Bravo & Brava • 1995 To 2000

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i.a Every 12 000 miles (20 000 km) 3.7 On some models, a special socket is required to loosen the sump drain plug 7 Using a special socket where necessary, slacken the drain plug (on the base of the sump) about half a turn (see illustration). Position the draining container under the drain plug, then remove the plug completely. Recover the sealing ring from the drain plug. 8 Allow some time for the old oil to drain, noting that it may be necessary to reposition the container as the oil flow slows to a trickle (see illustration). 9 After all the oil has drained, wipe off the drain plug with a clean rag, and fit a new sealing washer. Clean the area around the drain plug opening, and refit the plug. Tighten the plug securely. 10 Move the container into position under the 011 filter, which is located on the front of the cylinder block. 11 Using an oil filter removal tool if necessary, slacken the filter initially, then unscrew it by hand the rest of the way (see illustration). Empty the oil in the filter into the container. 12 Use a clean rag to remove all oil, dirt and sludge from the filter sealing area on the engine. Check the old filter to make sure that the rubber sealing ring has not stuck to the engine. If it has, carefully remove it. 13 Apply a light coating of clean engine oil to the sealing ring on the new filter, then screw it into position on the engine (see illustration). Tighten the filter firmly by hand only - do not use any tools. 14 Remove the old oil from under the car, then refit the undertray or access panel (as applicable). Lower the car to the ground. 3.13 Fit and tighten the new oil filter by hand only - do not use any tools rt'!' • 3.8 Draining the engine oil 15 With the car on level ground, fill the engine, using the correct grade and type of oil (see Lubricants and fluids). An oil can spout or funnel may help to reduce spillage (see illustration). Pour in half the specified quantity of oil first, then wait a few minutes for the oil to fall to the sump. 16 Continue adding oil a small quantity at a time until the level is up to the MIN mark on the dipstick. Adding around 1.0 litre of oil will now bring the level up to the MAX on the dipstick - do not worry if a little too much goes in, as some of the apparent excess will be taken up in filling the oil filter. Refit the dipstick and the filler cap. 17 Start the engine and run it for a few minutes; check for leaks around the oil filter seal and the sump drain plug. Note that there may be a few seconds' delay before the oil pressure warning light goes out when the engine is started, as the oil circulates through the engine oil galleries and the new oil filter before the pressure builds up. 18 Switch off the engine, and wait a few minutes for the oil to settle in the sump once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary. 19 Dispose of the used engine oil safely, with reference to General repair procedures in the Reference section of this manual. 4 Front brake pad check ^ 1 1 Firmly apply the handbrake, loosen the front road wheel bolts, then jack up the front of the car and support it securely on axle stands. Remove the front roadwheels. 2 For a comprehensive check, the brake pads should be removed and cleaned. The operation of the caliper can then also be checked, and the condition of the brake disc itself can be fully examined on both sides. Refer to Chapter 9. 3 If any pads friction material is worn to the specified thickness or less, all four pads must be renewed as a set. 4 Check the operation of the pad wear warning light by disconnecting the wiring plug 3.11 Removing the oil filter on a 1.8 litre model adjacent to the brake caliper. With the ignition on, touch the wiring plug to earth, and check that the warning light comes on. 5 Automatic transmission ^ fluid level check i| f| 1 Ideally, the fluid level must be checked with the engine/transmission at operating temperature. This can be achieved by checking the level after a journey of at least 10 miles. If the level is checked when cold, follow this up with a level check when the fluid is hot. 2 Park the car on level ground, and apply the handbrake very firmly. As an added precaution, chock the front and rear wheels, so that the car cannot move. 3 With the engine idling, move the selector lever gently from position P to position 1, and back to P. 4 The fluid level dipstick is located on the front of the transmission. Before removing the dipstick, thoroughly clean the area around it - no dirt or debris must be allowed to enter the transmission. 5 Extract the dipstick, and wipe it clean using a clean piece of rag or tissue. Re-insert the dipstick completely, then pull it out once more. The fluid level should be between the reference marks on the side of the dipstick marked HOT (if the level is checked when cold, use the markings on the COLD side of the dipstick). 6 If topping-up is required, this is done via the dipstick tube. It is most important that no dirt 3.15 Filling the engine with oil
A - -A 6.3 Topping-up the battery electrolyte or debris enters the transmission as this is done - use a clean funnel (preferably with a filter) and fresh fluid from a clean container. 7 Pour the fresh fluid a little at a time down the dipstick tube, checking the level frequently. 8 When the level is correct, refit the dipstick and switch off the engine. A Battery electrolyte level check Warning: The electrolyte inside a battery is diluted acid - it is a good idea to wear suitable rubber gloves. When topping-up, don't overfill the cells so that the electrolyte overflows. In the event of any spillage, rinse the electrolyte off without delay. Refit the cell covers and rinse the battery with copious quantities of clean water. Don't attempt to siphon out any excess electrolyte. 1 Models covered by this Manual are fitted with a 'limited-maintenance' battery as standard equipment (or may have had a 'maintenance-free' one fitted as a replacement). If the battery in your vehicle is marked 'Freedom', 'Maintenance-Free' or similar, no electrolyte level checking is required (the battery is often completely sealed, preventing any topping-up). 2 Batteries which do require their electrolyte level to be checked can be recognised by the presence of level markings and removable covers over the six battery cells - the battery casing is also sometimes translucent, so that the electrolyte level can be more easily checked. Some of the batteries fitted by FIAT have level markings, but no means of toppingup! 3 Remove the cell covers and either look down inside the battery to see the level web, or check the level using any markings provided on the battery casing. The electrolyte should at least cover the battery plates. If necessary, top up a little at a time with distilled (de-ionised) water until the level in all six cells is correct - don't fill the cells up to the brim (see illustration). Wipe up any spillage, then refit the cell covers. Every 12 000 miles (20 000 km) 1.9 4 On batteries where the level can be checked but not topped-up, if the level is low, consult a dealer or automotive electrical specialist as to the best course of action (likely to be fitting a replacement battery). 7 Auxiliary drivebelt tension check Note: On models with 1.4 and 1.8 litre engines, an automatic belt tensioner is used, and regular tension checks are not required. Check the belt condition at the specified intervals, however, as described in Section 21. 1 The only belt tension specifications quoted by FIAT are for use with their dedicated belt tensioning equipment, and are not of great practical help. The advice given below should be treated as a rough guide, and should be adequate in most cases. If there is serious concern over belt tension, refer to a FIAT dealer for advice. 2 If a drivebelt is set too tight, it will subject the driven unit to excess load, resulting in premature wear of the unit (and of the belt). If the belt is too slack, it will not transmit drive properly, and the belt will suffer wear due to slippage. 1.2 litre engine 3 Two or three separate belts are used on this engine, depending on whether or not air conditioning is fitted. 4 For improved access to the belts, remove the three bolts securing the engine top cover, and lift the cover away. 5 Each of the drivebelts is checked and adjusted in much the same way. To check the power steering pump drivebelt, remove the bolt securing the belt upper cover, and remove the cover. To access the air conditioning compressor drivebelt, refer to paragraphs 16 to 18. 6 Press on the belt at the centre-point between the two pulleys, and the drivebelt should deflect by approximately 5 mm. Alternator drivebelt 7 If adjustment is required, loosen the nuts and bolts on the two adjuster slots, and the lower mounting through-bolt. Pivot the alternator as necessary using a suitable lever to set the belt tension, then re-tighten all the fasteners (see illustration). Take care when levering the alternator that no damage is caused to the alternator or surrounding components. 8 On models with air conditioning, note that if the air conditioning compressor drivebelt needs adjusting, this will affect the alternator belt tension. Air conditioning compressor drivebelt 9 If adjustment is required, loosen the nut and bolt on the adjuster slot, and the lower mounting through-bolt. Pivot the compressor as necessary using a suitable lever to set the belt tension, then re-tighten all the fasteners. Take care when levering the compressor that no damage is caused to the compressor or surrounding components. 10 Note that if the air conditioning compressor drivebelt needs adjusting, this will affect the alternator belt tension. 7.7 Loosen the alternator mountings (arrowed) and pivot the alternator to tension the belt
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 and 24: 1 Washer reservoir 2 Inlet manifold
Page 25: 1 Introduction General information
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
Page 75 and 76: 11 »2 Bodywork and fittings which
Page 77 and 78:
11 »4 Bodywork and fittings 6 Fron
Page 79 and 80:
'\'\»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
Page 107 and 108:
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
Page 115 and 116:
9*4 Braking system 4.2 Disconnectin
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9*6 Braking system 5 Unhook the sel
Page 119 and 120:
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
Page 127 and 128:
9*16 Braking system 2 Unbolt the ex
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8*2 Driveshafts 1 General informati
Page 131 and 132:
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
Page 139 and 140:
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
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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
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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
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Unplug the wiring connectors and un
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5.10a Once the base of the unit has
Page 185 and 186:
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
Page 193 and 194:
Refitting 17 Refitting is a reversa
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Fuel system - single-point injectio
Page 197 and 198:
Disconnect the inlet manifold coola
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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
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4.20 Look for cracking between the
Page 221 and 222:
4.45a Locate the inner . 4.45b ...
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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
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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
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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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Page 263 and 264:
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
Page 269 and 270:
4.17 FIAT special tool used to lock
Page 271 and 272:
Section 4. It is essential that an
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
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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:
Page 293 and 294:
REF-2 Conversion factors Length (di
Page 295 and 296:
REF.4 Vehicle identification number
Page 297 and 298:
REF.6 Disconnecting the battery Sev
Page 299 and 300:
REF.8 Tools and working facilities
Page 301 and 302:
REF.10 MOT test checks This is a gu
Page 303 and 304:
REF«12 MOT test checks Exhaust sys
Page 305 and 306:
REF.14 Fault finding Engine • Eng
Page 307 and 308:
REF.16 Fault finding Engine (contin
Page 309 and 310:
REF.18 Fault finding Clutch Note: T
Page 311 and 312:
REF.20 Fault finding Braking system
Page 313 and 314:
REF.22 Fault finding Electrical sys
Page 315 and 316:
REF.24 Glossary of technical terms
Page 317 and 318:
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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