Engine Mechanical:
Complete engine overhaul, disassembly, assembly, component testing, specifications
Engine Management:
Electronic Control Module (ECM) operation, diagnostics, fuel injection, EGR systems
Cooling System:
Radiator, hoses, thermostat, water pump, fan, coolant specifications
Fuel System:
Fuel tank, pump, lines, injectors, pressure testing, evaporative emissions control
Lubrication System:
Oil pump, oil filter, oil pan, oil specifications, pressure testing
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, emissions control components
Clutch System:
Clutch operation, inspection, replacement, fluid specifications
Transmission Manual:
Manual transmission overhaul, repair, fluid specifications, gear selection
Transmission Auto:
Automatic transmission overhaul, repair, fluid specifications, shift control
Propulsion Mechanism:
Drivetrain components, driveshafts, CV joints
Axles Front Rear:
Front and rear axle assemblies, differential, bearing specifications
Suspension System:
Struts, shocks, springs, control arms, bushings, alignment specifications
Steering System:
Steering rack, power steering pump, fluid, tie rods, alignment
Brake System:
Brake calipers, rotors, pads, lines, master cylinder, fluid specifications, bleeding procedures
ABS:
Anti-lock Brake System components, sensors, hydraulic unit, diagnostics
Electrical System Main:
12V system, battery, charging system, starting system, wiring harness overview
Electrical Diagrams:
Detailed circuit diagrams for all vehicle systems
Body Systems:
Body panel removal/installation, doors, windows, interior trim
Wiper Washer:
Windshield wiper and washer system components, operation, troubleshooting
Instrument Cluster:
Dashboard instrumentation, gauges, warning lights, diagnostic indicators
Generator Starter:
Alternator and starter motor testing, removal, installation
Can Communication:
CAN (Controller Area Network) communication system architecture and troubleshooting
Speaker Antenna:
Audio system components, speaker wiring, antenna systems
General Maintenance:
Routine checks, fluid changes, filter replacements, lubrication
Troubleshooting:
Diagnostic procedures for common and complex issues across all systems
Repair Rebuild:
Detailed step-by-step instructions for component repair and complete system rebuilds
Removal Installation:
Procedures for removing and installing major components like engine, transmission, suspension, etc.
Diagnostics Testing:
Techniques for diagnosing faults using onboard diagnostics (OBD-II) and specialized tools
Specifications Data:
Torque values, clearances, fluid capacities, electrical values, performance data
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced diagnostics)
Target Audience:
DIY enthusiasts and professional mechanics
Engine 1 4L:
1.4L 4-Cylinder Inline, Z14XE, DOHC Petrol. Typically around 89-90 PS (88-89 hp / 65-66 kW) and 125-130 Nm (92-96 lb-ft) torque.
Engine 1 6L:
1.6L 4-Cylinder Inline, Z16XE, DOHC Petrol. Typically around 104-105 PS (103-104 hp / 76-77 kW) and 150-152 Nm (111-112 lb-ft) torque.
Engine 1 8L:
1.8L 4-Cylinder Inline, Z18XE, DOHC Petrol. Typically around 125 PS (123 hp / 92 kW) and 170 Nm (125 lb-ft) torque.
Engine 2 0L Turbo:
2.0L 4-Cylinder Turbo Intercooled, Z20LE DOHC Petrol (e.g., Z20LEH, Z20LER variants). Power outputs varied significantly by specific 'GSi' or 'VXR' trim, ranging from 170 PS (168 hp / 125 kW) to 200 PS (197 hp / 147 kW) and higher for performance variants.
Horsepower Range:
Approximately 89 hp (1.4L) to 200+ hp (2.0L Turbo variants).
Torque Range:
Approximately 92 lb-ft (1.4L) to 180+ lb-ft (2.0L Turbo variants).
Injection Type:
Multi-point fuel injection (MPI) or sequential fuel injection (SFI), depending on engine variant.
Oil Change Interval:
Typically 10,000 km or 12 months, whichever comes first. Consult manual for specific engine and oil type.
Timing Belt Interval:
For Z16XE and Z18XE engines, timing belt replacement is critical, typically around 60,000-90,000 miles (96,000-144,000 km) or 6 years. Crucial to check manual for precise intervals.
Engine Oil Spec 1 8L:
API SG/SH/SJ/SL or ACEA A3/B3/B4, viscosity typically 5W-30 or 5W-40. Check manual for exact specification.
Coolant Spec:
GM Dex-Cool (Orange) or equivalent silicate-free ethylene glycol-based coolant. Typically 50/50 mix with distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90 gear oil. Manual will specify exact type and capacity.
Coil Packs:
Ignition coil pack failure is a common issue, leading to misfires and rough running.
Thermostat Housing:
Plastic thermostat housing can become brittle and crack, leading to coolant leaks.
Eon Engine Management:
Some models with the Ecotec engines can suffer from various sensor issues or ECU problems, often flagged by engine warning lights.
Rear Axle Bushes:
Wear in rear axle suspension bushes can lead to poor handling and alignment issues.
