Engine Mechanical:
Detailed disassembly, assembly, and overhaul of the 2.0 HDi engine
Fuel System:
High-pressure common rail system, injectors, fuel pump, throttle body operation
Cooling System:
Radiator, coolant flow, thermostat, water pump, fan operation
Lubrication System:
Oil pump, oil filter, oil passages, oil pressure checks
Chassis Suspension:
Front and rear suspension components, steering system, wheel alignment
Brakes:
Hydraulic system, ABS (if equipped), brake pad/disc replacement, caliper service
Electrical System:
Battery, alternator, starter, lighting, auxiliary systems
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Emission Control:
Information on emission control systems, diagnostics, and components relevant to the non-particle filter variant
Body And Interior:
Body panel removal/installation, interior trim, seating mechanisms, door mechanisms, tailgate operation.
Heating Ventilation And Air Conditioning:
HVAC system operation, component replacement, refrigerant handling (basic).
Exhaust System:
Component identification, removal and installation procedures for exhaust sections (excluding DPF specificities for this model).
Wheels And Tires:
Tire pressure monitoring, wheel fitting, specifications.
Safety Systems:
Seat belts, airbag system diagnostics and replacement procedures.
Maintenance Schedule:
Recommended periodic maintenance intervals and tasks
Troubleshooting:
Diagnostic procedures for common faults and symptoms
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Diagnostic Testing:
Procedures for testing various systems and components, including electrical measurements
Engine Torque Specifications:
Detailed torque settings for all engine components during reassembly.
Alignment Specifications:
Wheel alignment parameters for optimal handling and tire wear.
Depth:
Comprehensive factory-level detail, suitable for both DIY and professional mechanics
Diagnostic Tools:
References to specific diagnostic tools and procedures (e.g., OBD-II scans, live data interpretation).
Engine Type:
Inline 4-cylinder Turbocharged Diesel (HDi)
Displacement:
1997 cc (2.0 Liters)
Bore X Stroke:
85.0 mm x 88.0 mm (typical for DW10ATED)
Compression Ratio:
17.5:1 (typical for DW10ATED)
Horsepower Ps:
109 PS @ 4000 rpm (approximate, common for this engine)
Torque Nm:
250 Nm @ 1750 rpm (approximate, common for this engine)
Injection System:
Common Rail Direct Injection (CRDi)
Dpf Status:
Without Diesel Particulate Filter (DPF)
Type:
Variable Geometry Turbocharger (VGT)
Oil Change Interval Km:
15,000 - 20,000 km or 12 months (typical for diesel engines of this era, check manual for exact)
Timing Belt Interval Km:
120,000 km or 5 years (critical for the DW10 engine, refer to manual for exact)
Engine Oil Specification:
ACEA B3/B4, API CF, SAE 5W-40 or 10W-40 (refer to manual for exact specification and viscosity)
Coolant Specification:
Paraflu UP (or equivalent OAT-based coolant, purple color)
Brake Fluid Specification:
DOT 4
Transmission Oil Manual:
API GL-4, SAE 75W-80 (typical for manual transmissions of this era)
Transmission Oil Automatic:
Specific ATF fluid for AL4 transmission (refer to manual for exact type and capacity)
Common Problems:
EGR valve clogging, turbocharger issues, DPF issues (though this specific manual is for non-DPF models), potential for turbo hose leaks, water pump seal failures, electrical gremlins, clutch slave cylinder issues.
Engine Reliability:
The DW10 HDi is generally a robust engine, but requires diligent maintenance, especially the timing belt and fuel system.
Specific Engine Notes:
The HDi engines are sensitive to fuel quality and injector maintenance. Timing belt replacement is crucial and must be done to manufacturer specifications.
