Engine Mechanical:
Engine assembly, cylinder head, pistons, connecting rods, crankshaft, timing, valve train, lubrication system, cooling system, fuel injection system (mechanical aspects)
Engine Management:
Engine control unit (ECU) operation, sensor diagnostics (MAP, CMP, CKP, TPS, O2, ECT), actuator control (injectors, ignition coils), emission control systems
Transmission Manual:
Gearbox assembly, clutch operation, shift linkage, internal components (gears, bearings, synchros), maintenance, troubleshooting
Transmission Automatic:
Automatic transmission operation, torque converter, valve body, planetary gear sets, hydraulic circuits, electronic control (if applicable to specific variant), maintenance, troubleshooting
Suspension:
Front suspension (McPherson struts, wishbones), rear suspension (torsion beam, trailing arms), shock absorbers, springs, anti-roll bars, bush replacement, alignment specifications
Steering:
Power steering system (hydraulic, potentially electric in later variants), steering rack, column, tie rods, hydraulic pump, fluid types, bleeding procedures
Brakes:
Front and rear brake systems (discs, pads, calipers, master cylinder), ABS system (components, diagnostics, bleeding), brake fluid specifications, parking brake mechanism
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting circuits (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM) functions (basic)
Body And Interior:
Body panel removal/installation, door mechanisms, interior trim, seating adjustment, dashboard removal, HVAC system (climate control), body sealing, rust prevention
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant, compressor, condenser, evaporator, blower motor, controls, diagnosis of common climate control faults
Safety Systems:
Airbag system (SRS components, deployment triggers, diagnostics), seatbelt mechanisms, pre-tensioners
Routine Maintenance:
Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid level checks and top-ups, brake pad inspection, tire rotation
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, cooling system problems, brake system malfunctions, guided symptom-to-cause analysis
Major Repairs:
Engine overhaul, cylinder head gasket replacement, transmission rebuilds (where applicable), suspension component replacement, brake caliper overhaul, power steering pump replacement
Diagnostic Procedures:
OBD-II (On-Board Diagnostics) code interpretation, component testing using multimeter and oscilloscope, specific diagnostic routines for ABS, ECU, etc.
Electrical Repairs:
Wiring harness repair, component replacement (sensors, actuators, modules), diagnostic testing of electrical circuits
Depth:
Comprehensive (covers from basic maintenance to complete vehicle overhauls and complex diagnostics)
Diagnostics Level:
Advanced (includes wiring diagrams, diagnostic flowcharts, and component testing procedures)
Rebuild Instructions:
Detailed procedures for engine and transmission disassembly, inspection, repair, and reassembly
Engine Code Examples:
TU3JP (1.4L), EW10J4 (2.0L 16V), DW8B (1.9D), DW10TD (1.9 HDi)
Engine Displacement Examples:
1.4L (1360cc), 1.6L (1587cc), 1.8L (1761cc), 2.0L (1997cc), 1.9L Diesel (1868cc)
Engine Type Examples:
Naturally Aspirated Petrol, Turbocharged Direct Injection Diesel (HDi)
Horsepower Range Petrol:
75 PS (1.4i) to 136 PS (2.0i 16V)
Horsepower Range Diesel:
70 PS (1.9D) to 90 PS (1.9 HDi)
Torque Peak Examples:
115 Nm (1.4i), 172 Nm (2.0i 16V), 125 Nm (1.9D), 205 Nm (1.9 HDi)
Petrol System:
Multi-point Fuel Injection (MPI)
Diesel System:
Direct Injection (DI) with Rotary Pump (DW8), Common Rail Direct Injection (CRDi) for HDi variants
Fuel Type Petrol:
Unleaded Petrol (RON 95 or 98 recommended)
Fuel Type Diesel:
Diesel Fuel
Oil Change Interval Petrol:
Typically 15,000 km or 12 months, whichever comes first (check specific engine/oil specification)
Oil Change Interval Diesel:
Typically 10,000-15,000 km or 12 months (especially for non-turbo diesel); HDi may vary, consult manual
Air Filter Replacement:
Every 30,000 km or 24 months
Fuel Filter Replacement Diesel:
Every 60,000 km
Timing Belt Replacement:
Crucial: Typically 90,000-120,000 km or 5-6 years for petrol engines; check specific engine variant. Failure can cause catastrophic engine damage. DW8/DW10 diesels also use a timing belt. Consult manual for precise interval and belt kit part numbers.
Engine Oil Spec Petrol:
API SG/SH/SJ/SL, ACEA A2/A3, viscosity typically 5W-40 or 10W-40 (check manual for exact spec based on engine and climate)
Engine Oil Spec Diesel:
API CF/CG-4/CH-4, ACEA B2/B3/B4, viscosity typically 5W-40 or 10W-40 (check manual for exact spec)
Coolant Type:
Ethylene glycol-based coolant, pink or blue (PSA specification, e.g., Type D or Type R)
Power Steering Fluid Type:
LDS fluid (for certain hydraulic systems) or Dexron III compatible ATF for standard hydraulic power steering.
Common Faults:
Suspension arm bushings, rear axle beam bearings (on some variants), EGR valve (diesel), catalytic converter issues, electrical gremlins (especially window regulators, central locking), ignition coil packs (petrol), clutch master cylinder leaks, thermostat housing leaks.
Timing Belt Risk:
Critical maintenance item. Delayed replacement leads to severe engine damage. The manual will detail the correct procedure and torque settings for components like the water pump often replaced with the belt.