The following checks refer to 1.6 litre petrol engine (1587cc), 1.8 litre petrol engine (1749cc), 2.0 litre high pressure diesel injection engine (1997cc).

 

Vehicle:

Petrol engine models

Complaint:

Engine oil and filter need renewing.

Remedy:

1.      Ensure engine oil is warm when draining, this allows the oil to drain better as well as removing all contamination.

2.      Take off the engine undertray, place a draining tray under the drain plug, and remove the plug completely.

3.      Once all the oil has cleared clean the drain plug with a cloth and fit a new sealing washer.

4.      Clean the drain plug area; replace the plug fitting it securely.

5.      Place the draining container under the oil filter.

6.      Early 1.6 and 1.8 litre engines have a disposable metal canister oil filter, therefore go to point 7. Later 1.6 litre engines have a disposable paper element within a plastic housing therefore go to point 8.

7.       

·        Firstly slacken the filter using a filter tool if necessary, and then unscrew it manually.

·        Pour the oil from the filter into the container; puncture the dome in two places to ensure all the oil has drained.

·        Remove all oil and dirt from the filter sealing area on the engine. Remove the rubber sealing ring from the engine if it has stuck.

·        Place a light coating of clean engine oil to the sealing ring on the new filter, and place in position manually.

8.

  • Firstly slacken the filter using a tool if necessary, then unscrew it manually. Notice the plunger tube which is inside the housing is lifted, allowing the oil to drain back to the sump.
  • Lift the filter cover off the housing and take off the paper element, also take the plunger tube out of the oil filter cover.
  • Remove all oil and dirt from the oil filter housing, and clean the filter cover thoroughly using appropriate solvent.
  • Put the new oil filter on the filter housing, and place the new plunger tube into position. Place a light coating of clean engine oil on the seal of the filter cover and the O-ring on the end of the plunger tube. Place filter cover onto housing tightening to correct torque.

9. Ensure engine undertray is replaced correctly.

10. Take out the dipstick, and half fill the engine with the correct oil, wait a few minutes in order to allow the oil to settle, then continue to fill until the dipstick measures correctly.

11. Check there are no leaks in the oil filter seal and the sump drain plug by running the engine for a few minutes.

12. Turn off the engine and again wait for a few minutes, then recheck the level on the dipstick, add more oil if needed.

 

Vehicle:

Petrol engine models

Complaint:

There is a hose fluid leak

Remedy:

  1. Ensure the radiator and heater coolant hoses are in good condition. Renew the hoses that are showing signs of damage such as cracks, or swelling.
  2. Check the clips that hold the hoses to the cooling system component as they can cause punctures if tightened too much.
  3. If there are any leaks found on any part of the cooling system components such as the hoses, then replace the component or gasket.

 

Vehicle:

Petrol engine models

Complaint:

There is a fuel leak

Remedy:

While it is difficult to establish where a fuel leak is coming from it may be easier to identify after the engine has been left to cool over night.

  1. Turn on engine with bonnet open.
  2. Check all connections between fuel lines and the fuel rail, also between the fuel pressure regulator and fuel filter.
  3. Check each rubber fuel hose for splits and cracks especially for leaks from the crimped joints which are located between the rubber and metal fuel lines.
  4. Ensure the connections on the metal fuel lines are functioning well.
  5. Look at the fuel injectors to ensure there are no leaks around the O-ring.
  6. When looking for leaks in the area between the fuel tank and the engine bay ensure the vehicle is raised, then ensure there are no punctures, damage or cracks in the petrol tank, or the filler neck.
  7. Some lines and hoses can become tangled or looped, this can create a variety of problems including loose connections, kinks in the lines and deterioration of the hoses.
  8. Replace any damaged sections of hose or line.

 

Vehicle:

Petrol engine models

Complaint:

There is engine oil leaking from the base of the timing belt cover or the transmission bellhousing.

Remedy:

These leaks indicate that the crankshaft or transmission input have a shaft oil seal failure, therefore:

Replace the ineffective gasket or oil seal.

 

Vehicle:

Petrol engine models

Complaint:

There is a leak from the power steering fluid

Remedy:

1.      Ensure the feed and return hoses and pipes that lie between the power steering pump and the steering rack are not damaged, looped or kinked.

2.      Ensure the area of pipe that uses clips to secure has not been damaged by the clips.

3.      Replace any damaged hoses or pipes.

 

Vehicle:

Petrol engine models

Complaint:

There is a loss of hydraulic fluid.

Remedy:

1.      Check for any signs of leakage from the brake pipe unions at the master cylinder.

2.      Ensure there are no leaks around the area by the base of fluid reservoir, which will be caused by seal failure.

3.      Ensure there are no leaks at the brake pipe unions at the ABS hydraulic unit.

4.      Next if there is a loss of fluid, however the leak cannot be identified in the engine bay then check the wheel cylinders, the brake callipers and underbody brake lines.

5.      When the leak has been identified, renew the damaged area immediately.

6.      On vehicles which have a hydraulically-operated clutch, ensure the clutch hydraulic pipes and connections at the master and slave cylinders are working correctly.

 

Vehicle:

Petrol engine models

Complaint:

There is an unidentified fluid leak.

Remedy:

Leave the car overnight with a large piece of card placed underneath. Provided the card is placed in the correct position the leaking fluid will land on the card showing the colour of the fluid as well as the location the leak is coming from.

If no leak shows then repeat the above with the engine running (though not overnight).

 

Vehicle:

Petrol engine models

Complaint:

There is a reduction in the effectiveness of the brakes.

Remedy:

This could be due to a leak in the medium-bore plastic hose which transports the vacuum to the servo. Therefore, check this hose for any leaks and replace any damaged hoses.

In order to identify a leak in a vacuum hose take an old length of vacuum hose, hold one end close to your ear, and use the other end to look in the suspected leak area. If a leak is present a distinct hissing sound will be heard. This is due to a defective hose drawing air in rather than letting it out. Replace any damaged vacuum hoses.

 

Vehicle:

Petrol engine models

Complaint:

The auxiliary drivebelt is damaged or needs tightening.

Remedy:

1.      Lift the front of the vehicle, and remove the right-hand front road wheel, and the centre section of the wheel arch plastic liner. The plastic liner is held with clips which need to be removed with a forked tool.

2.      Fit a socket and extension bar to the crankshaft pulley bolt then rotate the crankshaft in order to examine the entire drive-belt.

3.      Check the drive-belt for any damage such as cracks, splits or fraying. Also check there are no shiny patches, and the belt plies have not separated. If any of the above is found then replace the drive-belt.

4.      Ensure the drive-belt  has the correct tension. If the engine has an automatic spring-loaded tensioner then there is no need to check the tension of the drive-belt. If the drive-belt has a manual adjuster then proceed to step 5. If the drive-belt has an automatic adjuster then proceed to step 6.

5.      Remove the drive-belt from the pulley by loosening the tensioner pulley retaining nut. Fit the new drive-belt around the pulley ensuring all ribs are correctly fitted into the grooves. To ensure the correct tension there should be 5.0 mm of free movement mid-point between the pulleys on the longest belt run. Adjust the tension by rotating the pulley until the desired tension is achieved, then while holding this position tighten the retaining nut. Rotate the crankshaft through four complete turns in the normal direction of rotation and recheck the tension. If necessary readjust and repeat the rotations. Clip the coolant hoses into position, and refit the road wheel.

6.      Suitable for 1.6 litre engines:

The tensioner pulley needs to be moved away from the drive-belt using a ratchet handle or extension bar. When the tensioner has been loosened a hole will be exposed, place a 6.0 mm Allen key in this hole. Then take the drive-belt off the engine, and replace with the new drive-belt. Ensure that all ribs are correctly fitted into the grooves. Take the load from the tensioner arm and remove the Allen key. Release the tensioner arm, it will then automatically tension the belt. Clip the coolant hoses into position and refit the wheel arch liner and the road wheel.

 

Suitable for 1.8 litre engines:

Remove the drive-belt by rotating the tensioner pulley anti-clockwise, this will require a spanner on the tensioner pulley retaining bolt. Fit the new drive-belt ensuring that all ribs are correctly fitted into the grooves. Rotate the tensioner pulley anti-clockwise hold it in this position, and slide the belt around it, release the tensioner arm and it will then automatically tension the belt. Clip the coolant hoses into position and refit the wheel arch liner and the road wheel.

 

Vehicle:

Petrol engine models

Complaint:

The clutch is difficult to move, or seems to slip or drag.

Remedy:

Ensure the clutch cable is routed correctly. If not then route correctly.

Ensure the clutch cable is showing no signs of damage. If signs of damage are identified then replace the clutch cable.

Remove the pedal and make sure it has sufficient grease, if not rectify and replace the pedal.

 

Vehicle:

Petrol engine models

Complaint:

There are problems with the drive-shaft.

Remedy:

1.      Ensure the vehicle is raised, and the steering is on full lock. Slowly rotate the road wheel and check the outer CV joint rubber gaiters for any cracks, splits or general damage to the rubber. If any damage is found then replace the gaiters.

2.      Ensure the retaining clips are secure and are in good condition, if not then replace.

3.      Repeat the above checks for the inner CV joint rubber gaiters.

4.      Also ensure the CV joints are in good condition by holding the driveshaft and try to move the wheel. Then hold the inner joint and try to move the driveshaft. If any movement is noticed this will suggest wear in the joints, driveshaft splines, or a loose driveshaft retaining nut, therefore check these areas and replace them if necessary.

 

Vehicle:

Petrol engine models

Complaint:

There are problems with the steering or suspension.

Remedy:

1.      Ensure the vehicle is raised and supported, and remove the engine undertray.

2.      Ensure there are no splits, chafing, or signs of damage on the ball joint dust covers as well as the steering rack-and-pinion gaiters.  If there are any signs then replace any damaged areas.

3.      Ensure the power steering hoses have no chafing or signs of damage. The pipe and hose unions could have leaks and therefore will need changing. When put under pressure from the steering gear rubber gaiters, if there are fluid leaks this could suggest the fluid seals within the steering gear have failed, and will therefore need renewing.

4.      Wear in the suspension joints or mountings can be identified through the following checks:

·        Hold the road wheel at the 12 0’clock and 6 0’clock positions and attempt to rock it. If a significant movement is felt then continue to rock the wheel while someone else presses down the footbrake. If this stops the movement then the hub bearings will need changing, if the movement continues the suspension joints or mountings will need changing.

5.      Hold the wheel at the 9 0’clock and 3 0’clock positions, and attempt to rock it again. If significant movement is felt the hub bearings, and steering track rod ball joints  are worn, and will need renewing.

6.      Ensure there is no wear in the suspension mounting bushes by levering between the relevant suspension component and the join using a large screwdriver. Also ensure there are no splits, cracks or contamination of the rubber, if so then replace any damaged components.

7.      Ensure there is no movement lost between the steering wheel and the road wheels, if so then check the joints and mountings as well as the steering column universal joints and the rack-and-pinion steering gear. If there are any signs of deterioration then replace the necessary components.

8.      In order to establish a cause in the loss of suspension, then check the suspension strut and/or shock absorber body for any fluid leaks, also check there are no leaks from the rubber gaiter around the piston rod. If any leaks are detected then replace the suspension strut and/or the shock absorber.

 

Vehicle:

Petrol engine models

Condition:

There is a problem with the brakes.

Remedy:

1.      Ensure the vehicle is raised and supported, and the handbrake is on.

2.      Check the thickness of the brake pad friction material. If they are at the minimum thickness or less, all four brake pads must be replaced.

3.      If they are at the required thickness then remove and clean the pads, and examine the brake disc. If any discrepancies are noticed then replace the brake disc.

4.      The brake shoes must also be checked. The thickness of the friction material left on one of the brake shoes must measure to the specified minimum thickness. This can be measured by exposing the slot in the brake back plate through prising out its sealing grommet.

5.      When a rod of the same diameter of the minimum thickness is placed against the shoe thickness material the amount of wear can be measured. If they measure minimum thickness or less then all four brake shoes must be replaced.

6.      It is also necessary to remove, examine and clean the brake drums.

 

Vehicle:

Petrol engine model

Condition:

There is a problem with the exhaust system.

Remedy:

1.      Ensure the vehicle is raised and supported, and the engine has been switched off for at least an hour prior to checks.

2.      Visually examine the entire exhaust system checking for signs of leaks, corrosion, and damage. If any part shows any signs of the above then replace that component.

3.      Ensure the brackets and mountings are fixed securely with tight bolts and are showing no signs of damage. If any section is easily moving, or any of the mountings are showing signs of damage or leaks then replace the necessary components. If any section comes into contact with the body or suspension parts then twist the pipes in order to give them clearance, thereby eliminating the noise.

 

 Vehicle:

Petrol engine model

Condition:

Spark plugs need replacing

Remedy:

1.      Take out the ignition coil module unit.

2.      Remove dirt using a clean brush or a vacuum cleaner focusing on the spark plug recesses before removing the spark plugs.

3.      Unscrew the spark plugs using a suitable tool such as a spark plug spanner, and ensure the socket is aligned with the spark plug. The ceramic insulator may be broken if it has been moved to one side.

4.      When the spark plugs have been removed it is advisable to check them, as they are an indication of the state of the engine. Therefore when the spark plug is removed then inspect the insulator nose, if it is clean and white with no deposits it indicates a weak mixture or too hot a plug.

5.      If hard black looking deposits are noticeable on the tip and insulator nose it indicates a rich mixture, in addition if the plug is black and oily it indicates the engine is quite worn.

6.      If light tan to greyish-brown deposits are noticeable on the insulator nose this indicates the mixture is at the correct level and the engine is in good condition.

7.      Ensure the spark plug electrode gap is a correct size. If it is not then bend open or closed the outer plug electrode(s) until the correct measurement is achieved. Do not bend the centre electrode, this can crack the insulator and cause plug failure.

8.      Before replacing the spark plugs ensure the threaded connector sleeves are tight and the plug exterior and threads are clean.

9.      Tighten the plug to the required torque using the spark plug socket as well as a torque wrench.

10.  Refit the ignition coil module unit.

 

Vehicle:

Petrol engine model

Complaint:

The air filter needs renewing

Remedy:

1.      Take out the screws that hold the lid of the air filter housing down, and take out the air filter element.

2.      Clean the inside of the filter housing and fit the new element.

3.      Replace the air filter lid in position and secure with the screws.

 

Vehicle:

Petrol engine model

Complaint:

The transmission oil level needs checking and/or changing

Remedy:

1.      Ensure the engine has been switched off for at least 5 minutes to ensure an accurate oil reading.

2.      Ensure the vehicle is raised and supported with the handbrake on.

3.      Remove the left hand road wheel, remove the plastic clips that secure the left hand wheel arch plastic liner into place and remove the liner.

4.      Clean the area around the filler/level plug, then unscrew it and clean it. Throw away the sealing washer.

5.      When the plug is removed a certain amount of oil will trickle out. The correct level of oil is indicated by the oil level reaching the lower edge of the filler/level hole. Add oil until a trickle of new oil can be seen, the desired level is reached when the flow of oil stops. It is imperative the car is completely level during this procedure in order for a correct level to be taken.

6.      When the correct level is achieved place a new sealing washer to the filler/level plug.

7.      Refit the plug and tighten it to the required torque. Refit the wheel arch liner and the road wheel ensuring all bolts are tightened to the specific torque.

 

Vehicle:

Petrol engine model

Complaint:

The fuel filter needs replacing

Remedy:

1.      Ensure the vehicle is raised and supported.

2.      Seal too and from fuel hoses using correct hose clamps with rounded jaws.

3.      Unclip the filter retaining strap from the fuel tank. Undo the quick-release fittings and disconnect the fuel hoses from the filter.

4.      Take the filter from the car and dispose of it safely.

5.      Place the new filter into place and clip the filter strap back onto the fuel tank.

6.      Connect the fuel hoses to the filter by snapping them into position, and remove the hose clamps.

7.      Start the engine and look out for any leaks. If all is working correctly then lower to the vehicle. If any leaks are identified then repeat installation from step 1.

 

Vehicle:

Petrol engine model

Complaint:

The cooling system needs draining.

Remedy:

1.      Ensure the engine is cold, preferably been left over night.

2.      Turn the cap slowly until all the pressure is released, and then take the cap off.

3.      Ensure the handbrake is fully on. Raise and support the vehicle. Take off the engine under tray.

4.      Underneath the bottom hose connection on the radiator place a draining container. Undo the retaining clip, disconnect the hose and drain the coolant. DO NOT ALLOW TO COME INTO CONTACT WITH SKIN.

5.      If extra is needed to help the coolant drain then open the cooling system bleed screws in the heater matrix outlet hose union on the engine compartment  bulkhead, and on the coolant outlet housing on the left-hand end of the cylinder head.

6.      When this is completed also drain the cylinder block. Firstly place the draining container under the drain plug. This is found at the front left hand side of the cylinder block in 1.6 litre engines, and for 1.8 litre engines they are located at the rear left hand side of the cylinder block. Remove the drain plug and drain the coolant.

7.      Once the coolant has drained refit the radiator bottom hose and cylinder block drain plugs. Replace any removed components, replace the engine under tray and lower the vehicle.

 

Vehicle:

Petrol engine model

Complaint:

The cooling system has lost efficiency.

Remedy:

The cooling system needs flushing especially if passages have rust, scale and other sediment deposits in them. Therefore complete the following procedure:

1.      Disconnect the top and bottom hoses from the radiator.

2.      Place a garden hose in the top of the radiator inlet.

3.      Flush the water through the radiator until clean water comes from the bottom of the radiator.

4.      If the radiator water does not run clean then a cleaning product suitable for cleaning radiators that are plastic or aluminium can be used, following instructions carefully.

5.      It may also be necessary to flush the engine.

6.      Tighten the cooling system bleed screws, and remove the thermostat. Put back the thermostat cover without the thermostat.

7.      Disconnect the top and bottom hoses from the radiator.

8.      Place a garden hose in the top of the radiator inlet.

9.      Flush the water through the radiator until clean water comes from the radiator bottom hose.

10.  Refit the thermostat, and reconnect the hoses.

 

Vehicle:

Petrol engine model

Complaint:

The cooling system needs refilling

Remedy:

1.      Ensure all hoses are in good condition as well as the connecting clips. If not then replace these before completing the next steps.

2.      Remove the expansion tank filler cap and open all the cooling system bleed screws.

3.      A header tank must be used when refilling, to achieve this cut the bottom off an old antifreeze container, the seal (the neck of the bottle) must create an airtight seal.

4.      Place the header tank into the expansion tank and slowly fill the system.

5.      Watch the bleed screws as coolant will emerge from the bottom up. As soon as the coolant coming from each of the bleed screws is clear from air bubbles then tighten that screw.

6.      Ensure the header tank has at least 0.5 litres of coolant in it, and start the engine running at a fast idle speed (not exceeding 2000rpm).

7.      When the cooling fan cuts in and out three times stop the engine.

8.      As soon as the engine has cooled remove the header tank. Check the coolant level (see previous point), and top up if necessary, then refit the expansion tank cap.

 

Vehicle:

Petrol engine model

Complaint:

The antifreeze needs replacing

Remedy:

1.      Ensure the antifreeze being used is an ethylene-glycol base suitable for use in mixed-metal cooling systems.

2.      The cooling system must be drained, flushed prior to replacing antifreeze.

3.      Fill with antifreeze, then label the expansion tank with type and concentration used, so that other top-ups can use the same type and concentration.

 

Vehicle:

Diesel engine model

Complaint:

Engine oil and filter need renewing.

Remedy:

1.      Ensure engine oil is warm when draining, this allows the oil to drain better as well as removing all contamination.

2.      Raise the vehicle, ensuring it is completely level.

3.      Take off the engine undertray, place a draining tray under the sump drain plug, and remove the plug completely.

4.      Once all the oil has cleared clean the drain plug with a cloth and fit a new sealing washer.

5.      Clean the drain plug area, replace the plug fitting it securely.

6.      Place the draining container under the oil filter which is found on the front facing side of the cylinder block..

7.      Take off the four plastic fasteners and lift off the engine cover.

8.      Firstly slacken the filter using a filter tool if necessary, then unscrew it manually.

9.      Pour the oil from the filter into the container, puncture the filter dome in two places to ensure all the oil has drained.

10.  Remove all oil and dirt from the filter sealing area on the engine. Remove the rubber sealing ring from the engine if it has stuck.

11.  Place a light coating of clean engine oil to the sealing ring on the new filter, and place in position manually.

12.  Ensure engine undertray is replaced correctly.

13.  Take out the dipstick, and half fill the engine with the correct oil, wait a few minutes in order to allow the oil to settle, then continue to fill until the dipstick measures correctly. Replace the filler cap.

14.  Check there are no leaks in the oil filter seal and the sump drain plug by running the engine for a few minutes.

15.  Turn off the engine and again wait for a few minutes, then recheck the level on the dipstick, add more oil if needed.

16.  Replace the engine cover and secure with four fasteners.

 

Vehicle:

Diesel engine model

Complaint:

The fuel filter water needs draining.

Remedy:

1.      Take off the four plastic fasteners, and remove the engine cover from the top of the engine.

2.      Ensure the handbrake is fully on and raised the vehicle ensuring it is properly supported.

3.      Take off the engine under tray.

4.      Ensure a suitable draining container is placed under the fuel filter housing located at the front of the engine.

5.      Open the drain tap at the bottom of the filter, and drain the fuel and water. Keep going until fuel is draining without any water. Close the drain tap securely.

6.      Replace the engine under tray, refit the engine cover, and start the engine.

 

Vehicle:

Diesel engine models

Complaint:

There is a hose fluid leak

Remedy:

1.      Remove the four plastic fasteners, and remove the engine cover from the top of the engine.

2.      Ensure the radiator and heater coolant hoses are in good condition. Replace the hoses that are showing signs of damage such as cracks, or swelling.

3.      Check the clips that hold the hoses to the cooling system component as they can cause punctures if tightened too much.

4.      If there are any leaks found on any part of the cooling system components such as the hoses, then replace the component or gasket.

 

Vehicle:

Diesel engine models

Complaint:

There is a diesel leak

Remedy:

While it is easier to establish where a diesel leak is coming from, as it will settle on the surface around the point of leakage, it may still be easier to identify after the engine has been left to cool over night.

1.      Turn on engine with bonnet open.

2.      Check all connections to the high pressure fuel pump and the fuel filter.

3.      Check each rubber fuel hose for splits and cracks especially for leaks from the crimped joints which are located between the rubber and metal fuel lines.

4.      Ensure the fuel tank and filler neck have no punctures, cracks or similar damage. Also make sure the connections are functioning well.

5.      Some lines and hoses can become tangled or looped, this can create a variety of problems including loose connections, kinks in the lines and deterioration of the hoses. Especially the vent pipes and hoses.

6.      Replace any damaged sections of hose or line.

 

Vehicle:

Diesel engine models

Complaint:

There is engine oil leaking from the base of the timing belt cover or the transmission bell housing.

Remedy:

These leaks indicate that the crankshaft or transmission input have a shaft oil seal failure, therefore:

Replace the ineffective gasket or oil seal.

 

Vehicle:

Diesel engine models

Complaint:

There is a leak from the power steering fluid

Remedy:

1.      Ensure the feed and return hoses and pipes that lie between the power steering pump and the steering rack are not damaged, looped or kinked.

2.      Ensure the area of pipe that uses clips to secure has not been damaged by the clips.

3.      Replace any damaged hoses or pipes.

 

Vehicle:

Diesel engine models

Complaint:

There is a loss of hydraulic fluid.

Remedy:

1.      Check for any signs of leakage from the brake pipe unions at the master cylinder.

2.      Ensure there are no leaks around the area by the base of fluid reservoir, which will be caused by seal failure.

3.      Ensure there are no leaks at the brake pipe unions at the ABS hydraulic unit.

4.      Next, if there is a loss of fluid, however the leak cannot be identified in the engine bay then check the wheel cylinders, the brake callipers and the under body brake lines.

5.      When the leak has been identified, renew the damaged area immediately.

6.      On vehicles which have a hydraulically-operated clutch, ensure the clutch hydraulic pipes and connections at the master and slave cylinders are working correctly.

Vehicle:

Diesel engine models

Complaint:

There is an unidentified fluid leak.

Remedy:

Leave the car overnight with a large piece of card placed underneath. Provided the card is placed in the correct position the leaking fluid will land on the card showing the colour of the fluid as well as the location the leak is coming from.

If no leak shows then repeat the above with the engine running (though not overnight).

 

Vehicle:

Diesel engine models

Complaint:

There is a reduction in the effectiveness of the brakes.

Remedy:

This could be due to a leak in the medium-bore plastic hose which transports the vacuum to the servo. Therefore, check this hose for any leaks and replace any damaged hoses.

In order to identify a leak in a vacuum hose take an old length of vacuum hose, hold one end close to your ear, and use the other end to look in the suspected leak area. If a leak is present a distinct hissing sound will be heard. This is due to a defective hose drawing air in rather than letting it out. Replace any damaged vacuum hoses.

 

Vehicle:

Diesel engine models

Complaint:

The auxiliary drivebelt is damaged or needs tightening.

Remedy:

1.      Lift the front of the vehicle, and remove the right-hand front road wheel, and the centre section of the wheel arch plastic liner. The plastic liner is held with clips which need to be removed with a forked tool.

2.      Fit a socket and extension bar to the crankshaft pulley bolt then rotate the crankshaft in order to examine the entire drive-belt.

3.      Check the drive-belt for any damage such as cracks, splits or fraying. Also check there are no shiny patches, and the belt plies have not separated. If any of the above is found then replace the drive-belt.

4.      Using a hexagonal spanner in the hexagonal stud found in the centre of the automatic tensioner pulley. Move the pulley to the back of the vehicle in order to release the tension and take it off the pulleys.

5.      When the tensioner has been loosened a hole will be exposed, place a 4.0 mm bolt or bar in this hole.

6.      Slacken the retainer bolt which is found in the middle of the eccentric tensioner pulley.

7.      Place the new belt around the pulleys and make sure that all ribs are correctly fitted into the grooves.

8.      Next, turn the eccentric tensioner pulley which will cause tension on the drive belt, continue turning until the load is released from the locking tool in the automatic tensioner. Then tighten the retaining bolt to the specific torque without moving the position of the eccentric tensioner pulley.

9.      Take the locking tool from the automatic tensioner and turn the crankshaft four complete revolutions.

10.  The holes of the automatic adjuster and the mounting bracket should still be in line. Insert a 2.0mm diameter setting tool through both holes, if this is difficult then release the tension on the eccentric tensioner pulley retaining bolt and repeat points 8 – 10.

11.   Place the coolant hoses back, refit the wheel arch liner and road wheel.

 

 Vehicle:

Diesel engine models

Complaint:

The clutch is difficult to move, or seems to slip or drag.

Remedy:

Ensure the clutch cable is routed correctly. If not then route correctly.

Ensure the clutch cable is showing no signs of damage. If signs of damage are identified then replace the clutch cable.

Remove the pedal and make sure it has sufficient grease, if not rectify and replace the pedal.

 

Vehicle:

Diesel engine models

Complaint:

There are problems with the drive-shaft.

Remedy:

1.      Ensure the vehicle is raised, and the steering is on full lock. Slowly rotate the road wheel and check the outer CV joint rubber gaiters for any cracks, splits or general damage to the rubber. If any damage is found then replace the gaiters.

2.      Ensure the retaining clips are secure and are in good condition, if not then replace.

3.      Repeat the above checks for the inner CV joint rubber gaiters.

4.      Also ensure the CV joints are in good condition by holding the driveshaft and try to move the wheel. Then hold the inner joint and try to move the driveshaft. If any movement is noticed this will suggest wear in the joints, driveshaft splines, or a loose driveshaft retaining nut, therefore check these areas and replace them if necessary.

 

Vehicle:

Diesel engine models

Complaint:

There are problems with the steering or suspension.

Remedy:

1.      Ensure the handbrake is fully on, and the vehicle is raised and supported, and remove the engine undertray.

2.      Ensure there are no splits, chafing, or signs of damage on the ball joint dust covers as well as the steering rack-and-pinion gaiters.  If there any signs of damage are noticed then replace any damaged areas.

3.      Ensure the power steering fluid hoses have no chafing or signs of damage. The pipe and hose unions could have leaks and therefore will need changing. When put under pressure from the steering gear rubber gaiters, if there are fluid leaks this could suggest the fluid seals within the steering gear have failed, and will therefore need renewing.

4.      Wear in the suspension joints or mountings can be identified through the following checks:

·        Hold the road wheel at the 12 0’clock and 6 0’clock positions and attempt to rock it. If a significant movement is felt then continue to rock the wheel while someone else presses down the footbrake. If this stops the movement then the hub bearings will need changing, if the movement continues the suspension joints or mountings will need changing.

5.      Hold the wheel at the 9 0’clock and 3 0’clock positions, and attempt to rock it again. If significant movement is felt the hub bearings, and steering track rod ball joints  are worn, and will need renewing.

6.      Ensure there is no wear in the suspension mounting bushes by levering between the relevant suspension component and the join using a large screwdriver. Also ensure there are no splits, cracks or contamination of the rubber, if so then replace any damaged components.

7.      Ensure there is no movement lost between the steering wheel and the road wheels, if so then check the joints and mountings as well as the steering column universal joints and the rack-and-pinion steering gear. If there are any signs of deterioration then replace the necessary components.

In order to establish a cause in the loss of suspension, then check the suspension strut and/or shock absorber body for any fluid leaks, also check there are no leaks from the rubber gaiter around the piston rod. If any leaks are detected then replace the suspension strut and/or the shock absorber.

 

Vehicle:

Diesel engine models

Condition:

There is a problem with the brakes.

Remedy:

1.      Ensure the vehicle is raised and supported, and the handbrake is on. Then remove the front road wheels.

2.      Check the thickness of the brake pad friction material. If they are at the minimum thickness or less, all four brake pads must be replaced.

3.      If they are at the required thickness then remove and clean the pads, and examine the brake disc. If any discrepancies are noticed then replace the brake disc.

4.      The brake shoes must also be checked. The thickness of the friction material left on one of the brake shoes must measure to the specified minimum thickness. This can be measured by exposing the slot in the brake back plate through prising out its sealing grommet.

5.      When a rod of the same diameter of the minimum thickness is placed against the shoe thickness material the amount of wear can be measured. If they measure minimum thickness or less then all four brake shoes must be replaced.

6.      It is also necessary to remove, examine and clean the brake drums.

 

Vehicle:

Diesel engine model

Condition:

There is a problem with the exhaust system.

Remedy:

1.      Ensure the vehicle is raised and supported, and the engine has been switched off for at least an hour prior to checks.

2.      Visually examine the entire exhaust system checking for signs of leaks, corrosion, and damage. If any part shows any signs of the above then replace that component.

3.      Ensure the brackets and mountings are fixed securely with tight bolts and are showing no signs of damage. If any section is easily moving, or any of the mountings are showing signs of damage or leaks then replace the necessary components. If any section comes into contact with the body or suspension parts then twist the pipes in order to give them clearance, thereby eliminating the noise.

 

Vehicle:

Diesel engine model

Condition:

The brake fluid needs replacing.

Remedy:

1.      The brake fluid must be emptied through siphoning the master cylinder reservoir, using a clean poultry baster.

2.      Put in new fluid until the max is reached, but continue pumping until all the old oil has been removed, and only new oil has been left. This can be observed by looking at the loosened bleed screws, when only new oil comes through then tighten that screw, until all screws have been tightened.

3.      Ensure that the master cylinder reservoir remains topped up above the danger sign at all times to prevent air in the system.

4.      Replace all dust caps, and remove all traces of spilt fluid.

5.      Ensure the brakes are functioning correctly before taking it onto the road.

 

 Vehicle:

Diesel engine model

Complaint:

The fuel filter needs replacing

Remedy:

For the earlier type filter assembly-it has no electrical connector on the filter housing cover.

1.      Ensure the vehicle is raised and supported, and the handbrake is fully on.

2.      Take off the engine cover from the top of the engine.

3.      The fuel filter is at the front of the engine.

4.      Clean the outside of the filter housing especially the fuel hose unions and the area around the cover to housing joint.

5.      Place a draining container under the fuel filter drain outlet, and open the drain screw, drain the oil completely, when all the oil has drained tighten the drain screw.

6.       Disconnect the fuel supply and return hose quick release fittings. Cover the open hose unions to stop dirt entering.

7.      Using an hexagonal socket on the hexagonal moulding on the filter housing cover, turn the cover quarter of a turn to release the locking lugs.

8.      Taking off the housing cover, collect the metal sealing ring and the O-ring seal, and lift out the filter element.

9.      Remove all traces of dirt, and fit the new fuel filter element.

10.  Ensure the O-ring is in the correct position, and the metal sealing ring.

11.  Replace the housing cover, and turn until it is back in line with the filter drain outlet.

12.  Connect the fuel supply, and hoses. Turn on the engine and watch for any leaks.

13.  If there are no leaks then replace the engine cover and engine under tray.

 

In order to fit the later type filter assembly, which can be identified by an electrical connector on the filter housing cover, then use the following instructions.

 

1.      Ensure the vehicle is raised and supported, and the handbrake is fully on.

2.      Take off the engine cover from the top of the engine.

3.      The fuel filter is at the front of the engine.

4.      Clean the outside of the filter housing especially the fuel hose unions and the area around the cover to housing joint.

5.      Disconnect the fuel hose quick-release fittings, which are located at the connections on the filter housing cover. Release the locking clip, and then cover the open hose unions to stop dirt entering.

6.      Detach the wiring connector from the fuel heating element, and unscrew the locking ring, which holds the filter housing cover to the filter housing.

7.      Take off the housing cover and take out the filter element, ensuring all seals are removed.

8.      Clean all dirt from the inside of the filter housing, and fit the new fuel filter element.

9.      Put in the new seals and replace the housing cover.

10.  Screw the locking ring onto the housing and tighten it, reconnect all fuel hoses and then start the engine, visually checking for any leaks.

11.  If no leaks are present, replace the engine cover and under tray.

 

Vehicle:

Diesel engine model

Complaint:

The air filter needs renewing

Remedy:

1.      Detach the wiring connector from the underside of the air mass meter.

2.      Next, loosen the hose clip that holds the air mass meter inlet duct to the filter housing lid.

3.      Take out the screws that hold the lid of the air filter housing down, disconnect the air mass meter inlet duct and take out the air filter element.

4.      Clean the inside of the filter housing and fit the new element.

5.      Replace the air filter lid in position, tighten the hose clip and secure it all with the screws.

6.      Connect the air mass meter wiring connector.

 

Vehicle:

Diesel engine model

Complaint:

The transmission oil level needs checking and/or changing

Remedy:

1.      Ensure the engine has been switched off for at least 5 minutes to ensure an accurate oil reading.

2.      Ensure the vehicle is raised, supported and level with the handbrake on.

3.      Remove the left hand road wheel, remove the plastic clips that secure the left hand wheel arch plastic liner into place and remove the liner.

4.      Clean the area around the filler/level plug, then unscrew it and clean it. Throw away the sealing washer.

5.      When the plug is removed a certain amount of oil will trickle out. The correct level of oil is indicated by the oil level reaching the lower edge of the filler/level hole. Add oil until a trickle of new oil can be seen, the desired level is reached when the flow of oil stops. It is imperative the car is completely level during this procedure in order for a correct level to be taken.

6.      When the correct level is achieved place a new sealing washer to the filler/level plug.

7.      Refit the plug and tighten it to the required torque. Refit the wheel arch liner and the road wheel ensuring all bolts are tightened to the specific torque.

 

Vehicle:

Diesel engine model

Complaint:

There is a problem with the front and back brakes

Remedy:

1.      Ensure the vehicle is raised and supported with the handbrake on.

2.      Visually check the brake calliper area for any signs of  leaks from the piston seals, the brake pipe union or the bleed screw.

3.      Ensure the hoses are in good condition with no signs of damage. If so then replace the damaged hose.

4.      When the transmission is in neutral hold each front wheel hub and turn it by hand. If this proves difficult then the brake pads are binding usually because of a seized or half seized brake calliper piston. Therefore the callipers will need replacing and overhauling.

5.      Take out the front brake pads and ensure the friction material is at the correct level. If it is below the required amount all four brake pads will need replacing.

6.      Clean the brake callipers with a recommended brake cleaning fluid. Ensure the piston dust seal is in good condition and is sitting in the correct place.

7.      Ensure the brake disc is in good condition.

8.      Replace the front brake pads, and the road wheels and tighten the road wheel bolts to the correct torque.

9.      To check the rear brakes then ensure the vehicle is raised at the rear, and supported. Release the handbrake.

10.  Hold each rear road wheel and turn it by hand. If this proves difficult it can indicate a seized or half seized wheel cylinder, or possibly an incorrect handbrake adjustment.

11.  Take off the rear road wheels, and the rear brake shoes. Check they have the correct level of friction material, if not then replace all four brake shoes.

12.  Ensure the brake drums are in good condition and there are no leaks from the wheel cylinder piston seals. Also visually check there are no leaks from the brake pipe union or bleed screw. If there are any leaks then replace the wheel cylinder.

13.  Clean the wheel cylinders and backplates using a recommended brake cleaning fluid.

14.  Replace the brake shoes and brake drums. Refit the road wheels and lower the vehicle. Ensure the road wheel bolts are tightened correctly.

 

Vehicle:

Diesel engine model

Complaint:

The cooling system needs draining.

Remedy:

1.      Ensure the engine is cold, preferably been left over night.

2.      Turn the cap slowly until all the pressure is released, and then take the cap off.

3.      Ensure the handbrake is fully on. Raise and support the vehicle. Take off the engine under tray.

4.      Underneath the bottom hose connection on the radiator place a draining container. Undo the retaining clip, disconnect the hose and drain the coolant. DO NOT ALLOW TO COME INTO CONTACT WITH SKIN.

5.      If extra is needed to help the coolant drain then open the cooling system bleed screws in the heater matrix outlet hose union on the engine compartment  bulkhead, and on the thermostat cover.

6.      When this is completed also drain the cylinder block. Firstly place the draining container under the drain plug. This is found at the rear left hand side of the cylinder block. Remove the drain plug and drain the coolant.

7.      Once the coolant has drained refit the radiator bottom hose and cylinder block drain plugs. Replace any removed components, replace the engine under tray and lower the vehicle.

 

Vehicle:

Diesel engine model

Complaint:

The cooling system has lost efficiency.

Remedy:

The cooling system needs flushing especially if passages have rust, scale and other sediment deposits in them. Therefore complete the following procedure:

1.      Disconnect the top and bottom hoses from the radiator.

2.      Place a garden hose in the top of the radiator inlet.

3.      Flush the water through the radiator until clean water comes from the bottom of the radiator.

4.      If the radiator water does not run clean then a cleaning product suitable for cleaning radiators that are plastic or aluminium can be used, following instructions carefully.

5.      It may also be necessary to flush the engine.

6.      Tighten the cooling system bleed screws, and remove the thermostat. Put back the thermostat cover without the thermostat.

7.      Disconnect the top and bottom hoses from the radiator.

8.      Place a garden hose in the top of the radiator inlet.

9.      Flush the water through the radiator until clean water comes from the radiator bottom hose.

10.  Refit the thermostat, and reconnect the hoses.

 

Vehicle:

Diesel engine model

Complaint:

The cooling system needs refilling

Remedy:

1.      Ensure all hoses are in good condition as well as the connecting clips. If not then replace these before completing the next steps.

2.      Remove the expansion tank filler cap and open all the cooling system bleed screws.

3.      A header tank must be used when refilling, to achieve this cut the bottom off an old antifreeze container, the seal (the neck of the bottle) must create an airtight seal.

4.      Place the header tank into the expansion tank and slowly fill the system.

5.      Watch the bleed screws as coolant will emerge from the bottom up. As soon as the coolant coming from each of the bleed screws is clear from air bubbles then tighten that screw.

6.      Ensure the header tank has at least 0.5 litres of coolant in it, and start the engine running at a fast idle speed (not exceeding 2000rpm).

7.      When the cooling fan cuts in and out three times stop the engine.

8.      As soon as the engine has cooled remove the header tank. Check the coolant level (see previous point), and top up if necessary, then refit the expansion tank cap.

 

Vehicle:

Diesel engine model

Complaint:

The antifreeze needs replacing

Remedy:

1.      Ensure the antifreeze being used is an ethylene-glycol base suitable for use in mixed-metal cooling systems.

2.      The cooling system must be drained, flushed prior to replacing antifreeze.

3.      Fill with antifreeze, then label the expansion tank with type and concentration used, so that other top-ups can use the same type and concentration.