Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, oil pump, lubrication system, cooling system, fuel system (injection, pump, injectors, lines), emission control systems.
Engine Electrical:
Ignition system, starter motor, alternator, battery, engine control unit (ECU), sensors (oxygen, crankshaft position, camshaft position, throttle position, manifold absolute pressure), actuators (idle control valve, variable valve timing).
Transmission Manual:
Clutch, gearbox assembly, gear selection, shifting mechanisms, driveshafts, differentials.
Transmission Automatic:
Torque converter, gearbox internals, valve body, electronic control unit, cooling and lubrication.
Brakes:
Brake system components (master cylinder, brake booster, lines, hoses, calipers, pads, discs), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), ESP (Electronic Stability Program) components and diagnostics.
Suspension Steering:
Front suspension (McPherson struts, wishbones, anti-roll bar), rear suspension (torsion beam or multi-link), shock absorbers, springs, steering rack, power steering system (hydraulic or electric), wheel alignment specifications.
Electrical Body:
Lighting system (headlights, taillights, interior lights), power windows, power mirrors, central locking, wipers and washers, horn, dashboard instruments, climate control system, body control module (BCM).
Electrical Chassis:
Wiring diagrams for all major systems, fuses, relays, body control module, trailer wiring.
Comfort And Convenience:
Air conditioning (HVAC), seats, interior trim, door panels, headliner, sound system, navigation system.
Body And Chassis:
Body panel removal and installation, door hinges, latches, seals, glass replacement, underbody protection, chassis components.
Maintenance:
Oil and filter changes, air filter replacement, cabin filter replacement, spark plug replacement, fuel filter replacement, coolant flush and refill, brake fluid replacement, transmission fluid changes, differential oil changes.
Troubleshooting:
Diagnostic trouble codes (DTCs), common symptoms and their causes, diagnostic flowcharts, electrical system troubleshooting, engine performance issues, transmission problems.
Repair:
Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement, clutch replacement, transmission rebuild, brake system overhaul, suspension component replacement, steering system repair, electrical component replacement, body panel repair and replacement.
Diagnostics:
OBD-II diagnostic procedures, sensor testing, actuator testing, ECU diagnosis, module programming and configuration.
Depth:
Comprehensive (from routine maintenance to complete engine and transmission rebuilds).
Visuals:
Detailed photos and exploded diagrams.
Instructions:
Step-by-step instructions.
Oil Change Interval:
Typically 20,000 km (or 1 year) for petrol engines, 20,000 - 30,000 km (or 2 years) for diesel engines, whichever comes first (consult manual for specific engine/oil type).
Timing Belt Replacement:
For 1.4 VTi and 1.6 VTi (EP6) engines, timing chain is used. For 1.6 HDi, timing belt replacement typically around 180,000 km or 10 years. For 2.0 HDi, timing belt replacement around 150,000 km or 6 years. (Crucial to verify with manual).
Engine Oil Specification:
API SN/SP, ACEA C2/C3, PSA B71 2290 (for diesel with DPF), PSA B71 2312 (for newer petrol/diesel), or equivalent. Viscosity typically 0W-30 or 5W-30 (refer to manual for specific engine).
Coolant Specification:
PSA Type 052.358 (Infinium Blue/Purple antifreeze concentrate), typically a G30 or G48 based ethylene glycol coolant.
Brake Fluid Specification:
DOT 4 or DOT 4 LV (Low Viscosity) brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-80 (e.g., PSA specification B71 2330).
Transmission Fluid Automatic:
Specific ATF fluid for AL4 (e.g., LT 71141 or equivalent) or for 6-speed automatic. Consult manual for precise specification and capacity.
Common Problems:
Problems with the 1.6 THP engine (BMW-PSA co-developed) can include timing chain tensioner issues, carbon buildup on intake valves, and turbocharger problems. 1.6 HDi engines can suffer from turbocharger oil starvation (requiring specific oil change intervals and checking oil feed pipe) and DPF (Diesel Particulate Filter) regeneration issues if not driven appropriately. Electrical gremlins and issues with the CAN bus system can occur. The AL4 automatic gearbox can be prone to overheating and valve body issues.