Bravo & Brava • 1995 To 2000

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2B»10 1.4 litre engine in-car repair procedures 9.13f Unplug the fuel system coolant temperature sender ... 9.13i Disconnect the two wiring plugs behind the ignition coil - one seen disconnected (arrowed) g) Two wiring plugs on the bracket at the rear of the ignition coil (see illustration). 14 Remove the two bolts securing the wiring bracket at the rear of the ignition coil (see illustrations). Move the bracket clear of the 9.15a Unscrew the bolt below the wiring harness mounting bracket (arrowed)... 9.15c Check that the harness is free, and move it clear of the head 9.13g ... and the temperature gauge sender 9.14a Unscrew the top bolt (which also secures the injection wiring connector)... cylinder head, unclipping the connector plug halves from it as necessary. 15 If not already done, working along the wiring harness at the rear of the cylinder head, unscrew the harness clip mounting bolts and 9.15b ... and disconnect the earth lead 9.13h Disconnecting the oxygen sensor wiring plug 9.14b ... and the lower bolt securing the ignition coil wiring bracket release the harness from the head. A further bolt secures the engine earth lead, which must also be disconnected. When the harness is free, lift it from the rear of the head, and move it to the right of the engine compartment (see illustrations). 16 Free the wiring harness which runs along the base of the inlet manifold by prising open the plastic guide channel (some models may have a cable-tie holding the channel together) (see illustrations). Work along the harness towards the timing belt end of the engine. The fluid pipe(s) from the power steering pump hamper removal of the harness, but we found that disconnecting the pipes was unnecessary. 17 There are various potential options concerning the. exhaust manifold. It is possible to remove the head with the exhaust manifold attached; alternatively, unbolt the manifold from the head and leave the manifold attached 9.16a Cut the cable-tie (where fitted)... 9.16b ... and separate the plastic guide channel to release the wiring harness
to the downpipe. The safest option (although involving more work) is to remove the exhaust manifold completely, as described. 18 Working under the car, unscrew the four exhaust manifold-to-downpipe nuts, and separate the joint (see illustration). Recover the gasket. 19 Unscrew the manifold-to-cylinder head nuts, and withdraw the manifold from the cylinder head, recovering the gasket. 20 In some cases, the manifold studs will come out with the nuts - this poses no great problem, and the studs can be refitted if they are in good condition. For preference, however, a complete set of manifold and downpipe studs and nuts should be obtained as required, as the old ones are likely to be in less-than-perfect condition. 21 If the downpipe is lowered to the floor, check that the wiring to the oxygen sensor (at the top of the downpipe) is not placed under strain. The wiring plug has already been disconnected, so feed the wiring through. 22 Remove the bolt securing the upper end of the engine oil dipstick tube to the cylinder head, then pull the tube upwards to remove it (see illustration). Removing the tube may displace the seal at the base of the tube - if so, refit it now or store it with the tube for refitting. 23 Check around the head that there are no further wires, hoses or other obstructions which will prevent the head from being lifted off. 24 Unscrew the cylinder head Ribe bolts half a turn at a time, in the reverse order to that shown in illustration 9.42. When the bolts are free, remove them with their washers. 25 Lift the cylinder head from the block, together with the inlet manifold. If it is stuck tight, insert pieces of wood into the exhaust ports (if possible), and use them as levers to rock the head off the block. On no account drive levers into the gasket joint, nor attempt to tap the head sideways, as it is located on positioning dowels. 26 Remove and discard the cylinder head gasket and the manifold gaskets. 27 The cylinder head can be dismantled after removing the camshaft and cam followers as described in Chapter 2E. Further dismantling and decarbonising are also described in Chapter 2E. Preparation for refitting 28 The mating faces of the cylinder head and cylinder block must be perfectly clean before refitting the head. Use a hard plastic or wooden scraper to remove all traces of gasket and carbon; also clean the piston crowns. 29 Take particular care when cleaning the piston crowns, as the soft aluminium alloy is easily damaged. 30 Make sure that the carbon is not allowed to enter the oil and water passages - this is particularly important for the lubrication system, as carbon could block the oil supply 9.18 Exhaust manifold-to-downpipe joint to the engine's components. Using adhesive tape and paper, seal the water, oil and bolt holes in the cylinder block. 31 <strong>To</strong> prevent carbon entering the gap between the pistons and bores, smear a little grease in the gap. After cleaning each piston, use a small brush to remove all traces of grease and carbon from the gap, then wipe away the remainder with a clean rag. Clean all the pistons in the same way. 32 Check the mating surfaces of the cylinder block and the cylinder head for nicks, deep scratches and other damage. If slight, they may be removed carefully with a file, but if excessive, machining may be the only alternative to renewal. 33 If warpage of the cylinder head gasket surface is suspected, use a straight-edge to check it for distortion. Refer to Part E of this Chapter if necessary. 34 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed. Wash the bolts in a suitable solvent, and wipe them dry. Check each bolt for any sign of visible wear or damage, renewing them if necessary. Refitting 35 Before refitting the assembled cylinder head, make sure that the head and block mating surfaces are perfectly clean. 36 The bolt holes in the cylinder block must be mopped out to clear any oil or coolant. If the bolt holes have any significant amount of 1.4 litre engine in-car repair procedures 2B«11 9.22 Dipstick tube mounting bolt liquid in them, the block could be .cracked by hydraulic pressure when the head bolts are tightened. 37 Check that the camshaft marks made during dismantling (see Section 4) are aligned. 38 The new gasket should not be removed from its plastic bag until required for use. Fit the gasket dry - no grease or sealant should be used. 39 Place the gasket on the cylinder block so that the word ALTO can be read from above. 40 Lower the cylinder head onto the block so that it locates on the positioning dowels. 41 Ensure that the cylinder head bolts are cleaned of all debris, and check the threads for signs of damage. Especially if it is known that the bolts have been removed previously, it is advisable to renew all ten bolts as a set, rather than risk the bolts shearing when tightened. 9.42 Cylinder head bolt tightening sequence 42 Lightly oil the bolt threads. Screw the bolts in finger-tight, and tighten them in the 2B sequence shown to the Stage 1 torque (see illustration). 43 When all ten bolts have been tightened to the Stage 1 torque, go round again in sequence and tighten to the Stage 2 torque. 44 Again working in sequence, tighten the bolts through the specified Stage 3 angle. Note that 90° is equivalent to a quarter-turn or right-angle, making it easy to judge by noting the initial position of the socket handle. If available, use an angle gauge fitted to the socket handle for maximum accuracy.
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BRAVO & BRAVA • 1995 to 2000 (N t
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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
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o.i6 Weekly checks Washer fluid lev
Page 19 and 20:
Chapter 1 Routine maintenance & ser
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Torque wrench settings (continued)
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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
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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
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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 ...
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 and 270: 4.17 FIAT special tool used to lock
Page 271 and 272: Section 4. It is essential that an
Page 273: paragraph 17), then remove the heat
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
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Bravo & Brava • 1995 To 2000

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