Engine System:
Detailed disassembly, assembly, diagnostics, troubleshooting, repair procedures for all engine variants.
Clutch System:
Inspection, adjustment, replacement of clutch components (disc, pressure plate, release bearing).
Transmission Gearbox Diff:
Manual gearbox (5-speed and 6-speed options) and differential overhaul, repair, and fluid specifications.
Braking System:
Front and rear brake systems (disc/drum configurations), ABS, hydraulic components, bleeding procedures.
Steering System:
Power steering system diagnostics, pump, rack and pinion repair, fluid specifications.
Suspension System:
Front and rear suspension (MacPherson struts, torsion beams), shock absorbers, springs, bushings, alignment procedures.
Wheels And Tires:
Wheel bearing replacement, tire pressure recommendations, wheel bolt torque specifications.
Electrical Equipment:
Starter, alternator, battery system, lighting, horns, wipers, power windows, mirrors.
Electrical Systems:
Detailed wiring diagrams for all circuits, ECU troubleshooting, sensor testing, fuse and relay locations.
Instrument Panel:
Dashboard components, gauges, warning lights, instrument cluster removal and repair.
Bodywork:
Exterior panels, doors, bumpers, glass, interior trim, body repair specifications.
Fuel System:
Fuel pump, injectors, fuel filter replacement, fuel tank diagnostics, emissions control system.
Cooling System:
Radiator, thermostat, water pump, coolant specifications, bleeding procedures.
Exhaust System:
Catalytic converter, mufflers, exhaust pipe inspection and replacement.
Climate Control HVAC:
Air conditioning system operation, refrigerant, heater core, blower motor.
Alarm System:
Factory fitted alarm system diagnostics and troubleshooting.
Maintenance Procedures:
Oil changes, filter replacements, spark plug changes, belt replacements, fluid top-ups.
Diagnostic Procedures:
Troubleshooting common problems, identifying fault codes, component testing.
Repair Procedures:
Step-by-step instructions for major component repairs and overhauls.
Electrical Diagnostics:
Tracing electrical faults using wiring diagrams, testing sensors and actuators.
Torque Specifications:
Precise torque settings for all critical fasteners.
Fluid Capacities:
Exact fluid capacities for engine oil, coolant, transmission fluid, brake fluid, etc.
Depth Level:
Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds.
Detail Level:
Includes step-by-step diagrams and detailed explanations for all workshop procedures.
Engine Type:
Inline 4-cylinder, naturally aspirated petrol; Inline 4-cylinder diesel (including Turbo Diesel).
Power Output Range:
Approximately 75 PS (55 kW) to 155 PS (114 kW), depending on engine variant.
Torque Range:
Varies significantly by engine; detailed in manual.
Injection Type:
Multi-point fuel injection (MPI) for petrol engines; Common Rail or direct injection for diesel variants.
Common Petrol Engines:
1.4 Fire, 1.6 16v, 1.8 16v, 2.0 16v (HGT).
Common Diesel Engines:
1.9 TD, 1.9 JTD.
Timing Belt Replacement:
Critical maintenance item, interval specified in manual (typically around 60,000-90,000 km).
Transmission Type:
5-speed manual transmission.
Automatic Transmission:
Some models offered with a 4-speed automatic transmission (referred to as 'Auto trans' in product info).
Gear Ratios:
Detailed gear ratios for each model/engine variant provided in the manual.
Manual Transmission Fluid:
Manual will specify correct API GL-4 or GL-5 specification (e.g., SAE 75W-90, SAE 80W-90).
Automatic Transmission Fluid:
Specific ATF (Automatic Transmission Fluid) type (e.g., Dexron II/III equivalent) will be detailed.
Engine Oil Change:
Typically every 10,000-15,000 km or 1 year, whichever comes first. Manual will confirm specific interval.
Spark Plugs:
Interval varies by plug type (copper, platinum); consult manual for specific recommendations.
Air Filter Replacement:
Recommended at regular service intervals, or sooner if driving in dusty conditions.
Engine Oil Specification:
Refer to manual for specific API/ACEA ratings and viscosity grades (e.g., 10W-40, 5W-40).
Coolant Specification:
Ethylene glycol-based coolant, with specific concentration for freeze and corrosion protection. Manual will detail Type Fiat Paraflu or equivalent.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid. Manual will specify.
Common Problems:
Potential issues can include electrical gremlins, minor cooling system leaks, clutch wear, and suspension component wear over time.
Diesel Engine Specific:
Turbo diesel variants (especially earlier ones) may require attention to turbocharger health and glow plug system.