Bravo & Brava • 1995 To 2000

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Lis Every 24 000 miles (40 000 km) 21.25a Loosen the tensioner bolts ... c) Refit the wheelarch access panel and the roadwheel, and lower the car to the ground. Tighten the wheel bolts to the specified torque. Alternator/coolant pump drivebelt 24 Check the belt using the information in paragraphs 6 to 8. 25 If the belt is to be removed, either for servicing work or renewal, remove the air conditioning compressor belt (where applicable) as described previously. Loosen the tensioner bolts, and release the belt tension. Noting how the belt is fitted around the pulleys, slip the belt off and remove it (see illustrations). 26 Refitting the belt is a reversal of removal, noting the following points: a) Fit the belt around all the pulleys as noted on removal, apart from the tensioner pulley, making sure that the belt ribs engage properly with the pulley grooves. 21.30 Removing the drivebelt upper guard 21.25b ... and remove the auxiliary drivebelt from the pulleys Make sure that any slack in the belt is adjacent to the tensioner. b) Turn the tensioner pulley fully anticlockwise, then slip the flat side of the belt over the tensioner pulley. c) Tension the belt using the information in Section 7. d) Where applicable, refit the air conditioning compressor drivebelt as described previously. ej Refit the wheelarch access panel and the roadwheel, and lower the car to the ground. Tighten the wheel bolts to the specified torque. Power steering pump drivebelt 27 Check the belt using the information in paragraphs 6 to 8. 28 If the belt is to be removed, either for servicing work or renewal, the lower belt (which drives the alternator and coolant pump) must ^^^^^ 4\\ \\ A \ 21.28b ... and remove the drivebelt from the steering pump pulley 21.32 Release the belt tension, then slip the belt from the pulleys be removed first, as described previously. Loosen the pump mountings, the nut and bolt on the adjuster slot, and the adjuster locknut. Turn the adjuster bolt to slacken the belt tension, then slip the belt from the power steering pump pulley (see illustrations). 29 Refitting the belt'is a reversal of removal, making sure that the belt ribs engage properly with the pulley grooves. Tension the belt using the information in Section 7. 1.4 and 1.8 litre engines 30 To improve access, remove the wheelarch inner panel as described in paragraphs 2 to 4. Also remove the upper guard from the drivebelt, which is secured by two bolts - release the hose which is also clipped to the belt guard (see illustration). 31 Check the belt using the information in paragraphs 6 to 8. 32 If the belt is to be removed, either for servicing work or renewal, first note how the belt is fitted around the pulleys. Using a spanner on the drivebelt tensioner bolt, rotate the tensioner anti-clockwise to release the belt tension, then slip the belt from the pulleys (see illustration). 33 Refitting the belt is a reversal of removal, noting the following points: a) Fit the belt around all the pulleys as noted on removal, apart from the tensioner pulley, making sure that the belt ribs engage properly with the pulley grooves. Make sure that any slack in the belt is adjacent to the tensioner. b) Turn the tensioner pulley fully anticlockwise, then slip the flat side of the belt over the tensioner pulley. c) Release the tensioner, and allow it to tension the belt. d) Using a spanner on the crankshaft pulley bolt, turn the belt clockwise through one complete revolution, checking that the belt runs true, and that the belt ribs stay located in the pulley grooves. e) Refit the wheelarch access panel and the roadwheel, and lower the car to the ground. Tighten the wheel bolts to the specified torque. 22 Clutch cable adjustment Note: This check does not apply to models with a hydraulically-operated clutch - the clutch on these models is self-adjusting. Refer to Chapter 6, Section 2. 23 Handbrake adjustment % 1 The handbrake should be fully applied by the fifth click from the handbrake lever ratchet mechanism.
2 To fully check the operation of the handbrake, chock the front wheels, then jack up the rear of the car and support it on axle stands. 3 Release the handbrake completely, and check that both rear wheels are free to turn. If this is not the case, either the handbrake has been over-adjusted, the cable is binding, or there is a problem with the rear drums (investigate using the information in Chapter 9). 4 Apply the handbrake by three clicks of the ratchet. By this point, both rear wheels should become difficult to turn by hand. By the time the lever has been set to the fifth notch (if not before) the wheels should be completely locked. 5 In practice, it may be found that the lever will not travel five notches - provided the handbrake releases completely, and can be fully applied, it is perhaps unnecessary to adjust the cable in this instance. If the lever travels more than five notches, adjustment is required, as follows. 6 Remove the gaiter from the handbrake lever, for access to the adjuster nut. The gaiter clips into a collar/groove at the base of the handbrake grip, and has a lip around its base which clips into the hole in the centre console. Release the gaiter, and lift it over the handbrake lever. 7 Adjust the nut at the base of the lever as required, until the operation of the handbrake is satisfactory. On completion, lower the rear of the car to the ground. Every 24 000 miles (40 000 km) 1.19 24 Exhaust emissions check ^> This check is part of the manufacturer's maintenance schedule, and involves testing the exhaust emissions using an exhaust gas analyser. Unless a fault is suspected, this test is not essential, although it should be noted that it is recommended by the manufacturers. In the majority of cases, adjusting the idle speed and mixture is either not possible, or requires access to dedicated FIAT test equipment. Exhaust emissions testing is included as part of the MoT test. 25 Engine management system jK fault code check 1 This check is part of the manufacturer's maintenance schedule, and involves 'interrogating' the engine management control unit (and those for the automatic transmission and/or ABS, as applicable) using special dedicated test equipment. Such testing will allow the test equipment to read any fault codes stored in the electronic control unit memory (see illustration). Every 36 000 miles (60 000 km) 26 Brake fluid renewal A 1 Warning: Brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. Do not use fluid that has been standing open for some time, as it absorbs moisture from the air. Excess moisture can cause a dangerous loss of braking effectiveness. 1 The procedure is similar to that for the bleeding of the hydraulic system as described in Chapter 9. The brake fluid reservoir should be emptied by siphoning, using a clean poultry baster or similar before starting, and allowance should be made for the old fluid to be expelled when bleeding a section of the circuit. 2 Working as described in Chapter 9, open the first bleed screw in the sequence, and pump the brake pedal gently until nearly all the old fluid has been emptied from the master cylinder reservoir. ^ Old hydraulic fluid is often much darker in colour than the new, making it easy to distinguish the two. 3 Top-up to the MAX level with new fluid, and continue pumping until only the new fluid remains in the reservoir, and new fluid can be seen emerging from the bleed screw. Tighten the screw, and top the reservoir level up to the MAX level line. 4 Work through all the remaining bleed screws in the sequence until new fluid can be seen at all of them. Be careful to keep the master cylinder reservoir topped-up to above the MIN level at all times, or air may enter the system and greatly increase the length of the task. 5 When the operation is complete, check that all bleed screws are securely tightened, and that their dust caps are refitted. Wash off all traces of spilt fluid, and recheck the fluid level. 27.3 Unscrewing the transmission oil filler/level plug 25.1 Connector plug for use with diagnostic equipment -1.6 litre model shown 2 Unless a fault is suspected, this test is not essential, although it should be noted that it is recommended by the manufacturers. 3 It is possible for quite serious faults to occur in the engine management system without the owner being aware of it. Certain engine management system faults will cause the system to enter an emergency back-up mode, which is often so sophisticated that engine performance is not apparently much affected. If a problem has caused the system to enter its back-up mode, this will usually be most apparent when starting and running from cold. 6 Check the operation of the brakes before taking the car on the road. 27 Manual transmission oil level check 1 Park the car on a level surface. The oil level must be checked before the car is driven, or at least 5 minutes after the engine has been switched off. If.the oil is checked immediately after driving the car, some of the oil will remain distributed around the transmission components, resulting in an inaccurate level reading. 2 The filler/level plug is on the front of the transmission housing, typically next to the reversing light switch. Access is possible from above, but is better from below, once the engine undertray has been removed (where applicable). 3 Wipe clean the area around the filler/level plug. A large Allen key or socket will be required to remove the plug, which will probably be quite tight (see illustration). 4 Remove the plug, and check the oil level. This can be done with your finger; alternatively, a piece of bent wire can be inserted through the plug hole to assess the oil level inside the transmission - if this is
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: 5 Before removing the filter, note
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
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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 »20 Bodywork and fittings 23.3
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11 »22 Bodywork and fittings 16 Wi
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11 »24 Bodywork and fittings 23.27
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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
Page 109 and 110:
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
Page 121 and 122:
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
Page 133 and 134:
8*6 Driveshafts 4.7 Unbolt the inte
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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
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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
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Chapter 5 Part A: Starting and char
Page 163 and 164:
Starting and charging systems 5A»3
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5.13a Unscrew the bolts securing th
Page 167 and 168:
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
Page 185 and 186:
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
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
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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
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2.20a Removing the cover from the b
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2.33 Removing the left-hand wheelar
Page 217 and 218:
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 ...
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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
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Location of TDC on No 1 cylinder 1
Page 235 and 236:
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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2012 1.6 litre enginein-car repair
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Page 261 and 262:
Page 263 and 264:
2O20 1.6 litre engine in-car repair
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Chapter 2 Part B: 1.4 litre engine
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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
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2A«4 1.2 litre engine in-car repai
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2A»6 1.2 litre engine in-car repai
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2A»8 1.2 litre engine in-car repai
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2A»10 1.2 litre engine in-car repa
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Page 291 and 292:
Page 293 and 294:
REF-2 Conversion factors Length (di
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REF.4 Vehicle identification number
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REF.6 Disconnecting the battery Sev
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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 317 and 318:
Page 319 and 320:
Page 321 and 322:
REF
Page 323 and 324:
REF
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Bravo & Brava • 1995 To 2000

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