Bravo & Brava • 1995 To 2000

More documents

Recommendations

Info

4.9 Undo the retaining bolt in the centre of the lower timing cover 4.11b ... then slide the wiring plug and socket from the timing cover slot 11 Release the crankshaft TDC sensor wiring from the clip on the upper timing cover, then withdraw the cover slightly and slide the wiring plug and socket from the timing cover slot (see illustrations). 12 Release the TDC sensor wiring from the periphery of the upper and lower timing covers, and remove both covers (see illustrations). 13 Free the accelerator inner cable from the throttle cam, remove the outer cable spring clip, then pull the outer cable out from its mounting bracket rubber grommet. 14 From the side of the throttle body, disconnect the wiring connectors from the throttle potentiometer and the idle control stepper motor. Disconnect the coolant temperature sensor wiring connector located in the inlet manifold below the throttle body, 4.21a Screw the spark plug bodies of the home-made piston positioning tools into each spark plug hole ... 4.10 Undo the upper timing cover upper retaining bolt, and the rear retaining bolt d ''Jiff ***** r 1.2 litre engine in-car repair procedures 2A«5 4.11a Release the crankshaft TDC sensor wiring from the clip on the upper timing cover... 4.12a Remove the upper ... 4.12b ... and lower timing covers and disconnect the brake servo vacuum hose. 15 Disconnect the wiring connectors for the fuel injector harness and the intake air temperature/pressure sensor, then disconnect the fuel pressure regulator vacuum hose and the EVAP purge valve hose. 16 Undo the two bolts securing the plastic inlet manifold upper section to the lower section. Release the spark plug HT lead from the location groove in the manifold upper section, then lift the upper section, complete with throttle body, off the engine. Recover the O-rings from the manifold ports. 17 Unscrew the two bolts securing the fuel rail assembly to the inlet manifold lower section, then carefully pull the injectors from the manifold. Lift the fuel rail and injector assembly, with fuel hoses still connected, and position it to one side. 4.21b ... place a suitable washer or similar into the recess to keep the dowel rod vertical... 18 Undo the bolts securing the engine management ECU mounting brackets to the body, and move the ECU to one side without disconnecting the wiring connector. 19 Remove the spark plugs as described in Chapter 1. 20 Unscrew the two sealing plugs from the front and rear of the cylinder head extension to enable the camshaft locking tools to be inserted. 21 Screw the spark plug bodies of the homemade piston positioning tools into each spark plug hole, and insert the dowel rods into each body. To keep the dowel rods vertical, locate a suitable washer or similar over the rod and into the recess at the top of the spark plug hole. In the photos shown here, an old valve stem oil seal housing was used, but anything similar will suffice (see illustrations). 4.21c . then insert the dowel rods
2A»6 1.2 litre engine in-car repair procedures 4.22 Place a straight edge along the top of the rods and turn the crankshaft until the straight edge contacts all four rods 22 Using a socket on the crankshaft sprocket centre bolt, turn the crankshaft in the normal direction of rotation until all four dowel rods are protruding from the top of the cylinder head extension by the same amount. As the engine is turned, two of the rods will move up, and two will move down until the position is reached where they are all at the same height. The best way to check this is to place a straight-edge along the top of the rods and turn the crankshaft very slowly until the straight-edge contacts all four rods (see illustration). 23 When all four rods are at the same height, all the pistons will be at the mid-point of their stroke. Using a screwdriver or similar inserted into the front timing hole in the cylinder head extension, check that the timing slot in the exhaust camshaft is approximately aligned with the timing hole. If the camshaft slot cannot be felt, turn the crankshaft through one complete revolution and realign the dowel rods using the straight-edge. Check again for the camshaft slot. Note that, although the pistons can be at the mid-point of their stroke twice for each cycle of the engine, the camshaft slots will only be positioned correctly once per cycle. 24 With the pistons correctly set, it should now be possible to screw in the camshaft locking tools into the timing holes in the cylinder head extension. To provide the necessary degree of timing accuracy, the machined ends of the locking tools are a very close fit in the slots machined in the 4.25 Release the nut on the timing belt tensioner (arrowed) 4.24a Screw in the camshaft locking tools into the timing holes in the cylinder head extension camshafts. To allow the tools to be screwed fully into engagement, it may be necessary to move the crankshaft in one direction or another very slightly until the tools are felt to engage fully (see illustrations). 25 Release the nut on the timing belt tensioner to release the tension on the belt (see illustration). 26 If the timing belt is to be re-used, use white paint or chalk to mark the direction of rotation on the belt (if markings do not already exist), then slip the belt off the sprockets (see illustration). Note that the crankshaft must not be rotated whilst the belt is removed. 27 Check the timing belt carefully for any signs of uneven wear, splitting, or oil contamination. Pay particular attention to the roots of the teeth. Renew it if there is the slightest doubt about its condition. If the engine is undergoing an overhaul, renew the belt as a matter of course, regardless of its apparent condition. The cost of a new belt is nothing compared with the cost of repairs, should the belt break in service. If signs of oil contamination are found, trace the source of the oil leak and rectify it. Wash down the engine timing belt area and all related components, to remove all traces of oil. Refitting 28 Before refitting, thoroughly clean the timing belt sprockets. Check that the tensioner pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley as described in Section 5. 4.26 Slip the timing belt off the sprockets 4.24b The tools engage in the camshaft slots when fitted (shown removed for clarity) 29 The camshaft sprocket retaining bolt must now be slackened to allow the sprocket to move as the timing belt is refitted and tensioned. To hold the sprocket stationary while the retaining bolt is loosened, make up a tool as follows and engage it with the holes in the sprocket (see Tool Tip). With the sprocket held, slacken the retaining bolt. 30 Check that the pistons are still correctly positioned at the mid-point of their stroke and that the camshafts are locked with the locking tools. 31 Ensuring that the direction markings on the timing belt point in the normal direction of engine rotation, engage the timing belt with the crankshaft sprocket first, then place it around the coolant pump sprocket and the camshaft sprocket (see illustration). Finally slip the belt around the tensioner pulley. TOOL To make a camshaft sprocket holding tool, obtain two 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
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 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
Page 281: 2A«4 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?