Powertrain:
Engine mechanicals, fuel system, ignition system, emissions control, exhaust system, cooling system, lubrication system, starting system, charging system.
Drivetrain:
Manual transmission, clutch, driveshafts, differentials, wheel bearings.
Chassis Suspension:
Front suspension, rear suspension, shock absorbers, springs, bushings, wheel alignment specifications.
Brakes:
Hydraulic system, brake calipers, brake pads, brake discs, parking brake, ABS (Anti-lock Braking System) control.
Steering:
Steering system components, power steering, steering rack, steering column.
Electrical:
Battery, charging system, starter motor, ignition system, lighting system, instruments and warning systems, information and entertainment systems, electronic engine controls, electronic feature groups, fuse box diagrams, wiring schematics.
Body:
Body panels, interior trim, mirrors, seating, glass and mechanisms, instrument panel, console, wipers and washers, roof, bumpers, body repairs, metal repairs, subframe mounting systems.
Climate Control:
HVAC system, air conditioning, heater, air distribution, control components.
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication.
Repair:
Component removal and installation, assembly and disassembly, overhaul procedures for engine, transmission, brakes, suspension, steering, electrical components.
Diagnostics:
Troubleshooting guides, fault finding charts, diagnostic procedures for engine management and electronic systems.
Technical Specifications:
Torque specifications, clearances, timing settings, electrical values, fluid capacities, tire pressures.
Engine Rebuild:
Detailed steps for engine disassembly, cleaning, inspection, measuring clearances, replacing gaskets, seals, pistons, rings, bearings, valves, and camshafts. Includes information on engine timing and balancing.
Transmission Overhaul:
Instructions for removing, disassembling, inspecting, and reassembling manual and automatic transmissions, including gearset, synchromesh, clutch pack (for automatic), and bearing replacement.
Brake System Overhaul:
Procedures for caliper rebuilding, master cylinder replacement, bleeding the brake system, replacing brake lines, and servicing ABS components.
Electrical System Diagnostics:
Step-by-step guides for troubleshooting electrical faults using multimeters, oscilloscopes, and wiring diagrams. Includes testing of sensors, actuators, ECUs, and wiring harnesses.
Depth:
Dealer-level factory manual standard, encompassing detailed procedures from basic maintenance to complete engine and transmission rebuilds.
Length:
Approx. 4,290 mm (168.9 in)
Width:
Approx. 1,700 mm (66.9 in)
Height:
Approx. 1,425 mm (56.1 in)
Curb Weight:
Varies by engine and drivetrain, typically between 1,300 kg and 1,550 kg (2,866 lbs to 3,417 lbs).
Wheelbase:
Approx. 2,550 mm (100.4 in)
Wheel Bolt Pattern:
5x98 mm
Tire Sizes:
Common sizes included 195/55R15, 205/50R16, and 205/45R17 depending on trim and model year.
Oil Change Interval:
Typically 10,000 km (6,000 miles) or 12 months, whichever comes first, for synthetic or semi-synthetic oil. The manual will specify the exact interval and oil type.
Spark Plug Replacement:
For Twin Spark engines, spark plug replacement is a critical maintenance item. Intervals vary, but typically involve replacing all four plugs and sometimes an additional coil plug (total of 8 per cylinder on early Twin Spark versions). The manual will detail the specific procedure and part numbers.
Timing Belt Replacement:
The timing belt and tensioners for the Twin Spark engines require replacement at regular intervals, often around 70,000-100,000 km (43,000-60,000 miles) or 5 years. Failure to do so can result in severe engine damage. The manual will specify the exact interval and procedure.
Engine Oil Capacity:
Approx. 4.0 - 4.5 liters (4.2 - 4.8 US quarts) for 2.0L engines, and slightly more for V6. The manual will list exact capacities for each engine variant.
Engine Oil Grade:
Recommended grades typically include 10W-40 or 5W-40, often API SJ/SL or ACEA A3/B3 specification. The manual will provide precise recommendations.
Twin Spark Issues:
Potential issues can include spark plug wear, oil consumption, and ignition coil failures. The manual's diagnostic section will be crucial for addressing these.
Rust And Corrosion:
Like many European cars of this era, rust can be an issue, particularly around wheel arches, sills, and rear valence panels. The body repair section will be valuable for addressing this.
Suspension Wear:
Bushings and ball joints in the suspension can wear over time, leading to a less precise feel and potential noise. The manual provides detailed specifications for replacement and alignment.