Bravo & Brava • 1995 To 2000

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4A»6 Fuel system - single-point injection 5.5 Disconnecting the charcoal canister hose at the inner wing 4 Disconnect the accelerator cable inner from the remote throttle disc cam as described in Section 4, then disconnect the link rod from the spigot on the throttle disc cam. 5 Disconnect the vacuum hoses that serve the EVAP purge valve and intake air flap valve from the throttle body. Alternatively, the EVAP 5.6 Throttle body through-bolts (A), fuel pressure regulator screws (B) and injector securing screw (C) hose can be disconnected at the connector above the inner wing (see illustration). 6 Slacken and remove the four through-bolts securing the throttle body assembly to the inlet manifold, then remove the assembly along with its insulating spacer (see illustration). Unless specifically required, it is 5.12 Upper half of throttle body, showing injector fitting details Throttle body upper section Fuel pressure regulator O-ring Securing washer Gasket 6 Injector/air inlet temperature sensor securing screw Air inlet temperature sensor Fuel injector 9 Fuel supply connection 10 Upper-to lower section gasket 11 Fuel return connection 12 Seal 13 Fuel hose connection stub not recommended that the upper and lower halves of the throttle body are separated - these are held together by two inner throughbolts. If the two halves are split, a new gasket must be used on reassembly. Refitting 7 Refitting is a reversal of the removal procedure, bearing in mind the following points: a) Examine the insulating spacer for signs of damage, and renew if necessary. b) Ensure that the throttle body, inlet manifold and insulating spacer mating surfaces are clean and dry, then fit the throttle body and spacer, and securely tighten the retaining bolts. c) Ensure that all hoses are correctly reconnected and, where necessary, that their retaining clips are securely tightened. d) Adjust the accelerator cable as described in Section 4. Fuel injector Note: If a faulty injector is suspected, before condemning the injector, it is worth trying the effect of one of the proprietary injector cleaning treatments. Removal 8 Remove the air box and the associated air ducting from the top of the throttle body as described in Section 2. 9 Refer to Section 8 and depressurise the fuel system, then disconnect the battery negative lead and position it away from the terminal. 10 Unplug the wiring harness from the injector. 11 Remove the screw and lift off the injector retaining cap/inlet air temperature sensor housing. Recover the gasket. 12 Release the securing washer, then lift the injector out of the throttle body, recovering the O-ring seals (see illustration). Refitting 13 Refit the injector by following the removal procedure in reverse, renewing all O-ring seals and gaskets. Apply a suitable sealant to the screw threads, then insert and tighten the retaining screw. Fuel pressure regulator Removal 14 Remove the air box and the associated air ducting from the top of the throttle body as described in Section 2. 15 Using a marker pen, make alignment marks between the regulator cover and the throttle body, then undo the three <strong>To</strong>rx retaining screws. As the screws are loosened, place a rag over the cover to catch any fuel spray which may be released. 16 Lift off the cover, then remove the spring and withdraw the diaphragm, noting its correct fitted orientation. Remove all traces of dirt, and examine the diaphragm for signs of splitting. If damage is found, it may be necessary to renew the complete throttle body assembly - consult a FIAT dealer or Bosch agent.
Refitting 17 Refitting is a reversal of removal, ensuring that the diaphragm and cover are fitted the correct way round, and that the retaining screws are securely tightened. Idle control stepper motor Removal 18 Remove the air box and the associated air ducting from the top of the throttle body as described in Section 2. 19 Using a crosshead screwdriver, unscrew the three mounting screws and remove the stepper motor from the throttle body. Recover the gasket. 20 Clean the unit and check for damage and wear. Refitting 21 When refitting the unit, use a new gasket and make sure that the plunger is inserted correctly using the following procedure: a) Insert the unit and refit the mounting screws loosely. b) Reconnect the wiring, then switch on the ignition several times so that the unit centralises itself. c) Securely tighten the mounting screws. d) Disconnect the battery negative cable, and leave it disconnected for about 20 minutes - the injection/ignition ECU will then position the idle control stepper motor correctly when the battery is reconnected and the engine is started for the first time. Throttle potentiometer 22 The position of the throttle potentiometer with respect to the throttle disc is pre-set at the factory. Consequently, if the potentiometer is found to be faulty, the entire throttle body must be renewed. Inlet air temperature sensor 23 The inlet air temperature sensor is an integral part of the fuel injector assembly, and cannot apparently be renewed separately - check with a FIAT dealer or Bosch agent. Coolant temperature sensor Removal 24 The coolant temperature sensor is located 5.38a Remove the screw at the front... 5.26 Disconnect the wiring from the coolant temperature sensor on the left-hand side of the cylinder head, threaded into the coolant outlet elbow. 25 Drain the cooling system with reference to Chapter 1. 26 Unplug the wiring from the sensor at the connector (see illustration). 27 Unscrew the sensor and remove it from the cylinder head. Recover the sealing washer where fitted. If using a socket, take care not to damage the wiring connector on the sensor. Refitting 28 Refitting is a reversal of removal. Where applicable, fit a new sealing washer. Tighten the sensor to the specified torque. Do not exceed the specified torque otherwise the unit's threads may be damaged. Crankshaft TDC sensor 29 Refer to Chapter 5B, Section 6. Electronic control unit (ECU) Note: The ECU communicates with the antitheft/immobiliser system when the vehicle is started; once the ignition key electronic code has been stored by the ECU, it cannot be used on any other vehicle. For this reason, do not attempt to diagnose problems with the engine management system by connecting the ECU to another vehicle, or by substituting an ECU from another vehicle. Removal 30 The ECU (electronic control unit) is mounted on the bulkhead at the rear of the engine compartment. 31 Prior to removal, disconnect the battery negative cable from its terminal. Discon- 5.38b ... and at the rear... Fuel system - single-point injection 4A»7 5.32 Engine management ECU necting the ECU multi-plug while there is any power connected to it may well result in damage to the ECU. 32 Release the locking clip at the lower end of the multiway connector, then unhook the upper end by pivoting the connector away from the ECU. Undo the retaining screws and remove the ECU trom its bracket (see illustration). Refitting 33 Refitting is a reversal of removal, making sure that the wiring connector is securely reconnected. Inertia switch Removal - early models 34 The inertia safety switch is located underneath the driver's seat. Slide the seat back as far as possible then pull back the carpet for access. 35 Unscrew the two securing bolts, then disconnect the wiring and remove the switch from the vehicle. Refitting 36 Refitting is a reversal of removal. If the switch was tripped during removal, reset it after refitting by depressing the centre of the rubber cap. Removal - later models 37 On later models, the inertia switch is located behind a plastic panel to the left of the passenger's footwell. 38 Remove the sill trim panel by removing the two screws and releasing the securing clips (see illustrations). 5.38c ... then release the clips and remove the sill trim panel
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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
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Chapter 7 Part B: Automatic transmi
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2.19a Two of the six bolts securing
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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 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: 5.1 Disconnect the breather hose fr
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
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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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