Bravo & Brava • 1995 To 2000

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Chapter 9 Braking system Contents Anti-lock braking system (ABS) components - removal and refitting 19 Brake fluid - level check See Weekly checks Brake fluid - renewal See Chapter 1 Brake pedal - removal and refitting 11 Front brake caliper - removal, overhaul and refitting 8 Front brake disc - inspection, removal and refitting 6 Front brake pad - condition check See Chapter 1 Front brake pads - renewal 4 General information 1 Handbrake - checking and adjustment 14 Handbrake cables - removal and refitting 16 Degrees of difficulty Easy, suitable for |k novice with little ^ experience ^ Fairly easy, suitable for beginner with some experience ^ Fairiy difficult, ^ suitable for competent ^ DIY mechanic ^ 9»1 Handbrake lever - removal and refitting 15 Hydraulic pipes and hoses - renewal 3 Hydraulic system - bleeding 2 Master cylinder - removal, overhaul and refitting 10 Rear brake drum - removal, inspection and refitting 7 Rear brake pressure proportioning valve - removal and refitting ... 18 Rear brake shoes - condition check See Chapter 1 Rear brake shoes - renewal 5 Rear wheel cylinder - removal, overhaul and refitting 9 Stop-light switch - adjustment, removal and refitting 17 Vacuum servo unit - testing, removal and refitting 12 Vacuum servo unit check valve - removal, testing and refitting .... 13 Difficult, suitable for §^ experienced DIY ^ mechanic ^ Specifications Front brakes Type Disc with single-piston sliding calipers Disc diameter 257 mm Disc thickness (new): 1.2, 1.4 and 1.6 litre (manual) models 11.80 to 12.10 mm 1.6 litre (automatic) and 1.8 litre models 19.80 to 20.10 mm Minimum disc machining thickness: 1.2, 1.4 and 1.6 litre (manual) models 11.10 mm 1.6 litre (automatic) and 1.8 litre models 18.55 mm Minimum disc thickness (wear limit): 1.2,1.4 and 1.6 litre (manual) models 10.20 mm 1.6 litre (automatic) and 1.8 litre models 18.20 mm Maximum disc runout 0.15 mm (2.0 mm from outer edge) Brake pad friction material minimum thickness 1.5 mm Rear drum brakes Drum inner diameter (new): 1.2 and 1.4 litre models (without ABS) 180.00 to 180.25 mm 1.2 and 1.4 litre models (with ABS) 203.10 to 203.40 mm 1.6 and 1.8 litre models 203.10 to 203.40 mm Maximum drum machining diameter: 1.2 and 1.4 litre models (without ABS) 180.95 mm 1.2 and 1.4 litre models (with ABS) 204.10 mm 1.6 and 1.8 litre models 204.10 mm Maximum drum diameter (wear limit): 1.2 and 1.4 litre models (without ABS) 181.35 mm 1.2 and 1.4 litre models (with ABS) 204.70 mm 1.6 and 1.8 litre models 204.70 mm Minimum shoe lining thickness ' 1.5 mm Very difficult, suitable for expert DIY ^ or professional g^
9*2 Braking system Anti-lock braking system Type Teves MK20 <strong>To</strong>rque wrench settings Nm lb ft 6 4 Brake disc locating studs 12 9 Brake drum locating studs 12 9 Brake pedal pivot bolt 30 22 Brake pipe union 14 10 Caliper heat shield securing bolts 5 4 Front caliper bracket-to-hub carrier bolts 53 39 Front caliper-to-caliper bracket guide bolts 12 9 Hub carrier to strut 70 52 Pedal bracket mounting 15 11 Rear wheel cylinder mounting bolts 10 7 Roadwheel bolts 86 63 1 General information 1 The braking system is of vacuum servoassisted, dual-circuit hydraulic type. The arrangement of the hydraulic system is such that each circuit operates one front and one rear brake from a tandem master cylinder. Under normal circumstances, both circuits operate in unison. However, in the event of hydraulic failure in one circuit, full braking force will still be available at two diagonallyopposite wheels. 2 All models are fitted with front disc brakes and rear drum brakes. The front disc brakes are actuated by single-piston sliding type calipers. The rear drum brakes incorporate leading and trailing shoes, which are actuated by twin-piston wheel cylinders. A self-adjust mechanism is incorporated, to automatically compensate for brake shoe wear. As the brake shoe linings wear, the footbrake operation automatically operates the adjuster mechanism, which effectively lengthens the shoe strut and repositions the brake shoes, to remove the lining-to-drum clearance. 3 The mechanical handbrake linkage operates the brake shoes via a lever attached to the trailing brake shoe. 4 Load sensitive proportioning valves operate on the rear brake hydraulic circuits, to prevent the possibility of the rear wheels locking before the front wheels under heavy braking. Note: When servicing any part of the system, work carefully and methodically; also observe scrupulous cleanliness when overhauling any part of the hydraulic system. Always renew components (in axle sets, where applicable) if in doubt about their condition, and use only genuine FIAT replacement parts, or at least those of known good quality. Note the warnings given in Safety first! and at relevant points in this Chapter concerning the dangers of asbestos dust and hydraulic fluid. Models with anti-lock braking system (ABS) 5 Available as an option on certain models, the anti-lock braking system prevents skidding which not only optimises stopping distances but allows full steering control to be maintained under maximum braking. The ABS system is operative while the vehicle is travelling both forwards and rearwards. During aquaplaning the ABS system temporarily switches itself off, as it detects a faulty condition where the driving wheels rotate at a higher speed than the driven wheels. 6 By electronically monitoring the speed of each roadwheel in relation to the other wheels, the system can detect when a wheel is about to lock-up, before control is actually lost. The brake fluid pressure applied to that wheel's brake caliper is then decreased and restored (or modulated) several times a second until control is regained. 7 The system components comprise an Electronic Control Unit (ECU), four wheel speed sensors, a hydraulic unit, recycling pump, brake lines and dashboard mounted warning lamps. The ECU is located beneath the hydraulic unit, and the recycling pump is located on top of the hydraulic unit, the assembly being mounted in the left-hand side of the engine compartment. 8 The hydraulic unit incorporates a tandem master cylinder, a valve block which modulates the pressure in the brake hydraulic circuits during ABS operation, an accumulator which provides a supply of highly pressurised brake fluid, a hydraulic pump to charge the accumulator and an integral electronic control unit (ECU). 9 The four wheel sensors are mounted on the wheel hubs. The ECU uses the signals produced by the sensors to calculate the rotational speed of each wheel. 10 The ECU has a self-diagnostic capability and will inhibit the operation of the ABS if a fault is detected, lighting the dashboard mounted warning lamp. The braking system will then revert to conventional, non-ABS operation. If the nature of the fault is not immediately obvious upon inspection, the vehicle must be taken to a FIAT dealer, who will have the diagnostic equipment required to interrogate the ABS ECU electronically and pin-point the problem. 11 As from 10/97 (chassis number 4535478on) an additional electronic control was added to the ABS. The system is referred to as EBD (Electronically-operated Brake force Distribution) and it automatically controls the brake pressure between the front and rear brake hydraulic circuits at all times, as against control only during emergency braking for the ABS. Models with EBD are not fitted with a load sensitive proportioning valve. 12 On models with EBD, the failure warning light function is slightly different to that on models with only ABS. Failure of the ABS system only, causes the ABS warning light to come on. Failure of the EBD system causes both the ABS and handbrake warning lights to come on. If the handbrake warning light only comes on, this indicates that the hydraulic brake fluid is low or that the handbrake lever is not fully released. 2 Hydraulic system - |^ bleeding A Warning: Hydraulic fluid is poisonous; wash off immediately and thoroughly in the case of skin contact, and seek immediate medical advice if any fluid is swallowed, or gets into the eyes. Certain types of hydraulic fluid are inflammable, and may ignite when allowed into contact with hot components. When servicing any hydraulic system, it is safest to assume that the fluid IS inflammable, and to take precautions against the risk of fire as though it is petrol that is being handled. Hydraulic fluid is also an effective paint stripper, and will attack plastics; if any is spilt, it should be washed off immediately, using copious quantities of fresh water. Finally, it is hygroscopic (it absorbs moisture from the air) - old fluid may be contaminated and unfit for further use. When topping-up or renewing the fluid, always use the recommended type, and ensure that it comes from a freshly-opened sealed container. General 1 The correct operation of any hydraulic system is only possible after removing all air from the components and circuit; and this is achieved by bleeding the system.
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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 ..
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10.2 Prise the speaker grille from
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Body electrical systems 12»15 14.4
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15.3c ... and remove the inner meta
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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 105 and 106: 1f>8 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: 10*14 Suspension and steering syste
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
Page 155 and 156: 2.8 Diagnostic connector plug locat
Page 157 and 158: 4.4 Pull the HT leads off the spark
Page 159 and 160: 6.1 Crankshaft sensor on 1.6 litre
Page 161 and 162: 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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