Bravo & Brava • 1995 To 2000

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The pages which follow provide an easyreference guide to the more common problems which may occur during the operation of the vehicle. These problems and their possible causes are grouped under headings denoting various components or systems, such as Engine, Cooling system, etc. The general Chapter which deals with the problem is also shown in brackets; refer to the relevant Part of that Chapter for systemspecific information. Whatever the fault, certain basic principles apply. These are as follows: Verify the fault. This is simply a matter of being sure that you know what the symptoms are before starting work. This is particularly important if you are investigating a fault for someone else, who may not have described it very accurately. Engine Engine fails to rotate when attempting to start • Battery terminal connections loose or corroded {Weekly checks). • Battery discharged or faulty, or electrolyte level low (Chapter 1 or 5A). • Broken, loose or disconnected wiring in the starting circuit (Chapter 5A). • Defective starter solenoid or switch (Chapter 5A). • Defective starter motor (Chapter 5A). • Starter pinion or flywheel ring gear teeth loose or broken (relevant part of Chapter 2 or 5A). • Engine/transmission earth leads broken or disconnected (Chapter 2E or 5A). • Automatic transmission not in Park/Neutral position, or selector cable adjustment incorrect (Chapter 7B). Engine rotates but will not start • Fuel tank empty. • Fuel pump not working, or fuel lines blocked/damaged (Chapter 4A or 4B). • Fuel filter blocked, where applicable (Chapter 1). • Fuel injector wiring disconnected or damaged (Chapter 4A or 4B). • Battery discharged, or electrolyte level low (engine rotates slowly) (Chapter 1 or 5A). • Battery terminal connections loose or corroded [Weekly checks). • Ignition components damp or damaged (Chapter 1 or 5B). • Broken, loose or disconnected wiring in the ignition circuit (Chapter 1 or 5B). • Immobiliser fault (Chapter 12, or Disconnecting the battery). • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). • Low cylinder compressions (relevant part of Chapter 2). 22 Major mechanical failure (eg timing belt broken) (relevant part of Chapter 2). Engine difficult to start when cold 22 JBattery discharged or faulty, or electrolyte level low (Chapter 1 or 5A). • Battery terminal connections loose or corroded {Weekly checks). • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). ZZ Other ignition system fault (Chapter 1 or 5B). • Engine management system fault (Chapter 1, 4A, 4B or 5B). G Low cylinder compressions (relevant part of Chapter 2). Don't overlook the obvious. For example, if the vehicle won't start, is there petrol in the tank? (Don't take anyone else's word on this particular point, and don't trust the fuel gauge either!) If an electrical fault is indicated, look for loose or broken wires before digging out the test gear. Cure the disease, not the symptom. Substituting a flat battery with a fully-charged one will get you off the hard shoulder, but if the underlying cause is not attended to, the new battery will go the same way. Similarly, changing oil-fouled spark plugs for a new set will get you moving again, but remember that the reason for the fouling (if it wasn't simply an incorrect grade of plug) will have to be established and corrected. Don't take anything for granted. Particularly, don't forget that a 'new' component may itself Engine difficult to start when hot Fault finding REF.IS be defective (especially if it's been rattling around in the boot for months), and don't leave components out of a fault diagnosis sequence just because they are new or recently fitted. When you do finally diagnose a difficult fault, you'll probably realise that all the evidence was there from the start. Consider what work, if any, has recently been carried out. Many faults arise through careless or hurried work. For instance, if any work has been performed under the bonnet, could some of the wiring have been dislodged or incorrectly routed, or a hose trapped? Have all the fasteners been properly tightened? Were new, genuine parts and new gaskets used? There is often a certain amount of detective work to be done in this case, as an apparently-unrelated task can have farreaching consequences. 21 Air cleaner element dirty or clogged (Chapter 1). Z3 Engine management system fault (Chapter 1, 4A, 4B or 5B). • Low cylinder compressions (relevant part of Chapter 2). Starter motor noisy or excessively-rough in engagement ZZ Starter pinion or flywheel ring gear teeth loose or broken (Chapter 2 or 5A). • Starter motor mounting bolts loose or missing (Chapter 5A). • Starter motor internal components worn or damaged (Chapter 5A). Engine starts but stops immediately ZZ Loose or faulty electrical connections in the ignition circuit (Chapter 1 or 5B). • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). Engine idles erratically • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Fuel injectors partially blocked (Chapter 4A or 4B). • Air cleaner element dirty or clogged (Chapter 1). • Crankcase breather hoses blocked or damaged (Chapter 1 or 5B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). • Uneven or low cylinder compressions (relevant part of Chapter 2). • Camshaft lobes worn (relevant part of Chapter 2). Engine misfires at idle speed • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). • Faulty spark plug HT leads, where applicable (Chapter 5B). • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Fuel injector(s) partially blocked (Chapter 4A or 4B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Uneven or low cylinder compressions (relevant part of Chapter 2). • Disconnected, leaking or perished crankcase breather hoses (Chapter 1 or 5B). • Crankshaft sensor dirty or damaged (Chapter 5B).
REF.16 Fault finding Engine (continued) Engine misfires throughout the driving speed range • Fuel filter choked (Chapter 1). • Fuel pump faulty (relevant part of Chapter 4). • Fuel tank vent blocked or fuel pipes restricted (relevant part of Chapter 4). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). • Faulty spark plug HT leads, where applicable (Chapter 5B). • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Fuel injector(s) partially blocked (Chapter 4A or 4B). • Uneven or low cylinder compressions (relevant part of Chapter 2). • Crankshaft sensor dirty or damaged (Chapter 5B). Engine hesitates on acceleration • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Fuel injector(s) partially blocked (Chapter 4A or 4B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). Engine stalls • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Fuel injector(s) partially blocked (Chapter 4A or 4B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Fuel filter choked (Chapter 1). • Fuel pump faulty (relevant part of Chapter 4). • Fuel tank vent blocked or fuel pipes restricted (Chapter 4A or 4B). • Crankshaft sensor dirty or damaged (Chapter 5B). Engine lacks power • Engine management system fault - possibly in 'limp-home' mode (Chapter 1, 4A, 4B or5B). • Fuel injector(s) partially blocked (Chapter 4A or 4B). • Timing belt incorrectly fitted (relevant part of Chapter 2) • Fuel filter choked (Chapter 1). • Fuel pump faulty (relevant part of Chapter 4). • Knock sensor faulty - ignition retarded (Chapter 5B). • Uneven or low cylinder compressions (relevant part of Chapter 2). • Worn, faulty or incorrectly-gapped spark plugs (Chapter 1), • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Brakes binding (Chapter 1 or 9). • Clutch slipping (Chapter 6). • Automatic transmission fluid level incorrect (Chapter 1). Engine backfires • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Spark plug HT leads incorrectly fitted (Chapter 5B). • Timing belt incorrectly fitted (relevant part of Chapter 2). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1,4A or4B). • Emission control system fault (Chapter 4C). Oil pressure warning light illuminated with engine running • Low oil level or incorrect oil grade (Chapter 1). • Faulty oil pressure switch (relevant part of Chapter 2). • Worn engine bearings and/or oil pump (relevant part of Chapter 2). • High engine operating temperature (Chapter 3). • Oil pump pressure relief valve defective (relevant part of Chapter 2). • Oil pick-up pipe strainer clogged (relevant part of Chapter 2). Engine runs-on after switching off • Engine management system fault (Chapter 1, 4A, 4B or 5B). • Excessive carbon build-up on cylinder head/piston crowns (relevant part of Chapter 2). • High engine operating temperature (Chapter 3). Engine noises Pre-ignition (pinking) or knocking during acceleration or under load • Incorrect grade of fuel (Chapter 4A or 4B). • Knock sensor faulty (Chapter 5B). • Vacuum leak at the inlet manifold or associated hoses (Chapter 1, 4A or 4B). • Excessive carbon build-up on cylinder head/piston crowns (relevant part of Chapter 2). Whistling or wheezing noises • Leaking inlet manifold gasket (Chapter 4A or 4B). • Leaking exhaust manifold gasket or front pipe-to-manifold joint (Chapter 4C). • Leaking vacuum hose (Chapter 1, 4, 5B or 9). • Blowing cylinder head gasket (relevant part of Chapter 2). Tapping or rattling noises • Worn valve gear or camshafts (relevant part of Chapter 2). • Worn or faulty hydraulic tappets (relevant part of Chapter 2). • Worn timing belt, tensioner, or idler pulleys (relevant part of Chapter 2). • Ancillary component fault (coolant pump, alternator, etc) (Chapter 3 or 5A). Knocking or thumping noises • Worn big-end bearings (regular heavy knocking, perhaps less under load) (Chapter 2E). • Worn main bearings (rumbling and knocking, perhaps worsening under load) (Chapter 2E). • Piston slap (most noticeable when cold - engine worn) (Chapter 2E). • Ancillary component fault (coolant pump, alternator, etc) (Chapter 3 or 5A). Engine oil consumption excessive • Wrong grade of oil, or oil level too high {Weekly checks). • Oil filter or sump drain plug loose (Chapter 1). • Oil seal leaking (relevant part of Chapter 2). • Camshaft cover seal leaking (Chapter 2B or 2D). • Sump seal leaking (relevant part of Chapter 2). • Cylinder head gasket leaking (relevant part of Chapter 2). • Engine burning oil - piston ring or cylinder bore wear (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
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8.14 Three bore measurement points
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11.19 Lubricate the crankcase main
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2D»2 1.8 litre engine in-car repai
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Location of TDC on No 1 cylinder 1
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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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Page 265 and 266: Chapter 2 Part B: 1.4 litre engine
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Page 279 and 280: 2A«2 1.2 litre engine in-car repai
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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
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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: REF.14 Fault finding Engine • Eng
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
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Bravo & Brava • 1995 To 2000

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