Professional Documents
Culture Documents
(excl.Air Conditioner)
Repairsand
Maintenance
Content of Manual
Group81: Body
Design 5
Checkingfront end 1
Replacingbody parts lo
TP 11410/1
2000.2.79
Specifications
Group80
General
Specifications
't92.6'
L e n g t h. . . . . , . . . . . . . . . . 489 cm
wdfi................. 171 cm 67.3"
Heghr,curb weightjexcept245-265 56.5"
245-265 . . . . .. . . .. . . .. 146 cm 51.5"
W h e e l b a s. e. . . . . . . . . . . 264 cm 1o4"
T r a c lf r o n t. . . . . . . . . . . . 142 cm 55.9'
T r a c kr e a r. . . . . . . . . . . . . 135 cm
Turnrngcircle{belweencurbs) 9.8 m 32.5',
Culb weight (depending on typdl
242................... 1291-1389kg 2844-3060 lbs
244................... 1 3 1 G - 1 4 1kO
s 2886-3106 lbs
245 . . . . . . . . . . . . . . . . . . . 1394-1485kg 3071 3271 lbs
262................... 1425-144O ks 314O-3180lbs
264.. .... ... ... .... ... 1435 1465 kg 3160-3225 lbs
265................... 1480-15OOks 3260-3305 lbs
GrossVehicleWeight (GVW):
2 4 2 ,2 4 4 . . . . . . . . . . . . . 1830 kg 4030 lbs
2 4 5. . . . . . . . . . . . . . . . . . . 1950 kg 43OOlbs
2 6 2 ,2 6 4 . . . . . . . . . . . . . 1900 kg 4190 lbs
1950 kg 43OOlbs
Capacityw€ight:
E x c e p2r4 5 a n d2 6 5 . . . . . . . . . . . . . . . . . . 920 lbs
112Olbs
265................... 990 lbs
Pemissibleaxleweight,frontl
242, 244, 245 855 kg 1885 lbs
262, 264. 265 930 kg 2O5Olbs
Perm|ssible axle weighl rear:
242, 244 and 262, 264 990 ks 2180 lbs
245, 265 1 1 8 0k s 2600 lbs
lvlax.trailerweight 908 ks 2OOOlbs
Max. hitch load 75-90 ks 160-200 lbs
Cargospacs,245 and 265
L e n g tw
h i t h . e a rs e a tu p . . . . . . . . . . . . . . . . 1 1 3c m 44.5"
L e n g tw
h i l h r e a rs e a td o w n . . . , , . . . . . . , . 188 cm 74.O"
Maxrmumwdth 133 cm 52.4"
H e i g h t. . . . . . . . . . . . . . . . 84 cm
Volumewilh rearseatup . . .. . . ... . . 1.5 m3 53 cu-ft.
Volumewhh .€ar s€at down 1.9 m3 67 cu.ft.
Cargo,openang; maximumwidth 1 1 6c m 45.7"
max'mumheight 78 cm 3o.1'
Group80
Geneml
eEo?
o
o
o
o
O€)
Floor plan
Group80
General
:1--=
-.
. rF_-l
'-.r ., ;1
I \
Group80
Geneftl 3
Specifications
A =412):2 mm = distance between center lines of holes (O 10 mm) for impact absorber attachments.
SpecialTools
999 (SVO)
5 123 Fixture, andreartrailingarm6t-
sidemembers
5126 Gaugerod, side members6nd front cross
member.L,sedwith Fixture5123 and Gauge
5127.
5 127 Gaugesidemembers andfrontcrossm€mber.
Usedwith Gause Rod 5126
@
r4(io I
5125
Gtoup80
4 Genenl
Body dest:gn
Group81
Body
Design
iii,gt".
The vehiclehas 6 unitizedor integralbody, which Vehiclesequippedwith catalyticconverters are pro
meansthd body and frameare composedinto one videdwith extmheavyfloor insulation abovethe ca-
talyticconverterand ihe heatprotectionplates.The
The body is cornposedby severalsheetpanelsweld€d catalytic convertersystem increasesexhaustsystem
together to a strong shell.
The body couldbe dividedinto severalsubsections: foam rubberprovidesnoiseinsulation.
Self-adhesive
floor,sid€s,roof,front fendeq hood,doorsandtrunk A splashguardunderthe front enginecompahment
tid. alsoactsasanenginenoisesuppressot Somemodets
For fronl fendersand hood see croup 82. withautomarrctransmission
arealsofinedwith a noise
For doorsand trunk lid s€e croup 83. screenunderthe engineand t.ansmission houshg.
Heat iansfer from exhaustsystem to body is being
redocedby three hsat protectionshields.The galvan
ized steel sheet shieldsare attachedat tho joint f?e-
w€llfiont floor as wsll as abovellont and rsar mufft-
Group80
Genenl 5
Bodydesign
Roof sections
N
Group80
6 Genenl
Bdy alignment
Checkingfront end with tools 999 5123, -5124, =5125, =5126 and
-5127
1,
2.
NOTE:Do not force fixture into position.tt may be Attach fixture 5123
distonedand mis€lign.
5. Lift the fixturelront endandattachthe rear guid€
1. CleanareasoI thesidsm€mbers wherethefixrure
studs{2)to the sidemembsrgaugsholes.Lower
suppon block {4) are supposedto land.
thefixturesupport lsgsandadjustheightFosition.
2. Attachthefixtureadaprors { 1}tothesidemember 6. Thef6ceat the fronrguidestuds(3)shouldabut
gaugeholes.Do not tighren.
the sidemembers. The front guid€studsshould
3. Placethe fixtureunderthe vehicle.
4. Litt the fixturerearend and hook it on the act-
7. Attachr€tainingscrews.t the rear guidsstuds
t2t.
8. Tightenthe adaptorsThefixtureabutm€ntblocks
shouldtouch the side memb€rflanges
Group81
Bdv 7
Bdy alignment
A2
Checkside members
1. Check that side members align at front guide
|rr-l l-',rl
t] fl -t r 2. Installr€tainingscrewsat front guidesruds.Us€
llLr front axle member retainingscrews
Align front guid€studsin side membergauge
A3
Check position ot control arm brackets
1. Attachcontrolarmrsarbrackets to sid€members.
Spare parts can be used for this checL
2. Adjustgaugeson fixtureand checkbracketfit.
The gaugesare providedwith a slot which in
dicatestolemncepermitted.
A4
Check wheel housingheight and sido align-
m€nt
1. Installgaugsplat€5125inoneofthewheelhous-
ings.
2. Attachlixture5 124 to previously
installedfixture
5123.
Group8l
Rody
Bodyalvnment
MAX;T01. A5
Check wheel housing position, using gauge ol
{ixture 5124
Max. tolerance p€rmissible:
of gaugewill enterhol€o{ gauge
Side:shall cliametsr
plats5125.
Zero toleranc6:
Sid€:largsdiameterofgaugewillenterholeof gauge
plate5125.
0-r01.
\2620
A6
Checkalignmentof sidememberfront sedrcn
,'-/,,--...= Attachgaugerod 5126 to mainlixtur€5123. Placa
gauge5127 in impactabsorberattachment.Ch€ck
side memberalignment.
MaL r66dings p€rmitted: 0 mm and 4 mm
Zsro rsading: 2 mm
A7
Check alignmont of front cross membel
L Placegauge5127 on gaugerod 5126. Check
alignmenlof front memb€r.
Max rddings p€rmitt€dr O mm and 4 mm
Z€ro reading: 2 mm
2. Checkother side.
Group8,
Bdv I
Body alignment
YEIY?
B2
Removesheet metal oanels
1 . Cut loose Iront member kom side mem-
'wheerhousinS
be' whrh shou'dnol be.eplaceo.
2. Removeside member tie plate and jack support
Gtoup I I
10 Body
Body alignment
(Oper-
Fixture5123 mustnot beforcedintoposition. The fixturemust not be installed
when srraightening
ations 15-23). membersor wheelhousings.In thosecasesfixture
Forcescausedistortion
andresulting
measurementer- front pan shouldbe released.As alignmentgoeson,
fixturefront end can be raisedto checkalignment.
Prepare
Use a scrapefto clean inside of front side members
(intemediate and rear parts)
Attach fixtures
Attachmountingbrackets (A)for fixture5123 tOrear
endsof side members.
Let mountingbracketshang loose.
Fit fixture5123 undervehicle.Raisefixturerearend
and hook it to mountingbrackets.
Align
Raisefixture front end and guide rear guide pins into
the holes of side members.
Lower support legs and adjust height.
NOTE: the front guide pins should not be used.
Attach
Installattachments€rewsat rear guide pins.Then
tightenmountingbracketsA.
Group81
Eody
Sody alignment
B7
Checkfit
1. Thefixturesupportpadsshouldnow abutthe
flangesof the side memberc.
lf necessary,lower fixtoreand align members.
2. Checl rhar lhe srdemembersabursurfacesar
front guidepins.
3. lnstallaitachmentscrewsat frontguidepins.Use
front axle memberattachmentscrews.
88
Checkclearance
guidepinsin holerin sidemembers,
1. Installfront
see Fis.
Maximum cl€arancel
Small diameter of guide pin fits in hole of side
89
Check fit
'1. Adjustgaugesandcheck{it of the brackets,
see
Fig
The gaugesare providedwiih a groovewhich
indicatesdeviationpermitted.
NOTE:the bGcketsare somewhatadjustable,
2. Whenevernecessary,lower the fixture and
straighten,alt. replacemember.
Bto
Attach fixture
1. Attachfinure 5125 to wheelhousing
2. Attachfixture 5124 to fixture5123.
Gtoup81
12 Body
Bodyalignmmt
fixture5125
Bt2
Straighten
Whenever necessary,
removsfixtureandstraighten
A pullchaincanbeattached
to fixture5125,seeFig.
Bt3
Attach fixtures
'1. Attach gauge
rod 5126 to fixture,see Fig.
2. Placegaugs5127 in bumpershockabsorberar-
tachmentandcheckpositionot sidememb€r,ses
Fis.
3. Whenever necessary,
lowerfb,aureandstraighten
GroupI I
Bdv 13
Bdy alignment
Kp
Applyweldprimerto ail groundsurfaces.
815
Drill holes
Drillapprox.5 mm holesin ths sheetmetatpartsit-
R16
Connect parts
Connectsidemsmb€r parLjacksupport
intermediate
andtrailingarmbracketas shown.
R|7
Position parts
Positionthe parts ass€mbledaccordingto opstation
B16.
Firtailingalm bracketagainstgaugeon fixture5123,
6nd tighten.
Group8,
14 Rody
gdy alignmmt
Bt8
Position fixtur€s
1. Poshion whoelhousing onfixture5 | 23.Us€front
axlememberscrewsto fit it on fixture.
2. Position fixture5125inwh€elhousing andfinure
5124on tixture5123.
3. Attachgaugerod 5'126to fixture5123.
Bt9
Wheel housing
\\ to correctposition.
Adjustwh€elhousing
1\, \ Apply a coupleof smallweldsto connectwh€elhous-
ing member and side member.
:{-- -_\. ;,
820
Front cro6s member
1. Rais€and positionfront crossmsmbsr.
Wdd member to position (weld holes).
2. Wdd whs€lhousingand wheslhousingbracket
to firewall {weld holes).
3. Adjust cover plat€ into position.Welct it at the
bumpe. shock absorberattachment.
Group
8l
Bdv 15
Rodyal4qnment
821
@o@
W€ld holes
1. Wdd holesof oLrter.nd innertie platesto ioin
|]28ll
R22
Trailing arm brack€t
t. adjustthe trailingarm bracketpo-
lf necessary.
sition,seeFig.below.Thegaugeon fixturs5123
hasa groovewhich indicatesdeviationpemitted
Next,applya coupl€of smallwsldsto attachboth
ends of the side member interm€diateDart.
W6ld holes
1 . Wdd holesto connectjack support memberto
sidemember,intermediat€ part,androckerpanel,
2. Weld,from insidevehicle, sidememberinterm€-
diats pan, tie plate and jack supportmember
Rsstore
t . Removeall fixtures.
2. Wdd seamsai both endsof sid€ member,in-
termediatepart. Grind as necessary
3. Weld seamsandholssof baterv shelfandsuo-
port to sid€ memberand wheelhousing.
Re-installation
t. Installwhe€lhousehandware.
Rightsids.emem- 5. Installhood and front fenders
Installlsfl andighr sideplatsE,
floorplats,c€nte.
2. Installfront axle memberand springsnd strut suppon and cover pl6t€.
7. Installfront €nd components,
3. Install€ngin€and transmission. Install the battery.
4. Applysealingcompoundroundthe wheelhous- 9. lnstallremainingparts.
ings and on the t€nder attachmentsurfac€s.
Group I I
16 8dv
Design
Group82
Design
Gtwp 82
Frcnt Eti, Hod and FetdeE 17
ServiceProcedures
Frontfenders
N
Adjusting h@d hingss
Hood l@k
GtuupA2
18 Frcnt End,HoodandFenders
Design
Group83
DoorsandTrunk
The doors are built up of an innerand an outer ptate, door lock by a pull rod. The cloor opener inside the
flsnged and spot-welded together. Hinges are fitted car is attached to the inner door plate wilh screws.
to the inner plate. The doors are adjustablelongrru- The handletransmitsthe movementto a lever which
dinally,verticallyand laterally.Thedoor locksare ired lifts the locking pin by link rods in the lock. On rhe
to the doors wnh screws. The door handle on the front doors ihe lock mechanismis fined in a cyhnder
outsadeactuatesa leverwhich lifts tbe lock pin of the under the door handle.
Frontdoors
7-6
I-1
Group83
19
Design
The rear doors are equippedwith child'proof locks. Thewindowwindersconsistof lifringarmswith tooth
The locks incorporatea latch which prcventsths door ed segments.The window runs in sliding grooves In
frcm being opened frcm the inside when the latch the inner door ol6te and is set to thB d€sir€dDosition
by lifting alm lrom th€ tooth€d s€gment with the
The door latches are $eel and woldsd to the door. assistance ol a helos arm.
Rear doors
244 / 264 and 245 / 265
rp8?
I t8p ,"
fr$fI itt tt
7S i-.-n
1$
?1 6
tl
| 0,0 r332!
Grcup83
20 DooBand Trunk
Doors
ServiceProcedures
Doors
Removing/installing door stops
Replacedoor stop = Op No- 83106
Remove door panel according to instructionsunder
"Removrnq In_er handec ard upholsrery" fhen re-
move the bolt between the door stop and post, and
remove the rubber seal.
o 3-
Doorwindow crank
Gtoup83
Doorcand Ttunk 21
Doors
Lock,frcnt doo6
I
Removingouter handle,Jront doors 2.
3.
Op.No.83404= replaceouterdoorhandle
1. Crankup the window to closedposition.
2. Remove innerdoorhandle andupholstery
accord-
5.
Pullrod for lock button
Gtoup 83
22 DooB and Trunk
t, Le€ for remote conrrol
2. L€w for cl ld sfety door l@k
Strikor platos
The striker plate is madeof ste€land is install€dwith
6 floatingnut plateTh6strik$plateis adjustabte since
th€ holesin th€ body sre larg€rthan the diamster of
the attaching screws
Th6 v€rtical pqsitionof rhe stdker ptate is controlt€d
by closing th€ door, with th€ outside handl€ Dutt€d
out whsn the door latch should slid€ con€cdv into
the latchplate The strikorplateshouldhavean inward
Sirikor phte inclinationof 1.5o tor ths front doors end 2.5o tor
A. Front door 1.5o 8. R€8rd@r Z5o ths rear doors, s€e Fig. left
Group83
D@6andTrunk
Doors
Q'
o
3. Checkthat the window is aligneclin the windo\,!
Group83
24
Doors
Window mehanisn
I Installthe crankmechanism.
Do not rightenrhe
3. Clankthewiodowtoitsupperposition andtight
Front door interior
en the crankmechanism screws.
4. Installthe water prorectionsheet.
2. Window mechanismrelainingscrews
5. Insrallrhedoorpdnel.the arm restandthe win
6. Removethe crankmechanism
as shownl
Gtwp 83
Doorsati Trunk 25
Doors
ElectricallyOperatedWindow Winders
BATTERY
Er@
.lcNltlo sllTltt
l
FUSElOX SB - black
EI{ERGIZIN6
8E!AY GN - green
GR - gray
BL - blue
BR - brown
SIIITCH,
StlITCH, RTGHTSTOEI{INDOI{
LEFT SIDE I{IIIDON
RIGIII STDE
I,IOTOR
LEFT SIDEIIOTOR
Adjusting stop positions, front window win- Rundown th€ windowio the stop poshion.Chsck
ders that the lifting arm does not bottom in the slide
fork Adiust if necessarythe stop lug so that rhere
L Removedoorpanelandths waterproofing sheel.
is a clearanc€ of approx.1/32" {1 mml.
2. Runup the windowto the stop andreleas€rhe
Restoredoor paneland wat€rprootingsheet.
stop lug usinga 5 mm seGcrewwrsnch.Run
up the window as lar as it can go. Adjustthe
stop lug againstthe tooth segmentand tighten
up the lock bolt.
Group83
26 DooB and Ttunk
Replacing window winder or motor, frcnt 10. Securethe windowwinderin a viseandremove
the motor from the winder.
Figuresin bracketsapplyto replacement of winder.
1. Removedoor paneland wat€rprootingsheet.
2. Run down the window to the stop position.
3. Release the liftingarmsfrom the windowrailby
pushingloos€the s€fetybracketsandremovethe
washers.Then lever the arms towards you,
4. Removethe windowby liftingandturningit to-
wards the vehicleat the sametime,
o
T6Nioning window windor spring
Group83
Doorsand Trunk
17. Lift the window into ihe door with the pointed Make sure thai ihe window entersthe slot in the
part f rst and th€n turn it slighny away from the guide rails.
18. Fir the lifting alms for the window rail together
with pastic washers and safety brackets.
19. Reconnectconlacts and install fuse box.
20. Install side panel and under dash panel.
21. Connect the battery ground cable.
22. Adjust window winder stop positions,as descrb
ed under "Adjusting stop positions.
23. Fit waterproofing sheet and door panel.
I
l]
The trunk lid is moufted on two hinges,which are InsralLin the reverseorder,
attached by two bolts io the inner pate of the lid When removing hinges,first remove the spring sup
and with ihree boltsto the pillarundertherearw ndow, pon as described.bove.The lid isthen removedfrom
The trunk lid is counterbalanced by a spring support. the hinges and the h nges ffom the body.
The trunk lid is removed by removing the two bolts The holes in the part of the hlnges atrached to the
on each hinge and liftng it off. trunk lid are oval in ordef ro pefmir longitudinaiad-
When replacing,ihe lid is firsi openedfully. lt is then justment. For verticaladjustmentthe hotesin rhe pan
lowered slightly and clamp 2739 appliedand rhe lid of the hingesattachedto the bodyareovat.
openedfully again,after which lhe sping suppon can
be removed.When installinga new spring support,
p t p s st o o l 2 / 4 4 , s u s e d a s s h o w n I n l g . b e l o w I
order to nstall clamp 2739.
suo-2739
0
*t--l
tsl I
q
Gtoup 83
2A
Trunk lid
Ths lock (Fig, below) is instaled in th€ rear ssction clampwith piiersinsid€th3 trunk. The tock knob €n
and is releasedby tuming the tockabteknob. The tock thenbepullsdout backlv€rds.
catch on ths lowor €dge of rhe tid is adjustabts in To removsthe lock removsth6 tock knob and nen
order to permit variation of the ctosing tension of the ths tlvo bolts und€rthe upperdgs ot ihe r€€rsoction.
lid. Ths lockis sdjusrablelongitudinay sincethe bott hor€s
The lock knob is r€moved by taking out the hors€shoe
-'--'\T
i,
r
ar
I
22
11
e2-
Gtdlp 83
D@rs atd Trunk
Tail gate
{(
0.(
a
is removedand also the screws for the lock The lock
can then be moved to the left, from where it is raken
out of the taal$te. The lock cylinderis removed by
looseningthe lock screw inside the rail gate.
Tail garelock 245l265 To remove hingesfor replacement,detach the head-
lining at the rear (see under "Replacingheadlining").
Disconnectthe wire at the joints under the hinges.
3. Lalchingdevicelor inneropener Removethe screws secuing the hinges to the roof
4. ControLfor larchingd€vice and the tail gate. Remove the hinges.
Gtoup83
30 D@rsand Trunk
Sun Roof
Sun r@f A. Rear attachment lvhen r@f is o@n B. Rdr attachmat whon rool is closod
t_ 8. 11.
2. 9. 12,
3. to. 13.
Crank housingwith crank
Gtoup83
Mouldings
Group84
SealingStrips,Glassand
ExternalTrim Mouldings
O,r(
Then Iever the moulding loose.
In$tallings6alingsrrip
O,(
Removing
trim moulding
@(
Installing
Trim mouldings Installthe windshieldmouldingby pressingatin bet-
weenthe body frame and the clips.To ensurethat
Waist mouldings
the mouldingcoincides with the cornerioints,install
The waist mouldingsare attached with plastic clips. in the followingorder.
The mouldingsareremovedwith a wooden puttyknife First installthe lower mouldingwith a cornerjoint
with which they are carefullyleveredoff. The clips on. Theninstalla side mouldingalsowith a corner
can be removed by carefully pulling them off w|th on. Finally,installthe remainingmouldingtogether
with cornerson to the body frame.
Group84
32 Glassand Mouldings
Windshietd
Removing trim moulding for rear window Pushover thejoinifg piecesand repearrhe procedure
1. Remove the mouding from the rubber strip by w r r h t h e o r h p r h a r o f t h e - o L d r . q . aso t, T p o s o n
Insertrnga moistefed nylon puty knife;nd mov oi the joinlng pec€s over ihe joints.
ing it all roufd between the strips (do not pult
off the trim moutding). Windshield
2. Pushover the loin ng piecesro o.e of the ha ves
Removing windshield
of the mou ding.
3. Remove the trim moulding by evering out rhe Op. No. 84302 = replacewindshietd
ridge of the rubber strip from ihe trim moutding 1. Placeproiectlvecoveringov€r the hood anctrronr
with a moistenedwooden porry knife. Retease
thetrim mouldingin the midd ewilh anotherplny 2. Remove the windshied wiper arnrs.
knrfe as shown. 3. R e m o v e t h e x t e r n ar lr i mm o u t d i n gS. e e " F e m o v -
i n g w i n d s h i e dm o u l dn g " .
a. U n s . r . w L 1 ei n e r c o v e, g s r p c a r d , e a r v i e w
Removingtrim moulding
Installing windshield
1. Injectsealng agent lnto the hoes where rhe new
c l p s a r et o b e i n s t a l l e dU. s e P u m pN o . 2 1 0 j 6 3 .
2. Install new clips.
3. Cleanthe conlact surfacesfor the rape on Dooy
and windshield.Use ethyl or merhyt acetaie for
the ceaning. Be carefulnot to touch the ceaned
Group 84
Glassand Mouldings 33
5. Coat adhesiveon the cleanedsurfaceson the
body and windshied. Coat an edse betw€en 18
aft 2'l nm \3/4 and 7/8") in width round the
windshieldmeasuredfrom hs outer edge. Apply
the adhesivetwice to ensuretoral coverage.Any
adhesivespill on the body or glasssurfacescan
be rcmoved with methyl acetate.The adhesive
can be app ied within 5 minutesafterthe cleaning.
Installboth ihe spacerson the lower edge of the
windshieldopenins.They should Liebetweenthe
2nd and 3rd clipfromeachwindshieldpost.
Grcup84
34 Glassand Mouldings
Reat window
I
4. Start removingihe rubber strip in the upper lefi It may sometimesbe necessaryto adjustthe po
corner. Levef the rubber sfiip over the edge of stion of the .ear window whh the palm ot the
the sheet metalfrom insideand at the same t me hand. lf the cord is difficult to pull out, rh s nray
carefolly p!lling out the strip from oursidewrth damagethe strip, n which casethe rear window
a pair of wide-nosedgips. Then carefullypull off shoud be struck from insideor oursde wirh the
the stip by hand al round and remove the rear pa m of the hand if the rubber strip does noi
''creep
overtheedge of thesheet melsl properly.
Removeallsealingcompoundfrom thesheet me 4. Check that the rubber stip sealswell al rolnd.
tal. lf it has drled on, first carefullyscrapeoff rhe ll necessaryadjusttheposhionof the rearwindow
sealng compound and then wash clean wnh both vertca y and laterallyby striking with the
naphtha.Check that the sheet meta edge is not palm of the hand.
defomed. lf the sealingcompoundhas not dned 5. Sealthe joints belween the rubber strip anctr€ar
o n c l e a .r h er u b b e rs r p w r h - d p h l h ao. r h e r w F e window and rubber slrip and sheet metal with
sealingcompound using a 9un with a flar nyon
nozzle.Make s!re that the sealingconrpoundfi Ls
Installingrear window the joinr wel. Scrape off surpus seallng com
1. Moisten the outer edge of ihe windshield and pound and wash rear window and sheet meral
insralltherubberstrip startingal one of the corn- with kerosene.Cleanthe rear window and sheet
ers. Adjust the strip so that it lies coiiectly all metal around t with polish.
6. Installthetrim mouldingsaspreviouslydescribed.
2. Install a cord (preferablyterylene)of a suitable 7. Installthe cablesfor the eleciricallyheated rear
(tarl gate) window-
sizein the grooveofrhe rubberstripforthe sheet
metaledge,beginningatthetopcenterasshown:
Rearquarterwindows
See the correspondingsectlon under"Rear window'
Rearquarterwindows,242/ 262
To remove the glass in the rea. quader windows on
rhe 242/262 model, open frrst rhe quarter winclow
and remove the screws securingthe quarter window
opener io the body.
Removethe window from rhe fronr atrachrnentsby
t n s t o p e n , _ g , r9 0 o a n d a r r h e s a m e - e p u l n 9 t o
Placing@rd in rubberstrip
Group84
GlassandMouldings 35
Desisn
Group85
Upholstery,InteriorHeatingSystem{excl.Air Conditioner)
C, I
(
Front sear
Group85
36
Design
Headlining
242 / 244 and 262 / 2641
The headlinng consistsof mo! ded glass woot wrth
a plastrccover on th€ und€rside.
Glasswool headlinins242.
El.ctrically h6ated driv6r'6 3oat
It is made in one piece and cannot be folded. lt is
heldin positionby the sun visor,rearview mifior, curve
0 Somemodelshav6an electrically
controlledby a lhermostat.
heateddrivefsseat
h a n d l e a n tdh r e e p l u g s a t t hrec a r e n do l t h e h e a d l i n i n g .
244 / 265
Thetoalcurrentdrawis 60W Thethemostal olts outat Tbe headliningconsistsof plasticfabric stretchedon
26"C(78')andculs in al 14rc (57.). root bs. lt is securedin retainersfitted on the lpper
limit ofthe bodysides.
Ventilation
Roarseats
242./24/and26?./N 242 / 244 and 262 / 264:
Rearseatcushionandrcarseatbackarc madein pot- The ar ventsare locatedunderthe rear winduw:
yurelanfoam, mouldedon a frame of wireswhich
stabili?e
thefoamandretaintheuphotsrery.
245 / 265
Bearseat cushonand rear seat backare designed
as the front seats,but the frame is wood.
The rearseatcushioncanbe foldedfoMard anorne
back rest down to provideincreased cargospace.
Door upholstery
The door upholsteryconsistsof woodjiber sheeting
llned with non-wovenpaddingand coveredwith
upholsterymateial.h is securedto the doorby clips.
The arm restsare madeof mouldedplasticand are
screwedto the innerplate of the door.
Gtoup 85
37
245 / 264
Theairventsarelocaiedundertherearrightsidewin-
1,
2.
3.
ServiceProcedures
ol
Front seats Fit the new heater pad in $e seat back.
NOTE:theheaterelementbarbsshouldpointtowards
Replacing heater device for drive/s seat
Oi (
the padding.
1. Disconnectthe seat pad electricalwires at the Hook the plastic hooks to the suspensionmat lower
2. Removetheseat,completewith slidingrailgfrom The heater pad electdc wires should be routed towa.ds
the inboard side ot the clshion. Fit and attach front
3. Bemove the screws acc. to Fig. below, and rc- upholsterytorcarupholstsry,usingfour clamps.
move the seat cushion,
Ret.ining bolis
The heaterpadelecric wiresshouldbe routedtowards
rhe inboarclside of the cushion,see Fig. O,(
Seat back heater pad
Placethe cushionupsidedown on a table-
Cutandremovethefrontupholsteryretainingclamps.
Unhookthe plastichooksandpullout the heaterpad.
@(
R.moving st back h€t€r pad Fold back the upholsteryand installfive new clamps.
Gtoup85
38 lntetbr, Heating
Frcnt seats
Re-installthe seatcushion.Connectwiresfor seat back use . screwdrlverto press our the hand wheel
and seat cushion heater pads: cover through one of the hand wheel holes:
,]tl
'l
CI Wneslor heaterpads
Beplace:
Seat reclining
Removingplastic @ver
1. Unhooktheuphosteryfrom the seatreclininsme-
chanism.cut and removethe clampsat the seal
b a c ku p h o l s t e r y j o i n t .
Gtwp 85
39
Unhookthe plastichooks and pull our rhe heaier Replacinghead.estraint
D(
Heater pad
Removingbushing
O, (
Replacing seat reclining mechanism (B). Pry loose the fr.me for the catch release lev€r
A Unfold the upholsteryto ga n accessro rhe me
chanism relaining screws.
{B). Pul off the cablelocksand disconnecrthe caDres
trom the mechanism.
C. Fold down the padding,remove the screws and
tlre mechansm:
Removing
frame Qr {
C. Fold away the upholsteryuntil three clamps are
accessble. Cut and remove rhe clamps:
Removing
seat.eclininsmechanism
Group 85
40
L
t-
Front seats
D, Unfold the upholsterycompletety.Knocktoosethe (B). Pry loose ihe frame for the catch releaseLever.
headresrraint.Removeheadresvaintand uphot- C, Fold away the uphoisteryunri three clamps are
accessibe.Cul and remove the clamps.
D. Unfold rhe uphostery unti the releaseever is ac
Knockinglooseheadresrraint
Installing
machanism
andcowr
hstattingbushings
J,
G . Apply slue to the seat frame back sjde and fotd Attachcableswirh rerainers
io rhe reteaseme
Fold on the upholsreryslightty.Instal the head
restraint.Checkthat the headrestrainris securelv
$i
back latch
(Seeaiso"Beplacinsheadrestrainr
or seatbackuphol-
st€ry',prcvious
page)
A. Removethe lumbarsupporthand wheet.putl
loosethe oldsrkbushrngtr tt-e seal bact
Group85
lnteior. Heating 41
L. Hook the cablesto the seat recliningmechanisms 14. Benclouitheshe€tmetaltabsof theseatreclining
and lock the cable sheaths.
l/1. Anach the rod to the suspensionmat with three andthenre-
Fit andhookon the sideupholstery
shapethe tabs,
9. Fold on the upholsterycompletely.Checkfor
Gtoup 85
42
Headlinins
c
hning. Press in and rurn a quarier lurn.
6. Removethe nteror rear view m ffor by pressng
InsiaI curue handle and artachmenis over the
it forwards.Bemovethe rearvtew attachingptate
lront doors. Instal trirrl covers.
5. - g l _ r e ar 1 ea t l d . l - T e n t ql o r r l o p . i v r e w m . 4 o r
Install sun visors wirh suppod bearings.
6. Insta fronr cover srrp and panelson rhe front
Replacingheadlining,245 / 265
No.851O4
I Femovethe interiorlight.sunv sors.andreafvew
1 . Remove atiachmenls,inc. s!ppon bearings,for
2. P u r d o w n r l ' e e o q eo ' t - l c l o d d l i na q r h l g F l
sun visors. Remove the sun visors.
a r d l h u m b o n o n e s i d es o r l - d t t 1 e o r d c t p o g -
8. P ) l o o . e 1 1 " i n p l o r g l - r .D s c o n r e c rr t - ew i r € .
can be releasedfrorn hs fastenng if the ra L
L F e m o ! - ( r i 1 l d n d 9 F . . F e a r o v er h eh o J s- g t o r
3. Then pu I down the headining al rolnd.
1 0 . Removecutue handleand ailachmentsover ih€
dooron the drlver'sside.Bendlooserhe trim cov€r
10 garn access to the screws.
0
i
L. -1,*',,
Gtoup 85
4. Take down the stretchersbeginningfrom the 5. Removefie combined instrumentaccording to
backby bendinsthem down in the middleand instructionsin Section 3.
.eleasrng
rhemlro- the edge of lhe roo| Removelhe sreeringwheel locl accordrngto in-
siructions in Section 6.
Take out the bulb holders in the combined In-
strument lights and the hub holder in the clock.
Disconnectthe electricwire frcm the clock and
the harnessfromthe lower part of the instrument
panel.A clamp is situatedimmediatelyunder the
clock and another undeneath the combined in
strument to the left.
9- Bemovethe heatersidepanels.Removethe hoses
for the four air outlets on the instrument panel.
10. Removeboth lower screws for the control panel
and then tip it back as far as the wires permit.
11. Disconnectthe electricwires to the glove locker (
light byopeningthe lockerlid and pullingthe entire
Femoving rool str*hers
light inwsrds.The wires are disconnectedin this
cl (
NOTE| Be careful when removing and installing
12. Removeoutboardair outletsand the lightswitch.
the siretchers.Carelesshandlingcan cause the
Removethe screws securingthe instrumentpa
ends to damage the roof plate. nel. There are three on each side of the firewall.
5 . Installthe strctchelsin the new headlining. two underneathand one which is visible when
NoTE:the stretche6aredifferentlengths.
the outboard air outlets have been removed. A
Makesurethattheyare providedwith rubbercaps further two attachingscrews are located above
the upper attachingscrews for rhe control panel.
6. Installtheheadliningby first insertingthe stretch 14. Releasethe instrumentpanelfrom its attachment
els beginning with the front one. in the dashboardby pulling it backwardsand at
Streich the headliningforwards and tuck in the the $me time lifting it overthe control paneland
plastic srrip at the front edge.
thesupponr€gs,
8 . Then stretch the headliningbackwardsby pulling 15. Lift our the instrument panel.
both ends of a stretcherat the same time. Begin
at the front and pull on each stretcherworking
backwards,after which the rear plasticstrip can
be tucked into its groove.
9. Now pull over the headliningtowards one side Installinginstrumentpanel
andtuckin theplasticstrip.Thenstretchthe head- L Check to make sure that the tubber bushingsin
hnrngover towa.ds the olher side and tuck in lhF
Gtoup85
44
Glovebox
Removingstow box
Romovingimpact absorborhoulding
Replacingcenterair outlet
1. Loosenthe controlpaneland pull it out slighny.
2. Pressthe impactabsorber mouldingdownwards.
3. Removethe retainingscrewsand the outlets-
4. Removethe clock.
5- Instalblionin oppositeorder.
Gtoup85
45
CU heater
Combinedunit
20
Group85
46
I
CU heater
Central!nit, 16ftside
1 . Screwsror bortombfacker
2 , Screwsfor upperbracket Removing
lo.kingfor turbin
3. Upperscrewsfor supponlegs
Lowerscrewfor slppon eas
t o Place the new tubine wheel on the shaft and
Disconnecrthe battery ground cabte. instal the locking.
Fold rhe tloor carperlo t1e one sde and ,emove 1 1 . Installthe outer end and check at ihe same time
the sde panels fiom the cenrrat unir. that the heater control vatve capi[ary tube wjrh
3. Bemovescrews 4 and 5 for lhe conrotptare sup- rubber grommet is propedy insta ed in the air
pod legs on both sides,a.d nove the ptare as
lar bacl on the r.ansmrss,ontunnetasrheetectfic
5. Removethe combinedinstrument(seeinstruc
tions,Section3).
6. Disconnectvacuum hosesfrom vacuum motors
for left defrosier oltler and teft ftoor outlet.
Removedefrosrernozzleand air duct to teft air
15. Jnstall
the defrosternozzteandair ductandcor_
nect up the vacuumhose,
16. Installcombinedinstrument(see insrructions,
Section3).
17. Installrhe air duct to the rear ftoor.
18. Placetheconvolplateandsupporttegsin position
and screwtight the supporrtegs.
19. Putbacktheftoormatandinsra rhesidepanets.
Romoving clahps for outer red 20. Re-connect the batterygroundcabte.
Gtoup85
47
CU heatel
g.
the clamps, see Fig. previous page.
Connectbattery ground cable and make a func
Removinq
defic €bles for @ntactunit
@(
10. Disconnectbattery ground cable.
11. Install the hose beiween central uft and nghl
6. Removethe rubber grommet and pull down the
lnner air outlet.
electricwiresthroughtherightopeningin the cen_
12. Installdefrosternozzleand air dLrct.Connectthe
7. L,h ouI rheb'owe' moror I h'ough Ihe bft opering.
13. Install glove box, nsulationpanel and right side
8. Placethe blower motor in posirionin the central
unit and sc.ew tight the retainer.
14. Performpoints 17 to 20 under"Replacingturblne
9. Pullthroughthe electricwires and installthe rub_
whee, left side .
'lO.
Connectthe elecvic wires to thecontact unit and
the control plate, also connect the contact unit
Replacing blower motor to the blower motor control.
11- Installthe inner left end and adjust in the heater
Op. No. 85400
control valve capillarytube.
1- Rernovethe right and left turbinesaccordingto
12. Insrallrhe turoi.e wheels according lo plevious
previous instuctions.
2. Move the heater control valve capillarytube to
Gnup 85
48
CUheater
Contrclp.nel rsveFsside
1. Connecrorfor vacuum ho*
2. Contactunit for blowermolor @ntrol
{4). Bemove clampsfromthe hosesto the evaporator 18. Movethe controlplateas far backon the trans-
and removethe firewalldoor wilhouLloosening missiontunnelas the wires permit.
thehosestothe evaporator, 19. Removsthe screws,for the upper and lower
5. Removethe combin€dinstrument(seeinstruc- brackets,
from the firewallandthe transmissaon
tionq Section3),rheairhosebetwe€nthecenval
unit andthe lefr innerair vent alsothe vacuum 120)Disconnect the thermostatattachmenrFig.bel
hosesfrom vacuummotorsfor left defrosternoz- ow, from the centralunit.and both ctampsse-
zl€ and left floor outlet. cunngthe coverto the evaporaror.
6. Removethe left side panelfor the centralunk.
7. Foldthe floormatout of the way anddisconnecr
the rear floor air duct from the cenfialunit.
L Disconnectths joinr pipesfor the heatersystem's
war€r hoses from the firewall.
L Removethe upperand lower screwsfor the teft
support leg, and the screws for the upp€r and
lower bracke$, from firewall and transmission
Group85
49
CU heatel
(21) Bemove the evEporatorfrorn rhe central unit 8. lnstall ihe turbine wheel and the ouler end.
whholt disconnecting any of the refrigerant Location of clamps is shown below:
hoses,and place lt at the right side of the cowl:
Group85
50
Y
-l r^t
,L. '=- dI
I l'l:ll
Vacuuh moio. for air shutrerlo rearlloor
0 Lay-outdiasr.mfor vacuumcontrolsystem
1. Conrrolpane
1. Remove hose from vaculm moto..
2. Pry loose the vacuum motor outer plaslic lock,
see Fig. below. Removethe vacuum motor irom
the housing and remove the sprng.
3. Vacuummoior for reariool eft
4. VacLUmmororfor rear floor,righl
5. Vacuummotorfor tronr floor, eft
6. Vacuummotof tor front floor,.ighr
7. Vacuummotof ior defrosrer,leh
a. V:cuummotor lor defroster,righi
L Engne intakemanlold
10. CheckvaLve
11. Vacuum lank
12. Vacllm mororfor ar ntake cover
0 1.
2.
Dlsconnectihe batiery ground cable.
Bemovethe side panelfor the centralunh, righi
or left dependingon the vacuummotor to be re-
I
Group85
51
6. Positionrhe sping and insialla new vacuummo- 3. Remove the air intake left shutter shaft lock.
tor in theaifshutter, see below. Usea new plastic 4. Removethe screws 3 for the inner end and lift
Heating system
Positioning
c€llas$mbly
Removing cell assembly
Op. No.
9 . Install the left half. For location of clamps, se€
HeaterCore,replace = 85404
HeaterCore,pressuretest and repair
(solder),heatercore removed = 45419
The instructionsapply to a removed cenval unit.
L Femovethe leh ouler end rurbinewheel{seepre-
viods instructions).
2. Unscrewthe tlvo left screwsfor the tunnelbrack
Disassembling@nrral unit
t . Screws ior lowef brackel 3. Screws for innef end
2. Shutter shaft locking 4. Screws for bower motor
Group85
52
CU heatel
Group85
lnte or, Heating 53
Rumper
Group86
BumPers
Op. No,
85134= r.mM andiBtalllont bumper
86136= emowandi..n ll@rbump.r
86189 = replaceflDnt bump€rstrip,bunp€. r€mowd
86191 = €plae rcdrbumperstrip,bump€rFmovad
@06 = rcpla@frent bumpersh@k Eb3olb€r,bump€rr€-
Removing/ installingbumper
L Removethe retaining platss (4).
2. R€movethe nuts{2}for rh€ brackerand lift ofi
Group86
54 Bumpers
lmpact absorbers
The impact absorbeB contain gas and ftuid and arc
speedrelated. That means rhat the resisrancein-
creaseswiththespeed.
Thereby the whole impact abso.bing stroke can be
used also for low speed impacts.
The function is very much the same as for a com
bination of a spdng and a shock absorber.
When €ompressed,gas and fluid are forced throush
naiiow channels.The compressis dampedand at the Placethe impact absorberhorzonta y. To reteaserhe
same time the fluid comprcssesthe gas. When the gas. drill a hole 5/32 \4 td diam. approx. 1.06"
outside lorce is released,the sas expandsagain and {3O mm) from the end, as shown above.
p'essesrhp 'lLid ba.l .ro rrc bLrnperrelar s the on NOTE: Use safety glasseswhen dritttng.
ginal position.The fluid this way acts as a shock ab, A ' r q h o e s h a l e b e e r d r i l l e o c. l i t , n g . . 1 s a l e t ! b e
sorber and the gas as a spring.
Before scrapping,a damaged or otheNise replaced
The impact absorbers are partly gas filled and mpacl absorbershould be emptied by drittinghotes.
no welding on or close to them is permitted,
Heating mayexpand the gas to such an extent Replacing
that the impact absorbers are blown, L R e m o v et h e b u m p p .a s p t e v r o u s loy e s c r i b . d .
lJthorefore oxy-acetylene cutting must be per- 2. Removetwo retainingbolts 11)for rhe bracket.
formed to remove the impact absorbers, the
gas pressure should lirct be released.
io
.
3. Removerctainingbolt (3) in the side member. ti
. Placethe impactabsoberhorizontay. To retease
the is accessiblefrom inside the rrunk.
NOTE:emptygas beforcscrapins.
Attach b€cket and spacerto the new impact ab
positioned 1800 opposite each other.
NOTE: Use safety glasseswhen dritting. 5. Positionthe impactabsorberandfit the boh from
the sademember.
6. Install bracket bohs.
Gtoup 86
Bumperc 55
Bumpermouldings
l$ii.
Pullout rubbercover,completewilh retainingbars,
positionthe mouldingandpullin th€
Wheninstalling. Installationin oppositeorder.Ch€ckthat the retaaning
bar clips lock s€curely.
ifth€ studsarelubicatedwith
is facilitated
lnstallarion
Gtoup86
56 8umpe6
l{atlonal
hstitlt€ for
tu0lt0l|vE
$mvlcE
CEU.EilGE
v0lv0 suPPonTs
vor.uilTARY
ITtECHAiltC
CEmtFtCATt0t{
BYTHEI{.I.A.S.E.