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Introduction
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Market Position
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Positioning:
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Compact family hatchback with a focus on comfort, practicality, and unique styling
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Competitive Analysis
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Competitors:
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Ford Focus, Volkswagen Golf, Opel/Vauxhall Astra, Peugeot 307, Renault Megane
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Key Features
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Design:
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Distinctive 'space-ship' like dashboard design, flexible 'My Car' customization options, advanced electronics for its time
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Practicality:
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Spacious interior, versatile seating arrangements (depending on trim), good cargo capacity for its class
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Technology Integration:
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Early adoption of electronic systems, including sophisticated climate control and driver information systems
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, diagnosis, repair, and maintenance
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Transmission:
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Manual and automatic transmission service, repair, and adjustment
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Brakes:
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Hydraulic system, ABS, EBD, brake pad/rotor replacement, bleeding procedures
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Suspension:
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Front and rear suspension components, shock absorbers, springs, bushings, wheel alignment
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Steering:
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Power steering system, steering column, tie rods, alignment specifications
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Electrical:
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Wiring diagrams, component testing, diagnosis of lighting, ignition, charging, and accessory systems
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Bodywork:
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Panel removal/installation, door mechanisms, glass replacement, body repair techniques
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HVAC:
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Air conditioning, heating, ventilation system diagnosis and repair
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Fuel System:
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Fuel pump, injectors, fuel lines, evaporative emission control system
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Cooling System:
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Radiator, thermostat, water pump, coolant specifications, bleeding
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Exhaust System:
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Muffler, catalytic converter, exhaust manifold repair and replacement
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Safety Systems:
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Airbag system diagnosis and repair, seatbelt mechanisms
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Procedures Included
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Maintenance:
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Scheduled maintenance, fluid changes, filter replacements, inspections
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Troubleshooting:
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Diagnostic procedures for common and complex faults
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Repair:
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Step-by-step repair instructions for all major vehicle components
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Disassembly Assembly:
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Detailed guides for removing and reinstalling parts and systems
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Adjustment:
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Calibration and adjustment procedures for various systems
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Installation:
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Procedures for installing new or replacement components
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Technical Depth
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Depth:
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Comprehensive bumper-to-bumper coverage for DIY and professional mechanics
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Visuals:
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Detailed illustrations, exploded diagrams, drawings, and photos
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Special Tools:
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Reference to specific service tool numbers and their usage
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Specifications:
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Precise service data, factory specifications, allowable limits, and tightening torques
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Engine Specifications
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Primary Engine
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Engine Options Overview:
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A range of petrol and diesel engines were offered across the Stilo's lifecycle, including naturally aspirated and turbocharged variants.
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Performance
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Typical Petrol Engines:
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1.2L Fire, 1.4L Fire, 1.6L 16V Fire, 1.8L 16V Torque, 2.4L 20V Multijet (Abarth)
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Typical Diesel Engines:
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1.9L JTD (Common Rail Direct Injection) in various power outputs (e.g., 80, 115, 120, 130, 150 PS)
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Fuel System
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Fuel Delivery Petrol:
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Electronic Multi-Point Fuel Injection (MPI)
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Fuel Delivery Diesel:
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Common Rail Direct Injection (JTD)
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Technical Details
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Engine Management:
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ECU controlled with diagnostic capabilities (OBD-II compliant)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 20,000 km or 1 year, whichever comes first (check manual for specific engine variant)
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Timing Belt Replacement:
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Crucial for many petrol engines; typically around 100,000 - 120,000 km or 5 years (consult manual for specific engine)
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Fluid Specifications
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Engine Oil Spec:
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Refer to manual for specific API/ACEA rating and viscosity grade (e.g., SAE 5W-40, 10W-40, etc., meeting Fiat specifications like 9.55535-G1/G2/S2/T2)
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Coolant Spec:
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Paraflu UP or equivalent (ethylene glycol based, long-life coolant, typically purple or blue color)
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Brake Fluid Spec:
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DOT 3 or DOT 4 (refer to manual for precise specification)
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Power Steering Fluid:
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Tutela PSF or equivalent (often a specific hydraulic fluid)
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Known Issues
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Common Electrical Faults:
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Issues with Body Computer (BCM), dashboard warning lights, window regulators, CAN bus communication problems
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Common Mechanical Issues:
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Clutch wear (especially on higher mileage vehicles), suspension component wear (e.g., ball joints, drop links), exhaust system corrosion
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Diesel Engine Specific:
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Potential issues with turbocharger actuators, EGR valves, DPF (Diesel Particulate Filter) clogging on later models
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Interior Features:
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Some reports of 'creaky' interior trim, issues with the 'My Car' customization system failing to save settings
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