthtMd.,~ 31 / 3
200 Rear Wllldow remomg and lllStol’onQ ………. … ••. 31 / 3
51 32 000 W•ndow handkr remov.ng and 1nttalltng . • . . . • . • ••.••• 32 / 1
Window h.ond~: “‘echordm ‘omovmg ~nd in<8talling , , ,
Holdor tor w1ndow lift r&il removn-.g and installing . • . . •.•.• . •.• .
Window glass: adjusting . . • . • . • . • . . . . • . • . . . . . . . . . . . . • . . • . • …
Window glass: removing and inst&1111lg • . , . . • . • . . . . . . . . • . . . • . . . .
Knurltd knob for vent w1ndowa: removing and installing •.•.• .•…
Vent wlf’ldow remOVWlg and .nstel•ng . . . . . . . . . . . . . .•.•.•.
Wtxm gear fOt vent window ttmOVlng and instaJIIng , . . ..
WlftOow frames complete w.th “ent WWldow: r~ • . • ••
•net lnltalf•tlQ • • . . . . • . • • • , . . . . . • . . . • • • • •
Ooor panelling: removing and ,,stallmg . . . • . • • • . . . • • • • ••.•.••
Arm rest.s: removing and installing
100 St*f tr•m – remoVIng and N\Sta•ng ……… . . . 45/ 3
120 Padded ttwn on lower sect.IOn of steenng c:olumn surround
deladwlg 111<1 ouact.ng . . . • • . . . . . . . . . . . . . . . . . . . . . . 45 / 4
180 Lower left loc11 tnm · detac:t-ing and anachong . . . . . .. . 45 / 4
190 lower centre fet~~mm detaChing and attaChing ……. 45/ 4
200 Low• -tro ngln IIC>I tnm – detaching and anad>ng . • 45/ 4

41 35 000 Front side panel- renewing …………………………….. 3511
281 Rear side panel – renewing (partial replacement) . . . . . . . . . . . . . . . . . . 35 I 2
4 1 51 034 Door – adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 I 1
080 Doors – removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 I 2
1 0 1 Door – renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 I 2
41 61 000 Engine compartment (bonnet) lid – removing and fitting . . . . . . . . . . . 61 I 1
014 Engine compartment (bonnet) lid – adjusting . . . . . . . . . . . . . . . . . . . . . 61 I 1
41 62 000 Luggage compartment lid- removing and fitting …………….. 6211
014 Luggage compartment lid- adjusting ……………………… 6212
34 00 019 Checking brake pedal – high pressure, low pressure
and pre-load test …………………………………….. .
Bleeding brakes ……………………………………… .
Adjustment of handbrake ………………………………. .
Removal and fitting of brake pads ……………………….. .
Replacement of brake pads …………………………….. .
Removal and fitting of fixed calipers ……………………… .
072 Overhauling fixed calipers ……………………………… .
200 Removal and fitting of brake disc ………………………… .
250 Removal and fitting of shield plate ……………………….. .
589 Checking brake disc for runout and variations in thickness …….. .
Skimming brake disc ………………………………….. .
Removal and fitting of brake drum ………………………. .
Relining rear brakes …………………………………… .
Removal and fitting of brake shoes ………………………. .
Removal and fitting of wheel brake cylinder ……………….. .
Overhauling wheel brake cylinder ………………………… .
Replacement of rear brake backplate …………………….. .
R~moval and fitting of tandem master cylinder ……………… .
Overhauling tandem master cylinder ……………………… .
Replacement of stop light switch ….. .. ………………….. .
Replacement of fluid reservoir ………………………….. .
Replacement of. connecting hose from equalizing
reservoir to tandem master cylinder ……………………… .
Replacement of front brake hose ………………………… .
Replacement of rear brake hose …………………………. .
Removal and . fitting of brake servo with tandem
master cylinder ……………………. : ……………….. .
Replacement of brake servo ……………………………. .
Replacement of brake servo check valve ………………….. .
Removal and fitting of handbrake lever …………………… .
Replacement of locking sector ………………………….. .
Removal and fitting of handbrake cable …………………… .
Trouble shooting – brake system ………………………… .
12 11 004 Adjustment of ignition timing
060 Removal and fitting of distributor
109 Checking of distributor rotor .
141 Replacement of contact breakers
572 Overhaul of distributor
Distributor- trouble shooting . . .
12 12 011 Replacement of spark plugs
12 13 011 Replacement of coil
051 Replacement of coil primary resistor
12 31 019 Quick check of alternator and regulator
020 Removal and fitting of alternator
303 Replacement of V-belt . . . . . .
361 Replacement of joint bush in tightening belt
602 Overhaul of alternator . . . . . .
12 32 000 Removal and fitting of voltage regulator
Alternator- trouble shooting . . . .
12 41 009 Checking of starter in car ….
020 Removal and fitting of starter
513 Disassembly and assembly of starter
551 Replacement of carbon brushes
602 Overhaul of starter . . . . .
701 Replacement of exciter winding
Starter- trouble shooting . . . . . .
10.73 Alteration
61 13 001 Replacement of fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I 1
61 31 000 Removal and fitting of headlight dip switch . . . . . . . . . . . . . . . . . . . . . . 31 I 1
0 10 Removal and fitting of turn indicator switch . . . . . . . . . . . . . . . . . . . . . 31 I 2
0 15 Removal and fitting of turn indicator I dip witch . . . . . . . . . . . . . . . . . . 31 I 4
020 Removal and fitting of steering lock/ignition switch ………….. 31/5
030 Removal and fitting of light pull switch . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 5
040 Removal and fitting of wiper switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 5
360 Removal and fitting of hazard warning flasher switch . . . . . . . . . . . . . 31 I 6
040 Removal and fitting of screenwasher /wiper retard relay . . . . . . . . . . 31 /7
61 61 250 Removal and fitting of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 I 1
Trouble shooting -electrical system
11 00 009 BMW Program Test- engine . …………………………… 00/1
050 Removal and fitting of engine …………….. .. . . . . ……….. 00/2
11 12 000 Removal and fitting of rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/ 1
100 Removal and fitting of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/ 1
101 Replacement of cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 I 5
161 Replacement of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 I 5
561 Replacement of one valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 I 6
607 Re-working of valve seats and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/7
621 Replacement of one valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/7
719 Planing of cylinder head sealing surface . . . . . . . . . . . . . . . . . . . . . . . . . 12 I 8
11 13 000 Removal and fitting of oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/ 1
11 14 100 Removal and fitting of upper timing case cover . . . . . . . . . . . . . . . . . . 14 I 1
120 Removal and fitting of upper and lower timing case covers . . . . . . . . 14 I 1
57 1 Replacement of radial sealing ring in timing case cover . . . . . . . . . . . 14 I 3
611 Replacement of radial sealing ring in clutch end cover . . . . . . . . . . . . 14 I 3
11 2 1 000 Removal and fitting of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 I 1
501 Replacement of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 I 2
5 71 Replacement of ball bearing in crankshaft .. . . ……….. . … • · . . . 21 I 4
11 22 000 Removal and fitting of flywheel …… . …………….. . ……. 22/1
051 Replacement of driving disc for torque converter . . . . . . . . . . . . . . . . . 22/2
541 Replacement of starter gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I 2
11 24 501 Replacement of one connecting rod …………….. .. ….. _. . . . 24 I 1
60 1 Replacement of one small end bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 24 I 1
11 25 500 Removal and fitting of one piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 I 1
11 31 000 Removal and fitting of camshaft ……. . … . …………. . …. . – 31 I 1
051 Renewing timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 3
061 Renewing sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ 1 / .4
090 Remoying and installing chain tensioner piston . . . . . . . . . . . . . . . . . . . ’31 I 5
581 Replacement of chain iensioner rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 6
591 Replacement of sliding rail for timing chain _ ……….. . . .. … . … 31 / 6
11 33 020 Removal and fitting of rocker shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33/ 1
11 34 004 Adjustment of valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 I 1
509 Checking all valves for gastightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/ 1
550 Removal and fitting of valves ……………………………. 34/1
11 41 000 Removal and fitting of oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 I 1
151 Replacement of roller chain for oil pump drive . . . . . . . . . . . . . . . . . . . 41 I 2
512 Disassembly and assembly of oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 41 I 3
11 42 020 Full-flow oil filter ………… .. .. .. … …. ……….. …. . …. 42/ 1
11 51 000 Removal and fitting of water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 I 1
502 Disassembly and assembly of water pump . . . . . . . . . . . . . . . . . . . . . . 51 I 1
11 52 000 Removal and fitting of cooling fan …………….. …….. . . … 52/1
11 53 000 Removal and fitting of coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . 53/ 1
050 Removal and fitting of branch flange . ………… . …………. 53/1
081 Replacement of remote thermometer sensor . . . . . . . . . . . . . . . . . . . . 53 I 2
321 Replacement of all coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 I 2
11 61 000 Replacement of intake manifold gaskets . . . . . . . . . . . . . . . . . . . . . . . . 61 I 1
050 Removal and fitting of intake air collector with throttle butterfly stub pipes
Replacement of intake air collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 I 4
Replacement of auxiliary air hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 I 4
Replacement of front intake pipe gaskets . . . . . . . . . . . . . . . . . . . . . . . 61 I 5
Replacement of rear intake pipe gaskets . . . . . . . . . . . . . . . . . . . . . . . . 61 I 5
Replacement of cover gasket on intake manifold . . . . . . . . . . . . . . . . . 61 17
Removal and fitting of intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 I 8
Replacement of intake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 1 9
Removal and fitting of one intake ram air pipe . . . . . . . . . . . . . . . . . . . 61 1 9
Removal and fitting of all intake pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 61 1 9
Replacement of exhaust manifold gaskets . . . . . . . . . . . . . . . . . . . . . . . 62 I 1
Replacement of warm air guide jacket . . . . . . . . . . . . . . . . . . . . . . . . . . 62 I 1
Replacement of right – hand engine mounting . . . . . . . . . . . . . . . . . . . . . 81 I 1
Replacement of left-hand engine mounting . . . . . . . . . . . . . . . . . . . . . . 81 I 1
52 10 470 Subsequent fitting of reclining seat mechanism
71 60 010 Fitting of trailer bracket with electrical system
3. 7 3 Alteration
18 Exhaust System
Removing and fitting complete exhaust system
Renewing gasket- exhaust manifold/ front exhaust pipe ……… .
Renewing front exhaust pipe
Renewing secondary silencer
Renewing primary silencer .
Page 18 – 00/ 1
35 21 000 Removal and fitting of brake pedal
041 Replacement of brake pedal traction spring
35 31 000 Removal and fitting of clutch pedal
031 Replacement of clutch pedal torsion spring
041 Replacement of clutch pedal traction spring
35 41 030 Removal and fitting of pedal shaft . . . .
3. 73 Alteration
3 1 1 0 000 Rornoval and fitting of entJre front ax kt • . • • • • • • • • • . . . . . . . . • . . . • . 1 0 / 1
31 11 001 Reploc;emenl of fronl axle sub·frame . . . . . . • • .. • • .. .. .. .. . • . . . 11 / 1
3 1 12 000 Removal and fitOO!J of wishbone •• , • .. • .. .. .. .. .. • .. .. .. .. .. 12 / 1
050 Removal and fitOO!J of 1ra;!;ng lonk .. .. .. . .. .. • • . .. .. .. .. .. . 12/3
53 t Replacement of rWOer bush 1n front ex1e SUb -frame . • . . . . . . . . . . . 12/ 4
631 Replocemerll of nbber bush in w.shbooe . . .. .. .. • .. .. .. . .. .. 12/5
661 Replacemenl of guide joint . . . . . . . . • . • . . . . . . . . • . . . . . . . . . . . . . . 12/ 5
3 1 20 004 Adjustme<>l of wheel bearing play .. .. .. .. .. .. .. .. .. .. .. .. • .. .. 20/ 1
3 t 2 1 009 O.ecking wheel hub runout ………………………. , . . . . . . . 2 1/ 1
050 Ootaching and anaching end CliP ………… , ………. , • . . . . . . 2 1/ 1
100 Removal and fining of wheel hub . . . . .. . . • . . .. . . . . . . . . . . . . . . . . . 2 1/ 1
121 Replacement of wheel hub . . . . . . . . . . . . • . . . . . . . . • . . . • . • . • . . . . . . 2 1/2
31 3 1 000 Removal and fitting of ontire spring S1tut/lll0Ck ab sorber . …. . . . . 3 1/ 1
031 Replac&ment of entire spring strut I shock obsorber . . • . • . . . . . . . . . . 3 1 / 2
552 Overhauling of spring strut / shoc k absorber ……… . . . . . . . . … . 3 t / 2
31 32 001 Renewing shock obsorber .. .. .. .. • .. .. .. .. .. . .. .. .. .. .. .. .. .. • 3 211
31 32 001 Replecement of spnng strut suppon beer.ng . • . • . . . .. . • . . . • . • . • . • 33 / 1
051 Renew”‘9 sleeve ……. …………………………….. 33/2
100 Removal and fi100g of coil spmg .. .. . .. .. .. .. .. .. .. .. .. . .. . .. . 3312
101 Rep4acemern of coil sprinQ …………………………… 3313
31 35 000 Removal and fiiOOg of s~bokzer .. .. .. . . • . .. .. .. .. .. .. .. .. .. 35/ 1
0\ l Repllcement of n.bber nngs fc:w stabilizer on wiShbone . . . . • • • . • • • 35/ 1
021 Repta.oement of n..Cber mountings for stebt.zer bat •••••••••••••••
on front axle sub-frame
16 11 030 Removing and fitting fuel tank
031 Renewing fuel tank . . . . .
9.71 Modification
Checking starting valve /temperature-time switch / time switch ….. 64/1
031 Replacement of starter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 / 2
Fuel injection system -trouble shooting ……………………. 64/3
3 71 000 Removal and fitting of air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . 71 / 1
3 73 004 Adjustment of flap valve arm air control . . . . . . . . . . . . . . . . . . . . . . . . . 73 / 1
Removing and fitting selector lever . .
Renewing rubber rings in selector lever
Renewing ball cups for selector lever .
Renewing gaiter for selector lever. . .
Removing and fitting bracket with stay for
selector lever mounting . . . . . . . .
Removing and fitting selector lever -with bearing block
Renewing handle for selector lever . . .
Renewing pivot bush for selector rod . .
Renewing bearing bush for selector lever
Manual Gearbox  /Transmission
Specifications 0 0 0 0 0 0 0 0 0 0 0 0 0 0
23 00 005 Subsequent fitting of five-speed gearbox
020 Removal and fitting of gearbox
552 Stripping and reassembling of gearbox
3. 73 Alteration
A) Four-speed gearbox 0 0 0 0 0 0
B) Five-speed gearbox 0 0 0 0 0 0
Removal and fitting of guide sleeve for clutch release lever
Replacement of guide sleeve for clutch release lever
Replacement of radial seal on output flange
Replacement of radial seal on drive shaft
Replacement of radial seal on selector shaft
Removal and fitting of speedometer pinion
Stripping and reassembling of synchromesh
A) Porsche synchromesh
B) Borg-Warner synchromesh
Replacement of heater valve bowden cable . . . . .
071 Replacement of bowden cable for footwell air nozzles
081 Replacement of bowden cable for side window air nozzles
200 Removal and fitting of heater unit . . . . .
210 Removal and fitting of heater unit motor . . . . . .
270 Removal and fitting of heater unit water valve . . . .
64 21 071 Replacement of left-hand warm water hose for heater unit
081 Replacement of right-hand warm water hose for heater unit
101 Replacement of warm water hose between water valve and heater unit
Electrical system -trouble shooting . . . . . . . . . . . . .
10.73 Alteration
Removing and fitting combined instrument . . . . . . . . . . . . . . . . . . . . . . 11 I 1
090 Removing and fitting coolant thermometer . . . . . . . . . . . . . . . . . . . . . . 1 1 I 1
130 Removing and fitting fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 I 2
62 12 000 Removing and fitting speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 1
020 Removing and fitting speedometer drive shaft . . . . . . . . . . . . . . . . . . . 12 I 1
62 13 000 Removing and fitting revolution counter . . . . . . . . . . . . . . . . . . . . . . . . . 13 I 1
050 Removing and fitting clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I 1
62 16 000 Removing and fitting immersed-tube sensor for fuel gauge . . . . . . . . 16 I 1
005 Removing and fitting sensor for remote coolant …………….. .
thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I 2
62 21 000 Removing and fitting complete instrument panel
Checking coo ling system for leaks
17 11 000 Removing and fitting radiator
Radio with loudspeaker and suppressor kit- installing
Front antenna- installing 0
Removing and fitting final drive . .
33 11 011 Renewing shaft sealing ring for input flange.
060 Removing and fitting driving flange . . . .
091 Renewing driving flange . . . . . . . .
151 Renewing shaft sealing ring for driviny flange
33 12 510 Removing and fitting input bevel pinion . .
551 Renewing input bevel pinion with crownwheel
33 13 510 Removing and fitting differential housing . .
591 Renewing differential pinions . . . . . . .
33 14 010 Removing and fitting limited slip differential .
011 Renewing limited slip differential I subsequent
installation ·. . . . . . . . . . . . . . .
Stripping and assembling limited slip differential.
Renewing cross member for final drive .
Removing and fitting output shaft
Renewing gaiter . . . . . . .
Renewing universal joint . . . . . .
Renewing rear axle carrier . . . . .
Removing and fitting trailing arm . . . . . . .
Renewing both silentblocs/facing blocks for trailing arm.
Checking alignment of trailing arm . . . . . .
Renewing tie bar for rear axle carrier . . . . .
Renewing rubber bush for rear axle carrier . . .
Removing and fitting driving flange on half-shaft.
Removing and fitting half-shaft · . . . . . . .
Renewing wheel bearing and shaft sealing rings of half-shaft . . . . . . . . . . . . . . . .
33 52 000 Removing and fitting shoe!<- absorbers . . . . .
001 Renewing shock absorbers . . . . . . . . .
031 Renewing rubber bush for shock absorber mounting
33 53 000 Removing and fitting coil spring
001 Renewing coil spring . . . .
33 55 000 Removing and fitting stabilizer
Trouble shooting – rear axle
Removal and fitting of front seat . . . . . .
100 Removal and fitting of outer seat rail for front seat
110 Removal and fitting of inner seat rail for front seat
180 Removal and fitting of front seat adjustment catch.
261 Replacement of hand wheel for adjusting front seat backrest angle
424 Adjustment of cable for backrest location
52 20 000 Removal and fitting of rear seat and backrest
100 Removal and fitting of rear seat
Optical alignment of front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 I 1
054 Optical alignment of rear axle ……………………………. 0012
32 1 0 004 Adjustment of seering box . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 1 0 I 1
32 11 000 Removal and fitting of steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 I 1
503 Disassembly and reassembly of steering box . . . . . . . . . . . . . . . . . . . . 11 I 2
32 21 080 Removal and fitting of steering arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 I 1
10 1 Replacement of track rod arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 I 2
231 Replacement of outer track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 I 4
28 1 Replacement of centre track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 I 5
32 31 000 Removing and installing upper steering column surround . . . . . . . . . . 31 I 1
020 Removal and fitting of lower steering column surround . . . . . . . . . . . 31 I 1
04 1 Replacement of joint flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 2
050 Removing and installing joint disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 I 2
060 Removal and fitting of steering spindle . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 3
061 Replacement of steering spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I 3
090 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . 3 1 I 4
13 1 Renewing cancelling cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 I 5
32 32 001 Replacement of steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 I 1
32 33 000 Removal and fitting of steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 I 1
031 Replacement of cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 I 1
081 Replacement of carbon contacts for horn . . . . . . . . . . . . . . . . . . . . . . . 33 I 2
5 51 Replacement of horn contact slipring
Electronic balancing of front wheel on car
058 Electronic balancing of rear wheel on car
108 Stationary balancing of front wheel – static and dynamic
209 Checking wheel for lateral and vertical runout
300 Removal and fitting of front wheel
320 Removal and fitting of rear wheel
Wiring Diagrams / Schematics

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