Bravo & Brava • 1995 To 2000

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Chapter 2 Part A: 1.2 litre engine in-car repair procedures Contents Auxiliary drivebelts - removal and refitting See Chapter 1 Camshaft oil seal - renewal 6 Camshafts and tappets - removal, inspection and refitting 9 Crankshaft oil seals - renewal 7 Cylinder compression test 3 Cylinder head - dismantling and overhaul See Chapter 2E Cylinder head - removal and refitting -. 10 Cylinder head extension - removal and refitting 8 Engine assembly/valve timing holes - general information and usage 2 Degrees of difficulty 2A»1 Engine mountings - inspection and renewal 12 Engine oil and filter - renewal See Chapter 1 Engine oil level - check See Weekly checks Flywheel - removal, inspection and refitting 11 General information 1 Oil pressure switch - removal and refitting 15 Oil pump and pick-up tube - removal and refitting 14 Sump - removal and refitting 13 Timing belt and covers - removal and refitting 4 Timing belt tensioner and sprockets - removal and refitting 5 Easy, suitable for Fairty easy, suitable Fairty difficult, | N, Difficult, suitable for Very difficult, ^ novice with little f? for beginner with suitable for competent ^ experienced DIY suitable for expert DIY 3^ experience some experience DIY mechanic g^ mechanic or professional g^ Specifications General Engine code* 182.B2.000 Bore 70.8 mm Stroke 78.86 mm Capacity 1242 cc Compression ratio 10.2:1 Firing order 1-3-4-2 No 1 cylinder location Timing belt 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 0.100 to 0.210 mm Axial clearance 0.025 to 0.070 mm Camshafts Drive <strong>To</strong>othed belt to exhaust camshaft, gear drive to inlet camshaft No of bearings 3 Camshaft bearing journal diameters: No 1 bearing 35.000 to 35.015 mm No 2 bearing 48.000 to 48.015 mm No 3 bearing 49.000 to 49.015 mm Camshaft bearing journal running clearance 0.030 to 0.070 mm Camshaft endfloat 0.15 to 0.34 mm Cylinder head extensions Camshaft bearing diameters: No 1 bearing 35.045 to 35.070 mm No 2 bearing 48.045 to 48.070 mm No 3 bearing 49.045 to 49.070 mm Hydraulic tappet diameter 28.353 to 28.370 mm Hydraulic tappet bore diameter 28.400 to 28.421 mm Hydraulic tappet running clearance 0.046 to 0.051 mm
2A«2 1.2 litre engine in-car repair procedures <strong>To</strong>rque wrench settings Nm ibf ft Air conditioning compressor mounting bracket-to-block 50 37 Auxiliary drivebelt pulley bolts 22 16 Big-end (connecting rod) bearing cap bolts 41 30 Camshaft bearing caps 15 11 Camshaft gears 120 89 Camshaft sprocket 120 89 Crankshaft sprocket centre bolt (left-hand thread): Stage 1 20 15 Stage 2 Angle-tighten a further 90° Cylinder head: Stage 1 20 15 Stage 2 30 22 Stage 3 Angle-tighten a further 90° Stage 4 Angle-tighten a further 90° Cylinder head extension to cylinder head 15 11 Dipstick tube nut and bolt 9 7 Engine/transmission mountings: Mounting brackets to transmission: M10 bolts 50 37 M12 bolts 85 63 Mounting through-bolts 80 59 Mountings to bodyshell 32 24 Right-hand mounting bracket to block 50 37 Right-hand mounting reaction rod 28 21 Exhaust manifold nuts 27 20 Flywheel* 44 32 Inlet manifold nuts 15 11 Main bearing cap bolts: Stage 1 40 30 Stage 2 Angle-tighten a further 90° Oil pressure switch 32 24 Oil pump bolts 9 7 Sump bolts 10 7 Timing belt tensioner nut 25 18 "Although not specifically recommended by FIAT, use locking fluid. 1 General information Using this Chapter Chapter 2 is divided into five Parts: A to E. Repair operations that can be carried out with the engine in the vehicle are described in Parts A to D. Part E covers the removal of the engine/transmission as a unit, and describes the engine dismantling and overhaul procedures. In Parts A to D, the assumption is made that the engine is installed in the vehicle, with all ancillaries connected. If the engine has been removed for overhaul, the preliminary dismantling information which precedes each operation may be ignored. Engine description The 1.2 litre engine is a water-cooled, double overhead camshaft, in-line fourcylinder unit, with cast-iron cylinder block and aluminium-alloy cylinder head. The unit is mounted transversely at the front of the vehicle, with the transmission bolted to the left-hand side of the engine. The cylinder head houses the eight inlet and eight exhaust valves, which are closed by single coil springs, and which run in guides pressed into the cylinder head. The two camshafts are housed in a cylinder head extension which is bolted to the top of the cylinder head. The exhaust camshaft is driven by a toothed timing belt and in turn drives the inlet camshaft via a pair of gears located at the left-hand end of the cylinder head extension. The camshafts each have three bearings, and actuate the valves directly via self-adjusting hydraulic tappets mounted in the cylinder head extension. The crankshaft is supported by five main bearings, and endfloat is controlled by the thrust flanges fitted to the upper half of the centre main bearing shell. Engine coolant is circulated by a pump, driven by the timing belt. For details of the cooling system, refer to Chapter 3. Lubricant is circulated under pressure by a pump, driven from the front of the crankshaft. Oil is drawn from the sump through a strainer, and then forced through an externallymounted, replaceable screw-on filter. From there, it is distributed to the cylinder head and cylinder head extension, where it lubricates the camshaft journals and tappets, and also to the crankcase, where it lubricates the main bearings, connecting rod big and small-ends, gudgeon pins and cylinder bores. Oil jets are fitted to the base of each cylinder bore - these spray oil onto the underside of the pistons, to improve cooling. Repair operations possible with the engine in the car The following work can be carried out with the engine in the car: a) Auxiliary drivebelt - removal and refitting (refer to Chapter 1). b) Oil pump and pick-up tube assembly - removal, inspection and refitting. c) Timing belt and covers - removal and refitting. d) Timing belt tensioner and sprockets - removal and refitting. e) Cylinder head - removal and refitting". f) Cylinder head extension - removal and refitting. g) Camshaft and tappets - removal and refitting. h) Camshaft oil seal - renewal. i) Crankshaft oil seals - renewal. j) Flywheel - removal, inspection and refitting. kj Engine mountings - inspection and renewal. I) Sump - removal and refitting. 'Cylinder head dismantling procedures are detailed in Chapter 2E.
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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
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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
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
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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 and 274: paragraph 17), then remove the heat
Page 275 and 276: to the downpipe. The safest option
Page 277: 13.8 Using an impact screwdriver to
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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