Bravo & Brava • 1995 To 2000

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REPAIRS & OVERHAUL Engine and associated systems Contents 1.2 litre engine in-car repair procedures Page 2A»1 1.4 litre engine in-car repair procedures Page 2B»1 1.6 litre engine in-car repair procedures Page 201 1.8 litre engine in-car repair procedures Page 2D»1 Engine removal and overhaul procedures Page 2E»1 Cooling, heating and ventilation systems Page 3«1 Fuel system - single-point injection Page 4A»1 Fuel system - multi-point injection Page 4B«1 Exhaust and emission control systems Page 401 Starting and charging systems Page 5A»1 Ignition system Page 5B»1 Transmission Clutch Page 6»1 Manual transmission Page 7A»1 Automatic transmission Page 7B»1 Driveshafts Page 8*1 Brakes and suspension Braking system Page 9»1 Suspension and steering Page 10*1 Body equipment Bodywork and fittings Page 11»1 Body electrical systems Page 12»1 Wiring diagrams Page 12*23 REFERENCE Dimensions and weights Page REF»1 Conversion factors Page REF»2 Buying spare parts Page REF»3 Vehicle identification numbers Page REF»4 Jacking and vehicle support Page REF»5 Disconnecting the battery Page REF»6 General repair procedures Page REF»7 Tools and working facilities Page REF»8 MOT test checks Page REF»10 Fault finding Page REF»14 Glossary of technical terms Page REF»24 Index Page REF»29
o.4 Introduction The 3-door FIAT Bravo and 5-door Brava models were introduced at the end of 1995, as part of a new range of FIAT models which began with the successful Punto a year earlier. The elegant all-new design won the coveted Car of the Year award in 1996. The engines are all fuel-injected, in-line, multi-valve four-cylinder units of 1370 cc, 1581 cc or 1747 cc displacement, and all feature a comprehensive engine management system with extensive emission control equipment. In early 1999, the range received a minor facelift, and the 1370 cc 12-valve engine was replaced by the 1242 cc 16-valve engine from the FIAT Punto. The 3- and 5-door bodyshells are extensively galvanised and particularly rigid, and offer spacious accommodation. The cars have many crash safety measures, such as a driver's airbag, side impact bars, anti-submarine seats, and front seat belt pre-tensioners. Transmissions are either 5-speed manual, or 4-speed automatic with computer control. The automatic transmission features mode FIAT Bravo 1.4 SX The Fiat Bravo/Brava Team Haynes manuals are produced by dedicated and enthusiastic people working in close co-operation. The team responsible for the creation of this book included: Authors AK Legg LAE MIMI Spencer Drayton RM Jex Page Make-up Steve Churchill James Robertson Workshop manager Paul Buckland Photo Scans John Martin Cover illustration & Line Art Roger Healing Wiring diagrams Steve Tanswell We hope the book will help you to get the maximum enjoyment from your car. By carrying out routine maintenance as described you will ensure your car's reliability and preserve its resale value. control selection, allowing the driver to alter the transmission characteristics to suit normal, sport or winter driving requirements. Braking is by discs at the front, and drums at the rear, with the handbrake acting on the rear drums. Anti-lock braking (ABS) is available as an option. The suspension is conventional, with struts and wishbones at the front, and a torsion beam rear axle. Power-assisted rack and pinion steering is standard on all models. A high level of standard equipment, and a wide range of optional equipment, is available within the range to suit virtually all tastes. All models have a driver's airbag, tinted glass, high-level brake light and central locking, with several featuring electric windows, electric sunroof and alloy wheels. Provided that regular servicing is carried out in accordance with the manufacturer's recommendations, the FIAT Bravo and Brava will provide reliable and economical family motoring. The engine compartment is relatively spacious, and most of the items requiring frequent attention are easily accessible. FIAT Brava 1.8 ELX Your FIAT Bravo/Brava manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence. The illustrations are numbered by the Section number and paragraph number to which they relate - if there is more than one illustration per paragraph, the sequence is denoted alphabetically. References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat, facing forwards. Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions, and to Duckhams Oils, who provided lubrication data. Thanks are also due to Draper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given.
Page 1 and 2: BRAVO & BRAVA • 1995 to 2000 (N t
Page 3: Contents LIVING WITH YOUR FIAT BRAV
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
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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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Page 95 and 96:
11 »22 Bodywork and fittings 16 Wi
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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
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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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^^^^^ 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
Page 257 and 258:
Page 259 and 260:
Page 261 and 262:
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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 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 289 and 290:
Page 291 and 292:
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 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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