Bravo & Brava • 1995 To 2000

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4B«14 Fuel system - multi-point injection 8.20 Disconnecting the EVAP hose from the inlet manifold 23 Unbolt the two manifold support brackets from the rear of the engine. The two bolts securing each one are not easy to get to - the first pair is just above the bearing/shield for the right-hand driveshaft, with the second pair (on an alloy bracket) directly above the first. 24 Returning to the engine compartment, progressively loosen and remove the nuts securing the inlet manifold assembly to the cylinder head. Carefully withdraw the manifold from the studs, and out from the engine compartment. Recover the gasket. Refitting - all models 25 Refitting is a reverse of the removal procedure, noting the following points: a) Ensure that the manifold and cylinder head mating surfaces are clean and dry, and fit a new manifold gasket. Refit the manifold and securely tighten its retaining nuts. b) Ensure all relevant hoses are reconnected to their original positions and are securely held (where necessary) by the retaining clips. c) Refit the fuel rail and injectors, and the throttle body assembly (Section 4). d) On completion, refill the cooling system as described in Chapter 1. 9 Fuel injection system - gS Checking checking and adjustment S Note: Also see Chapter 5B, Section 3. 1 Before disconnecting any of the injection system wiring, ensure that the ignition is switched off (take out the key). 9.9a Diagnostic connector on 1.6 litre model 8.21 Ignition power module wiring plugs (arrowed) 2 If a fault appears in the fuel injection system, first ensure that all the system wiring connectors are securely connected and free of corrosion. Also check the wiring harness for signs of damage, such as may result if the wiring is routed too close to a hot component, for example. 3 Remove the cover(s) from the fuse/relay box(es) on the engine compartment bulkhead, and check the connections to the fuses and relays. With the ignition switched off, remove the fuses and relays in turn, and check that the fuse and relay contacts, and their sockets in the box, are clean. Refit the fuses and relays securely. 4 The system's main earth point varies according to model, as follows: 1.2 litre engine - adjacent to the knock sensor, at the rear of the engine, between cylinders 2 and 3. 1.6 litre engine - on the rear bolt securing the exhaust camshaft housing end cover. 1.8 litre engine - at the rear of the cylinder block, just behind the timing belt cover. 5 Remove the nut or bolt securing the earth terminal, and clean all contact surfaces thoroughly. Refit the terminal, and tighten the nut or bolt securely. 6 Then ensure that the fault is not due to poor maintenance; ie, check that the air cleaner filter element is clean, the spark plugs are in good condition and correctly gapped, the HT leads are securely connected and in good condition, and that the engine breather hoses are clear and undamaged. 7 Check all the ignition system components and wiring as far as possible, using the information in Chapters 1 and 5B. Sometimes 9.9b Diagnostic connector on 1.8 litre model it can be difficult to determine whether a misfire is fuel or ignition-related. 8 If the engine is difficult to start, or runs poorly, when cold, the problem may be that the engine management system has gone into emergency back-up mode. This, and the nature of the fault that caused it to happen, can only be determined using diagnostic equipment such as a fault code reader. 9 A diagnostic connector is provided, into which a fault code reader can be plugged. The test equipment is capable of 'interrogating' the engine management system electronically and accessing its internal fault log. The location of the diagnostic connector varies according to model, as follows: 1.2 litre engine - on the fuse/relay box at the left-hand rear of the engine compartment. 1.6 litre engine - adjacent to the injection/ignition ECU, or on the fuse/relay box at the left-hand rear of the engine compartment (see illustration). 1.8 litre engine - at the rear right-hand side of the engine compartment, just in front of the suspension strut top mounting, or between the battery and air cleaner (see illustration). 10 Fault codes can only be extracted from the ECU using a dedicated fault code reader. A FIAT dealer will obviously have such a reader, but they are also available from other suppliers, including Haynes. It is unlikely to be cost-effective for the private owner to purchase a fault code reader, but a wellequipped local garage or automotive electrical specialist will have one. 11 Using this equipment, faults can be pinpointed quickly and simply, even if their occurrence is intermittent. Testing all the system components individually in an attempt to locate the fault by elimination is a timeconsuming operation that is unlikely to be fruitful (particularly if the fault occurs dynamically), and carries high risk of damage to the ECU'S internal components. Adjustment 12 Experienced home mechanics equipped with an accurate tachometer and a carefullycalibrated exhaust gas analyser may be able to check the exhaust gas CO content and the engine idle speed; if these are found to be out of specification, then the vehicle must be taken to a suitably-equipped FIAT dealer for assessment. 13 Neither the air/fuel mixture (exhaust gas CO content) nor the engine idle speed are manually adjustable; incorrect test results indicate the need for maintenance (possibly, injector cleaning) or a fault within the fuel injection system. 10 Unleaded petrol - general information and usage Refer to Section 11 in Chapter 4A.
Chapter 4 Part A: Fuel system - single-point injection Contents Accelerator cable - removal, refitting and adjustment 4 Air cleaner and inlet system - removal and refitting 2 Air cleaner filter element - renewal See Chapter 1 Engine management system components - removal and refitting .. 5 Fuel filter - renewal See Chapter 1 Fuel injection system - depressurisation 8 Fuel injection system - testing and adjusting 10 Degrees of difficulty Easy, suitable for |k novice with little Jk experience g^ Specifications System type 1.4 litre models . Fairty easy, suitable |k for beginner with ^ some experience g^ Fairty difficult, |k suitable for competent g^ DIY mechanic g^ 4A«1 Fuel pump/fuel gauge sender unit - removal and refitting 6 Fuel tank - removal and refitting 7 General information and precautions 1 Inlet air temperature regulator - removal and refitting 3 Inlet manifold - removal and refitting 9 Unleaded petrol - general information and usage 11 Bosch Mono-Motronic Difficult, suitable for |k experienced DIY ^ mechanic g^ Fuel injection system data Fuel pump type Electric, immersed in fuel tank Fuel pump delivery rate 120 litres/hour minimum Regulated fuel pressure Inlet air temperature sensor resistance (approx.): 1.0 ± 0.2 bar At 20°C 2300 ohms At-10°C Coolant temperature sensor resistance (approx.): 9000 ohms At-10°C 9000 ohms At 20°C 2300 ohms At 100°C 180 ohms Injector duration (at idle) 1.5 ms Engine idle speed (not adjustable) Exhaust emissions limits: 850 ± 50 rpm CO 0.35 % maximum HC 90 ppm maximum C0 2 13 % maximum Accelerator cable throttle disc cam-to-stop clearance 0.2 to 0.5 mm Recommended fuel Minimum octane rating <strong>To</strong>rque wrench settings Fuel tank Inlet manifold Inlet-union to filter Outlet union to filter Throttle body-to-manifold bolts: M6 bolts M8 bolts 95 RON unleaded (Premium unleaded) Nm Ibf ft 25 18 5 4 28 21 4 3 25 18 31 23 15 11 9 7 25 18 Throttle potentiometer 25 18 Very difficult, suitable for expert DIY ^ or professional g^ 4A
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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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10*14 Suspension and steering syste
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9*2 Braking system Anti-lock brakin
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9*4 Braking system 4.2 Disconnectin
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9*6 Braking system 5 Unhook the sel
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9*8 Braking system 5.27 Removing th
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9*10 Braking system 8.4 Disconnecti
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9»12 Braking system K-0 10.13 Cros
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9»14 Braking system 25 Working ins
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9*16 Braking system 2 Unbolt the ex
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8*2 Driveshafts 1 General informati
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8*4 Driveshafts 3.23a Extract the c
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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
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: 8.8b ... and remove this wiring har
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
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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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