Bravo & Brava • 1995 To 2000

More documents

Recommendations

Info

Chapter 6 Clutch Contents Clutch - adjustment 2 Clutch assembly - removal, inspection and refitting 7 Clutch cable - removal and refitting 3 Clutch hydraulic system - bleeding 4 Clutch master cylinder - removal and refitting 5 Degrees of difficulty Easy, suitable for §^ novice with little expenence g^ Fairly easy, suitable §k for beginner with ^ some experience g^ Fairly difficult, ^ suitable for competent g^ DIY mechanic g^ 6»1 Clutch pedal - removal and refitting 9 Clutch release mechanism - removal, inspection and refitting 8 Clutch slave cylinder - removal and refitting 6 General information 1 Difficult, suitable for ^ experienced DIY ^ mechanic g^ Very difficult, suitable for expert DIY 2^ or professional gQ Specifications General Type Single friction disc with diaphragm spring pressure plate, cable- or hydraulically-operated according to model Clutch pedal travel (cable-operated type) 1.2 litre models 155.0 ± 10 mm 1.4 litre models 155.0 ± 10 mm 1.6 litre models 170.0 ± 10 mm 1.8 litre models 170.0 ±10 mm Friction disc diameter 1.2and 1.4 litre models 190.0 mm 1.6 litre models 200.0 mm 1.8 litre models 215.0 mm <strong>To</strong>rque wrench setting Nm ibfft Pressure plate retaining bolts 25 18
6*2 Clutch 1 General information Vehicles with manual transmission are fitted with a single friction disc with diaphragm spring pressure plate clutch system. When the clutch pedal is depressed, effort is transmitted to the clutch release mechanism either mechanically by means of a cable, or hydraulically by means of a master cylinder and slave cylinder. The release fork forces the release bearing against the centre of the diaphragm spring, which withdraws the pressure plate from the flywheel and releases the friction disc. Where applicable, the hydraulic fluid employed in the clutch system is the same as that used in the braking system, hence fluid is supplied to the master cylinder from a tapping on the brake fluid reservoir. The clutch hydraulic system must be sealed before work is carried out on any of its components and then on completion, topped up and bled to purge any accumulated air. 2 Clutchadjustment I Note: This procedure applies to models fitted with a cable-operated clutch release mechanism. No adjustment is possible on models with the hydraulically-operated system. 1 The clutch adjustment is checked by measuring the clutch pedal travel. If a new cable has been fitted, settle it in position by depressing the clutch pedal at least five times. 2 Ensure that there are no obstructions beneath the clutch pedal, then measure the distance from the upper edge of the clutch pedal pad to the floor by resting a ruler on the floor. Position the ruler directly in line with the movement of the clutch pedal. 3 Have an assistant fully depress the pedal, then measure the distance from the same point on the pedal to the floor. 2.6 Clutch cable adjustment 4 Subtract the second measurement from the first to obtain the clutch pedal travel. If this is not within the range given in the Specifications at the start of this Chapter, adjust the clutch as follows. 5 The clutch cable is adjusted by means of the adjuster nut on the transmission end of the cable. Access to the nut is best achieved from under the vehicle. Apply the handbrake, then jack up the front of the vehicle and support it on axle stands (see Jacking and vehicle support). 6 Working under the left-hand side of the engine compartment, loosen the locknut on the end of the clutch cable. Adjust the position of the adjuster nut, then depress the clutch pedal several times and re-measure the clutch pedal travel. Repeat this procedure until the clutch pedal travel is as specified (see illustration). 7 Once the adjuster nut is correctly positioned, and the pedal travel is correctly set, securely tighten the cable locknut then lower the vehicle to the ground. 3 Clutch cable - removal and refitting Note: This procedure applies to models fitted with a cable-operated clutch release mechanism. Removal 1 Remove the battery and battery tray as described in Chapter 5A, and unbolt the battery mounting bracket. Move the relay holder box to one side after removing the cover and unscrewing the mounting bolts. 2 On 1.2 and 1.4 litre models, unscrew the adjustment locknut and adjuster nut from the end of the cable fitting, then release the inner and outer cables from the transmission housing. Note the position of the damper block. 3 On 1.6 and 1.8 litre models, release the outer cable from the transmission and unhook the inner cable from the release lever. 4 Working inside the vehicle, fold back the carpet then unhook the inner cable from the top of the clutch pedal. 5 Returning to the engine compartment, release the cable from the supports then pull it from the bulkhead at the same time releasing the rubber buffer. Withdraw the cable assembly from the engine, compartment. Refitting 6 Apply a smear of multi-purpose grease to the inner cable and end fittings, then pass the cable through the bulkhead. Make sure that the rubber buffer is pressed firmly into the bulkhead before locating the end of the outer cable in it. 7 Inside the vehicle, hook the inner cable onto the top of the clutch pedal. 8 On 1.2 and 1.4 litre models, locate the outer cable on the transmission housing, then refit the adjustment and lock nuts. 9 On 1.6 and 1.8 litre models, hook the inner cable onto the release lever and locate the outer cable on the transmission. 10 Adjust the cable as described in Section 2. 11 Refit the relay holder box, battery and mounting bracket, referring to Chapter 5A as necessary. Also refit the carpet inside the vehicle. 4 Clutch hydraulic system bleeding Note: This procedure applies to models fitted with the hydraulically-operated clutch release mechanism. A Warning: Hydraulic fluid is poisonous; thoroughly wash off spills from bare skin without delay. 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 brought 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 were petrol that was being handled. Hydraulic fluid is an effective paint stripper and will also attack many plastics. If spillage occurs onto painted bodywork or fittings, it should be washed off immediately, using copious quantities of fresh water. It is also hygroscopic - it can absorb moisture from the air, which then renders it useless. Old fluid may have suffered contamination, and should never be re-used. When topping-up or renewing the fluid, always use the recommended grade, and ensure that it comes from a new sealed container. General information 1 Whenever the clutch hydraulic lines are disconnected for service or repair, a certain amount of air will enter the system. The presence of air in any hydraulic system will introduce a degree of elasticity, and in the clutch system this will translate into poor pedal feel and reduced travel, leading to inefficient gear changes and even clutch system failure. For this reason, the hydraulic lines must be sealed using hose clamps before any work is carried out and then on completion, topped up and bled to remove any air bubbles. 2 The most effective way of bleeding the clutch hydraulic system is to use a pressure brake bleeding kit. These are readily available in motor accessories shops and are extremely
Page 1 and 2:
BRAVO & BRAVA • 1995 to 2000 (N t
Page 3 and 4:
Contents LIVING WITH YOUR FIAT BRAV
Page 5 and 6:
o.4 Introduction The 3-door FIAT Br
Page 7 and 8:
o.6 Roadside repairs The following
Page 9 and 10:
o.8 Roadside repairs Wheel changing
Page 11 and 12:
o«io Weekly checks Introduction Th
Page 13 and 14:
o-i2 Weekly checks Engine oil level
Page 15 and 16:
o.i4 Weekly checks Tyre condition a
Page 17 and 18:
o.i6 Weekly checks Washer fluid lev
Page 19 and 20:
Chapter 1 Routine maintenance & ser
Page 21 and 22:
Torque wrench settings (continued)
Page 23 and 24:
1 Washer reservoir 2 Inlet manifold
Page 25 and 26:
1 Introduction General information
Page 27 and 28:
A - -A 6.3 Topping-up the battery e
Page 29 and 30:
7.21 Set the belt tension, then tig
Page 31 and 32:
Try to move the pipes and silencers
Page 33 and 34:
18.6 Pull the HT leads off the spar
Page 35 and 36:
5 Before removing the filter, note
Page 37 and 38:
2 To fully check the operation of t
Page 39 and 40:
31.3a Opening the radiator bleed sc
Page 41 and 42:
Chapter 12 Body electrical systems
Page 43 and 44:
1 General information and precautio
Page 45 and 46:
to release the clip, then withdraw
Page 47 and 48:
Body electrical systems 12»7 4.35a
Page 49 and 50:
14 Extract the festoon-type bulb fr
Page 51 and 52:
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 93 and 94:
11 »20 Bodywork and fittings 23.3
Page 95 and 96:
11 »22 Bodywork and fittings 16 Wi
Page 97 and 98: 11 »24 Bodywork and fittings 23.27
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 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: ) Apply a smear of high-melting-poi
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
Page 163 and 164: Starting and charging systems 5A»3
Page 165 and 166: 5.13a Unscrew the bolts securing th
Page 167 and 168: 6 Unscrew and remove the starter mo
Page 169 and 170: 402 Exhaust and emission control sy
Page 171 and 172: 404 Exhaust and emission control sy
Page 173 and 174: Chapter 4 Part B: Fuel system - mul
Page 175 and 176: 2.5 Disconnecting the breather hose
Page 177 and 178: 4.3c Disconnecting the throttle pot
Page 179 and 180: Refitting 20 Refit the injectors an
Page 181 and 182: Unplug the wiring connectors and un
Page 183 and 184: 5.10a Once the base of the unit has
Page 185 and 186: 8.8b ... and remove this wiring har
Page 187 and 188: Chapter 4 Part A: Fuel system - sin
Page 189 and 190: 6 Slacken and withdraw the securing
Page 191 and 192: 5.1 Disconnect the breather hose fr
Page 193 and 194: Refitting 17 Refitting is a reversa
Page 195 and 196: Fuel system - single-point injectio
Page 197 and 198: Disconnect the inlet manifold coola
Page 199 and 200:
Chapter 3 Cooling, heating and vent
Page 201 and 202:
eveal a faulty hose, it must be ren
Page 203 and 204:
Refitting 14 Ensure that the cylind
Page 205 and 206:
36 Unbolt and remove the timing bel
Page 207 and 208:
Cooling, heating and ventilation sy
Page 209 and 210:
Chapter 2 Part E: Engine removal an
Page 211 and 212:
Crankshaft Main bearing journal dia
Page 213 and 214:
2.20a Removing the cover from the b
Page 215 and 216:
2.33 Removing the left-hand wheelar
Page 217 and 218:
Automatic transmission models 64 Re
Page 219 and 220:
4.20 Look for cracking between the
Page 221 and 222:
4.45a Locate the inner . 4.45b ...
Page 223 and 224:
5.24a Using a small screwdriver ...
Page 225 and 226:
5.47 Tightening the big-end bearing
Page 227 and 228:
8.14 Three bore measurement points
Page 229 and 230:
11.19 Lubricate the crankcase main
Page 231 and 232:
2D»2 1.8 litre engine in-car repai
Page 233 and 234:
Location of TDC on No 1 cylinder 1
Page 235 and 236:
4.13a Removing No 3 exhaust camshaf
Page 237 and 238:
camshaft oil seals for signs of lea
Page 239 and 240:
14 If necessary, remove and clean t
Page 241 and 242:
37 Again working in sequence, tight
Page 243 and 244:
^^^^^ 13.8 Using an impact screwdri
Page 245 and 246:
202 1.6 litre engine in-car repair
Page 247 and 248:
Page 249 and 250:
Page 251 and 252:
Page 253 and 254:
2O10 1.6 litre engine in-car repair
Page 255 and 256:
2012 1.6 litre enginein-car repair
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
Page 263 and 264:
2O20 1.6 litre engine in-car repair
Page 265 and 266:
Chapter 2 Part B: 1.4 litre engine
Page 267 and 268:
6 Once pressure is felt, continue t
Page 269 and 270:
4.17 FIAT special tool used to lock
Page 271 and 272:
Section 4. It is essential that an
Page 273 and 274:
paragraph 17), then remove the heat
Page 275 and 276:
to the downpipe. The safest option
Page 277 and 278:
13.8 Using an impact screwdriver to
Page 279 and 280:
2A«2 1.2 litre engine in-car repai
Page 281 and 282:
2A«4 1.2 litre engine in-car repai
Page 283 and 284:
2A»6 1.2 litre engine in-car repai
Page 285 and 286:
2A»8 1.2 litre engine in-car repai
Page 287 and 288:
2A»10 1.2 litre engine in-car repa
Page 289 and 290:
Page 291 and 292:
Page 293 and 294:
REF-2 Conversion factors Length (di
Page 295 and 296:
REF.4 Vehicle identification number
Page 297 and 298:
REF.6 Disconnecting the battery Sev
Page 299 and 300:
REF.8 Tools and working facilities
Page 301 and 302:
REF.10 MOT test checks This is a gu
Page 303 and 304:
REF«12 MOT test checks Exhaust sys
Page 305 and 306:
REF.14 Fault finding Engine • Eng
Page 307 and 308:
REF.16 Fault finding Engine (contin
Page 309 and 310:
REF.18 Fault finding Clutch Note: T
Page 311 and 312:
REF.20 Fault finding Braking system
Page 313 and 314:
REF.22 Fault finding Electrical sys
Page 315 and 316:
REF.24 Glossary of technical terms
Page 317 and 318:
Page 319 and 320:
Page 321 and 322:
REF
Page 323 and 324:
REF
show all

Bravo & Brava • 1995 To 2000

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?