Ka 1997 (09.1996-) Workshop Manual
- Mechanical Repairs
- 1 General Information
- 100 Service Information
- 100-00 General Information
- 100-01 Identification Codes
- Description and Operation
- 100-02 Jacking and Lifting
- Description and Operation
- 100-04 Noise, Vibration and Harshness
- Description and Operation
- Noise, Vibration and Harshness (NVH)
- Diagnosis and Testing
- Noise, Vibration and Harshness (NVH)
- General Procedures
- Description and Operation
- 100 Service Information
- 2 Chassis
- 204 Suspension
- 204-00 Suspension System - General Information
- 204-00 Suspension System - General Information|Specifications
- Diagnosis and Testing
- Suspension System
- General Procedures
- 204-01 Front Suspension
- 204-01 Front Suspension|Specifications
- Description and Operation
- Diagnosis and Testing
- Front Suspension
- Removal and Installation
- Front Suspension
- Diagnosis and Testing
- 204-02 Rear Suspension
- Description and Operation
- Rear Suspension
- Diagnosis and Testing
- Rear Suspension
- Removal and Installation
- Beam Axle
- Rear Wheel Bearing
- Rear Strut and Spring Assembly
- Trailing Arm Bushing
- Disassembly and Assembly
- 204-02 Rear Suspension|Specifications
- Description and Operation
- 204-04 Wheels and Tires
- 204-04 Wheels and Tires|Specifications
- Diagnosis and Testing
- Wheels and Tires
- Removal and Installation
- 204-00 Suspension System - General Information
- 205 Driveline
- 205-04 Front Drive Halfshafts
- 205-04 Front Drive Halfshafts|Specifications
- Removal and Installation
- 205-04 Front Drive Halfshafts
- 206 Brake System
- 206-00 Brake System - General Information
- Description and Operation
- Brake System
- Diagnosis and Testing
- Brake System
- General Procedures
- Description and Operation
- 206-02 Drum Brake
- Description and Operation
- Drum Brake
- Diagnosis and Testing
- Drum Brake
- Removal and Installation
- 206-02 Drum Brake|Specifications
- Description and Operation
- 206-03 Front Disc Brake
- 206-03 Front Disc Brake|Specifications
- Description and Operation
- Diagnosis and Testing
- Front Disc Brake
- Removal and Installation
- Front Disc Brake
- Diagnosis and Testing
- 206-05 Parking Brake and Actuation
- 206-05 Parking Brake and Actuation|Specifications
- Diagnosis and Testing
- Parking Brake
- General Procedures
- Parking Brake Cable Adjustment
- Removal and Installation
- 206-06 Hydraulic Brake Actuation
- 206-06 Hydraulic Brake Actuation|Specifications
- Diagnosis and Testing
- 206-07 Power Brake Actuation
- Diagnosis and Testing
- Power Brake System
- Removal and Installation
- 206-07 Power Brake Actuation|Specifications
- Diagnosis and Testing
- 206-09 Anti-Lock Control
- 206-09 Anti-Lock Control|Specifications
- Description and Operation
- 206-00 Brake System - General Information
- 211 Steering System
- 211-00 Steering System - General Information
- 211-01 Manual Steering
- 211-01 Manual Steering|Specifications
- Description and Operation
- Manual Steering
- Diagnosis and Testing
- Manual Steering
- Removal and Installation
- 211-02 Power Steering
- 211-02 Power Steering|Specifications
- Description and Operation
- Diagnosis and Testing
- Power Steering
- 211-03 Steering Linkage
- Diagnosis and Testing
- Steering Linkage
- Removal and Installation
- 211-03 Steering Linkage|Specifications
- Diagnosis and Testing
- 211-04 Steering Column
- Diagnosis and Testing
- Steering Column
- Removal and Installation
- Ignition Switch Lock Cylinder
- Steering Column
- Steering Wheel
- Disassembly and Assembly
- 211-04 Steering Column|Specifications
- Diagnosis and Testing
- 211-05 Steering Column Switches
- Removal and Installation
- 204 Suspension
- 3 Powertrain
- 303 Engine
- 303-00 Engine System - General Information
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- General Procedures
- Camshaft Bearing Journal Diameter
- Camshaft Bearing Journal Clearance
- Camshaft End Play
- Camshaft Surface Inspection
- Crankshaft Main Bearing Journal Diameter
- Camshaft Lobe Lift
- Crankshaft End Play
- Cylinder Bore Taper
- Piston Pin to Bore Diameter
- Piston Inspection
- Piston Ring End Gap
- Piston Diameter
- Piston Ring-to-Groove Clearance
- Piston Pin Diameter
- Connecting Rod Large End Bore
- Flywheel Inspection
- Valve Stem Diameter
- Cylinder Block Distortion
- Cylinder Head Distortion
- Exhaust Manifold Cleaning and Inspection
- Bearing Inspection
- Valve Seat Inspection
- Diagnosis and Testing
- 303-01A Engine - 1.3L Endura-E (HCS)
- Description and Operation
- 303-01A Engine - 1.3L Endura-E (HCS)|Engine
- General Procedures
- Valve Clearance
- In-vehicle Repair
- Intake Manifold
- Crankshaft Front Seal
- Crankshaft Rear Seal
- Valve Seals
- Cylinder Head
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01A Engine - 1.3L Endura-E (HCS)|Specifications
- Description and Operation
- 303-01B Engine - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- 303-01B Engine - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)|Specifications
- Description and Operation
- Diagnosis and Testing
- Diagnosis and Testing|Engine
- In-vehicle Repair
- Intake Manifold
- Valve Cover
- Crankshaft Front Seal
- Valve Seals
- Camshaft
- Camshaft Followers
- Timing Chain
- Cylinder Head
- In-vehicle Repair|Oil Pan
- Crankshaft Rear Seal
- Oil Pump
- Removal
- In-vehicle Repair|Engine
- Disassembly
- In-vehicle Repair|Disassembly|Engine
- Disassembly and Assembly of Subassemblies
- Cylinder Head
- Assembly
- Assembly|Engine
- Installation
- 303-01B Engine - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)|Engine
- Diagnosis and Testing
- 303-03A Engine Cooling - 1.3L Endura-E (HCS)
- 303-03A Engine Cooling - 1.3L Endura-E (HCS)|Specifications
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- 303-03B Engine Cooling - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- 303-03B Engine Cooling - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)|Specifications
- Description and Operation
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Engine Cooling
- Diagnosis and Testing
- 303-04A Fuel Charging and Controls - 1.3L Endura-E (HCS)
- 303-04A Fuel Charging and Controls - 1.3L Endura-E (HCS)|Specifications
- Description and Operation
- Diagnosis and Testing
- Fuel Charging and Controls
- 303-04B Fuel Charging and Controls - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- 303-04B Fuel Charging and Controls - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)|Specifications
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- 303-05 Accessory Drive
- 303-05 Accessory Drive|Specifications
- Description and Operation
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- Diagnosis and Testing
- 303-06 Starting System
- 303-06 Starting System|Specifications
- Description and Operation
- Starting System
- Diagnosis and Testing
- 303-07 Engine Ignition
- 303-07 Engine Ignition|Specifications
- Diagnosis and Testing
- Engine Ignition
- Removal and Installation
- 303-08 Engine Emission Control
- Diagnosis and Testing
- 303-12 Intake Air Distribution and Filtering
- Description and Operation
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Intake Air Distribution and Filtering - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- Diagnosis and Testing
- Description and Operation
- 303-13 Evaporative Emissions
- Diagnosis and Testing
- 303-14A Electronic Engine Controls - 1.3L Endura-E (HCS)
- Description and Operation
- Electronic Engine Controls
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- 303-14A Electronic Engine Controls - 1.3L Endura-E (HCS)|Specifications
- Description and Operation
- 303-14B Electronic Engine Controls - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- 303-14B Electronic Engine Controls - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)|Specifications
- Description and Operation
- 303-00 Engine System - General Information
- 308 Manual Transmission-Transaxle, Clutch and Transfer Case
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- 308-00 Manual Transmission-Transaxle and Clutch - General Information|Specifications
- Description and Operation
- Manual Transaxle and Clutch
- Diagnosis and Testing
- Manual Transaxle and Clutch
- General Procedures
- 308-01 Clutch
- Description and Operation
- 308-01 Clutch|Clutch
- Diagnosis and Testing
- Diagnosis and Testing|Clutch
- Removal and Installation
- 308-01 Clutch|Specifications
- Description and Operation
- 308-02 Clutch Controls
- 308-02 Clutch Controls|Specifications
- Description and Operation
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- Clutch Controls
- Diagnosis and Testing
- 308-03 Manual Transmission-Transaxle
- 308-03 Manual Transmission-Transaxle|Specifications
- Description and Operation
- Manual Transaxle
- Diagnosis and Testing
- Manual Transaxle
- General Procedures
- Bearing Check
- In-vehicle Repair
- Halfshaft Seal LH
- Halfshaft Seal RH
- Vehicle Speed Sensor (VSS)
- Removal
- Transaxle - 1.3L Endura-E (HCS)
- Transaxle - 1.3L Duratec-8V (Rocam)-1.6L Duratec-8V (Rocam)
- Disassembly
- Transaxle - Vehicles Built Up To: 07-2000
- Transaxle - Vehicles Built From: 07-2000
- Disassembly and Assembly of Subassemblies
- 308-06 Manual Transmission-Transaxle External Controls
- Description and Operation
- External Controls
- Diagnosis and Testing
- External Controls
- Removal and Installation
- Gearshift Stabilizer Bar
- Gearshift Stabilizer Bar Bushing
- Gearshift Lever
- Gearshift Linkage
- Disassembly and Assembly
- 308-06 Manual Transmission-Transaxle External Controls|Specifications
- Description and Operation
- 308-00 Manual Transmission-Transaxle and Clutch - General Information
- 309 Exhaust System
- 309-00 Exhaust System
- 309-00 Exhaust System|Specifications
- Description and Operation
- Exhaust System
- Removal and Installation
- 309-00 Exhaust System
- 310 Fuel System
- 310-00 Fuel System - General Information
- Diagnosis and Testing
- Fuel System
- General Procedures
- Diagnosis and Testing
- 310-01 Fuel Tank and Lines
- Diagnosis and Testing
- 310-02 Acceleration Control
- Diagnosis and Testing
- Acceleration Control
- General Procedures
- Diagnosis and Testing
- 310-00 Fuel System - General Information
- 303 Engine
- 4 Electrical
- 412 Climate Control System
- 412-00 Climate Control System - General Information
- 412-00 Climate Control System - General Information|Specifications
- Diagnosis and Testing
- Climate Control System - Vehicles Built Up To: 02-2005
- Climate Control System - Vehicles Built From: 02-2005
- General Procedures
- Air Conditioning (A-C) Clutch Air Gap Adjustment
- Air Conditioning (A-C) System Recovery, Evacuation and Charging
- Refrigerant Oil Adding
- Air Distribution System Cleaning
- Spring Lock Coupling
- Contaminated Refrigerant Handling
- Electronic Leak Detection
- Fluorescent Dye Leak Detection
- Vacuum Leak Detection
- 412-02 Heating and Ventilation
- 412-02 Heating and Ventilation|Specifications
- Description and Operation
- Heating and Ventilation
- Removal and Installation
- 412-03 Air Conditioning
- 412-03 Air Conditioning|Specifications
- Description and Operation
- Air Conditioning
- Removal and Installation
- Air Conditioning (A-C) Compressor
- Clutch and Clutch Field Coil
- Evaporator Core Orifice
- Evaporator Core
- Low-Pressure Cutoff Switch
- Suction Accumulator
- High-Pressure Cutoff Switch
- Condenser Core
- Suction Accumulator to Condenser Line
- Condenser to Receiver Drier Line
- Evaporator to Condenser Suction Line
- 412-04 Control Components
- Removal and Installation
- 412-00 Climate Control System - General Information
- 413 Instrumentation and Warning Systems
- 413-00 Instrument Cluster and Panel Illumination
- Diagnosis and Testing
- 413-01 Instrument Cluster
- Description and Operation
- Instrument Cluster
- Diagnosis and Testing
- Instrument Cluster
- Removal and Installation
- Description and Operation
- 413-06 Horn
- Diagnosis and Testing
- 413-07 Clock
- Diagnosis and Testing
- 413-09 Warning Devices
- 413-13 Parking Aid
- Diagnosis and Testing
- 413-00 Instrument Cluster and Panel Illumination
- 414 Battery and Charging System
- 414-00 Charging System - General Information
- Diagnosis and Testing
- Charging System
- General Procedures
- Diagnosis and Testing
- 414-01 Battery, Mounting and Cables
- Diagnosis and Testing
- Diagnosis and Testing|Battery
- General Procedures
- 414-01 Battery, Mounting and Cables|Specifications
- Diagnosis and Testing
- 414-02 Generator and Regulator
- 414-02 Generator and Regulator|Specifications
- Description and Operation
- 414-00 Charging System - General Information
- 415 Information and Entertainment Systems
- 415-00 Information and Entertainment System - General Information
- Diagnosis and Testing
- 415-01 Audio Unit
- Description and Operation
- Audio System
- Diagnosis and Testing
- Removal and Installation
- Audio System
- Description and Operation
- 415-02 Antenna
- Diagnosis and Testing
- Removal and Installation
- Diagnosis and Testing|Antenna
- Diagnosis and Testing
- 415-03 Speakers
- Diagnosis and Testing
- Speakers
- Removal and Installation
- Diagnosis and Testing
- 415-00 Information and Entertainment System - General Information
- 417 Lighting
- 417-01 Exterior Lighting
- 417-01 Exterior Lighting|Specifications
- Description and Operation
- Exterior Lighting
- Diagnosis and Testing
- Headlamps - Vehicles Built Up To: 02-2005
- Headlamps - Vehicles Built From: 02-2005
- Stoplamps - Vehicles Built Up To: 02-2005
- Stoplamps - Vehicles Built From: 02-2005
- Turn Signal and Hazard Lamps - Vehicles Built Up To: 02-2005
- Turn Signal and Hazard Lamps - Vehicles Built From: 02-2005
- Parking, Rear and License Plate Lamps - Vehicles Built Up To: 02-2005
- Parking, Rear and License Plate Lamps - Vehicles Built From: 02-2005
- Fog Lamps - Vehicles Built Up To: 02-2005
- Fog Lamps - Vehicles Built From: 02-2005
- Reversing Lamps - Vehicles Built Up To: 02-2005
- Reversing Lamps - Vehicles Built From: 02-2005
- Headlamp Leveling - Vehicles Built Up To: 02-2005
- Headlamp Leveling - Vehicles Built From: 02-2005
- General Procedures
- Headlamp Adjustment
- Headlamp Masking
- Front Fog Lamp Adjustment
- Removal and Installation
- 417-02 Interior Lighting
- 417-01 Exterior Lighting
- 418 Electrical Distribution
- 418-00 Module Communications Network
- Description and Operation
- 418-00 Module Communications Network
- 419 Electronic Feature Group
- 419-01A Anti-Theft - Active
- Description and Operation
- 419-01B Anti-Theft - Passive
- Description and Operation
- Anti-Theft - Passive
- Diagnosis and Testing
- Anti-Theft - Passive
- General Procedures
- Description and Operation
- 419-07 Navigation System - Vehicles With: Traffic Pro
- Diagnosis and Testing
- 419-08 Cellular Phone
- Diagnosis and Testing
- 419-10 Multifunction Electronic Modules
- Description and Operation
- Module Controlled Functions
- Diagnosis and Testing
- Removal and Installation
- Generic Electronic Module (GEM)
- Description and Operation
- 419-01A Anti-Theft - Active
- 412 Climate Control System
- 5 Body and Paint
- 501 Body and Paint
- 501-00 Body System - General Information
- 501-03 Body Closures
- 501-03 Body Closures|Specifications
- Removal and Installation
- 501-05 Interior Trim and Ornamentation
- 501-05 Interior Trim and Ornamentation|Specifications
- Removal and Installation
- 501-09 Rear View Mirrors
- Diagnosis and Testing
- 501-10 Seating
- 501-10 Seating|Specifications
- Description and Operation
- 501-10 Seating|Seats
- Removal and Installation
- 501-11 Glass, Frames and Mechanisms
- Description and Operation
- Glass, Frames and Mechanisms
- Diagnosis and Testing
- Glass, Frames and Mechanisms
- Glass, Frames and Mechanisms - Vehicles With: Remote Keyless Entry (RKE)
- Removal and Installation
- 501-11 Glass, Frames and Mechanisms|Specifications
- Description and Operation
- 501-12 Instrument Panel and Console
- Removal and Installation
- 501-14 Handles, Locks, Latches and Entry Systems
- Description and Operation
- Handles, Locks, Latches and Entry Systems
- Diagnosis and Testing
- Locks, Latches and Entry Systems
- General Procedures
- Remote Transmitter Programming
- Removal and Installation
- Description and Operation
- 501-16 Wipers and Washers
- 501-16 Wipers and Washers|Specifications
- Diagnosis and Testing
- 501-17 Roof Opening Panel
- 501-17 Roof Opening Panel|Specifications
- Removal and Installation
- Roof Opening Panel - Vehicles With: Sliding Roof Opening Panel
- Roof Opening Panel Motor - Vehicles With: Sliding Roof Opening Panel
- Air Deflector - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel Headliner - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel Module - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel Motor - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel Outer Cover - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel Wiring Harness - Vehicles With: Folding Roof Opening Panel
- Roof Opening Panel - Vehicles With: Folding Roof Opening Panel
- 501-19 Bumpers
- Removal and Installation
- 501-20A Safety Belt System
- 501-20A Safety Belt System|Specifications
- Description and Operation
- Diagnosis and Testing
- Safety Belt System
- 501-20B Supplemental Restraint System
- 501-20B Supplemental Restraint System|Specifications
- Description and Operation
- Air Bag Supplemental Restraint System (SRS)
- Diagnosis and Testing
- Air Bag Supplemental Restraint System (SRS) - Vehicles Built From: 02-2000
- Air Bag Supplemental Restraint System (SRS) - Vehicles Built Up To: 02-2000
- General Procedures
- Scrapped Vehicle Undeployed Air Bag Disposal - Vehicles Built Up To: 02-2000
- Deployed Air Bag Disposal
- Unserviceable Air Bag Disposal
- Air Bag and Safety Belt Pretensioner Disposal - Vehicles Built From: 02-2000
- Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal - Vehicles Built Up To: 02-2000
- Scrapped Vehicle Air Bag and Safety Belt Pretensioner Disposal - In-Vehicle Disposal - Vehicles Built From: 02-2000
- Removal and Installation
- Passenger Air Bag Module
- Driver Air Bag Module
- Air Bag Sliding Contact - Vehicles Built Up To: 02-2000
- Clockspring - Vehicles Built From: 02-2000
- Side Air Bag Module
- Side Impact Sensor
- Air Bag Control Module - Vehicles Built Up To: 02-2000
- Air Bag Control Module - Vehicles Built From: 02-2000
- Passenger Air Bag Deactivation (PAD) Switch - Vehicles Built Up To: 02-2005
- Passenger Air Bag Deactivation (PAD) Switch - Vehicles Built From: 02-2005
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- Description and Operation
- Body and Frame
- General Procedures
- Description and Operation
- 501-27 Front End Sheet Metal Repairs
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501 Body and Paint
- 1 General Information
- Body and Paint
- 5 Body and Paint
- 501 Body and Paint
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- Description and Operation
- Body and Frame
- General Procedures
- Description and Operation
- 501-27 Front End Sheet Metal Repairs
- Removal and Installation
- Fender Apron Panel Reinforcement
- Click to view this Labor Time
- Front Side Member and Fender Apron Panel LH
- Removal and Installation
- 501-28 Roof Sheet Metal Repairs
- Removal and Installation
- 501-29 Side Panel Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs
- 501-30 Rear End Sheet Metal Repairs|Specifications
- Removal and Installation
- 501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks
- 501 Body and Paint
- 5 Body and Paint
