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 experience g^ Fairty easy, suitable |k for beginner with some experience g^ Fairly difficult, |k suitable for competent ^ 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 ^ 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 <strong>To</strong>rque 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
Location of TDC on No 1 cylinder 1 Remove the camshaft cover as described in Section 6. 2 With the car parked on a level surface, apply the handbrake and chock the rear wheels. Loosen the right-hand front wheel bolts. 3 Raise the front of the car, rest it securely on axle stands and remove the right-hand front roadwheel. 4 Unscrew and release the fasteners, and remove the wheelarch inner panel, to gain access to the crankshaft pulley. 5 Have an assistant turn the engine using a spanner or socket on the crankshaft pulley bolt. As this is done, place your hand over No 1 spark plug hole, and feel for pressure build-up. 6 Once pressure is felt, insert the shaft of a large screwdriver (or, if available, a dial gauge and probe) down No 1 spark plug hole. When TDC is reached, the screwdriver will stop rising (or the reading on the dial gauge will stop increasing). 7 Once the screwdriver (or dial gauge reading) starts to rise, continue turning the engine until the crankshaft pulley timing mark is aligned with the mark on the timing belt lower cover (see illustration). 8 A further TDC mark is provided on the flywheel, and this can be viewed through the aperture in the transmission bellhousing (remove the aperture cover, where fitted) (see illustrations). When the flywheel mark aligns with the notch on the bellhousing, the engine is set to TDC. This mark is quite difficult to see, however, without further dismantling. 9 The engine is now set at TDC on No 1 cylinder. 3 Cylinder compression test 1 When engine performance is down, or if misfiring occurs which cannot be attributed to the ignition or fuel systems, a compression test can provide diagnostic clues as to the engine's condition. If the test is performed regularly, it can give warning of trouble before any other symptoms become apparent. 2 The engine must be fully warmed-up to normal operating temperature, the battery must be fully charged, and all the spark plugs must be removed (Chapter 1). The aid of an assistant will also be required. 3 Disable the ignition system by disconnecting the LT wiring plug to the ignition coil. 4 <strong>To</strong> prevent possible damage to the catalytic converter, depressurise and disable the fuel injection system by removing the fuel pump fuse or relay (see Chapter 4B, Section 7). 5 Fit a compression tester to the No 1 cylinder spark plug hole - the type of tester which 2.7 Camshaft pulley timing mark aligned with mark on timing belt lower cover screws into the plug thread is to be preferred. 6 Have the assistant hold the throttle wide open, and crank the engine on the starter motor; after one or two revolutions, the compression pressure should build up to a maximum figure, and then stabilise. Record the highest reading obtained. 7 Repeat the test on the remaining cylinders, recording the pressure in each. 8 All cylinders should produce very similar pressures; any excessive difference indicates the existence of a fault. Note that the compression should build up quickly in a healthy engine; low compression on the first stroke, followed by gradually increasing pressure on successive strokes, indicates worn piston rings. A low compression reading on the first stroke, which does not build up during successive strokes, indicates leaking valves or a blown head gasket (a cracked head could also be the cause). 1.8 litre engine in-car repair procedures 2D»3 2.8a Removing the flywheel aperture cover - seen with the airflow meter removed 9 If the pressure in any cylinder is very low, carry out the following test to isolate the cause. Introduce a teaspoonful of clean oil into that cylinder through its spark plug hole and repeat the test. 10 If the addition of oil temporarily improves the compression pressure, this indicates that bore or piston wear is responsible for the pressure loss. No improvement suggests that leaking or burnt valves, or a blown head gasket, may be to blame. 11 A low reading from two adjacent cylinders is almost certainly due to the head gasket having blown between them; the presence of coolant in the engine oil will confirm this. 12 If one cylinder is about 20 percent lower than the others and the engine has a slightly rough idle, a worn camshaft lobe could be the cause. 13 On completion of the test, refit the spark plugs and restore the ignition and fuel systems. 2.8b Showing flywheel alignment at TDC - also shows crankshaft sprocket alignment with sump
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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
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Refitting 20 Refit the injectors an
Page 181 and 182: Unplug the wiring connectors and un
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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 and 230: 11.19 Lubricate the crankcase main
Page 231: 2D»2 1.8 litre engine in-car repai
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
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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 273 and 274: paragraph 17), then remove the heat
Page 275 and 276: to the downpipe. The safest option
Page 277 and 278: 13.8 Using an impact screwdriver to
Page 279 and 280: 2A«2 1.2 litre engine in-car repai
Page 281 and 282: 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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