Bravo & Brava • 1995 To 2000

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1-2 Servicing specifications Lubricants and fluids Refer to end of Weekly checks on page 0*17 Capacities Engine oil (including filter): 1.2 litre engine 2.8 litres 1.4 litre engine 4.1 litres 1.6 litre engine 3.8 litres 1.8 litre engine 4.3 litres Cooling system (approximate): 1.2 and 1.4 litre engines 6.0 litres 1.6 and 1.8 litre engines 7.0 litres Transmission (approximate): Manual transmission: 1.2 and 1.4 litre engine models 1.65 litres 1.6 and 1.8 litre engine models 2.0 litres Automatic transmission (fluid change) 4.3 litres Fuel tank (approximate): Except 1.8 litre models 50 litres 1.8 litre models 60 litres Washer reservoir: Models with headlight washers 6.4 litres Models without headlight washers 5.0 litres Engine Oil filter: 1.2,1.4 and 1.6 litre engines Champion F107* 1.8 litre engine: Up to March 1996 Champion F107* April 1996 onwards Champion F133* *Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283. Cooling system Antifreeze mixture: 40% antifreeze Protection down to -25°C 50% antifreeze Protection down to -35°C Note: Refer to antifreeze manufacturer for latest recommendations. Fuel system Air filter element: Except 1.2 litre engine Champion U564* 1.2 litre engine Champion type not available* Fuel filter Champion L225* *Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283. Ignition system Ignition timing Refer to Chapter 5B Spark plugs: Except 1.2 litre engine Champion RC8BYC or RC7YC* 1.2 litre engine Champion RA4HCX or RA4HC* Electrode gap**: Champion RC8BYC Not adjustable Champion RA4HCX 0.8 mm (0.032 in) Champion RC7YC or RA4HC 0.7 mm (0.028 in) *Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283. "The spark plug electrode gap is as quoted by Champion for their recommended plugs. If spark plugs of any other type are to be used, refer to their manufacturer's specifications. Clutch Clutch pedal stroke (see Section 22): 1.2 and 1.4 litre models (where applicable) 155 ±10 mm 1.6 and 1.8 litre models 170 ±10 mm Brakes Brake pad/shoe friction material minimum thickness 1.5 mm Torque wrench settings Nm ibfft Manual transmission drain plug 46 34 Manual transmission filler/level plug 46 34 Roadwheel bolts 86 63
Torque wrench settings (continued) Spark plugs: All except 1.6 litre engine 1.6 litre engine Sump drain plug: Maintenance schedule The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum intervals recommended for vehicles driven daily. If you wish to keep your Every 250 miles (400 km) or weekly • Refer to Weekly checks Every 12 000 miles (20 000 km) or 12 months In addition to the items listed in the previous services, carry out the following: • Renew the engine oil and filter (Section 3) • Check the front brake pad thickness (Section 4) • Check the automatic transmission fluid level (Section 5) • Check battery electrolyte level - where applicable (Section 6) • Check the tension of the auxiliary drivebelt(s) (Section 7) • Renew the pollen filter element (Section 8) • Check all underbonnet/underbody components and hoses for fluid leaks (Section 9) • Check the transmission and driveshaft gaiters for leaks and damage (Section 10) • Check the brake pipes and hoses for leaks and damage (Section 11) • Check the condition of the exhaust system and its mountings (Section 12) • Check the steering and suspension components for condition and security (Section 13) • Check underbody protection for damage (Section 14) • Check operation of all lights and horn (Section 15) • Lubricate all hinges, locks and door check straps (Section 16) • Carry out a road test (Section 17) Every 24 000 miles (40 000 km) or 2 years In addition to the items listed in the previous services, carry out the following: • Renew the spark plugs (Section 18) • Renew the air filter element (Section 19) • Renew the fuel filter, where applicable (Section 20) Servicing specifications 1.3 Nm Ibf ft 25 18 27 20 10 7 25 "18 50 37 20 15 vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, since it enhances the efficiency, performance and resale value of your vehicle. When the vehicle is new, it should be serviced by a dealer service department, in order to preserve the factory warranty. Every 24 000 miles (40 000 km) or 2 years (continued) • Check the condition of the auxiliary drivebelt(s), and renew if necessary (Section 21) i"l Check clutch cable adjustment, where applicable (Section 22) U Check handbrake adjustment (Section 23) i i Check exhaust gas emissions (Section 24) 1 i Check engine management system for fault codes (Section 25) Every 36 000 miles (60 000 km) or 2 years In addition to the items listed in the previous services, carry out the following: i I Renew the brake fluid (Section 26) • Check the manual transmission oil level (Section 27) • Check the rear brake shoe lining thickness (Section 28) Every 48 000 miles (80 000 km) or 4 years In addition to the items listed in the previous services, carry out the following: i i Check the evaporative emissions control system (Section 29) Every 72 000 miles (120 000 km) In addition to all the items listed above, carry out the following: • Renew the timing belt (Section 30) Note: It is strongly recommended that the interval is halved to 36 000 miles (60 000 km), particularly on vehicles which are subjected to intensive use, ie. mainly short journeys or a lot of stopstart driving. The actual belt renewal interval is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks. Every 2 years (regardless of mileage) Li Renew the coolant (Section 31)
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: Chapter 1 Routine maintenance & ser
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
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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
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Chapter 7 Part A: Manual transmissi
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2 Gearchange lever and linkage remo
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hoist to the left-hand end of the i
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) Apply a smear of high-melting-poi
Page 149 and 150:
6*2 Clutch 1 General information Ve
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6«4 Clutch 6.4 Clutch slave cylind
Page 153 and 154:
Chapter 5 Part B: Ignition system C
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2.8 Diagnostic connector plug locat
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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
Page 203 and 204:
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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Page 291 and 292:
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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
Page 305 and 306:
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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Page 319 and 320:
Page 321 and 322:
REF
Page 323 and 324:
REF
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Bravo & Brava • 1995 To 2000

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