Bravo & Brava • 1995 To 2000

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Chapter 2 Part D: 1.8 litre engine in-car repair procedures Contents Auxiliary drivebelt - removal and refitting See Chapter 1 Camshaft cover - removal and refitting 6 Camshaft oil seals - renewal 7 Camshafts - removal and refitting See Chapter 2E, Section 4 Crankshaft oil seals - renewal 8 Cylinder compression test 3 Cylinder head - dismantling and overhaul See Chapter 2E Cylinder head - removal and refitting 9 Engine mountings - inspection and renewal 11 Engine oil and filter - renewal See Chapter 1 Degrees of difficulty Easy, suitable for |k novice with little expenence g^ Fairty easy, suitable |k for beginner with some experience g^ Fairty difficult ^ suitable for competent g^ DIY mechanic g^ 2D-1 Engine oil level - check See Weekly Checks Flywheel - removal, inspection and refitting 10 General information 1 Location of TDC on No 1 cylinder 2 Oil pressure switch - removal and refitting 14 Oil pump and pick-up tube - removal and refitting 13 Sump - removal and refitting 12 Timing belt and covers - removal and refitting 4 Timing belt sprockets and tensioner - removal and refitting 5 Difficult, suitable for |k experienced DIY 3^ mechanic g^ Specifications General Engine code* 182A2.000 Bore 82.0 mm Stroke 82.7 mm Compression ratio 10.3:1 Firing order 1-3-4-2 No 1 cylinder location Timing (right-hand) end of engine *Note: See 'Vehicle identification numbers' for the location of code marking on the engine. Lubrication system Oil pump type Bi-rotor driven from front of crankshaft Outer rotor-to-housing clearance 0.080 to 0.186 mm Axial clearance 0.025 to 0.070 mm Oil pressure (at operating temperature) 15 psi at idle, 50 to 72 psi at 4000 rpm Torque wrench settings Nm ibf ft Air conditioning compressor mounting bracket-to-block 50 37 Alternator mounting bracket-to-block: M8 bolts 25 18 M10 bolts 70 52 Big-end (connecting rod) bearing cap bolts: Stage 1 25 18 Stage 2 Angle-tighten a further 60° Camshaft bearing caps 15 11 Camshaft cover 9 7 Camshaft sprocket bolt 120 89 Coolant pipe to block 9 7 Crankshaft pulley-to-sprocket bolts 32 24 Crankshaft sensor 9 7 Crankshaft sprocket bolt (left-hand thread) 360 266 Cylinder head: Stage 1 20 15 Stage 2 40 30 Stage 3 Angle-tighten a further 90° Stage 4 Angle-tighten a further 90° Stage 5 Angle-tighten a further 90° Very difficult, suitable for expert DIY 3^ or professional g^
2D»2 1.8 litre engine in-car repair procedures Torque wrench settings (continued) Nm ibf ft Engine/transmission mountings: Mounting brackets-to-transmission: M10 bolts 50 37 M12 bolts 80 59 Mounting through-bolts: Front mounting 38 28 Left- and right-hand mountings 80 59 Reaction rod through-bolt 25 18 Mountings to bodyshell 32 24 Right-hand mounting brackets-to-block 70 52 Right-hand mounting reaction rod to strut bracket 50 37 Exhaust manifold nuts 25 18 Flywheel* 160 118 Inlet manifold nuts 25 18 Knock sensor 25 18 Main bearing cap bolts: Stage 1 25 18 Stage 2 Angle-tighten a further 100° Oil pressure switch 32 24 Oil pump bolts: M6bolt 9 7 M8bolt 25 18 Sump bolts: M6bolt 9 7 M8bolt 25 18 Thermostat housing bolts 25 18 Timing belt covers 9 7 Timing belt fixed guide pulley bolt 25 18 Timing belt tensioner nut 25 18 'Although not specifically recommended by FIAT, use new bolts and locking fluid. 1 General information Using this Chapter Chapter 2 is divided into five Parts; A to E. Repair operations that can be carried out with the engine in the car are described in Parts A to D. Part E covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A to D, the assumption is made that the engine is installed in the car, with all ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored. Engine description The 1.8 litre engine is a water-cooled, double overhead camshaft, in-line fourcylinder unit, with cast-iron cylinder block and aluminium-alloy cylinder head. The engine is a 16-valve unit, with two inlet valves and two exhaust valves per cylinder. The engine is mounted transversely at the front of the car, with the transmission bolted to the left-hand side of the engine. The cylinder head carries the camshafts, which are driven by a toothed timing belt. Each camshaft runs in six bearings. The cylinder head also houses the inlet and exhaust valves, which are closed by single coil springs, and which run in guides pressed into the cylinder head. The camshafts actuate the valves directly via hydraulic tappets mounted in the cylinder head. The cylinder head contains integral oilways which supply and lubricate the tappets. The crankshaft is supported by five main bearings, and endfloat is controlled by thrust washers fitted either side of the centre main bearing. Engine coolant is circulated by a pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from the sump through a strainer, and then forced through an externallymounted, replaceable screw-on filter. From there, it is distributed to the cylinder head, where it lubricates the camshaft journals and tappets, and also to the crankcase, where it lubricates the main bearings, connecting rod big and small-ends, gudgeon pins and cylinder bores. Four jets mounted on the base of the crankcase spray oil onto the undersides of the pistons, to aid cooling. Note: Several components are secured by Ribe bolts, which are similar in appearance to Torx types, but require different tools. A set of Ribe sockets can be obtained from good tool stockists. Among the components affected are the camshaft cover, sump and cylinder head. Repair operations possible with the engine in the car The following work can be carried out with the engine in the car: a) Auxiliary drivebelt - removal and refitting (see Chapter 1). b) Camshafts - removal and refitting*. c) Camshaft oil seals - renewal. d) Camshaft sprockets - removal and refitting. ej Coolant pump - removal and refitting (refer to Chapter 3). fj Crankshaft oil seals - renewal. g) Crankshaft sprocket - removal and refitting. h) Cylinder head - removal and refitting. i) Engine mountings - inspection and renewal. j) Oil pump and pickup assembly - removal and refitting, k) Sump. I) Timing belt, sprockets and cover - removal, inspection and refitting. 'Cylinder head dismantling procedures are detailed in Chapter 2E, with details of camshaft and tappet removal. Note: It is possible to remove the pistons and connecting rods (after removing the cylinder head and sump) without removing the engine. However, this is not recommended. Work of this nature is more easily and thoroughly completed with the engine on the bench, as described in Chapter 2E.
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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
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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
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6*2 Clutch 1 General information Ve
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6«4 Clutch 6.4 Clutch slave cylind
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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
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6.1 Crankshaft sensor on 1.6 litre
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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
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
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: 11.19 Lubricate the crankcase main
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 253 and 254: 2O10 1.6 litre engine in-car repair
Page 255 and 256: 2012 1.6 litre enginein-car repair
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
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Page 279 and 280: 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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