Bravo & Brava • 1995 To 2000

More documents

Recommendations

Info

2B»6 1.4 litre engine in-car repair procedures 4.27 Belt tensioner correctly set - pointer aligned with hole tensioner pointer with the small hole on the tensioner backplate. Hold the tensioner in this position, and tighten the tensioner nut securely (see illustration). 28 Refit the timing belt lower cover, and secure with the two bolts. 29 Refit the crankshaft pulley, locating the pulley over the peg on the crankshaft sprocket and tightening the four bolts to the specified torque. 30 If the crankshaft has not turned, check that the mark on the crankshaft pulley aligns with the mark on the belt lower cover. 31 Further refitting is a reversal of removal. Refit and tension the auxiliary drivebelt as described in Chapter 1. 5 Timing belt sprockets and tensioner - removal arid refitting Timing belt tensioner Removal 1 Remove the air cleaner and air ducting as described in Chapter 4A. 2 Remove the auxiliary drivebelt as described in Chapter 1. 3 Remove the two bolts securing the coolant hose mounting bracket to the timing belt cover, and move the hose out of the way. 4 Unbolt and remove the timing belt upper cover, which is secured by six bolts. Caution: Provided the timing belt is kept fully engaged with the camshaft, crankshaft and coolant pump sprockets during the 5.14 Hold the camshaft sprocket as the bolt is loosened | following procedure, it is not necessary to align the timing TDC marks. However if any doubt exists, read through the full procedure given in Section 4, noting the advice on setting to TDC, and ensuring that the timing is not lost. The timing belt does not have to be removed for this procedure, but if the belt slips from the sprockets, the timing could be lost. 5 Loosen the nut on the timing belt tensioner and move the pulley away from the belt. If necessary, keep the belt engaged with the sprockets using cable-ties, elastic bands or string. 6 Completely unscrew the nut, and slide the tensioner off the mounting stud. Inspection 7 Wipe the tensioner clean, but do not use excessive amounts of solvent, as these may contaminate the bearings. Spin the tensioner pulley on its hub by hand. Stiff movement or excessive freeplay is an indication of severe wear; the tensioner is not a serviceable component, and should be renewed if its condition is suspect, or as a precaution at the time of a major engine overhaul. Refitting 8 Hold the timing belt aside, then slide the tensioner over the mounting stud and secure loosely with the nut. Ensuring that all slack is taken out of the belt, engage the timing belt with tensioner sprocket. 9 Set the belt tension with reference to Section 4, paragraphs 20 to 23. 10 Refit the timing belt cover and tighten the bolts. Refit the bolts securing the coolant hose to the timing belt cover. 11 Refit and tension the auxiliary drivebelt as described in Chapter 1. 12 Refit the air cleaner and air ducting as described in Chapter 4A. Camshaft sprocket Removal 13 Remove the timing belt as described in Section 4. It is essential that an alignment mark is made between the sprocket and the cylinder head, to preserve the camshaft timing - make your own if none are present, particularly if the camshaft holding tool described in Section 4 is not available. 5.16a Remove the camshaft sprocket bolt... 14 The camshaft sprocket must now be held stationary while the retaining bolt is loosened; if the sprocket turns very far, there is a risk that the valves will hit the pistons. Make up a tool as follows and engage it with the holes in the sprocket (see illustration). rTJTJTB <strong>To</strong> make a camshaft sprocket 12 holding tool, obtain two I I P lengths of steel strip about 6 mm thick by 30 mm wide or similar, one 600 mm long, the other 200 mm long (all dimensions approximate). Bolt the two strips together to form a forked end, leaving the bolt slack so that the shorter strip can pivot freely. At the end of each 'prong' of the fork, secure a bolt with a nut and a locknut, to act as the fulcrums; these will engage with the cut-outs in the sprocket, and should protrude by about 30 mm. 15 Alternatively, pass a rod through one of the holes in the camshaft sprocket to prevent it rotating. Position a pad of rag or a piece of wood under the rod to avoid damaging the cylinder head. 16 Unscrew the bolt, and slide the sprocket from the end of the camshaft. Note the integral location key on the inner face of the sprocket (see illustrations). Inspection 17 With the sprocket removed, examine the camshaft oil seal for signs of leaking. If necessary, refer to Section 7 and renew it. 18 Check the sprocket teeth for damage. 19 Wipe clean the sprocket and camshaft mating surfaces. Refitting 20 Locate the sprocket on the end of the camshaft. Refit the bolt and tighten to the specified torque while holding the camshaft stationary using the method described previously. 21 Align the marks made between the camshaft sprocket and cylinder head, then refit the timing belt as described in Section 4. Crankshaft sprocket Removal 22 Remove the timing belt as described in 5.16b ... and remove the sprocket - note keyway (arrowed)
Section 4. It is essential that an alignment mark is made between the sprocket and the oil pump housing, to preserve the timing - make your own if none are present, particularly if the sprocket holding tool described in Section 4 is not available. 23 Working beneath the engine, unbolt and remove the flywheel lower cover, then hold the flywheel stationary, preferably using a tool which engages the flywheel starter ring gear (see Section 10). Alternatively, have an assistant engage a wide-bladed screwdriver with the starter ring gear. 24 Unscrew the crankshaft sprocket retaining bolt - this is tightened to a particularly high torque, so ensure that the car is adequately supported. Use only goodquality, close-fitting tools, and take precautions against personal injury, especially when the bolt eventually loosens (wear gloves to protect your hands). The bolt has a lefthand thread - ie it unscrews clockwise. 25 Slide the sprocket off the end of the crankshaft. If it is tight, remove it using a puller or a pair of suitable screwdrivers. The sprocket may have an integral location key on its inner face, or a separate key which locates in a groove in the crankshaft nose. Inspection 26 With the sprocket removed, examine the crankshaft oil seal for signs of leaking. If necessary, refer to Section 8 and renew it. 27 Wipe clean the sprocket and crankshaft mating surfaces. Check the sprocket teeth for damage. Refitting 28 Slide the sprocket onto the crankshaft, making sure it engages the integral key or separate key. Fit the washer to a new bolt - do not lubricate the threads. It is not advisable to re-use the old bolt, given the extremely high torque to which it is tightened. 29 Fit the new bolt and washer, tightening the bolt to the specified torque while holding the crankshaft stationary using the method described in paragraph 23. Also bear in mind the advice in paragraph 24. 30 Refit the timing belt as described in Section 4. 6.1 Disconnecting the breather hose from the camshaft cover Camshaft cover - removal and refitting 1.4 litre engine in-car repair procedures 2B»7 1 Note: The camshaft cover is secured by Ribe bolts, which are similar in appearance to <strong>To</strong>rx types, but require different tools. A set of Ribe sockets can be obtained from good tool stockists - larger Ribe bolts are used to secure the cylinder head. Removal 1 Remove the air cleaner top cover and inlet duct as described in Chapter 4A (see illustration). 2 Remove the three bolts securing the engine top cover, and loosen the fourth bolt at the rear of the engine, behind the timing belt cover. Remove the top cover from the engine compartment. 3 Loosen and remove the two bolts securing the wiring harness brackets to the rear of the cylinder head, and move the harness back out of the way (see illustration). ^ If the spark plugs have been removed as part of another procedure, place rags over the spark plug holes, to prevent the bolts falling into the engine. 6.3 Remove the two wiring harness brackets from the rear of the head 4 Remove the two top Allen bolts securing the timing belt upper cover to the camshaft cover - there is no need to remove the timing belt upper cover completely. 5 Progressively unscrew the six Ribe bolts from the top of the camshaft cover and lift off the cover - note the location of any supports on the bolts (see illustrations). If it sticks, do not attempt to lever it off - instead free it by working around the cover and tapping it lightly with a soft-faced mallet. 6 Recover the camshaft cover gasket. Inspect the gasket carefully, and renew it if damage or deterioration is evident. 7 Clean the mating surfaces of the cylinder head and camshaft cover thoroughly, removing all traces of oil and old gasket - take care to avoid damaging the surfaces as you do this. Refitting 8 Before refitting the cover, pull out the breather filter from the breather hose connection stub (see illustration). Clean the filter using suitable solvent, then refit it. 9 Locate a new gasket on the cylinder head and make sure it is correctly seated. 10 Lower the cover onto the gasket, making sure the gasket is not displaced. 11 Insert the mounting bolts and tighten them progressively to the specified torque. 12 Refit the components removed for access using a reversal of the relevant removal procedure. 6.5a Unscrew the camshaft cover bolts ... 6.5b ... and lift off the cover 6.8 Removing the breather filter from the camshaft cover
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 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
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
Page 81 and 82:
11 »8 Bodywork and fittings 10.11
Page 83 and 84:
11*10 Bodywork and fittings 7 If wo
Page 85 and 86:
11*12 Bodywork and fittings 16.10 R
Page 87 and 88:
11*14 Bodywork and fittings 18.3a U
Page 89 and 90:
11*16 Bodywork and fittings 18.23a
Page 91 and 92:
11*18 Bodywork and fittings 20.15b
Page 93 and 94:
Page 95 and 96:
11 »22 Bodywork and fittings 16 Wi
Page 97 and 98:
Page 99 and 100:
10*2 Suspension and steering system
Page 101 and 102:
Page 103 and 104:
Page 105 and 106:
1f>8 Suspension and steering system
Page 107 and 108:
10*10 Suspension and steering syste
Page 109 and 110:
10«12 Suspension and steering syst
Page 111 and 112:
10*14 Suspension and steering syste
Page 113 and 114:
9*2 Braking system Anti-lock brakin
Page 115 and 116:
9*4 Braking system 4.2 Disconnectin
Page 117 and 118:
9*6 Braking system 5 Unhook the sel
Page 119 and 120:
9*8 Braking system 5.27 Removing th
Page 121 and 122:
9*10 Braking system 8.4 Disconnecti
Page 123 and 124:
9»12 Braking system K-0 10.13 Cros
Page 125 and 126:
9»14 Braking system 25 Working ins
Page 127 and 128:
9*16 Braking system 2 Unbolt the ex
Page 129 and 130:
8*2 Driveshafts 1 General informati
Page 131 and 132:
8*4 Driveshafts 3.23a Extract the c
Page 133 and 134:
8*6 Driveshafts 4.7 Unbolt the inte
Page 135 and 136:
Chapter 7 Part B: Automatic transmi
Page 137 and 138:
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
Page 145 and 146:
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
Page 171 and 172:
404 Exhaust and emission control sy
Page 173 and 174:
Chapter 4 Part B: Fuel system - mul
Page 175 and 176:
2.5 Disconnecting the breather hose
Page 177 and 178:
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
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
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 and 232: 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
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: 4.17 FIAT special tool used to lock
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
Page 283 and 284: 2A»6 1.2 litre engine in-car repai
Page 285 and 286: 2A»8 1.2 litre engine in-car repai
Page 287 and 288: 2A»10 1.2 litre engine in-car repa
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 321 and 322:
REF
Page 323 and 324:
REF
show all

Bravo & Brava • 1995 To 2000

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?