Bravo & Brava • 1995 To 2000

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1.22 Every 2 years 31.24a Remove the expansion tank cap... 14 If after a reasonable period, the water still does not run clear, the radiator can be flushed with a good proprietary cooling system cleaning agent. It is important that their manufacturer's instructions are followed carefully. If the contamination is particularly bad, insert the hose in the radiator bottom outlet, and reverse-flush the radiator. Engine flushing 15 <strong>To</strong> flush the engine, remove the thermostat as described in Chapter 3, then temporarily refit the thermostat cover. 16 With the top and bottom hoses disconnected from the radiator, insert a garden hose into the radiator top hose. Direct a clean flow of water through the engine, and continue flushing until clean water emerges from the radiator bottom hose. 17 On completion of flushing, refit the thermostat and reconnect the hoses with reference to Chapter 3. Antifreeze type and mixture 18 The antifreeze should always be renewed at the specified intervals. This is necessary not only to maintain the antifreeze properties, but also to prevent corrosion which would otherwise occur as the corrosion inhibitors become progressively less effective. 19 Always use ethylene-glycol-based antifreeze suitable for use in mixed-metal cooling systems. The total system capacity is quoted in the Specifications, as well as the percentage of neat antifreeze required to give adequate protection against freezing (and corrosion). 31.27 Bleed screw (arrowed) on heater hose 31.24b ... and fill the system slowly 20 Before adding antifreeze, the cooling system should be completely drained, preferably flushed, and all hoses checked for condition and security. 21 After filling with antifreeze, a label should be attached to the expansion tank, stating the type and concentration of antifreeze used, and the date installed. Any subsequent topping-up should be made with the same type and concentration of antifreeze. 22 Do not use engine antifreeze in the washer system, as it will cause damage to the vehicle paintwork. Cooling system filling 23 Before attempting to fill the cooling system, make sure that all hoses and clips are in good condition, and that the clips are tight. Note that an antifreeze mixture must be used all year round, to prevent corrosion of the engine components (see following sub- Section). 24 Remove the expansion tank filler cap, and fill the system by slowly pouring the coolant into the expansion tank to prevent airlocks from forming (see illustrations). 25 If the coolant is being renewed, begin by pouring in a litre of water, followed by the correct quantity of antifreeze to make up the required mixture, then top-up with more water. The best option, if suitable clean containers are available, is to make up the mixture before pouring it in. Bear in mind that the system capacities quoted are only approximate - it is unlikely that all the old coolant will have drained, so allowance must be made when refilling. 26 During the initial stages of filling, squeeze the radiator top and bottom hoses to help expel any trapped air in the system. Fill the system until coolant (free of air bubbles) emerges from the radiator bleed screw(s), then tighten them securely. 27 Continue filling the system until coolant emerges from the bleed screws on the heater hoses, then tighten the screws (see illustration). 28 Now top-up the coolant level to the MAX mark and refit the expansion tank cap loosely. Particularly on models with air conditioning, it is important not to overfill the expansion tank at this stage. 29 Start the engine and run it at idle. 30 Particularly on models with air conditioning, have an assistant raise the engine speed to approximately 3000 rpm every 30 seconds while the engine is warming-up. When this is done, carefully open the bleed screw on the heater hose - bear in mind the dangers of hot coolant - and bleed out any trapped air. 31 Initially, add more coolant as necessary to keep the level up to the MAX mark, but only for the first few minutes after the engine is started. 32 Once the coolant level has stabilised, refit the expansion tank cap securely. Let the engine continue to warm up until normal operating temperature is reached, indicated by the temperature gauge, or by the radiator fan cutting in. Keep the engine running for a few more minutes, then switch it off and allow it to cool for several hours (preferably, overnight). 33 Check for leaks, particularly around disturbed components. 34 Check the coolant level in the expansion tank, and top-up if necessary. Note that the system must be cold before an accurate level is indicated in the expansion tank. Airlocks 35 If, after draining and refilling the system, symptoms of overheating are found which did not occur previously, then the fault is almost certainly due to trapped air at some point in the system, causing an airlock and restricting the flow of coolant; usually, the air is trapped because the system was refilled too quickly. 36 If an-airlock is suspected, first try gently squeezing all visible coolant hoses. A coolant hose which is full of air feels quite different to one full of coolant, when squeezed. After refilling the system, most airlocks will clear once the system has cooled, and been topped up. 37 While the engine is running at operating temperature, switch on the heater and heater fan, and check for heat output. Provided there is sufficient coolant in the system, lack of heat output could be due to an airlock in the system. 38 Airlocks can have more serious effects than simply reducing heater output - a severe airlock could reduce coolant flow around the engine. Check that the radiator top hose is hot when the engine is at operating temperature - a top hose which stays cold could be the result of an airlock (or a non-opening thermostat). 39 If the problem persists, stop the engine and allow it to cool down completely, before unscrewing the expansion tank filler cap or opening the bleed screws and squeezing the hoses to bleed out the trapped air. In the worst case, the system will have to be at least partially drained (this time, the coolant can be saved for re-use) and flushed to clear the problem.
Chapter 12 Body electrical systems Contents Airbag system - precautions and general information 21 Airbag system components - removal and refitting 22 Anti-theft alarm/engine immobiliser system - general information 20 Bulbs (exterior lights) - renewal 4 Bulbs (interior lights) - renewal 5 Cigarette lighter - removal and refitting 15 Electrical fault finding - general information 2 Exterior light units - removal and refitting 6 Fuses and relays - general information 3 General information and precautions 1 Headlight beam alignment - general information 8 Degrees of difficulty Easy, suitable for |k novice with little §x expenence jj^ Fairly easy, suitable |k for beginner with some experience Fairly difficult, §k suitable for competent ^ DIY mechanic 12»1 Horn - removal and refitting 9 Instrument panel - removal and refitting 7 Loudspeakers - removal and refitting 10 Radio aerial - removal and refitting 11 Radio/cassette player - removal and refitting 12 Speedometer sender unit - removal and refitting 13 Switches - removal and refitting 14 Tailgate wiper motor - removal and refitting 16 Windscreen wiper motor - removal and refitting 18 Windscreen/tailgate/headlight washer system components - removal and refitting 17 Wiper arm - removal and refitting 19 Difficult suitable for ^ experienced DIY mechanic ^ Specifications Note: The following fuse information is for pre-1998 models. Refer to your handbook for information on later models. Main fusebox Fuse Amp Circuit Very difficult, suitable for expert DIY ^ or professional 1 15 Reversing lights, stop lights, direction indicators, instrument panel power supply, check panel power supply, electric mirrors control, radio power supply, remote control power supply 2 10 Radio power supply, internal lighting, glove compartment light, boot light, door lock/unlock remote control power supply, alarm system power supply, clock power supply 3 10 Right side light and left tail light, right number plate light, radio illumination, instrument panel illumination and side/tail lights warning lamp, cigar lighter illumination, switch panel illumination 4 10 Left side light and right tail light, left number plate light, manual climate control/heater controls illumination 5 10 Left dipped beam headlight 6 10 Right dipped beam headlight, headlight alignment control 7 10 Right main beam headlight 8 10 Left main beam headlight, main beam headlight warning light 9 10 Rearfoglight 10 10 Hazard lights 11 - 30 Heated rear window, heated rear window warning light 12 30 Electric climate control motor (manual version) 13 20 Horn 14 20 Windscreen wiper, windscreen washer, rear window wiper, rear window washer, headlamp washers 15 30 Electric heater motor, cigar lighter, manual climate control relay
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: 31.3a Opening the radiator bleed sc
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
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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
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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
Page 149 and 150:
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
Page 159 and 160:
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 ...
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
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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
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
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
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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
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paragraph 17), then remove the heat
Page 275 and 276:
to the downpipe. The safest option
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13.8 Using an impact screwdriver to
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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
Page 287 and 288:
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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