Engine Mechanical:
Detailed diagnosis, overhaul, and repair of all engine variants (e.g., 1.4, 1.6, 1.8 petrol; 1.9 TD/JTD diesel)
Engine Electrical:
Ignition system, fuel injection system (including EFI/MPI), starting and charging systems, emission control systems
Clutch System:
Hydraulic clutch operation, clutch disc, pressure plate, release bearing replacement and adjustment
Transmission Gearbox:
Manual transmission overhaul, gear synchromesh, differential, driveshafts, fluid specifications and change intervals
Automatic Transmission:
if applicable for certain models, diagnosis, fluid, and service procedures
Braking System Front:
Disc brake caliper overhaul, pad replacement, rotor specifications, hydraulic lines, ABS system components
Braking System Rear:
Disc or drum brake service, handbrake mechanism, fluid flushing and bleeding procedures
Steering System:
Power steering pump, rack and pinion, steering column, alignment specifications, fluid types
Suspension System:
Front and rear suspension components (struts, shocks, control arms, bushings), wheel bearing replacement, alignment procedures
Wheels Tires:
Wheel nut torque specifications, tire pressure recommendations, rim compatibility
Electrical Equipment:
Lighting system (headlamps, taillamps, interior), horns, wipers, washers, mirrors, power accessories
Electrical Systems Wiring:
Complete wiring diagrams for all circuits, fuse box locations and ratings, relay functions
Instrument Panel:
Gauges, warning lights, odometer, tachometer, fuel gauge, temperature gauge, diagnosis and repair
Bodywork Exterior:
Door panel removal, bumper replacement, panel alignment, rust repair techniques, paint codes (if included)
Bodywork Interior:
Seat removal, dashboard components, headliner, carpet replacement, trim pieces
Fuel System:
Fuel tank, fuel pump, fuel filter replacement, fuel lines, injection system components
Alarm Security:
Factory alarm system wiring and troubleshooting (if applicable)
Chassis Identification:
VIN decoder and chassis number locations
Maintenance Schedule:
Scheduled maintenance intervals for oil changes, filter replacements, spark plugs, timing belts/chains
Basic Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fluid top-offs
Intermediate Repair:
Brake pad and rotor replacement, clutch adjustments, exhaust system repair, cooling system service
Advanced Diagnosis:
Troubleshooting engine performance issues, electrical faults, transmission problems, ABS warnings
Rebuilding Overhaul:
Detailed instructions for engine, transmission, and differential rebuilds
Electrical Troubleshooting:
Step-by-step diagnostic procedures for common electrical faults using wiring diagrams
Diagnostic Charts:
Includes analytical charts for identifying and resolving problems
Torque Specifications:
Precise torque settings for all critical fasteners
Fluid Capacities:
Exact fluid capacities for engine oil, coolant, transmission fluid, brake fluid, power steering fluid
Diagrams Illustrations:
Step-by-step diagrams and exploded views for visual guidance
Engine Variants Covered:
1.4L FIRE, 1.6L 16V, 1.8L 16V (DOHC), 1.9L TD (Turbo Diesel), 1.9L JTD (Common Rail Diesel - later variants)
Power Output Range:
Approx. 75 hp (1.4) to 113 hp (1.8) for petrol engines; approx. 75 hp (TD) to 105 hp (JTD)
Torque Specifications:
Detailed torque values for cylinder head bolts, main bearings, connecting rods, etc.
Injection Type:
Electronic Fuel Injection (EFI) / Multi-Point Injection (MPI) for petrol; Indirect Injection or Common Rail Injection for diesel
Fuel Type:
Unleaded petrol (RON 95/98), Diesel fuel
Timing Belt Replacement:
Specific intervals and procedures for timing belt replacement (critical for interference engines)
Spark Plug Specifications:
Correct spark plug type and gap for each engine variant (e.g., NGK BKR6EK, Champion RC10PMC4)
Engine Oil Change:
Every 15,000 km or 12 months, whichever comes first (or 10,000 km for severe conditions).
Timing Belt Interval:
Typically 60,000 km or 4-5 years (crucial to verify for specific engine)
Coolant Change:
Every 2-3 years or as specified in manual.
Engine Oil Specification:
Refer to manual, commonly SAE 10W-40 or 5W-40 (e.g., Fiat 9.55535-G2 or MS-10725 standard)
Coolant Specification:
Ethylene glycol based coolant, typically Fiat 9.55523 standard (e.g., Paraflu UP)
Brake Fluid Specification:
DOT 4
Power Steering Fluid:
Refer to manual, often specific ATF or hydraulic fluid
Common Problems:
Ignition coil failure, dashboard warning light issues (ABS, Airbag), exhaust manifold cracks (petrol engines), thermostat issues, central locking problems, rust (especially on wheel arches and sills).