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TECDATA autoTechniCAL Database ultra-PRO Online  

Extensive version for detailed adjustements, useful mechanical and electronical repair instructions and diagnostics of vehicles.

VEHICLE IDENTIFICATION NUMBER ( VIN )

  • Location VIN and identification label
  • VIN decoder

 

Click on the identification label to obtain specific vehicle information. Click on the vehicle label to get details regarding the vehicle, engine, gearbox and optional equipment.

 

LOCATION EOBD / OBD II CONNECTOR

  • Location of the EOBD connector in the vehicle

 

 

MAINTENANCE

  • Maintencance schedules ( based on OEM )
  • Printable work sheets
  • Link to general components
  • Follow-up tasks
  • Maintenance times
  • Service indicator reset
  • Replacement intervals of timing belts
  • Tyre pressure monitoring systems

 

START - AND STOP SYSTEM: DEACTIVATING / ACTIVATING

General:

When instructions on the engine have to be performed.

Deactivating:

Option 1 : Press the button

Note: The telltale of the start- and stop system should be activated.

The system has now been deactivated.

Option 2 : Remove the safety belt of the driver from belt lock.

Open the door of the driver.

 

SERVICE INDICATOR RESET

Resetting the service interval indicator.

Method 1
To perform reset diagnostic equipment is required.

Method 2

Switch off the ignition lock. Press button (2)
Hold the reset button and switch on the ignition lock
On the display of the day counter appears 'Service INSP'
Release the button
Press the button shortly
Within 20 seconds
The system has been reset.

 

LUBRICANTS AND LIQUIDS

All specifications for oil and liquids in one overview.

All thinkable specifications are available here, with handy links to related information for additional convenience and techncial illustrions of fill and drain plugs.

Engine

Motoroil (Synthetic)               SAE 0W-30    PSA B71 2312     From -45 °C to 45 °C
Motoroil (Synthetic)               SAE 5W-30    PSA B71 2290     From -30 °C to 40 °C
Motoroil (Synthetic)               SAE 5W-40    PSA B71 2296     From -30 °C to 50 °C
Motoroil (Semi-synthetic  )    SAE 10W-40  PSA B71 2300     From -20 °C to 50 °C

•    Engine sump, including filter 4.2 (l)
•    Engine oil drain plug ( renew the bolt )  40 (Nm)

Cooling system

Coolant        Super Longlife coolant L255

Basic data

Brake fluid       DOT 4            Brake system 1.0 (l)

(Manual transmission), (F5M43)

Transmission oil    SAE 75W-80    API GL-3
•    Manual transmission
•    Gearbox refill 2.0 (l)
•    Location plug  (1 - Drain plug; 2 - Fill and level plug)

Air conditioning

Refrigerant        R134a
Air conditioning compressor oil        SUN PAG 56
Refirgerant        500 (g)
Air conditioning compressor oil  70 (ml)

 

SETTINGS

Engine ( specifications )

Firing order
Valve clearance
Number of spark plugs
Compression pressure
Oil pressure
Maximum cilinder head distortion
Drive belt layout   
(without air conditioning)


 
Ancillary drive belt: removal / installation

 

Engine ( general )

Engine code
Capacity
Distribution type
Tming belt
Engine speed at maximum power
Number of cylinders
Valves per cylinder

 

Emissions

Engine
Idle speed, minimum / maximum
CO-percentage
Fast idle speed
CO at fast idle speed
Olie temperature during test
Lambda
Emissions
Fuel consumption  

 

Cooling system

Engine
Cap pressure (Blue cap, black cap)

 

 


 

Electrical

Basic data
Alternator   
Battery location

Luggage compartment
Battery
Procedures for disconnection / reconnection


Absorbed glass mat (AGM)         Cold cranking amperes

 

Brakes

Basic data
Equipment code: Refer to the identification label
Brake test conditions
Test speed
Front disc brakes, Disc diameter
Disc thickness
Brake pad thickness
Rear disc brakes, Disc diameter

 

Wheel alignment

Basic data
Wheel base
Condition of the vehicle
Ride height


Toe-in
Camber
Maximum difference between the left-hand side and right-hand side
Front-wheel steering angle, inner
Thrust angle

Wheels and tyres

Basic data
Speed index, minimum
(Based on the maximum speed as listed in the European Type Approval data sheets)
Tyre size
Tyre pressure
Wheel offset ( ET )
Rim size


Air conditioning

Basic data
Location of the dust and pollen filter


Capacities

Engine
Engine sump, including filter
Basic data
Brake system   
Automatic transmission
Manual transmission
Gerabox refill
Location plug location
  (1 - Filler plug; 2 - Drain plug)

 

Torque settings

Engine

Note: Always renew stretch bolts and self-locking nuts
Cylinder head



Furthermore all important tightening torques related to engine, timing belts, breaks, gearbox etc.

 

REPAIR INSTRUCTIONS

Detailed step-by step instructions for:

•    Removal and installation of timing belt and chain
•    Removal and installation of ancillary belthulpdrijfriemen
•    Removal and installation of clutch
•    Removal and installation of gearbox
•    Drain and fill of refigerant system
•    Removal and installation cylinder head
•    Removal and installation of engine
•    Removal and installation of airbags

 

REMOVAL / INSTALLATION OF TIMING BELT

•   Removal and installation instructions
•   Recommended replacement times
•   Required special tools
•   Clear drawings with marks
•   Valve timing
•   Tightening torques

 

Removing
Remove mass cable battery
Remove air channel

Remove filling pressure sensor
Remove air intake pipe


Remove vacuum hose of the carbon filter system
Remove de engine sump air hose


Put the cable tree aside
Replace the cover of the drive belt of the water pump


Remove air channel


 

Remove camshaft cover


Disconnect the hoses
Remove top cover timing belt

Remove cover of pulley of the exhaust camshaft



 


    Turn the crankshaft clockwise
Use tool T40263, T40314
Remove access plug

Fit crankshaft locking tool 30 Nm  
Till stop. Turn crankshaft till it hits the TDC locking tool
If special tool does not fit
Remove crankshaft locking tool. Turn crankshaft 90° in teh direction of the rotation.
Fit crankshaft locking tool 30 Nm  
Till stop
Turn crankshaft clockwise.
Till crankshaft hits special tool ( T10340 )
Check timing belt marks of camshafts
Fly wheel side:   
Intake camshaft 

 

AIRBAGS: REMOVAL / INSTALLATION

Airbag control unit removal

Remarks installing airbag control unit

Driver's airbag and spiral cable removal

Remarks installing driver's airbag and spiral cable

Passenger airbag removal

Remarks installing passanger airbag

Side airbag removal

Remarks installing side airbag

Removal curtain airbag

Remarks installing curtain airbag

Remval airbag sensor

Remarks installting airbag sensor

 

MANUAL TRANSMISSION: REMOVAL / INSTALLATION

Removal

Installation

Tightening torques

Special tools

 

CLUTCH: REMOVAL / INSTALLATION

 

Warnings and recommandations  

Removing

Installing

Tightening torques

Special equipment

 

BATTERY: REMOVAL / INSTALLATION

    

Before disconnecting the battery        

After disconnecting the battery

Before connecting the battery

After connecting the battery

Initialise electrical windows

 

 

REPAIR TIMES

PRICE OFFER
The price is the starting point for fast cost estimations based on intelligent links between data, repair times and parts. The result can be easily exported in order to use when ordering parts.
Compressed air system
Lubrication system
Cooling system
Engine starting system
Air inlet system
Fuel system
Exhaust system
Gearbox
Automatic transmission
Drive train
Elektrical components
Steering
Front axle
Front suspension
Rear axle
Rear suspension
Wheels and tyres
Pedals
Brakes ( mechanical )
Brakes ( elektrical )
Brakes ( hydraulic )
Brakes ( servo )

 Engine assembly
Checks - Adjustments

Check the engine for abnormal noise 0,40  
Carry out a vehicle electronics test    1,00  
Check the engine compression OE: 01EHNA   0,50  
Measure the cylinders 0,50  
Illuminate the cylinder with an endoscope (opening exposed)   0,30  
Check the cylinder tightness (opening exposed) 0,30  
Carry out a dynamometer test on a roller test bench 0,50  
Clean the engine        0,20  
Clean the engine lower section 0,10  
Clean the engine and the engine compartment    0,20  
Carry out cleaning of valve and combustion chamber 1,20  
Check the engine for leaks 0,10  
Clean any oil sludge from the engine 0,80  
Carry out cold start behaviour diagnostics    0,16  
Check the vehicle speed sensor signal OE: 63E0EA              0,20  
Test drive 1,00   

 

Complete engne unit
Engine cover
Engine mount
Piston
Cylinder head
Flywheel

 

Most important functions and features:

•    Gecombined overview of selected maintenance and repair activities.

•    Ability to add activities and parts manually.

 

 

 

 

 

WHEEL ALIGNEMENT

Generall
 
Start position for wheel alignment
Check / adjust the front camber
Check / adjust the front toe
Check / adjust the rear camber
Check / adjust the rear toe  
Special tools            

 

   

 

 

 

  

 

 

  • Complete information 
  • Instructions for adjustments
  • Images of adjustements points
  • Tightening torques

 

TYRE SPECIFICATION

  • Specifications of rims and tyres

     

  • Tyre pressures

       205 (A)   Bandbreedte (mm)

        50 (B)  Tyre aspect ratio ( height as percenage of width tyre )

        R    Radial tyre

       16 (C)   Rim diameter (inch)

       94   Load index

        V    Speed index

       XL   Extra load (reinforced tyre)

        1 - 205/50 R16 94V XL

 

TYRE PRESSURE MONITORING SYSTEM

Reset
Reset with multimedia display.
Switch on contact
Select 'SETTINGS VEHICLE'
Select 'RDC'
Select 'Reset' in the menu
Switch off the contact

Reset is required after   tyre pressure check, adjustement or replacement of one or more wheels / tyres.

 

ELEKTRONIC PARKING BRAKE ( EPB )

General

Emergency release

Brake pad replacement Basic settings

Special equipment

 

FUSES AND RELAYS

      

FL1 [SB1]   Alternator ( 175 A )

FL2     Low power / Heating relay /
           Extra air heater ( 40 A )

FL3   Supply voltage of not used ( 110 A )

FL4   Power steering control unit ( 80 A )

FL5   Radiator fan conrol unit thermostat ( 40 A also used ) ( 50 A )

FL6   Glow plug control unit ( 50 A )

FL7 [SB7]   High power heating relay /
      Battery monitoring control unit /       
      Additional air heater ( 60 A )


Relay box engine bay:



R1 Relay, additional extra pump refrigerant
R2 Window wiper relay nr.1
R3 Widows wiper relay nr. 2

 

WARNING LAMPS AND INDICATORS

Specifically per manufacturer with short descriptions and solutions.
Brand specific overview of availabe warning lamps. For European as well as for American car market.

 

 

RECALLS

Contains officile information about reaclls so that vehicles can alsways meet the security demands.    

Functions

  • OEM recalls for security reasons
  • Links towards trouble codes and related cases.


Defect:
Interrupted electrical connection inside the crankshaft position sensor
Number of vehicles affected:
19331

Solution:
Renew the crankshaft position sensor

 

TECHNICAL DRAWINGS

With tightening torques and links towards parts.

 

   

 

 

 

KNOWN PROBLEMS AND SOLUTIONS

The ABS/ESP warning light illuminates


Symptom

The ESP warning light illuminates
Possible fault code: P0571

 

Cause

Incorrect brake light switch adjustment

 

Solution

Incorrect brake light switch adjustment
Solution
Remove the driver's side storage compartment
Check the brake light switch voltage
A diagnostic tool must be used for this operation
If the values are correct
Follow the procedure:
Push the plunger in until it stops
A Turn the knob anti-clockwise to full lock
B Release the plunger

Note: Do not press the brake pedal during the procedure
Turn the knob clockwise to full lock and slot it in

 

 

 

 

 

 

 

 

Refit the driver's side storage compartment
Delete all the fault codes
A diagnostic tool must be used for this operation

 

Repair time

Remove the driver's side storage compartment
Refit the driver's side storage compartment 0.4h(OE: 68 18 19 00)
Check the brake light switch voltage 0.1h(OE: 94 36 05 99)
Delete all the fault codes

 

LOCATION OF COMPONENTS

Thanks to this functions the required components can be located within a blink of an eye.

Available locations:

EOBD CONNECTOR MASS POINTS FUSES AND RELAYS
CONTROL UNITS ENGINE MANAGEMENT HEATING, VENTILATION AND AIR CONDITIONING


ENGINE COMPARTMENT

E1  Engine control unit
       Engine compartment, left side
E3 ( semi- ) automatic transmission control unit
        On the gearbox
E8 Glowplug control unit
      Engine compartment, rear side in the middle
E11 ESP control unit
        Engine compartment, left side
E13   Power steering control unit
          On steering house 
E14   NOx control unit
          Engine compartment, left side
E24   Transmission control unit
          On gearbox

PASSENGER AND LUGGAGE COMPARTMENT

 

ELEKTRICAL WIRING DIAGRAMS

Electrical wiring diagrams for electrical systems and components such as central locking, electrical windows, window wipers and washers, electrical windows and head lamps, airbags, exterior lights and starting and charging systems.

Electrical windows

Components:
D11 Power window switch pack
D12 Power windows switch pack rear
E6  Power control unit
E21 Comfort system control unit
E154 Front left door control unit
E155 Front right control unit
E156 Rear left door control unit
E157 Rear right door control unit
S144 Front right power window switch
S145 Rear left power window switch
S146 Rear right power window switch
S152 Passenger power window isolation switch

 

COMPONENT DIAGNOSIS

A unique system of guided diagnostics based on the CANBUS data of the vehicle in order to sort out problems and malfunctions of components. It reduces the rather complicatied manufacturer wiring diagrams to a diagrams that is much more comprehensable and clear and zooms in the the specific component of wire.



Diagnosis 1/12

1: Check feeding:
                                  Switch on the contact. Measure the voltage on pin A 5. Is it bewteen 12 and 14.4 V?    Yes  No
2: Check connection to mass:
3: Check connectivity of pin A 10.
4: Check feeding::
5: Check connection to mass:
6: Check connectivity of pin A 44.
7: Check feeding voltage:
8: Check connectivity of pin A 56.
9: Check feeding voltage:
10: Check connectivity of pin A 70.
11: Check connectivity of pin A 80.
12: Check connectivity of pin A 87.

 

Pin number Wire color  Component   Pinnumber Wire color
A 1   Brown E1 Engine control unit A 2 Brown
A 1   Brown  G3 Clutch position sensor 1 Brown

                  
                               

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