Bravo & Brava • 1995 To 2000

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5A«2 Starting and charging systems 1 General information and precautions General information The engine electrical system consists mainly of the charging and starting systems. Because of their engine-related functions, these components are covered separately from the body electrical devices such as the lights, instruments, etc (which are covered in Chapter 12). Refer to Part B for information on the ignition system. The electrical system is of 12-volt negativeearth type. The battery fitted as original equipment is of 'limited-maintenance' type and is charged by the alternator, which is belt-driven from the crankshaft pulley. The original-equipment battery does not require regular topping-up, and some of the types fitted cannot be topped-up (see Chapter 1). The starter motor is of the pre-engaged type, incorporating an integral solenoid. On starting, the solenoid moves the drive pinion into engagement with the flywheel ring gear before the starter motor is energised. Once the engine has started, a one-way clutch prevents the motor armature being driven by the engine until the pinion disengages from the flywheel. Further details of the various systems are given in the relevant Sections of this Chapter. While some repair procedures are given, the usual course of action is to renew the component concerned. The owner whose interest extends beyond mere component renewal should obtain a copy of the Automobile Electrical & Electronic Systems Manual, available from the publishers of this manual. Precautions Warning: It is necessary to take extra care when working on the electrical system to avoid damage to semi-conductor devices (diodes and transistors), and to avoid the risk of personal injury. In addition to the precautions given in Safety first!, observe the following when working on the system: Always remove rings, watches, etc before working on the electrical system. Even with the battery disconnected, capacitive discharge could occur if a component's live terminal is earthed through a metal object. This could cause a shock or nasty burn. Do not reverse the battery connections. Components such as the alternator, electronic control units, or any other components having semi-conductor circuitry could be irreparably damaged. Never disconnect the battery terminals, the alternator, any electrical wiring or any test instruments when the engine is running. Do not allow the engine to turn the alternator when the alternator is not connected. Never 'test' for alternator output by 'flashing' the output lead to earth. Always ensure that the battery negative lead is disconnected when working on the electrical system. If the engine is being started using jump leads and a slave battery, connect the batteries positive-to-positive and negativeto-negative (see Jump starting). This also applies when connecting a battery charger. Never use an ohmmeter of the type incorporating a hand-cranked generator for circuit or continuity testing. Before using electric-arc welding equipment on the car, disconnect the battery, alternator and components such as the electronic control units (where applicable) to protect them from the risk of damage. The radio/cassette unit fitted as standard equipment by FIAT is equipped with a built-in security code, to deter thieves. If the power source to the unit is cut, the anti-theft system will activate - see Disconnecting the battery in the Reference section for more information. 2 Battery- % testing and charging ^ Standard or limitedmaintenance battery - testing Note: Some models are fitted with a limitedmaintenance battery which is sealed, meaning that the electrolyte specific gravity cannot be checked. The condition of the battery can therefore only be tested using a voltmeter - refer to paragraphs 6 to 8. 1 If the vehicle covers a small annual mileage, it is worthwhile checking the specific gravity of the electrolyte every three months to determine the state of charge of the battery. Use a hydrometer to make the check, and compare the results with the following table. Note that the specific gravity readings assume an electrolyte temperature of 15°C (60°F); for every 10°C (18°F) below 15°C (60°F) subtract 0.007. For every 10°C (18°F) above 15°C (60°F)add 0.007. Above 25°C Below 25°C Fully charged 1.210 to 1.230 1.270 to 1.290 70% charged 1.170 to 1.190 1.230 to 1.250 Discharged 1.050 to 1.070 1.110 to 1.130 2 If the battery condition is suspect, first check the specific gravity of electrolyte in each cell. A variation of 0.040 or more between any cells indicates loss of electrolyte or deterioration of the internal plates. 3 If the specific gravity variation is 0.040 or more, the battery should be renewed. If the cell variation is satisfactory but the battery is discharged, it should be charged as described later in this Section. Maintenance-free battery - testing 4 In cases where a 'sealed for life' maintenance-free battery is fitted, topping-up and testing of the electrolyte in each cell is not possible. The condition of the battery can therefore only be assessed using the battery condition indicator or a voltmeter. 5 Certain models may have been fitted with a maintenance-free battery with a built-in charge condition indicator. The indicator is located in the top of the battery casing, and indicates the condition of the battery from its colour. If the indicator shows green, then the battery is in a good state of charge. If the indicator turns darker, eventually to black, then the battery requires charging, as described later in this Section. If the indicator shows clear/yellow, then the electrolyte level in the battery is too low to allow further use, and the battery should be renewed. Do not attempt to charge, load or jump start a battery when the indicator shows clear or yellow. 6 If testing the battery using a voltmeter, connect the voltmeter across the battery terminals. The test is only accurate if the battery has not been subjected to any kind of charge for the previous six hours. If this is not the case, switch on the headlights for 30 seconds, then wait four to five minutes before testing the battery after switching off the headlights. All other electrical circuits must be switched off, so check that the doors and tailgate are fully shut when making the test. 7 If the voltage reading is less than 12 volts, then the battery is discharged, whilst a reading of 12.0 to 12.4 volts indicates a partially-discharged condition. 8 If the battery is to be charged, remove it from the vehicle (Section 3) and charge it as described later in this Section. Standard or limitedmaintenance battery <strong>•</strong> charging Note: The following is intended as a guide only. Always refer to the manufacturer's recommendations (often printed on a label attached to the battery) before charging a battery. 9 Charge the battery at a rate of 3.5 to 4 amps and continue to charge the battery at this rate until no further rise in specific gravity is noted over a 4-hour period. 10 Alternatively, a trickle charger charging at the rate of 1.5 amps can safely be used overnight. 11 Specially rapid 'boost' charges which are claimed to restore the power of the battery in 1 to 2 hours are not recommended, as they can cause serious damage to the battery plates through overheating. 12 While charging the battery, note that the temperature of the electrolyte should never exceed 37.8°C (100°F).
Starting and charging systems 5A»3 3.3a Unscrew the clamp plate bolt... 3.3b ... then lift away the holding strap 3.4 Removing the battery Maintenance-free battery - charging Note: The following is intended as a guide only. Always refer to the manufacturer's recommendations (often printed on a label attached to the battery) before charging a battery. 13 This battery type takes considerably longer to fully recharge than the standard type, the time taken being dependent on the extent of discharge, but it can take anything up to three days. 14 A constant voltage type charger is required, to be set, when connected, to 13.9 to 14.9 volts with a charger current below 25 amps. Using this method, the battery should be usable within three hours, giving a voltage reading of 12.5 volts, but this is for a partially discharged battery and, as mentioned, full charging can take considerably longer. 3.5a Removing the battery drip tray 15 If the battery is to be charged from a fully discharged state (condition reading less than 12 volts), have it recharged by your FIAT dealer or local automotive electrician, as the charge rate is higher and constant supervision during charging is necessary. 3 Batteryremoval and refitting ^ Note: If the vehicle has a security-coded radio, check that you have a copy of the code number before disconnecting the battery cable; refer to Disconnecting the battery in the Reference section for details. Removal 1 Loosen the clamp bolt and disconnect the 3.5b Lift off the fuse/relay carrier lid ... battery negative cable from the terminal (see illustration). 2 Lift up the plastic cover, and disconnect the positive cable in the same manner (see illustrations). 3 At the base of the battery, unscrew the bolt from the battery holding clamp plate, and lift away the clamp plate and battery holding strap (see illustrations). 4 Remove the battery from the engine compartment (see illustration). 5 If necessary, the plastic tray beneath the battery can be lifted out. The main battery tray may be removed by unscrewing the bolts - note, however, that on 1.6 litre models, this also entails removing the ECU - see Chapter 4B, Section 4. Before removing the tray completely, unbolt the relay holder(s) (where applicable) and place to one side (see illustrations). 3.5c ... for access to the mounting nuts
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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
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22.3b Disconnect the yellow wiring
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Key to symbols — t ; j^g. Item nu
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Wire colours W White R Red Y Yellow
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Wire colours W White O Orange R Red
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Wire colours W White O Orange R Red
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Wire colours W R Y Br P Bl Gr G B V
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Wire colours Key to items w R Y Br
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11 »2 Bodywork and fittings which
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11 »4 Bodywork and fittings 6 Fron
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'\'\»6 Bodywork and fittings the c
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11 »8 Bodywork and fittings 10.11
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11*10 Bodywork and fittings 7 If wo
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11*12 Bodywork and fittings 16.10 R
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11*14 Bodywork and fittings 18.3a U
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11*16 Bodywork and fittings 18.23a
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11*18 Bodywork and fittings 20.15b
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11 »22 Bodywork and fittings 16 Wi
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10*2 Suspension and steering system
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1f>8 Suspension and steering system
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10*10 Suspension and steering syste
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10«12 Suspension and steering syst
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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
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: Chapter 5 Part A: Starting and char
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
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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
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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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