Bravo & Brava • 1995 To 2000

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not apply grease or oil as this will attack the rubber. 7 Check the anti-roll bar for signs of damage, wear or serious corrosion. Refitting 8 Refitting is a reversal of removal, but tighten all nuts and bolts to the specified torque where given. 7 Front suspension subframe - |t-= removal and refitting ^ Removal 1 Apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see Jacking and vehicle support). Remove both front roadwheels. 2 Remove the exhaust front downpipe with reference to Chapter 4C. 3 Remove both front suspension lower arms as described in Section 4. 4 Remove the anti-roll bar as described in Section 6. 5 Unbolt the rear engine mounting from the subframe, then unbolt the bracket from the transmission and withdraw the mounting and bracket from under the vehicle. 6 Undo the screws and remove the exhaust heatshield from the underbody. 7 Unscrew and remove the two central bolts securing the steering gear to the subframe. 8 Support the weight of the subframe on a trolley jack and length of wood. 9 Unscrew and remove the remaining mounting bolts and lower the subframe to the ground. Withdraw the subframe from under the car. Refitting 10 Lift the subframe on the trolley jack, and insert the mounting bolts, hand-tight at this stage. 11 Using two 12.0 mm diameter metal rods inserted through the two holes at the rear of the subframe, align the subframe, then tighten the mounting bolts progressively to the specified torque. 12 Insert and tighten the steering gear mounting bolts to the specified torque. - k *** 9.3 Rear shock absorber lower mounting bolt 8.4 Prise the dust cap from the hub with a screwdriver 13 Refit the exhaust heatshield. 14 Refit the rear engine mounting and bracket and tighten the bolts to the specified torque. 15 Refit the anti-roll bar with reference to Section 6. 16 Refit both front suspension lower arms with reference to Section 4. 17 Refit the exhaust front downpipe with reference to Chapter 4C. 18 Refit the roadwheels and lower the vehicle to the ground. 8 Rear hub bearings - §^ renewal Sjk Note: A new rear hub nut must be used on refitting. 1 The rear hub bearings are integral with the hubs themselves, and cannot be renewed separately. If the bearings are worn excessively, the complete hub assembly must be renewed. 2 Chock the front roadwheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the appropriate rear roadwheel. 3 Remove the brake drum as described in Chapter 9. Do not depress the brake pedal whilst the brake drum is removed. 4 Prise the dust cap from the hub with a screwdriver (see illustration). 5 Unscrew and remove the hub nut and recover the washer (see illustration). 9.4 Rear shock absorber upper mounting bolt Suspension and steering systems 10«7 8.5 The rear hub nut Caution: The nut is tightened to a high torque. Use a socket and long extension bar and ensure that you have access to torque wrench capable of tightening the new nut to the specified torque setting, before removing the existing nut. 6 Withdraw the hub and bearing assembly from the stub axle, and recover the inner washer. Discard the hub nut - a new one must be used on refitting. 7 Thoroughly clean the stub axle, then slide the inner washer and new hub assembly into position. 8 Fit the outer washer, then screw on the new hub nut. Hold the stub axle stationary using a suitable Allen key, then tighten the hub nut to the specified torque. 9 Apply a little grease around the edge of the dust cap, then carefully tap it into the hub. Refit the brake drum with reference to Chapter 9. 10 Refit the roadwheel then lower the vehicle to the ground. 9 Rear shock absorber - removal and refitting ^ Removal 1 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the relevant rear roadwheel. 2 Using a trolley jack positioned under the trailing arm, raise the trailing arm slightly to compress the coil spring. 3 Unscrew and remove the lower mounting bolt (see illustration). 4 Unscrew and remove the upper mounting bolt using a socket through the access hole (see illustration), then pull the top of the shock absorber from the rear suspension subframe. Refitting 5 Refitting is a reversal of removal. Tighten the upper and lower mounting bolts to the specified torque with the trolley jack supporting the weight of the car so that the rear suspension is compressed.
1f>8 Suspension and steering systems 13.5 Rear brake hydraulic line and union nut on the underbody in front of the rear axle 10 Rear suspension coil spring - removal and refitting Sfc Removal 1 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the relevant rear roadwheel. 2 Using a trolley jack positioned under the trailing arm, raise the trailing arm slightly to compress the coil spring. 3 Unscrew and remove the shock absorber lower mounting bolt. 4 Lower the trailing arm gradually on the trolley jack, until the coil spring is released from its lower seat on the trailing arm and its upper seat on the subframe. Make a note of the orientation of the coil spring, to ensure correct refitting later. 5 Remove the upper and lower spring seats, and the bump stop rubbers. Refitting 6 Refitting is a reversal of removal. Tighten the shock absorber lower mounting bolt to the specified torque. 11 Rear suspension trailing arm % - removal and refitting ^ Removal 1 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the relevant rear roadwheel. 2 Remove the brake drum and rear brake shoes as described in Chapter 9. Do not depress the brake pedal whilst the brake drum is removed. 3 Fit a brake hose clamp to the flexible hose leading to the relevant rear brake. Unscrew the union nut from the rear of the rear wheel cylinder, then unbolt the brake line support from the trailing arm. 4 Remove the handbrake cable from the backplate, then unbolt the backplate from the trailing arm. 13.9 One of the rear axle mountings 5 Remove the rear hub (Section 8) and coil spring (paragraphs 6 to 9 of this Section). 6 Unbolt the anti-roll bar from the trailing arm. 7 Unscrew and remove the front pivot bolt and withdraw the trailing arm from the rear suspension subframe. 8 Check the bearings for excessive wear, particularly on the outer bearing. Note that it is not possible to renew the bearings separately; the complete trailing arm must be renewed. Refitting 9 Refitting is a reversal of removal. Tighten all suspension fixings to the specified torque settings, but delay this operation until the full weight of the vehicle is resting on the roadwheels. 10 On completion, bleed the brake hydraulic system and adjust the operation of the handbrake, with reference to Chapter 9. 12 Rear suspension anti-roll bar %; - removal and refitting *k Removal 1 Chock the front roadwheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove both rear roadwheels. 2 Where fitted, disconnect the rear brake pressure proportioning valve spring from the middle of the rear anti-roll bar. 3 Unscrew the bolts securing the anti-roll bar to the trailing arms, and withdraw it from under the car. Refitting 4 Refitting is a reversal of removal, but tighten the mounting bolts securely. 13 Rear axle assemblyremoval and refitting Sjk Removal 1 Chock the front wheels, then jack up the rear of the vehicle and support on axle stands (see Jacking and vehicle support). Remove the relevant rear roadwheel. 2 Remove the fuel tank as described in Chapter 4A or 4B. 3 Remove the rear section of the exhaust system as described in Chapter 4C. 4 Unscrew the filler cap from the brake fluid reservoir, and tighten it down onto a piece of polythene sheeting. This will reduce the loss of fluid when the brake lines are disconnected. 5 Working under the rear of the car, identify for position then unscrew the union nuts and disconnect the rear brake hydraulic lines on the underbody in front of the rear axle (see illustration). Plug the lines to prevent loss of fluid. 6 Back off the handbrake cable adjustment (see Chapter 9), and disconnect the cables from the equaliser bar. Also detach the outer cables from the underbody. 7 Where necessary, unbolt and remove the ABS sensors from each rear brake backplate. 8 Support the rear axle assembly with a trolley jack and length of wood. An assistant would also be helpful to steady the assembly as it is being lowered to the ground. 9 Unscrew the four mounting bolts securing the rear axle assembly to the underbody, then lower it to the floor (see illustration). 10 Remove the component parts of the rear axle assembly with reference to the relevant Sections of this Chapter. Refitting 11 Refitting is a reversal of removal; tighten all nuts and bolts to the specified torque where given. Bleed the brake hydraulic system and adjust the handbrake cables as described in Chapter 9. 14 Steering wheel - §^ removal and refitting ^ A Warning: For safety reasons, owners are strongly advised to entrust to an authorised FIAT dealer any work which involves disturbing the airbag system components. The airbag inflation devices contain explosive material and legislation exists to control their handling and storage. In addition, specialised test equipment is needed to check that the airbag system is fully operational following reassembly. The following information is given for the home mechanic who may have access to the necessary equipment and storage. Removal 1 Disconnect the battery negative (earth) lead (see Disconnecting the battery). Note: The ignition must be switched off before
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BRAVO & BRAVA • 1995 to 2000 (N t
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Contents LIVING WITH YOUR FIAT BRAV
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o.4 Introduction The 3-door FIAT Br
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o.6 Roadside repairs The following
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o.8 Roadside repairs Wheel changing
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o«io Weekly checks Introduction Th
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o-i2 Weekly checks Engine oil level
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o.i4 Weekly checks Tyre condition a
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o.i6 Weekly checks Washer fluid lev
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Chapter 1 Routine maintenance & ser
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Torque wrench settings (continued)
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1 Washer reservoir 2 Inlet manifold
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1 Introduction General information
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A - -A 6.3 Topping-up the battery e
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7.21 Set the belt tension, then tig
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Try to move the pipes and silencers
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18.6 Pull the HT leads off the spar
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5 Before removing the filter, note
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2 To fully check the operation of t
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31.3a Opening the radiator bleed sc
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Chapter 12 Body electrical systems
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1 General information and precautio
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to release the clip, then withdraw
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Body electrical systems 12»7 4.35a
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14 Extract the festoon-type bulb fr
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6.18a Unscrew the mounting bolts ..
Page 53 and 54: 10.2 Prise the speaker grille from
Page 55 and 56: Body electrical systems 12»15 14.4
Page 57 and 58: 15.3c ... and remove the inner meta
Page 59 and 60: 18.6b Wiper mounting bolt located o
Page 61 and 62: 22.3b Disconnect the yellow wiring
Page 63 and 64: Key to symbols — t ; j^g. Item nu
Page 65 and 66: Wire colours W White R Red Y Yellow
Page 67 and 68: Wire colours W White O Orange R Red
Page 69 and 70: Wire colours W White O Orange R Red
Page 71 and 72: Wire colours W R Y Br P Bl Gr G B V
Page 73 and 74: Wire colours Key to items w R Y Br
Page 75 and 76: 11 »2 Bodywork and fittings which
Page 77 and 78: 11 »4 Bodywork and fittings 6 Fron
Page 79 and 80: '\'\»6 Bodywork and fittings the c
Page 81 and 82: 11 »8 Bodywork and fittings 10.11
Page 83 and 84: 11*10 Bodywork and fittings 7 If wo
Page 85 and 86: 11*12 Bodywork and fittings 16.10 R
Page 87 and 88: 11*14 Bodywork and fittings 18.3a U
Page 89 and 90: 11*16 Bodywork and fittings 18.23a
Page 91 and 92: 11*18 Bodywork and fittings 20.15b
Page 95 and 96: 11 »22 Bodywork and fittings 16 Wi
Page 99 and 100: 10*2 Suspension and steering system
Page 101 and 102: 10*4 Suspension and steering system
Page 103: 10*6 Suspension and steering system
Page 107 and 108: 10*10 Suspension and steering syste
Page 109 and 110: 10«12 Suspension and steering syst
Page 111 and 112: 10*14 Suspension and steering syste
Page 113 and 114: 9*2 Braking system Anti-lock brakin
Page 115 and 116: 9*4 Braking system 4.2 Disconnectin
Page 117 and 118: 9*6 Braking system 5 Unhook the sel
Page 119 and 120: 9*8 Braking system 5.27 Removing th
Page 121 and 122: 9*10 Braking system 8.4 Disconnecti
Page 123 and 124: 9»12 Braking system K-0 10.13 Cros
Page 125 and 126: 9»14 Braking system 25 Working ins
Page 127 and 128: 9*16 Braking system 2 Unbolt the ex
Page 129 and 130: 8*2 Driveshafts 1 General informati
Page 131 and 132: 8*4 Driveshafts 3.23a Extract the c
Page 133 and 134: 8*6 Driveshafts 4.7 Unbolt the inte
Page 135 and 136: Chapter 7 Part B: Automatic transmi
Page 137 and 138: 2.19a Two of the six bolts securing
Page 139 and 140: S§^)/ H31468 6.11 Selector lever p
Page 141 and 142: Chapter 7 Part A: Manual transmissi
Page 143 and 144: 2 Gearchange lever and linkage remo
Page 145 and 146: hoist to the left-hand end of the i
Page 147 and 148: ) Apply a smear of high-melting-poi
Page 149 and 150: 6*2 Clutch 1 General information Ve
Page 151 and 152: 6«4 Clutch 6.4 Clutch slave cylind
Page 153 and 154: Chapter 5 Part B: Ignition system C
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2.8 Diagnostic connector plug locat
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4.4 Pull the HT leads off the spark
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6.1 Crankshaft sensor on 1.6 litre
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Chapter 5 Part A: Starting and char
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Starting and charging systems 5A»3
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5.13a Unscrew the bolts securing th
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6 Unscrew and remove the starter mo
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402 Exhaust and emission control sy
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404 Exhaust and emission control sy
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Chapter 4 Part B: Fuel system - mul
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2.5 Disconnecting the breather hose
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4.3c Disconnecting the throttle pot
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Refitting 20 Refit the injectors an
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Unplug the wiring connectors and un
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5.10a Once the base of the unit has
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8.8b ... and remove this wiring har
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Chapter 4 Part A: Fuel system - sin
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6 Slacken and withdraw the securing
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5.1 Disconnect the breather hose fr
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Refitting 17 Refitting is a reversa
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Fuel system - single-point injectio
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Disconnect the inlet manifold coola
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Chapter 3 Cooling, heating and vent
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eveal a faulty hose, it must be ren
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Refitting 14 Ensure that the cylind
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36 Unbolt and remove the timing bel
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Cooling, heating and ventilation sy
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Chapter 2 Part E: Engine removal an
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Crankshaft Main bearing journal dia
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2.20a Removing the cover from the b
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2.33 Removing the left-hand wheelar
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Automatic transmission models 64 Re
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4.20 Look for cracking between the
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4.45a Locate the inner . 4.45b ...
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5.24a Using a small screwdriver ...
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5.47 Tightening the big-end bearing
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8.14 Three bore measurement points
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11.19 Lubricate the crankcase main
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2D»2 1.8 litre engine in-car repai
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Location of TDC on No 1 cylinder 1
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4.13a Removing No 3 exhaust camshaf
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camshaft oil seals for signs of lea
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14 If necessary, remove and clean t
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37 Again working in sequence, tight
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^^^^^ 13.8 Using an impact screwdri
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202 1.6 litre engine in-car repair
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2O10 1.6 litre engine in-car repair
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2012 1.6 litre enginein-car repair
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2O20 1.6 litre engine in-car repair
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Chapter 2 Part B: 1.4 litre engine
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6 Once pressure is felt, continue t
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4.17 FIAT special tool used to lock
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Section 4. It is essential that an
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paragraph 17), then remove the heat
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to the downpipe. The safest option
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13.8 Using an impact screwdriver to
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2A«2 1.2 litre engine in-car repai
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2A«4 1.2 litre engine in-car repai
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2A»6 1.2 litre engine in-car repai
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2A»8 1.2 litre engine in-car repai
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2A»10 1.2 litre engine in-car repa
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REF-2 Conversion factors Length (di
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REF.4 Vehicle identification number
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REF.6 Disconnecting the battery Sev
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REF.8 Tools and working facilities
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REF.10 MOT test checks This is a gu
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REF«12 MOT test checks Exhaust sys
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REF.14 Fault finding Engine • Eng
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REF.16 Fault finding Engine (contin
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REF.18 Fault finding Clutch Note: T
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REF.20 Fault finding Braking system
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REF.22 Fault finding Electrical sys
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REF.24 Glossary of technical terms
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REF
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REF
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Bravo & Brava • 1995 To 2000

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