Engine Mechanical:
Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshaft, valve train.
Engine Fuel System:
Injection pump, injectors, fuel lines, fuel filter, high-pressure pump, diesel particulate filter (if applicable).
Engine Cooling System:
Radiator, water pump, thermostat, coolant hoses, fan, temperature sensors.
Engine Lubrication System:
Oil pump, oil filter, oil sump, oil pressure.
Engine Ignition System:
Glow plugs, pre-heating system, starting system.
Transmission Manual:
Clutch operation, gearbox assembly, gear ratios, internal components, synchromesh, shift mechanism.
Transmission Automatic:
Not applicable for the 1.9 D model.
Drivetrain:
Front-wheel drive system, drive shafts, CV joints, differential.
Suspension Front:
MacPherson struts, coil springs, shock absorbers, wishbones, anti-roll bar.
Suspension Rear:
Torsion beam suspension, shock absorbers, springs.
Steering System:
Steering rack, power steering pump, steering column, tie rods.
Braking System:
Front disc brakes, rear drum brakes, brake lines, master cylinder, brake booster, ABS (if equipped).
Electrical System General:
Battery, starter motor, alternator, wiring diagrams.
Lighting System:
Headlights, taillights, indicators, interior lighting, bulb types.
Instrumentation Gauges:
Dashboard layout, warning lights, speedometer, tachometer, fuel gauge, temperature gauge.
Body And Chassis:
Body panel removal and installation, door mechanisms, window regulators, bumper systems, underbody protection.
Interior Trim:
Seat removal, dashboard components, center console, door panels.
HVAC System:
Heating, ventilation, and air conditioning system components, refrigerant, cabin filter.
Preventive Maintenance:
Oil and filter changes, air filter replacement, fuel filter replacement, coolant checks, brake fluid checks, tire rotation.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon faults across all systems.
Engine Repair:
Engine assembly and disassembly, component replacement, timing belt replacement, cylinder head gasket replacement.
Transmission Repair:
Clutch replacement, gearbox rebuild, linkage adjustments.
Brake System Repair:
Brake pad and disc replacement, drum brake servicing, brake fluid bleeding, caliper and wheel cylinder replacement.
Suspension And Steering Repair:
Shock absorber replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement.
Electrical Diagnostics:
Wiring harness inspection, fuse and relay testing, component testing, use of multimeters.
Bodywork Repair:
Minor dent repair, panel alignment, door hinge adjustment, lock mechanism repair.
HVAC System Repair:
Component replacement (blower motor, evaporator, condenser), leak detection, refrigerant charging.
Technical Specifications:
Detailed torque specifications, clearances, fluid capacities, engine timing, electrical system voltages.
Depth:
Comprehensive (covers complete disassembly and reassembly of all major components).
Target Audience:
DIY enthusiasts, home mechanics, and professional technicians.
Service Intervals Engine Oil
Interval Months:
12 months
Interval Notes:
Whichever comes first. Consider shorter intervals for severe driving conditions.
Service Intervals Timing Belt
Interval Notes:
Crucial to replace at interval to prevent catastrophic engine damage. Always replace tensioner and idler pulleys.
Engine Oil Type:
ACEA B4, API CF-4, SAE 5W-40 (or 10W-40 depending on climate).
Engine Oil Capacity:
4.25 liters (with filter)
Coolant Type:
Antifreeze/Coolant, PSA specification (e.g., G33 or equivalent)
Coolant Capacity:
Approx. 6.0 liters
Transmission Oil Type:
GL-4, SAE 75W-80 (manual gearbox)
Glow Plugs:
Can fail, leading to starting difficulties in cold weather.
Clutch Wear:
Clutch can wear prematurely, especially with heavy use. Symptoms include slipping or difficulty engaging gears.
Suspension Bushings:
Front suspension control arm bushings and rear axle mounting bushes can wear, causing knocking noises and poor handling.
Exhaust System:
Rust and corrosion can affect the exhaust system over time, particularly the rear silencer.
Electrical Connections:
Corroded electrical connections, particularly ground points, can lead to intermittent electrical faults.
