Bravo & Brava • 1995 To 2000

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1.6 Maintenance - component locations Front underside view of 1.6 litre model Rear underside view of 1.6 litre model Horn unit Oil filter Radiator cooling fan 4 Starter motor Radiator bottom hose Front brake caliper Driveshaft CV joint gaiter Track rod end Manual transmission drain plug 10 Engine oil drain plug 11 Right-hand driveshaft 12 Exhaust downpipe 13 Oxygen sensor 14 Subframe 15 Suspension arm 1 Brake pipe/hose connection 2 Fuel tank 3 Handbrake cables 4 Fuel tank retaining straps 5 Rear suspension arm 6 Rear shock absorber mounting 7 Rear coil spring 8 Exhaust rear silencer 9 Exhaust heat shield 10 Brake pressure proportioning valve
1 Introduction General information This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components. Servicing your vehicle in accordance with the mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service intervals, will not produce the same results. As you service your vehicle, you will discover that many of the procedures can - and should - be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwise unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components. The first step in this maintenance programme is to prepare yourself before the actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department. 2 Regular maintenance 1 If, from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised. 2 It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out, outside of the regular maintenance intervals. 3 If engine wear is suspected, a compression test (refer to the relevant part of Chapter 2) will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to be carried out. If, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this Chapter will not greatly improve the perform Every 12 000 miles (20 000 km) 3 Engine oil and filter renewal % I 1 Frequent oil and filter changes are the most important maintenance procedures which can be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear. 2 The oil change interval given in this Manual is the same as quoted by the manufacturer, but owners of older vehicles (or those covering a small annual mileage) may feel justified in changing the oil and filter more frequently, perhaps every 6000 miles, or every 6 months. The quality of engine oil used is a significant factor in this - the 12 000-mile interval only applies if a high-quality synthetic-based oil is used. 3 Before starting this procedure, gather all the necessary tools and materials. Also make sure that you have plenty of clean rags and newspapers handy, to mop up any spills. Ideally, the engine oil should be warm, as it will drain better, and more built-up sludge will be removed with it. Take care, however, not to touch the exhaust or any other hot parts of the engine when working under the vehicle. <strong>To</strong> avoid any possibility of scalding, and to protect yourself from possible skin irritants and other harmful contaminants in used engine oils, it is advisable to wear gloves when carrying out this work. 4 Remove the oil filler cap (see illustration), and take out the dipstick. 5 Access to the underside of the vehicle will be greatly improved if it can be raised on a lift, driven onto ramps, or jacked up and 3.4 Removing the oil filler cap on a 1.6 litre model Maintenance procedures w ance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first. 4 The following series of operations are those most often required to improve the performance of a generally poor-running engine: Primary operations a) Clean, inspect and test the battery (See Weekly checks and Section 6, where applicable). b) Check all the engine-related fluids (See Weekly checks). c) Check the condition and tension of the auxiliary drivebelt (Sections 7 and 21). d) Renew the spark plugs (Section 18). e) Check the condition of the air filter, and renew if necessary (Section 19). f) Check the fuel filter, where applicable (Section 20). g) Check the condition of all hoses, and check for fluid leaks (Section 9). h) Check the exhaust gas emissions (Section 24). 5 If the above operations do not prove fully effective, carry out the following secondary operations: Secondary operations All items listed under Primary operations, plus the following: a) Check the charging system (see Chapter 5A, Section 4). b) Check the ignition system (see Chapter 5B). c) Check the fuel system (see relevant Part of Chapter 4). d) Renew the ignition HT leads, if applicable. supported on axle stands (see Jacking and vehicle support). Whichever method is chosen, make sure that the vehicle remains level, or if it is at an angle, that the drain plug is at the lowest point. 6 Where applicable, unscrew the fasteners and remove the engine undertray, for access to the drain plug. On 1.8 litre engines, the drain plug can be reached from the back of the engine, and a panel is provided in the undertray, which can be hinged down to get to the filter (see illustration). 3.6 Removing the oil filter access panel on a 1.8 litre model
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 and 20: Chapter 1 Routine maintenance & ser
Page 21 and 22: Torque wrench settings (continued)
Page 23: 1 Washer reservoir 2 Inlet manifold
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
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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
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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
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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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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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