Engine Mechanical:
Complete overhaul, diagnosis, component replacement (pistons, rings, bearings, valve train, timing belt/chain, seals, gaskets)
Engine Electrical:
Ignition system, fuel injection system (ECU, sensors, injectors), starting system, charging system, wiring diagrams
Transmission Manual:
Overhaul, clutch system, gear shift mechanism, bearings, seals
Transmission Automatic:
Diagnosis, fluid changes, potential component replacement (if applicable to the 1580cc variant)
Brakes:
Hydraulic system (master cylinder, calipers, lines), disc/drum brake overhaul, ABS (if equipped), parking brake
Suspension:
Front suspension (MacPherson struts, wishbones, anti-roll bar), rear suspension (trailing arms, torsion bars, spherical drag links - a key ZX feature), shock absorbers, springs
Steering:
Power steering system, steering rack, column, universal joints
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, injectors
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, heater matrix
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, hangers
Body And Chassis:
Body panel removal/installation, rust repair, structural integrity, underbody coatings
Electrical Comfort And Convenience:
Lighting, wipers, horn, power windows, central locking, interior trim
HVAC:
Air conditioning system diagnosis and repair, heater controls, blower motor
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, timing belt replacement
Troubleshooting:
Systematic diagnostic procedures for common faults, fault codes (OBD-I for this era), symptom-based troubleshooting guides
Engine Rebuild:
Step-by-step instructions for full engine disassembly, inspection, component replacement, and reassembly, including torque specifications
Transmission Overhaul:
Detailed instructions for dismantling, inspecting, and rebuilding both manual and automatic transmissions
Brake System Repair:
Calipers, master cylinder, wheel cylinders, brake lines, bleeding procedures
Suspension And Steering Repair:
Replacement of ball joints, tie rod ends, bushings, shock absorbers, steering rack seals
Electrical Component Replacement:
Alternator, starter motor, fuel pump, ignition coil, sensors
Bodywork Repair:
Panel alignment, welding, rust treatment, dent repair
Diagnostic Procedures:
Advanced diagnostic techniques, multimeter usage, oscilloscope interpretation (basic), fuel pressure testing
Wiring Diagrams:
Comprehensive, color-coded wiring diagrams for all major electrical systems
Torque Specifications:
Detailed torque values for all critical fasteners throughout the vehicle
Measurement Specifications:
Clearance measurements, tolerances for engine and chassis components
Special Tool Requirements:
Identification of proprietary Citroen tools and common automotive tools required for specific tasks
Engine Oil Change:
Every 15,000 km or 12 months, whichever comes first
Timing Belt Replacement:
Every 90,000 km or 5 years (crucial for XU engines)
Spark Plugs Replacement:
Every 40,000 km (standard spark plugs), 80,000 km (platinum)
Engine Oil Grade:
SAE 10W-40 or 5W-40 (synthetic recommended for extended intervals)
Engine Oil Capacity Liters:
Approx. 3.5 - 4.0 liters (depending on filter)
Coolant Type:
Ethylene glycol based antifreeze, mixture of 50/50 with distilled water
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90 gear oil
Transmission Fluid Automatic:
ESSO LT 71141 or equivalent ATF (Dexron III compatible)
Rear Axle Bushes:
Wear in the spherical bearings of the rear trailing arms can lead to alignment issues and a knocking noise.
Electrical Gremlins:
Older wiring looms can develop intermittent faults, particularly in door switches, central locking, and dashboard lighting.
Cooling System Leaks:
Plastic coolant expansion tanks can become brittle and crack; radiator seams can also leak.
Exhaust Hangers:
Rubber exhaust hangers can degrade, causing the exhaust system to sag or rattle.
