Fiat 1995 Brava Service Manual Download Page 342

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Gearbox and differential

Removing-refitting

Bravo-Brava fto

2 1 - 2 7 .

1. Remove the nuts securing the fuse and re-

lay box to the battery cage, then move the
box over to one side.

2. Remove the battery cage by undoing the

bolts shown in the figure; also undo the
nuts securing the mounting bracket for the

starter motor supply cables.

3. Disconnect the speedometer sensor con-

nector.

4. Disconnect the clutch cable by undoing

the nut ( 1 ) and locknut (2) shown in the
figure. Also disconnect the earth lead (3)
from the gearbox.

5. Disconnect the reaction link shown in the

detail and the gear selector engagement
rods from the gearbox.

P4A040B02

Publication no. 506.670

Summary of Contents for 1995 Brava

Page 1: ...Fiat Bravo a Service Manual Volume 1 Click here to c h o o s e chapter Gearbox Jk Oiff Broking System 1 y Braking System 2 file D Volume 201 Voll htm08 07 2006 16 03 54...

Page 2: ...nts v Counter balance shaft Lubrication Cooling system Fuel system F u e l system 12 17 gear IS 23 24 27 28 E N G I N E D i p TD Characteristics 32 Typical curves 33 Cylinder block crankcase crankshaf...

Page 3: ...Bravo Btava I n t r o d u c t i o n Car exterior OO o P4A001A01 3 4 front view Bravo P4A001A02 3 4 front view Brava Copyright by Fiat Auto 1...

Page 4: ...1AA 11 p 16V ZFA 182 000 182 A4 000 182 BB 1 AA 11 B A ZFA 182 000 182 A6 000 182 AH 1 AA 08 ZFA 182 000 182 A6 000 182 BH 1 AA 17 ZFA 182 000 182 A2 000 182 AC 1AA 03 ZFA 182 000 182 A2 000 182 AC 1A...

Page 5: ...S20V A B C D E F G H I L M N Name of manufacturer Homologation number Vehicle type identification code Chassis manufacture number Maximum authorized weight of vehicle fully laden Maximum authorized w...

Page 6: ...uel consumption figures according to the 80 1268 EEC standards given overleaf have been defined in the course of official tests and in accordance with procedures laid d o w n by EEC regulations In par...

Page 7: ...m Constant speed 120 kph C 7 7 5 7 6 6 9 8 7 6 9 N D Fuel consumption according to 80 1268 CEE stand litres 100 km Av consumption CCMC proposal A B C 3 7 1 7 4 7 7 7 3 8 9 6 1 N D Fuel consumption acc...

Page 8: ...5 8 2 5 4 0 6 2 7 4 0 2 5 1 4 1 6 1 4 3 9 1 4 4 1 1 7 5 5 1 7 4 7 1 6 V 6JX14 43 6JX15 40 8 5 8 2 5 4 0 6 2 7 4 0 2 5 1 4 1 6 1 4 3 9 1 4 4 2 1 4 4 1 1 4 4 7 1 7 5 5 1 9 9 8 2 0 V 6JX15 49 61 2 x15 4...

Page 9: ...V51 2 JM4 37 6JX14 43 858 2540 789 4187 1413 1 4 5 1 1439 1453 1 4 4 1 1 7 7 1 1747 1 6 V 5 1 4 J x 1 4 3 7 6Jxi4 43 858 2540 789 4187 1413 1 4 5 1 1439 1453 1 4 4 1 1 7 4 1 1929 D 51 4JX14 37 858 25...

Page 10: ...gines SELENIA Turbo Diesel SAE 15 W 4 0 1581 3 8 3 5 3 4 3 1 1747 4 3 3 9 3 9 3 5 Partial capacity periodic replacement 1998 5 4 5 4 45 4 1929 D 4 9 4 2 4 4 3 8 a T U T E L A ZC 7 5 Synt b T U T E L A...

Page 11: ...s are not consistent with actual capacities of the engine OPERATIONS IN THE NETWORK When changing the engine oil stick to the figures given below which update the corresponding ones in the Service Man...

Page 12: ...pipes and oil filter 1st filling dm3 Kg dm3 Kg dm3 Kg Fiat Bravo TD 75 and TD 100 5 4 35 4 2 3 75 4 5 4 0 Fiat Brava TD 75 and TD 100 5 4 35 4 2 3 75 4 5 4 0 Fiat Marea TD 75 4 7 4 2 4 2 3 75 4 5 4 0...

Page 13: ...RK When changing the engine oil refer to the figures given below which update the corresponding figures given in the Service Manual and the Owner s Handbook Please provide the Customer with suitable i...

Page 14: ...ilter and pipes 1st filling dm3 Fiat Bravo TD 75 and TD 100 4 7 Fiat Brava TD 75 and TD 100 4 7 Fiat Marea TD 75 and TD 100 4 7 Kg 4 2 4 2 4 2 Engine sump dm3 4 2 4 2 4 2 Kg 3 75 3 75 3 75 Engine sump...

Page 15: ...assisted steering TUTELA CVT Universal Oil for continuous variation automatic transmissions Continuous variation automatic transmissions TUTELA J0TA1 Lithium soap based grease consistency NLGI 1 Grea...

Page 16: ...ylinder liner bore mm 82 86 4 82 82 Stroke mm 64 87 67 4 82 7 75 65 Q b i b J Capacity cc 1370 1581 1747 1998 Compression ratio 9 85 0 15 10 15 0 15 10 3 0 15 10 0 15 Max power EEC kW CV 59 59 80 75 C...

Page 17: ...H 1 1 1 1 1 I 1000 2000 3000 4000 5000 6000 7000 rpm Engine power curves obtained by E E C method The power curves illustrated can be obtained with the engine overhauled and run in without a fan and w...

Page 18: ...in bearing supports 21 72 21 80 0 56 705 56 718 22 14 22 20 54 507 54 520 21 72 21 80 56 705 56 718 63 705 63 718 0 01 BP J Auxiliary shaft bush housings 38 700 38 730 02 35 036 35 066 0 0 Cylinder bo...

Page 19: ...diameter value indicated in the Service Manual 10 05 96 A l With reference to what is stated on page 13 of section 00 in the Service Manual Print no 506 670 we wish to point out that the exact values...

Page 20: ......

Page 21: ...81 978 Piston 0 0 4 Difference in weight between pistons 5 g 0 038 0 058 3 1 Of Piston Cylinder bore 0 B 0 039 0 061 0 042 0 062 Gudgeon pin housing 0 20 002 20 007 21 997 22 001 20 002 20 007 4 0 19...

Page 22: ...0 055 3 0 075 0 105 0 065 0 095 0 030 0 065 0 020 0 055 Opening at end of 5_1 u i p piston rings f H in cylinder bore 1 0 250 0 500 0 200 0 450 0 300 0 500 Opening at end of 5_1 u i p piston rings f H...

Page 23: ...0i i r l r I N 3 52 994 53 000 50 790 50 800 52 994 53 000 59 994 60 000 52 988 52 994 50 780 50 790 52 988 52 994 52 982 52 988 52 982 52 988 Crank pins 02 40 884 40 890 45 513 45 523 50 799 50 805 4...

Page 24: ...1 531 1 536 1 540 1 0 p i 0 l W w r u r a n K s n a n i m 1 bearings L P B 1 539 1 543 1 540 1 546 1 530 1 534 1 539 1 543 1 0 p i 0 l W I I c 1 542 1 546 1 533 1 537 1 542 1 54 1 0 p i 0 l W 0 i a F...

Page 25: ...in mm 23 1 Bushes for auxiliary shaft in housing 35 664 35 684 32 000 32 020 24 02 0 0 Auxiliary shaft bear ings 0 35 593 35 618 31 940 31 960 23 1 Bushes for shaft Cylinder block seats must be an int...

Page 26: ...V 20V DESCRIPTION Values in mm Camshaft supports in cylinder head lESL i2v i2bH i i i __n__ri 0 0 26 045 26 070 20V L 19 100 19 150 26 045 26 070 19 100 19 150 i Valve guide bore in cylinder head 0 12...

Page 27: ...82 7 000 6 975 6 990 H Q 0 30 200 34 500 33 400 37 700 29 900 30 200 a 45 30 5 Valve S3 0 6 982 7 000 0 34 500 35 700 6 974 6 992 29 750 30 050 27 900 28 200 6 960 6 975 25 900 26 200 a 45 30 5 14 13...

Page 28: ...a 02 03 17b j 0 3H2V ani6v 04 05 iBpi 20V 0 0 0 i0 i0 i0 0 26 000 26 015 1 7 c M Ifll UjUgJ 19 250 19 330 29 944 29 960 52 400 52 415 52 800 52 815 53 200 53 215 53 600 53 615 26 000 26 015 19 250 19...

Page 29: ...shaft housing 03 52 845 52 870 04 53 245 53 270 05 53 645 53 670 n r ir in_ ur 1 BB3PB Tappet housings 0 0 k 30 000 33 025 17 18 jp Camshaft bearings Camshaft housing supports 0 030 0 070 19 c b Tappe...

Page 30: ...and valve gear components OO io TIMING DIAGRAMS Timing angles 12V I B 16V I P l6V 20V A Inlet HQ opens before TDC 8 4 0 9 after TDC B Inlet HQ closes after BDC 25 34 27 49 C Exhaust opens before BDC...

Page 31: ...il pump driven gear 2 7 0 2 O U 0 1 20 01 02 Ball bearings for counter balance shaft 19 900 20 000 46 989 47 000 0 2 5 10 10 Counter balance shaft bearings H i 0 19 980 19 993 Bear seats in cyl block...

Page 32: ...ugh crankshaft Oil pressure relief valve incorporated in crankshaft front cover between pump casing housing and driven 0 080 0 186 between the upper side of the gears and the pump cover 0 025 0 061 0...

Page 33: ...aive incorporated in oil pump Full flow filter cartridge insufficient oil pressure sender unit electrical between the edge of the gears and the pump cover 0 110 0 180 between the upper side of the gea...

Page 34: ...alve incorporated in crankshaft front cover Full flow filter cartridge Insufficient oil pressure sender unit electrical _ J L between the edge of I I fl HI the gears and the 2 5 1 0 pump casing 0 110...

Page 35: ...ing H 0 3 1 1 mm Press for checking rad water tightness 0 98 bar Pressure for checking calibration of exhaust spring on expansion tank cap 0 98 bar For versions with air conditioning For the 1747 16v...

Page 36: ...nit Bosch 0 261 203 868 Butterfly casing Bosch 0 438 201 523 TDC and rpm sensor Bosch 0 281 002 102 Fuel vapour solenoid valve Bosch 0 280 142 300 Detonation sensor Bosch 0 261 231 007 Coolant tempera...

Page 37: ...Air temperature sender unit JAEGER ATS 04 01 Fuel pressure regulator M Marelli RPM 40 Coolant temperature sender unit JAEGER 401930 01 Top dead centre and rpm sensor JAEGER CVM 01 Throttle valve posit...

Page 38: ...e sensor Bosch 0 280 130 055 Electric fuel pump WALBRO MSS 071 01 Lambda probe NTK 0ZA112 A2 Fuel filter G M 25121074 Idle actuator HITACHI GL 326716 Throttle valve position sensor potentiometer HITAC...

Page 39: ...ch 0 280 140 553 Electric fuel pump Bosch 0 580 453 408 Air flow meter Bosch 0 280 217 111 Fuel filter Bosch A 450 024 262 Butterfly valve position sensor potentiometer Bosch 0 280 122 001 Coolant tem...

Page 40: ...head camshaft Indirect mechanical injection Number of cylinders 1 0 Cylinder liner bore mm 82 6 N D Stroke mm 90 N D Capacity cc 1929 N D 9 Compression ratio 21 0 5 N D Total volume of combustion cham...

Page 41: ...les of overhauled engines During the bench test of the overhauled en gine it is not advisable to run the engine at maximum speed but to stick to the figures given in the table complete the running in...

Page 42: ...21 720 21 800 56 705 56 718 0 Cylinder bore 0 A I F c 82 600 82 610 82 000 82 010 82 610 82 620 82 010 H 82 020 82 620 82 630 82 020 82 030 X 15 10 3 3 82 520 82 555 81 930 81 940 82 530 82 540 81 94...

Page 43: ...5 987 Gudgeon pin 0 0 2 4 3 Gudgeon pin Housing 0 003 5 0 012 0 004 0 014 0 4 2 075 2 095 2 575 2 595 1 978 1 990 1 970 1 990 2 975 2 990 2 975 3 010 Piston rings 0 0 4 0 080 0 130 5 3 P Piston rings...

Page 44: ...nce in weight between con rods 2 5 g 01 27 020 27 060 29 018 29 038 02 25 004 25 009 26 006 26 012 Small end bush Gudgeon pin Small end bush 0 013 0 022 0 019 0 030 7 6 r Small end bush Bush housing 0...

Page 45: ...27 1 531 1 533 1 537 1 530 1 534 1 533 1 537 0 0 254 0 508 10 8 f Big end bearings Main journals 0 028 0 061 0 030 0 056 11 Thrust washers 2 310 2 360 2 342 2 358 0 127 11 8 Crankshaft end float 0 055...

Page 46: ...3 977 H Q 45 5 a 45 5 Valve seats about 2 7 Camshaft bearing housings in cylinder head 0 43 020 43 040 j 0 1 j 0 2 g 4 p_i i_j i_JT_JT i i JT_rT j LrT_n_r j_ i JT_n i n 0 25 545 s 25 570 0 24 045 24 0...

Page 47: ...cylinder head 0 061 s 0 108 0 033 0 080 1 4 01 0 i 7 974 7 992 ft Li HQ 0 37 300 37 600 a 45 30 7 Valve 02 3 7 974 7 992 0 33 300 33 600 30 900 31 200 a 45 30 7 1 4 1 3 Valve Valve guide 0 030 0 066 1...

Page 48: ...in mm 1 7 1 2 f radial 0 030 0 070 axial 0 070 0 250 0 100 0 230 17 H Q 9 7 8 5 Cam lift 9 7 8 5 n J U IT L l0k Tappet 0 36 975 36 995 1 9 1 2 p Tappet Cylinder head 0 005 0 050 n n r i T L OA U L l c...

Page 49: ...01 5 29 990 30 015 17 21 a Q p Camshaft 1 7 2 1 b Supports 0 030 0 070 3 2 1 2 9T j Variation between an S L te chamber plane and j B cylinder head plane 0 765 0 055 0 150 0 3 TIMING DIAGRAMS P4A023A0...

Page 50: ...perated through crankshaft Oil pressure relief valve incorporated in crankshaft front cover t between pump casing housing and driven gear 0 080 0 186 J between the upper side of the gears and the pump...

Page 51: ...tting clearance between Oi p impeller vanes and pump casing w k 0 53 1 37 mm Press for checking rad water tightness 0 78 bar Pressure for checking calibration of exhaust valve on expansion tank cap 0...

Page 52: ...2 M 2 J I a a o u a 2 S O 09 cc a 0 3 t i l l o o o z s s S I Q E H c o TJ C O TJ o o TJ i co C O x C O a E 3 a _ co C O a _ _ co o E TJ C C O D O 03 C C O 4 C O o o U c C O C O O M C D C O c t o o o...

Page 53: ...e valve lever 1 3 1 7 0 0 1 Apply a pressure of 80 bar simultaneously to the 4 high pressure outlets and 2 bar compressed air to the diesel inlet union Fit the special instrument and rotate the pump s...

Page 54: ...ng OO io SUPERCHARGING Turbocharger operated by exhaust gases with waste gate valve and air air heat ex changer intercooler Turbocharger type Garrett Maximum supercharging pressure N D P4A046A01 CROSS...

Page 55: ...pring loading daN 400 450 500 525 420 485 0 190 200 215 230 200 0 Lining 130 137 145 155 137 215 145 Distance between pedal in end of travel position and rest posi tion 155 10 170 10 Clutch release me...

Page 56: ...Technical data Gearbox and differential 00 21 27 Bravo Brava 48 Print no 506 670 70...

Page 57: ...13 107 13 107 11 934 13 924 Differential internal casing bearing conical roller bearings Adjustment of bearing pre loading by shims Thickness of shims 0 05 mm 0 10 2 00 3 00 1 70 2 60 Interference to...

Page 58: ...Technical data Gearbox and differential 00 21 27 Bravo Brava 50 Print no 506 670...

Page 59: ...nical roller bearings Adjustment of bearing pre loading by shims mm o 05 1 70 2 60 Thickness of shims mm o 07 1 70 2 89 n fldgb T Interference to obtain exact bear ing pre loading mm Bearings not pre...

Page 60: ...2 225 7 8 o r Brake servo Iso Vac 8 pneumatic vacuum servo acting on all four wheels y J Distance of hydraulic Q S oJ k piston push rod l_ T P from master cylinder L support plate 22 45 22 65 With aut...

Page 61: ...linder pump 0 23 81 15 16 Servo brake ISO VAC 8 7 pneumatic vacuum servo acting on all four wheels iJ Distance of hydraulic piston push rod from master cylinder support plate 22 45 22 65 REAR BRAKES s...

Page 62: ...d r o T I nn nf turns Innk 3 5 3 t o lock Ratio I Wm rack travel 142 0 8 mm 142 1 5 mm Turning circle 10 4 m f outer T 1 wheel a 1 I J 31 30 31 30 30 i n e r a 2 0 4 V wheel Steering angle v 37 20 30...

Page 63: ...x 14 _ 43 175 65 R14 82H 185 60 R14 82H 2 2 2 3 2 2 2 5 Bravo 6J x 14 _ 43 6J x 15 40 6J x 15 40 185 60 R14 82H 185 55 R15 8 1 V B 195 50 R15 82V 2 2 2 3 2 2 2 5 i pi 20v Bravo 6J x 15 49 6 J x 1 5 4...

Page 64: ...Rear suspension toe in r 2 5 1 5 mm 0 4 from chassis no 4 050 320 rear wheel thrust angle A Angles cannot be adjusted With tyres inflated to the correct pressure and vehicle in running order with 5 l...

Page 65: ...subdivided into t w o cate gories identifiable by a mark 319 daN I 333 5 daN height of mm 1 9 2 yellow 1 for J those under a load of 1 354 daN 367 daN height of mm 1 9 2 yellow 1 for J those under a l...

Page 66: ...ries identifiable by a mark yellow 1 for f 1 height in mm t h c c under 1 192 a load of M 7 d a N h e i ght in mm 192 green 1 for n A n height in mm thn e under 1 192 a toad of 6 7 d a N _ h e i g h t...

Page 67: ...daN mm 194 The springs are subdivided into t w o cate gories identifiable by a mark 284 daN 301 da h e i g h t o f m m 1 9 4 yellow 1 for J those under 272 daN height of mm 1 9 4 a load ot 1 301 daN...

Page 68: ...IGNITION SYSTEM Bosch SPI Monomotronic integrated electronic injection ignition Weber Marelli I A W MPI integrated electronic injection ignition HITACHI MPI integrated electronic injection ignition sy...

Page 69: ...Ah 380A PRE HEATING ELECTRONIC CONTROL UNIT SI PEA 2961 BITRON CCD 48C Bosch 0 281 003 004 SI PEA 2904 BITRON CCD 47uP F2 INJECTION ADVANCE ELECTRONIC CONTROL U N I T B LUCAS 41000087 101 EGR ELECTRO...

Page 70: ...9 1 6 Engagement test current A voltage V torque developed daNm 324 440 7 1 7 6 0 97 1 25 680 700 4 9 3 11 1110 1150 4 4 4 6 3 9 Free running test current A voltage V speed rpm 40 44 48 l l 4 11 4 M1...

Page 71: ...nal current at 6000 rpm A 65 65 75 85 Field winding resistance between the slip rings n O 2 4 2 587 2 613 Direction of rotation seen from control side clockwise Diode rectifiers bridge Data obtained a...

Page 72: ...esistance of primary winding at 20 C Q 0 45 0 55 Ohmic resistance of secondary winding at 20 C Q 12000 14600 TDC AND RPM SENSOR Make and type Bosch 0 281 002 102 Sensor winding resistance at 20 C Q 48...

Page 73: ...NSION OUTLETS Type M Marelli Code BAE 920 A Resistance of primary winding at 20 C Q 0 580 Resistance of secondary winding at 20 C Q 9100 SPARK PLUGS Make and type NGK BKR6EKC GOLDEN LODGE 2HLDR Thread...

Page 74: ...at 20 C Q RPM AND TOP DEAD CENTRE SENSOR Make and type HITACHI GE 1 0 8 1 0 1 Sensor winding resistance 0 5 1 3 627 Distance gap between sensor and crankshaft pulley tooth mm 0 4 1 2 KNOCK SENSOR Mak...

Page 75: ...ance of primary winding at 20 C Q 0 4 Ohmic resistance of secondary winding at 20 C Q 8500 TDC AND RPM SENSOR Make and type Bosch 0 2 8 1 0 0 2 1 0 2 Sensor winding resistance at 2 0 C Q 774 946 Dista...

Page 76: ...852154000 Spanner 1 2 socket for cylinder head fixing bolts 1852157000 Spanner 1 2 socket for cylinder head fixing bolts 1852159000 Spanner for removing refitting belt tensioner 1852161000 Spanner for...

Page 77: ...ool for removing and refitting valves to be used with 1860322000 1860644000 Tool for removing and refitting valves to be used with 1860749000 1860647000 Flywheel lock at the bench 1860650000 Drift 0 2...

Page 78: ...emoving and refitting valves to be used with 1860786000 1860787000 1860788000 1860789000 1860810000 Dummy spark plug for ante chamber to be used when refit ting ante chamber fixing bush 1860812000 Too...

Page 79: ...000 Spanner for tensioning timing belt 1860846000 Flywheel lock operations at the bench 1860848000 Spanner for camshaft pulley exhaust side 1860856000 Spanner for timing pulley inlet side 1860859000 S...

Page 80: ...Tool for fitting crankshaft rear cover gasket to be used with 1860879000 1860882000 Tool for fitting camshaft cover gasket and auxiliary shaft cov er 1860883000 Pin for centering ante chamber 1860884...

Page 81: ...r fixing engine to rotating stand 1865091000 Tool for checking injection pump advance 1867019000 Drift for removing and refitting bush in crankcase for oil pump drive gear 1867029000 Flywheel lock 186...

Page 82: ...ng and gearbox gear 1842134000 Tool for removing gearbox gears and hubs 1845028000 Reaction tool for removing differential bearings 1845057000 Tool for removing bush for lay shaft 5 h speed gear 18450...

Page 83: ...017001 o 1870007000 Universal handle 1870152000 Drift for fitting hubs and gears on main and lay shafts 1870419000 Tool for fitting main shaft gasket on bell housing to be used with 1870007000 1870448...

Page 84: ...lay shaft bearings 1881124000 Pliers for adjusting main and lay shaft rear bearing circlips 1895411000 Pipe and 1 4 connectors for checking automatic gearbox oil pressure 1895424000 Pressure gauge 0 2...

Page 85: ...or compressing suspension springs when re moving shock absorber 1875055000 Drift to fit front wheel hub bearings to be used with 1870007000 1875059000 Drift for fitting rear wheel hub caps ELECTRICAL...

Page 86: ...jections to be used with 1895881000 1871000000 Rotating column for overhauling gearboxes and differentials 1876048000 Extractor for MINI HYLOK CONTACT MHF 0 2 15 mm type terminals 1881138000 Adjustabl...

Page 87: ...2 5 5 Cylinder head to crankcase fixing bolt M1 Ox 1 25 4 90 90 Cylinder head to crankcase fixing bolt M10 4 90 90 90 Cylinder head to crankcase fixing bolt M10 5 90 90 90 Cylinder head to crankcase...

Page 88: ...ation sensor to cylinder block crankcase fixing bolt M8 2 5 Coils support to cylinder head fixing bolt M6 0 9 Connector mounting bracket to inlet manifold and coils support fixing bolt M6 0 9 Oil pump...

Page 89: ...g ring nut M 3 2 x l 5 11 8 Injection pump fixing nut for stud M8 2 5 Injection pump fixing bolt M8 2 5 Flexible mounting to water pump casing fixing nut M12x 25 8 Injection pump drive gear fixing nut...

Page 90: ...10x1 25 5 Alternator mounting fixing nut M 1 0 X 1 2 5 4 3 Alternator to mounting fixing nut M12x1 25 7 Turbocharger to exhaust union fixing nut M8 2 5 Bolt for bracket strengthening exhaust manifold...

Page 91: ...R valve fixing bolt M8 2 5 Engine oil pressure sender unit M 1 4 X 1 5 3 Engine oil pressure switch M 1 4 X 1 5 3 2 Thermal switch for pollution control M 1 4 x l 5 1 5 Thermal switch for pollution c...

Page 92: ...ifferential support to gearbox fixing nut M12x1 25 8 Bracket differential side to gearbox fixing bolt 1929 D 1910 TD M10x1 25 5 Support to gearbox fixing bolt with flange 1370 M10x1 25 5 Connecting ro...

Page 93: ...and engagement rod to gear lever fixing bolt M8 2 8 Intermediate idler fixing pin nut M8 1 5 Heads to levers fixing nut M8 1 5 Idler selector to gearbox fixing nut for bolt M8 1 5 Reverse gear pipe to...

Page 94: ...lange retaining differential casing to gearbox casing fixing bolt M1 Ox 1 25 4 9 Flange retaining differential casing to gearbox casing fixing bolt M8 2 5 Speedometer mounting fixing bolt M6 1 2 Taper...

Page 95: ...ing bolt with wide flange M12x1 25 10 8 Front cross member to bodyshell rear fixing bolt with normal flange for nut M10x1 25 8 Bolt with flat and tapered washer for fixing front and rear exter nal U b...

Page 96: ...shell fixing bolt with wide flange M12x1 25 10 8 Rear flexible mounting to bodyshell fixing bolt with wide flange M12x1 25 10 8 Rear suspension track control arm to frame fixing nut for bolt M16x1 5 1...

Page 97: ...ead size Tightening torques daNm BODYWORK Luggage compartment retaining hook fixing bolt M8 2 Side door lock fixing bolt with tapered washer M6 0 75 Rear door fixed hinge fixing bolt M10x1 25 4 5 Fron...

Page 98: ...t it it Check condition and wear of rear brake discs only for 1998 20v it it Check condition and wear of rear brake linings drum brakes it Visually inspect condition of exterior bodywork and underbody...

Page 99: ...tions In addition to what is laid down in the Planned maintenace programme the following checks should also be carried out Every 500 km or before long journies check engine oil level engine coolant le...

Page 100: ......

Page 101: ...Untitled Document Removing Refitting file D Volume 201 engine htm08 07 2006 16 06 14...

Page 102: ...Inertia switch 38 Multifunction valve and safety and ventilation valve 38 CHECKS ADJUSTMENTS AND RE PAIRS ON BOSCH MONOMOTRONIC S Y S T E M 39 Checking fuel supply circuit 39 Adjusting butterfly valv...

Page 103: ...ed loop control system is therefore set up SYSTEM OPERATING STRATEGIES The management software resident in the ECU memory comprises a set of strategies Each of these con trols a specific system contro...

Page 104: ...e to stoichiometric levels 14 7 parts air to 1 part petrol To maintain this ratio constant the ECU uses two different modes for the control of injector opening The first mode is synchronous operation...

Page 105: ...urn supplies fuel pump A with power through a 10 A fuse The pump puts the fuel system under pressure for about 1 2 seconds When the engine is started up an rpm signal from rpm and TDC sensor D reaches...

Page 106: ...ve closer to a stoichiometric ratio The control unit also contains an anti flood function controlled by an internal timer that gradually re duces mixture enrichment when the engine fails to start for...

Page 107: ...ngular position sensor 3 When the engine is working at full power base pulse constnants ti are increased by a factor K ac cording to opening angle a of throttle valve 3 When the butterfly valve openin...

Page 108: ...gine rpm in excess of 1800 min If the above over run conditions exist idle contact 1 throttle closed earths terminal 3 of the control unit which cuts off fuel injection via terminal 21 In addition to...

Page 109: ...two end poles The LAMBDA probe sends a voltage difference signal to the control unit through terminals 12 and 13 LAM B DA probe measurements of exhaust gas composition allow the control unit to corre...

Page 110: ...ects the appropriate advance value according to the memory maps rpm D coolant tem perature E and engine load F knock G and governs the ignition unit power module accordingly The control unit contains...

Page 111: ...e actuator is dependent on engine conditions rpm and vehicle speed Start up stage When the key is inserted the actuator takes up a position dependent on engine temperature and battery voltage open loo...

Page 112: ...t if the ECU is disconnected FIAT CODE IGNITION LOCK FUNCTION MANAGEMENT The system features an ignition lock function This is implemented through a special FIAT CODE control unit able to dialogue wit...

Page 113: ...2 Coil 3 Air temperature sensor 4 Speedometer sensor 5 Lambda probe 6 Coolant sensor 7 Throttle position sensor 8 Rpm and TDC sensor 9 Ignition switch 10 Electric fuel pump 11 Injector 12 FIAT CODE co...

Page 114: ...ed to the engine under different service conditions The intake of warm or cold air is selected by deflector 2 which may or may not be affected by the vacu um in the intake manifold according to positi...

Page 115: ...e 5 Vent pipe 6 Union with vent and pressure relief valve 7 Tank 8 Electric pump 9 Pressure regulator 10 Injector N OTE Due to the specific shape of the tank when fuel is added an air lock may build u...

Page 116: ...ctions for med in the tank to escape into the atmosphere 1 Pipe carrying fuel vapour to butterfly val ve case 2 Fuel vapour cut off solenoid 3 Carbon filter 4 Pipe carrying fuel vapour from tank to ca...

Page 117: ...intake Gases emerge from outlet 1 which contains a flame trap 5 designed to prevent combustion caused by flame flashing back from the butterfly valve case With the accelerator throttle open gases are...

Page 118: ...l system Bravo Brava 1 112v 10 INJECTION IGNITION SYSTEM WIRING DIAGRAM C M 8 C H W L H C C O C M I oc 1 i oc fie 0 0 C O p cH voil I 15 3 co 3 o CM oo t S 3 T O C M CM C M C M C O C M 16 Publication...

Page 119: ...nsor 10 I e system supply relay 11 Ignition switch 12 Fuel pump and lambda probe relay 13 Battery positive 30 14 10A fuse for fuel pump 15 10A fuse for lambda probe heating coil 16 Fuel vapour cut off...

Page 120: ...Engine Bravo Brava Fuel system 10 ENGINE EXHAUST ASSEMBLY DIAGRAM P4A18AJ01 Key 1 Exhaust manifold 2 Lambda probe 3 Catalytic converter 4 Silencers 18 Publication no 506 670...

Page 121: ...n system 4 Throttle position sensor 5 Pump and injection ignition system re lays 6 Injector 7 Air temperature sensor 8 Fuel pressure regulator 9 Engine idle speed actuator 10 Diagnostic socket 11 Lamb...

Page 122: ...Fuses and relays The following components are housed on a bracket located against the rear wall of the engine bay 1 10A fuse for fuel pump 2 10A injection ignition system fuse 3 Injection ignition sys...

Page 123: ...IC strategy for both input and output sensors It also contains a special memory able to record any faults received during testing When a Fiat Lancia TESTER is connected to the system it is therefore p...

Page 124: ...ion sensor and in take air temperature sensor 12 Lambda probe 13 Lambda probe 14 Knock sensor 15 Knock sensor 16 Rpm and TDC sensor 17 Rev counter signal 18 Speedometer sensor 19 Power supply 30 20 En...

Page 125: ...eeth plus a space equivalent to the gap left by two miss ing teeth The reference point defined by the gap left by two missing teeth is used as a basis for recording synchronism point TDC Refer to Fuel...

Page 126: ...surface and phonic wheel tooth corresponds to the sum of sensor probe length 34 5 mm and gap 0 8 1 5 mm KNOCK SENSOR 0 261 231 007 The knock sensor is located on the rear of then engine block between...

Page 127: ...elerator throttle position sensor potentiometer 4 Fuel pressure regulator 5 Intake air temperature sensor 4 Injector 7 Director current motor for idle speed control 8 Throttle closed recognition micro...

Page 128: ...n measuring angle a The position of potentiometer 2 is adjusted in relation to the butterfly valve in the factory and should never be removed for any reason Replace butterfly valve case assemby if fou...

Page 129: ...eter B i e terminal of second race D This signal is sent to terminal 10 of the ECU and relates to engine service conditions at medium and full loads The field of the second race is divided into ECU ma...

Page 130: ...switch C which is closed when the accelerator pedal is at rest released Contact closure activates the two fold CUT OFF function during over run and automatic idle adjust ment P4A28AJ01 Injection pulse...

Page 131: ...s an individual part P4A29AJ01 Recovery In the case of an error on the idle contact short circuit or circuit open the ECU implements one of two strategies according to time of recognition recognition...

Page 132: ...e ECU reach the injector through electrical contacts 7 to set up a magnetic field about core 3 through winding 2 Plunger 5 then lifts from its seat to overcome the load of counter spring 4 and bring a...

Page 133: ...essure on membrane 4 exceeds a level of 1 bar it overcomes the load on counter spring 5 and moves plate 6 to allow fu el to flow out through a channel 7 in the tank Hole 9 in the top chamber 8 of the...

Page 134: ...0 360 O Terminal 13 of the ECU A supplies terminal 1 of sensor B the circuit is earthed from terminal 2 of the sensor to terminal 27 of the ECU When the sensor is disconnected the ECU supplies a volt...

Page 135: ...e sensor Terminal 8 of ECU A supplies sensor B The circuit is earthed through the sensor terminal to terminal 11 of the ECU 80 100 120 Checking resistance The graph in the figure shows the sensor resi...

Page 136: ...580 453 514 The fuel pump submerged in the tank is a two stage turbo pump and integral with the fuel level gauge assembly The pump is designed to work with a 12 V supply at a nominal pressure of 1 1...

Page 137: ...ing resistance Primary circuit A cylinders 2 3 B cylinders 1 4 Bring the terminals of an ohmmeter into con tact with positive strip central pin and neg ative strip pin 1 for circuit A and pin 2 for ci...

Page 138: ...f even slight amounts of lead in the fuel Removing refitting Place the vehicle on a lift Disconnect battery negative lead Raise the vehicle Disconnect electrical connection Remove the lambda probe fro...

Page 139: ...d cut off solenoid refer to Fuel Sys tem section of 1998 20V manual 1 Vapour cut off solenoid 2 Carbon filter Vapour cut off solenoid 0 280 142 300 Wiring connector NOTE The numbers in boxes indicate...

Page 140: ...moval refitting procedure refer to Fuel System section of the 1581 16V manual After even an apparently light collision if a smell of petrol is noted or fuel leaks are seen do not activate the switch a...

Page 141: ...MAR CIA position a ways disconnect battery negative lead before carrying out electrical we ding on vehicle Note that the memory of this system is active at all times memory on stand by and con tains...

Page 142: ...f pressure gauge a if it reaches 1 1 0 1 bar replace the fuel return pipe to the tank because it is blocked or kinked b if it exceeds 1 1 0 1 bar replace the pressure regulator because it is defective...

Page 143: ...er be taut or excessively slack so that accelerator pedal free travel is taken up If pedal shows free travel adjust accelerator control cable nut and lock nut Connect link 1 to head of lever 2 and war...

Page 144: ...blow by gas recirculation lines by unfastening at the points indicated 2 Disconnect fuel lines evaporation con trol line and vacuum duct 3 Disconnect electrical connections 4 5 Release accelerator li...

Page 145: ...of carbon monoxide CO and unburnt hydrocarbons HC with the catalytic converter hot 300 350 C it is advisable to push the car engine on the road for about 5 10 minutes to ensure that the catalytic conv...

Page 146: ...ts for the recognition time the defect is memorised as permanent If this defect then disappears it is memorised as intermittent If it reap pears it again becomes permanent Classification of a fault as...

Page 147: ...l line line K using standard Bosch communication Protocol The Tester is able to perform the following functions Error display Engine parameter display Active diagnosis List of errors RPM sensor Thrott...

Page 148: ...allowing the vehicle to be driven to a service centre The value is also relayed to the Fiat Lancia tester and therefore it should be noted when diagnosing that in the event of a malfunction the Fiat L...

Page 149: ...m showing Input output be tween injection ignition system sen sors actuators 15 Air intake circuitmanagement 15 Fuel supply circuit diagram 16 Fuel evaporation control circuit dia gram 17 Blow by gas...

Page 150: ...l devices The system is able to monitor the following parameters by means of dedicated sensors 1 instantaneous engine rpm 2 position of each piston pair in relation to TDC of cylinder 1 3 intake air t...

Page 151: ...entified by interpreting a series of signals from an rpm sensor located on the crankshaft pul ley and a timing sensor located on the camshaft pulley intake side NOTE The term signal framework denotes...

Page 152: ...and intake manifold pressure In practice the the ECU performs calculations in order to control sequential phased opening of the four injectors one per cylinder for the length of time strictly necessar...

Page 153: ...strategy is designed to correct base pulse constants so that mixture concentration oscillates contin ually and at a high rate between 0 98 and 1 02 This oscillation rate varies according to engine lo...

Page 154: ...tart up has taken place the factor is gradually reduced to zero within a given time period which is in inverse proportion to engine temperature k enrichment factor t time a decrease proportional to en...

Page 155: ...strategies are superimposed during this stage 1 Transitory negative strategy to reduce the amount of fuel required by the engine lower emissions This stage is recognized by the ECU when the potentiome...

Page 156: ...ue on the basis of signals from the following sensors throttle potentiometer absolute pressure sensor rpm and TDC sensor The base pulse constant is multiplied by a factor according to coolant temperat...

Page 157: ...GEMENT The system features an anti theft function This is implemented through a special FIAT CODE control unit able to dialogue with the engine control unit and an electronic key with a specific sende...

Page 158: ...s also subject to correction under the following conditions during start up during transitory stages of acceleration and over run during cut off when rpm is excessive For the ignition system to work e...

Page 159: ...ssed by the computer advance a varies according to rpm The control unit ECU then controls spark advance in the different cylinders in relation to top dead cen tre and conduction time necessary for the...

Page 160: ...iods of heavy rain The spark plugs of cylinders 1 4 and 2 3 are connected directly in pairs by means of high tension leads to coil secondary winding terminals and may be considered to be connected in...

Page 161: ...remains closed to prevent fuel vapours enriching the mixture excessively This condition persists until coolant temperature reaches 65 C with the engine warm the ECU sends the solenoid a square wave s...

Page 162: ...it increases the speed by adjusting the air flow by means of the step mo tor When a power requirement is identified throttle position higher than a given threshold the ECU in hibits air conditioner o...

Page 163: ...sensor 6 Rpm and TDC sensor 7 Ignition switch 8 Dual relay 9 Electric fuel pump 10 Throttle position sensor 11 Air temperature sensor 12 Engine idle speed actuator 13 Injectors 14 Fuel vapour cut off...

Page 164: ...aporation control system socket 3 Socket for absolute pressure sensor 4 Socket for servo brake 5 Socket for fuel pressure regulator 6 Air temperature sensor 7 Throttle case 8 Upper resonator 9 Gas upt...

Page 165: ...s 5 Return line 6 Vent pipe 7 Union with vent and pressure relief valve 8 Tank 9 Fuel pump 10 Pressure regulator 11 Injectors NOTE Due to the specific shape of the tank when fuel is added an air lock...

Page 166: ...vapour mainly comprising lighter hydrocarbon fractions formed in the tank to escape into the atmosphere 1 Fuel vapour cut off valve 2 Active carbon trap filter 3 Safety and ventilation valve 4 Multif...

Page 167: ...to the intake With the accelerator throttle open vent gases from the engine block reach the sleeve connecting the air cleaner butterfly valve case 4 through pipe 2 This contains a flame trap 1 which...

Page 168: ...relay 7 Lambda probe 8 Inertia switch 9 Electric fuel pump 10 Rev counter 11 Ignition coils 12 Spark plugs 13 Earth on body shell 14 Fuel vapour cut off solenoid 15 Earth on engine 16 Injectors 17 Sy...

Page 169: ...ECU 14 Timing sensor 5 20A fuse for components supplied 15 Lambda probe through dual relay electric pump lamb da probe injectors and fuel vapour 16 Lambda probe coupling solenoid 17 Injectors 6 Dual r...

Page 170: ...upplied through dual relay electric pump lambda probe injectors and fuel vapour cut off solenoid 4 Dual relay Unscrew ring nut and remove cover to gain access to the above components EARTH POINTS The...

Page 171: ...s These are grouped in special ducts fitted to the engine prewiring INJECTION IGNITION ECU The I A W 1 AF 13 I A W 1AF 23 for vehicles with automatic transmission injection ignition system ECU adopted...

Page 172: ...nal to modify and store an injection time correction factor that influences mixture concentration this ECU is therefore defined SELF ADAPTIVE These values require a continual supply from the battery i...

Page 173: ...ng bolts and remove the control unit It is absolutely prohibited to exchange injection control units between different vehicles in or der to check their efficiency Before replacing an ECU as a result...

Page 174: ...signal Throttle valve position sensor signal Fuel vapour solenoid N C Air conditioner compressor N C Speedometer signal Intake air temperature sensor 30 Rpm and TDC sensor earth 31 Diagnostic socket...

Page 175: ...ve teeth facing sensor and negative gap facing sensor voltage is set up at coil terminals The sensor output voltage peak value depends on the gap beteween sensor and phonic wheel teeth if all other fa...

Page 176: ...ing control unit pins NOTE Whenever repairs to the rpm and TDC sensor mount are necessary e g gap not as specified sensor not aligned etc the sensor must be positioned and aligned with the mount as de...

Page 177: ...age is set up at its terminals If current intensity remains constant the volt age generated depends solely on the intensi ty of the magnetic field magnetic field inten sity need therefore only vary pe...

Page 178: ...these conditions the throttle opening lever comes into contact with an anti bind screw which prevents the throttle becoming locked in closed position To prevent the build up of ice around the throttle...

Page 179: ...a voltage of 5 Volt The pa rameter measured is throttle position from idle to full opening for injection control man agement The following graph indicates the voltage level supplied by the sensor as...

Page 180: ...reduction of rpm at idling speed dashpot are inhibited P4A33CJ03 Self adaptivity of idle speed is inhibited Self adaptivity of the mixture strength is in hibited Removing refitting Undo the two bolts...

Page 181: ...iations in the sensor s resistance via changes in the voltage and thus obtain infromation concern ing the intake air temperature Together with the absolute pressure information this information is use...

Page 182: ...vels To the quantity of air Qo that leaks through the closed but terfly valve 4 during idling an additional quantity of air Q must be added to allow the engine to maintain rpm lev els constant particu...

Page 183: ...position by means of the idle flow law DASH POT laws In other words it slows the return of pluger 3 to its seat so that a quantity of air by passing hole 2 reaches the engine and re duces levels of po...

Page 184: ...rubber pipe 3 When the engine is off the diaphragm bends according to atmospheric pressure level Ex act information on altitude is therefore pro vided when the key is inserted When running the engine...

Page 185: ...gh voltage changes and thus obtain information on intake air temperature Recovery The last reading is adopted If the tempera ture does not correspond to steady state lev els this is gradually increase...

Page 186: ...ECU The motor is submerged in the fuel in order to clean and cool the brushes and commutator The pump is fitted with a pressure relief valve which short circuits delivery to intake if inlet circuit p...

Page 187: ...and from fuel level sending unit Disconnect fuel lines inlet outlet and breather Unscrew lock ring retaining pump to tank using tool 1860893000 and a box wrench Remove fuel pump assembly When refittin...

Page 188: ...ly 1 Fuel inlet 2 Arrow position 3 Fuel outlet Removing refitting To remove the fuel filter proceed as follows Raise the vehicle Undo the bolts indicated and remove the protective cover Disconnect the...

Page 189: ...ulator The fuel inlet comprises an attachment with tapered sealing screw The fuel is recirculated by means of a pipe contained in the manifold and connected at one end to the regulator and at the othe...

Page 190: ...uld never therefore be tam pered with otherwise the mixture concentration specified for the engine will be altered CARBON FILTER AND FUEL VAPOUR CUT OFF VALVE These components form part of the fuel ev...

Page 191: ...opening in ac cordance with the signal empty full pattern In this way the ECU controls the quantity of fuel vapour sent to the intake to prevent significant changes in mixture concentration Under the...

Page 192: ...m reaching active carbon filter and hence damage to the filter b the tank fuel level drops float 2 is lowered and rests upon ball 3 to open hole 1 When the pres sure exercised by fuel vapours on plate...

Page 193: ...e speed can therefore be calculated from pulse frequency Removing refitting Disconnect electrical connection and remove the sensor Tightening torque 0 8 daNm Wiring diagram SAFETY AND VENTILATION VALV...

Page 194: ...nsion stage up to a time when intake has already begun The fuel manifold presses against the injectors to fasten them into the seats on the intake ducts They are also anchored to the fuel manifold by...

Page 195: ...p earth connection and thus the fuel supply to the injection system To restore the pump earth connection push the seat back and press the switch until it clicks on Removing refitting 1 Move driver s s...

Page 196: ...xceptional dielectric properties Because the primary winding is so close to the magnetic core little magnetic flux is lost and coupling with the secondary winding is maximised 1 HT socket for cylinder...

Page 197: ...econdary winding resistance reading on the gauge must be between 8645 and 9555 ohm at 23 C Recovery Inhibition of injectors for cylinders in which ingnition is not taking place Open loop concentration...

Page 198: ...1 0 2 3 9 1 15 8 7 14 1 2 1 3 6 5 4 8 r KSA H U 204 J 11 13 521 24 38 1 Battery 2 Ignition coils 3 Lambda probe 4 Injectors 5 Electronic control unit 6 Ignition switch 7 20A system fuse 8 5A control...

Page 199: ...starting does not not take place with the ignition key in MAR position the electronic control unit 5 deactivates section of relay 9 pin 7 pump components and automati cally stops the pump 11 Timed en...

Page 200: ...ine in relation to the theoretical required level the air fuel mixture is a ratio between these two substances that react chemically when combined The stoichiometric proportions depend on fuel type us...

Page 201: ...1 020 Below 300 C the ceramic material is not active and the probe does not send usable signals A special circuit in the control unit blocks loop mixture regulation while the probe is warming up To e...

Page 202: ...ad Disconnect electrical connection located against the rear wall of the engine bay and protected by a cover Remove the lambda probe from its seat on the exhaust pipe When refitting spread the threade...

Page 203: ...he ignition key in MARC A posi tion a ways disconnect battery negative lead before carrying out electrical we ding on vehicle Note that the memory of this system is active at all times memory on stand...

Page 204: ...ld 2 Unscrew the bolts fastening both sections of the intake manifold together 3 Unscrew screws fastening the second sec tion of the intake manifold to the engine block and remove 4 Disconnect the fue...

Page 205: ...t operation is carried out by selecting fuel pump test on a Fiat Lancia tester Under these conditions the pressure gauge reading should stabilise at 3 0 bar If pressure is insufficient carry out the t...

Page 206: ...pump with the engine off When the regulation pressure is reached close control lever B and simultaneously con strict fuel return line to tank use pliers for this purpose and avoid damaging the pipe Th...

Page 207: ...s of carbon monoxide CO and unburnt hydrocarbons HC with the catalytic converter hot 300 350 C it is advisable to push the car engine on the road for about 5 10 minutes to ensure that the catalytic co...

Page 208: ...s memorised temporarily by the system control unit in order to facilitate repairs When the ignition key is removed these are transferred to the permanent memory where the can be read by a Fiat Lancia...

Page 209: ...elays Control unit A C D C A C D C A C D C A C D C A C D C Power supply 15 5V Power supply 5V Status not plausible probe disconnected or faulty D C A C D C A C D C No of subsequent steps A C D C A C D...

Page 210: ...sensor 24 Engine timing sensor 25 Air flow meter 26 Lambda sensor 27 Butterfly position sensor 28 Engine coolant temperature sensor 28 Vehicle speed sensor 29 Detonation sensor 29 Ignition system 30 I...

Page 211: ...usually of an analogue type is converted into digital signals by analogue digital A D converters in order to be able to be used by the control unit In particular any engine operating point is detected...

Page 212: ...elays 26 Detonation sensor 9 Climate control compressor 27 Coolant temperature sensor 10 Inertia switch 28 Charcoal filter solenoid valve 11 Vehicle speed sensor 29 Charcoal filter 12 F L Tester conne...

Page 213: ...r 7 Engine rpm sensor 8 Coolant temperature sensor 9 Butterfly position sensor 10 Lambda sensor 11 Ignition switch 12 Detonation sensor 13 Engine timing sensor 14 Climate control compressor 15 F L Tes...

Page 214: ...re sensor 5 Vehicle speed sensor 6 Air flow meter 7 Engine idle speed adjustment solenoid valve 8 Butterfly position sensor 9 Fuel pressure regulator 10 Engine rpm sensor 11 Detonation sensor 12 Fuel...

Page 215: ...y the control unit with a synchronized sequence of signals which the control unit is capable of recognizing In particular the signals are made up as follows flywheel on the crankshaft equipped with tw...

Page 216: ...quantity of fuel to be injected into each cylinder The latter in turn multiplies the quantity of air drawn in by each cylinder calculated on the basis of the quantity of intake air and on the engine...

Page 217: ...Lambda 1 The strategy has the function of correcting the basic injection times so that the mixture strength con stantly oscillates at a high frequency between 0 98 and 1 02 The oscillation frequency...

Page 218: ...given time which the lower the engine temperature the longer the time taken k ON 1 OFF k enrichment coefficient t time a decrease depending on the engine temperature ON engine driven crank OFF engine...

Page 219: ...ctor re opening extra pulse C injection time including enrichment OFF engine at stationary speed ON engine in transition Operation during deceleration During this stage a negative transit strategy is...

Page 220: ...ecial control unit FIAT CODE capable of dialogue with the engine control unit and an electronic key equipped with a special transmitter for sending a recognition code Each time the key is turned to th...

Page 221: ...corrected depending on the different engine operating conditions The control unit determines the moment of the start of the conduction of the current in the coil primary winding on the basis of the en...

Page 222: ...el signal A a fixed ignition advance 10 engine ON activated coil conduction OFF de activated coil conduction Operation during cut off The ignition advance is increased at the entry into cut off from t...

Page 223: ...peed of the vehicle Starting stage When the key is inserted the actuator assumes a position which depends on the temperature of the en gine and the battery voltage open loop position Engine started wi...

Page 224: ...opriate sensor there is no longer a thermal contact on the radiator Version without climate control There is an electric fan which switches on when the temperature of the coolant exceeds 95 C It switc...

Page 225: ...on the state of the three stage pressure switch for the climate control system which determines the engagement of the first speed and with a certain delay that of the second and the subsequent switch...

Page 226: ...e engine is idling the control unit increases the air flow rate which goes from the idle actuator in advance of the switching on of the compressor and viceversa places the actuator in the normal posit...

Page 227: ...epaired The detection of a confirmed fault usually in volves the warning light in the dashboard coming on the warning light goes out when the fault is repaired Working with the Fiat Lancia Tester it i...

Page 228: ...ult is decreased each time the engine is started up without the fault reappearing when the counter reaches zero the fault is automatically cancelled from the memory Failure warning light The failure w...

Page 229: ...r recovery during starting T 20 C otherwise T 20 C increased by 1 C every 6 seconds until reaching 80 C during starting or with the key in the OFF position the radiator fan is off otherwise it is acti...

Page 230: ...electric pump cut out inertia switch ignition power module ignition coils devices connected to the cotnrol unit radiator fan relays climate control compressor relay if fitted Fiat CODE control unit L...

Page 231: ...C 14 Positive for air flow meter 15 Positive for coolant temperature sensor 16 Positive for Lambda sensor 17 Signal for three stage pressure switch if fitted 18 N C 19 N C 20 Connection w i t h FIAT...

Page 232: ...2 CQ 5 C Q E E c L U i f 2 a Z 5 ui o 1 o...

Page 233: ...speed adjustment sol valve 25 Injectors 26 Charcoal filter solenoid valve 27 Inertia switch 28 Electric fuel pump 29 Electric fuel pump relay 30 System relay feed 31 A W signal from ignition key 50 32...

Page 234: ...cillations resulting from the variation of the gap These oscillations create an electro motive force in the winding 2 which produces a voltage which is alternatively positive tooth facing the sensor a...

Page 235: ...o the di rection of the current generates a difference in power known as Hall effect voltage If the intensity of the current remains con stant the voltage generated only depends on the intensity of th...

Page 236: ...y part of the mass of air which passes through the flow meter is mea sured this quantity is however proportional to the total mass in the flow meter The electrical voltage leaving the flow meter is th...

Page 237: ...800 mV the con trol unit recognizes a rich mixture and de creases the injection time This sequence of operations is repeated with a frequency in the order of tens of Hertz so that the engine operates...

Page 238: ...resistive element made up of an NTC Negative Temperature Coefficient thermis tor where the electrical resistance decreases as the temperature increases The reference voltage is 5 Volt since the con t...

Page 239: ...onding travel of one metre on the basis of the frequency of the impulses it is therefore possible to know the speed of the vehicle Wiring connector DETONATION SENSOR This sensor is the piezoelectric t...

Page 240: ...supplied by the battery voltage via the system relay and is connect ed to the control module for connection to earth The optimum ignition advance is calculated by the control unit depending on the en...

Page 241: ...vent the overheating of the coil if the ignition takes place with the engine switched off the module has a rest closing device when the ignition impulses cease arriving from the control unit Wiring co...

Page 242: ...em 10 Bravo Brava 10M DIAGRAM SHOWING INTAKE CIRCUIT P4A32BJ01 1 Air filter 2 Air flow meter 3 Inlet 4 Butterfly casing 5 Engine idle adjustment solenoid valve 6 Inlet manifold 7 Exhaust manifold 32 P...

Page 243: ...and viceversa large angle openings with the pedal strongly pressed With the pedal completely released engine decelerating or idling the additional air required is supplied by the engine idle adjustmen...

Page 244: ...y OFF signal low effective value mainly ON signal high effective value B effective value V Operating principle The position of the shutter depends on the intensity of the effective value of the curren...

Page 245: ...Fuel filter 5 Fuel supply 6 Fuel return 7 Fuel manifold FUEL SUPPLY CIRCUIT The fuel supply circuit is made up of the following components fuel tank electric pump immersed in the tank equipped with g...

Page 246: ...to prevent the electric motor from overheating In addition a one way valve on the supply prevents the draining of the entire fuel circuit when the pump is not working The nominal capacity of the pump...

Page 247: ...truck by the ball the mechanism changes position to the normal lyopen NA circuit thereby interrupting the electrical supply to the electric pump causing it to cut out The calibration of the switch cau...

Page 248: ...sed by the cali brated spring 8 When the calibration pressure is exceeded the flow valve opens and the excess fuel returns to the tank thereby stabilizing the pressure in the circuit In addition via t...

Page 249: ...ng the magnetic field produced attracts the shutter causing the opening of the injector and the flow of fuel As the pressure differential between the in side and the outside of the injector is con sta...

Page 250: ...mixture strength at which the engine operates is constantly oscillating around the stoichiometric value which is achieved thanks to the feed back control carried out by the control unit on the basis...

Page 251: ...ION SYSTEM 2 Lambda sensor 3 Catalytic silencer Location of anti evaporation system components 1 Fuel tank 2 Vapour separator 3 Float valve 4 Cap with safety valve 5 Engine control unit 6 Charcoal fil...

Page 252: ...from escaping When the pressure inside the tank reaches about 30 40 mbar the multi purpose valve 8 opens and the fuel vapours reach the charcoal filter 6 The valve 8 also allows an intake of air into...

Page 253: ...s valve open 2 The fuel pushes the float upwards as a result of strong acceleration valve closed 3 Vehicle overturned valve closed Fuel vapour separator and multi purpose valve The fuel vapours coming...

Page 254: ...h the inlet 5 The scavenging air which enters through the inlet 1 passes through the paper filter 3 comes into contact with the charcoal gran ules removing the vapours and directs them towards the out...

Page 255: ...pours from escaping by means of an O ring 5 1 Anti evaporation system rapid attachment pipe 2 Cartridge 3 Pipe retaining clamp 4 Flexible washer 5 0 ring In order to extract the pipe 1 push the clamp...

Page 256: ...ate the operation move the clamp aside using a screwdriver working very carefully Pull outwards and rotate the actual clamp Extract the 0 ring 5 inside the cartridge Clean the interior of the cartridg...

Page 257: ...intake 1 in which there is a PCV limiting valve 3 Positive Crank Ventilation which shutters the intake The PCV valve in effect can be modulated and the quantity of gases which pass through is proporti...

Page 258: ...ques for the HITACHI injection ignition system components are given below values in Nm butterfly casing 6 3 0 4 PCV valve on butterfly casing 18 0 2 0 vehicle speed sensor 22 5 2 5 engine rpm sensor 4...

Page 259: ...ctly supplied by the battery even with the ignition swit ched off where the values obtained during self adjustment are stored The operation of dis connecting the battery causes the loss of this data w...

Page 260: ...disconnect the electrical connector for the fuel level gauge 3 and the one for the pump 4 supply remove the rapid attachment fuel supply 5 and return 6 unions from the tray NOTE When removing and refi...

Page 261: ...ut arrow fixing the shield and remove the shield 2 disconnect the fuel rapid inlet 1 and outlet 2 connectors from the filter and collect the fuel which comes out during the operation in a suitable con...

Page 262: ...ump relay from the socket make a connection as shown in the diagram using a suitable bridge for this purpose The pressure reading on the gauge should stabilize in these conditions at 3 0 bar 0 2 bar I...

Page 263: ...inlet manifold is damaged or the regulator itself is defective and should be replaced P4A51BJ01 Checking injector seal In order to check if the injectors are dripping make the connection as described...

Page 264: ...sor take care that the operating lever fitted on the butterfly shaft 3 is above the sensor driving element 4 as shown in the diagram Removing refitting air flow meter 1 Remove the battery disconnect t...

Page 265: ...butterfly cas ing arrow to the inlet manifold release the end of the accelerator cable from the control lever remove the coolant connecting pipes from the inlet and outlet pipes sealing them as appro...

Page 266: ...from underneath the vehicle disconnect the electrical connector undo the bolt fixing the sensor and remove it from its housing NOTE The sensor is fitted in production with tolerances which ensure a ga...

Page 267: ...ation sensor and remove it 3 Disconnect the electrical connector and undo the casing for the vehicle speed sensor removing it from its housing P4A5SBJ05 Removing refitting coolant temperature sensor D...

Page 268: ...g Do not dismantle the two compo nents so as not to risk losing the in ternal contact or getting it dirty In the case of replacement it is not necessary to separate the coil from the extension because...

Page 269: ...atalytic silencer In order to check the concentration of carbon monoxide CO and unburnt hydrocarbons HC up stream of the catalyzer proceed as follows 1 Undo the cap located in the exhaust pipe upstrea...

Page 270: ...of the recommended limits whilst that previously measured upstream of the catalyzer was okay then the engine parameters are taken to be correct and the cause of the problem should be sought in the dec...

Page 271: ...4 Driven disc pressure plate 4 Refitting 4 CLUTCH OPERATION Thrust bearing 5 Fork control shaft 5 Thrust bearing sleeve 6 Clutch pedal 6 Clutch pedal position adjustment 7 Removi ng refitting cable cl...

Page 272: ...ease is obtained by means of a cable mechanically operated by the pedal The mechanical clutches adopted are all the Thrust type see section which follows Technical data 1370 1581 1747 1929 D Spring lo...

Page 273: ...table because there will be a reduction in the vibrations transmit ted by the power unit due to the damping effect of the hydraulic system The adoption of this device dispenses with the need for perio...

Page 274: ...AFT Removing refitting 2 Remove the circlip for the release lever and remove the actual lever 3 Remove the upper bush NOTE The bush in question is replaced eachtime the clearance for the fork control...

Page 275: ...sealant which will act as a seal CLUTCH PEDAL 2 Remove the clip fixing the clutch pump to the pedal only for versions fitted with hy draulic mechanism 1998 20v Removing refitting clutch pedal 3 Remove...

Page 276: ...e line of the pedal and corresponds to the distance between the position in the end of travel position pedal in contact with the dashboard bulkhead and that of the pedal in the rest position Any adjus...

Page 277: ...ch cable it is necessary to position the flexible rub ber buffer 1 on the dashboard bulk head and then insert the rigid buffer 2 in the opening in the flexible buffer When the operation is com pleted...

Page 278: ...ng the resonator 3 Remove the relay box cover 4 Remove the nuts fixing the relay box to the battery drip tray then place it at the side 5 Remove the bolts 1 and loosen the bolt 2 fixing the battery dr...

Page 279: ...ic sys tem from the clutch pump Before disconnecting the pipe it is ne cessary to drain the hydraulic system 3 Remove the clip fixing the clutch pump to the pedal 4 Undo the nuts fixing the clutch pum...

Page 280: ...g cylinder 2 Undo the nuts shown and remove the clutch operating cylinder 3 View of clutch operating cylinder assem bly BLEEDING 1998 20v 4 Do not under any circumstances reuse the fluid recovered The...

Page 281: ......

Page 282: ...9 REMOTE CONTROL ASSEMBLY Diagram of rem control assy 30 Removing refitting 31 Dismantling at the bench 34 ft 16V REMOVING REFITTING 35 DRIVE SHAFTS Removing refitting drive shafts 43 Dismantling 44 R...

Page 283: ...ve terminal and disconnect the latter un do the nut securing the battery mounting bracket to the battery cage and remove the battery 2 Release the electrical cables shown in the figure from their clam...

Page 284: ...of the gear engage ment flexible transmission cable discon nect the odometer connection then move the assembly aside in the engine compart ment 3 Undo the top bolts securing the starter motor to the...

Page 285: ...he other side Disconnect the brake pad connector then withdraw the central dust guard from the car Repeat the procedure on the right si de Remove the front dust guard by undoing the attachments illust...

Page 286: ...way from the working area 2 Disconnect the Lambda probe wiring connector 3 Undo the nuts securing the first section of the exhaust pipe to the manifold 4 Undo the rear attachments and remove the first...

Page 287: ...s and disconnect the starter motor 3 Remove the flywheel cover by undoing the bolts illustrated 4 Remove the mounting bracket securing the first section of the exhaust pipe to en able a spanner to be...

Page 288: ...ne 3 Fit the engine support stand 1860851000 on its mounting points a Front mounting insert the tool in the seat of the safety catch so that it rests on the front crossframe b Rear mounting position t...

Page 289: ...power unit mounting from the bodywork and the gearbox 2 3 Install the tool illustrated to support the gearbox during the removal operation 4 Undo the remaining bolts securing the gearbox to the engine...

Page 290: ...elease bear ing has remained in the bellhousing and has not engaged with the clutch Carry out the operations below 2 Check that the clutch release bearing is positioned correctly on the gearbox main s...

Page 291: ...e front wheels and then proceed as follows 1 Using a hammer and chisel relieve the staking on the hub nut 2 Unscrew the hub nut 3 Undo the bolt on the tie rod end then use tool 1847038000 to disconnec...

Page 292: ...ing the hub nut to the specified torque DISMANTLING 2 Place the drive shaft in a vice remove the protective gaiter from the joint on the gearbox side then remove the joint 3 Remove the circlip from th...

Page 293: ...the protective gaiter on the constant velocity joint wheel side then withdraw it from the side oppo site the drive shaft 3 Clean the grease off the inside of the con stant velocity joint and using too...

Page 294: ...ur A Blue A Blue B White B White B Red C Red When refitting the constant velocity joints must be coupled to the shaft as shown in the table Category B joints are coupled with both cate gories of drive...

Page 295: ...ON COMPONENTS Key 1 Constant velocity joint wheel side 2 Circlip securing constant velocity joint 3 Protective gaiter 4 Drive shaft 5 Protective gaiter 6 Tripod joint 7 Circlip securing tripod joint 8...

Page 296: ...e knob 1 of the gearlever downwards this by means of the flexible ca ble 2 lifts the pushrod of the device 7 which in turn permits the travel of the control shaft 6 for se lecting reverse gear P4A014B...

Page 297: ...s described below 1 From inside the car remove the gearlever trim 2 Remove the protective boot from the handbrake then disconnect the electrical connection underneath 3 Disconnect the gear engagement...

Page 298: ...bracket 2 After disconnecting the Lambda probe electrical connection undo the bolts se curing the first section of the exhaust pipe to the manifold 3 Disconnect the first section of the exhaust pipe f...

Page 299: ...g the bolts indicated 3 Undo the front and rear bolts of the hand brake and remote control assembly mounting 4 Carefully lower the assembly from its seat ing and undo the nuts securing the re mote con...

Page 300: ...thdraw it from the assembly Dismantling refitting gear engagement flexible transmission cable Remove the gearlever circlip and clip from the gearlever then withdraw the flexible cable after releasing...

Page 301: ...then withdraw the re action link REMOVING CAR REFITTING GEARLEVER ON Remove the gearlever trim disconnect the reverse gear inhibitor cable from the gearlever after withdrawing the circlip disconnect t...

Page 302: ...in the figure securing it to the front crossframe 2 Remove the air intake duct by undoing the clips shown in the figure then remove it from the engine compartment complete with oil vapour recovery pi...

Page 303: ...ket then remove the control unit from the engine compartment The nuts indicated also secure the starter motor supply wiring and connection between the front ca ble and fuel injection cable 4 Remove th...

Page 304: ...earbox also discon nect the speedometer sensor wiring con nector 2 Disconnect the reversing lights switch connector from the gearbox 3 Remove the fan by undoing its attachment bolts making sure to dis...

Page 305: ...e to hook the power unit onto during removal of the gearbox 3 Undo the nut securing the right wind screen wiper arm after removing the pro tective cap 4 Remove the right side cover of the anti pollen...

Page 306: ...ing insert the tool in the seat of the bonnet catch so that it rests on the front crossframe Rear mounting fit the tool level with the cen tral reinforcement of the fire proof bulkhead Secure the hook...

Page 307: ...nector repeat the procedure on the other side 2 Remove the nut securing the steering tie rod end then withdraw the latter from the vertical link arm using the puller 1847038000 repeat the procedure fo...

Page 308: ...rt tool can be installed 2 3 Place the gearbox support tool 1860873000 on a hydraulic jack then secure it to the gearbox at the points in dicated in the figure 4 Remove the central power unit mounting...

Page 309: ...so facilitate withdrawal of the gearbox If this is still not sufficient disconnect the coolant inlet and outlet pipes from the heater 4 Manoeuvre the hydraulic jack as appropri ate to disengage the ge...

Page 310: ...370 12v engine REMOVING REFITTING DRIVE SHAFTS To remove and refit the drive shafts refer to the procedure described for the 1370 12v en gine with the difference that the drive shafts are secured to t...

Page 311: ...the in structions below 1 Refitting differential casing oil seal bearing Alternative Fit and install the I NA seal bearing for the differential casing oil seal gaiter using the appropriate drift Fit...

Page 312: ...gagement and selector linkage 1 Gear selector rod mounting 2 Control rod 3 Relay mounting supporting gear engagement and selector linkage 4 Gear selector rod linkage 5 Gear engagement rod linkage 6 Re...

Page 313: ...emove the gearlever trim from inside the car 2 Undo the bolt securing the remote control assembly mounting to the bodywork 3 Remove the handbrake lever trim and dis connect the electrical connection u...

Page 314: ...irst sec tion of the exhaust pipe from the front mountings 2 Release the exhaust pipe from the rubber mount indicated 3 Undo the bolts securing the exhaust pipe front mounting 4 Undo the bolts securin...

Page 315: ...eaction link then un do the nut and disconnect the relay as sembly from the control rod 2 Undo the bolts securing the remote con trol assembly mounting and handbrake to the bodywork 3 Withdraw the con...

Page 316: ...tting gearlever Undo the bolts securing the gearlever to the mounting and the bolt securing the control rod to the gearlever then discon nect it from the assembly Dismantling refitting control rod Und...

Page 317: ...et duct by undoing the bolts illustrated 2 Lift the protective cover on the positive terminal disconnect the positive terminal then undo the nut securing the battery to the cage and remove the battery...

Page 318: ...positive terminal 3 Remove the screws 1 and slacken the bolt 2 securing the battery cage to the bodywork Before removing the cage dis connect the cable clip underneath 4 Disconnect the clutch cable b...

Page 319: ...c tions Undo the bolts securing it to the ra diator then remove it from the car 2 Undo the top bolts securing the gearbox to the power unit 3 Remove the engine reaction link 4 Remove the left windscre...

Page 320: ...for hooking the power unit support stand Fit the engine support stand 1860851000 and adaptor 1860851001 in the appropri ate mountings Front mounting place the tool in the seat of the safety catch so t...

Page 321: ...s and release the dust guard from its seating Disconnect the brake pad connection then withdraw the central dust guard from the car Remove the front dust guard by undoing the screws illustrated Undo t...

Page 322: ...he other side 2 Disconnect the gear engagement and sec tor rods from the gearbox 3 Raise the car and remove the front bolts securing the first section of the exhaust pipe 4 Remove the rear bolts and r...

Page 323: ...ne release it from the gearbox and move it away from the work ing area securing it in an appropriate manner 3 Remove the power unit s central mount ing 4 Remove the power unit mounting on the gearbox...

Page 324: ...t illustrated securing the gearbox to the power unit and unscrew the gearbox bolt illustrated in order to then be able to secure the supporting tool for removing the gearbox differential unit 3 4 Fit...

Page 325: ...ly tighten bolts 1 and 2 to a torque of 0 5 daNm Lightly tighten bolts 3 and 4 to a torque of 0 5 daNm then tighten them to the specified torque Tighten bolts 1 and 2 to the specified torque To refit...

Page 326: ...joint and using tools 1847017001 and 1860889000 remove the constant velocity joint and then with draw the protective gaiter previously mo ved aside from the drive shaft 3 Remove the protective cover f...

Page 327: ...the outer diameter and by two thrust washers which define the outside dimensions of the damping weight 3 Check that the drive shaft is not deformed or out of true and that the surface in con tact wit...

Page 328: ...A must line up with A and B with B otherwise the joint will remain jammed After carrying out the following checks refit the parts reversing the procedure for removal bearing in mind that the bolts se...

Page 329: ...nents 21 27 1 Constant velocity joint wheel side 2 Retaining clips 3 Rubber buffer 4 Damping half shells 5 Drive shaft 6 Protective gaiter 7 Flange for constant velocity joint gearbox side 8 Constant...

Page 330: ...intermediate shaft to the mounting 2 Withdraw the intermediate shaft from its seating then remove the dust excluder 3 Withdraw the intermediate shaft from the engine compartment 4 Check that the inte...

Page 331: ...take duct by undoing the bolts shown in the figure 2 Disconnect the battery s positive terminal then remove the battery from the engine compartment by undoing the nut securing the retaining bracket 3...

Page 332: ...e also disconnect the electrical wiring clips indicated Disconnect the hydraulic clutch actuating cylinder from the gearbox the earth cable and reversing lights switch Disconnect the gear selector rod...

Page 333: ...cover then remove the windscreen wiper arm by undoing its at tachment nut 3 Remove the right side cover from the anti pollen filter to facilitate removal undo the screws of the left side cover 4 Plac...

Page 334: ...Front mounting insert the tool in the seat of the safety catch so that it rests on the front crossframe Rear mounting position the tool level with the central reinforcement of the fire proof bulkhead...

Page 335: ...t section of the exhaust pipe by undoing the attachments shown in the figure 3 Remove the wheelarch trim on the gear box side and timing gear side 4 Disconnect the tie rod end from the verti cal link...

Page 336: ...ds accessible from the wheelarch on the gearbox side 3 Remove the power unit central mounting 4 Remove the bolts securing the power steering gear to the crossframe Secure the steering gear to the body...

Page 337: ...to permit the subsequent withdrawal of the front crossframe If nec essary shim the shield to keep it raised off the bodywork and so facilitate the with drawal of the crossframe 3 Undo the bolts securi...

Page 338: ...curing it in an appropriate manner 2 Remove the starter motor by undoing its bolts 3 Remove the bottom bolts securing the gearbox to the power unit 4 Undo the bolt shown in the figure from the bellhou...

Page 339: ...een the mounting and the gearbox resulting in deformation and subsequent oil leak closely follow the bolt tightening sequence below Tighten bolts 1 and 2 to a prelimi nary torque di 0 5 daNm Tighten b...

Page 340: ...s on the 1998 20V engine do not have the damping weight General view of drive shaft constant veloci ty joint couplings and distance between the joint centres REMOVING REFITTING INTERMEDIATE SHAFT To r...

Page 341: ...sframe 2 Remove the air inlet duct complete with resonator by undoing the clips shown in the figure making sure to disconnect the pipe shown in the detail 3 Lift the protective cover from the battery...

Page 342: ...in the figure also undo the nuts securing the mounting bracket for the starter motor supply cables 3 Disconnect the speedometer sensor con nector 4 Disconnect the clutch cable by undoing the nut 1 an...

Page 343: ...switch connector from the gearbox 2 Disconnect the fan supply connections then remove the fan by undoing its attach ment bolts 3 Disconnect the starter motor supply ca bles 4 Remove the starter motor...

Page 344: ...unit during removal of the gearbox Remove the nut securing the right wind screen wiper arm after removing its pro tective cover Remove the right side cover from the anti pollen filter by undoing the s...

Page 345: ...nsert the tool in the seating of the bonnet catch so that it rests on the front crossframe b Rear mounting position the tool level to the central reinforcement of the fire proof bulkhead c Secure the...

Page 346: ...the procedure on the other side Remove the nut securing the tie rod end to the vertical link then withdraw the tie rod end from the vertical link arm using puller 1847038000 repeat the procedure for t...

Page 347: ...on the bellhousing to enable the gearbox sup port tool to be installed 3 Remove the power unit central mounting to enable the gearbox support tool to be subsequently installed 4 5 Place the gearbox s...

Page 348: ...ding components Gradually lower the jack and withdraw the gearbox complete with drive shafts If this operation proves difficult remove the at tachments securing the first section of the exhaust pipe t...

Page 349: ...r refitting the gearbox of the 1370 12V engine alternative Left drive shaft 133 mm 135 mm J Jmm 110mmi Right drive shaft alternative REMOVING REFITTING DRIVE SHAFTS To remove and refit the drive shaft...

Page 350: ......

Page 351: ...tion coils and injectors 15 FUSES RELAYS AND EARTH POINTS 16 INJECTION IGNITION SYSTEM COM PONENTS 17 I n j e c t i o n i g n i t k M i system wiring 17 Injection ignitaon system electronic control un...

Page 352: ...essure of the air drawn may vary it is necessary to adjust the quantity of petrol to be injected so as not to alter the weight ratio between the air and the petrol The constancy of this ratio is obtai...

Page 353: ...1 and 2 and the other between cylinders 4 and 5 allowing the control unit to recognize the cylinder which is detonating or is in the early stages of detonation and to correct the ignition ad vance for...

Page 354: ...e basis of the coolant temperature signal the temperature of the intake air the battery voltage and the engine speed The ignition advance is only dependent on the number of revs and the temperature of...

Page 355: ...t not only by the actuator but also by the adjustment of the ignition advance angle because it has a more rapid effect NOTE The self adjustment function makes it possible to dispense with all idle spe...

Page 356: ...the coolant exceeds 40 C and when the engine speed is higher than the idle speed and lower than 4 800 rpm with the butterfly angle greater than about 8 the control unit sends a signal to the solenoid...

Page 357: ...ol unit responds by sending the secret code only after it in turn has received the recognition code transmitted by the ignition key which contains a special transponder inside 3 The recognition of the...

Page 358: ...inlet solenoid valve 5 Speedometer sensor 18 Intake air temperature sensor 6 Flow meter 19 Engine idle speed actuator 7 Rpm sensor 20 Rev counter signal 8 Coolant temperature sensor 21 Injectors 9 Bu...

Page 359: ...Breather pipe 7 Filler with ventilation and safety valve 8 Tank 9 Electric pump 10 Pressure regulator 11 Injectors NOTE Given the special shape of the tank when fuel is being introduced an air pocket...

Page 360: ...G AIR INTAKE CIRCUIT 1 Inlet manifold 2 Engine idle speed actuator 3 Butterfly casing 4 Butterfly valve position sensor 5 Air temperature sensor 6 Flow meter 7 Air filter 8 Lower resonator 9 Upper res...

Page 361: ...reventing the fuel vapours made up of the lightest sections of hydrocarbons which form in the tank from being discharged into the atmosphere 1 Fuel vapour cut out valve 2 Charcoal filter 3 Injection i...

Page 362: ...me returns from the butterfly casing From the intake 5 the breather gases reach the T union 3 With the butterfly open the gases flow through the intakes 1 and 2 to be drawn into the manifold With the...

Page 363: ...Engine Bravo igiuov Fuel system 10 DIAGRAM SHOWING ENGINE EXHAUST ASSEMBLY P4A12FJ01 Key 1 Exhaust manifold 2 Lambda sensor 3 Catalytic silencer 4 Silencers 12 Print no 506 670...

Page 364: ...14 Lambda sensor 4 Fuses and relays 15 Join between front cable and injection 5 Diagnostic socket cabte 6 Injectors 16 Coolant temperature sensor 7 Rpm sensor 17 Earth connection 8 Engine idle speed...

Page 365: ...Engine Bravo Fuel system 10 WIRING DIAGRAM SHOWING INJECTION IGNITION SYSTEM P4A14FJ01 14 Print no 506 670...

Page 366: ...witch 16 I E system failure warning light 17 Flow meter 18 Phase transformer solenoid valve relay 19 Engine idle speed actuator 20 Phase transformer solenoid valve 21 I E system relay feed 22 Fuel vap...

Page 367: ...1 Phase transformer solenoid valve relay 2 Injection system relay 3 Electric fuel pump relay 4 Lambda sensor fuse 10A 5 Electric fuel pump fuse 10A 3 4 Earth points In order to improve electro magneti...

Page 368: ...ows into the control unit By means of this data and with the aid of characteristic programmes written indelibly in its memory the control unit is capable of achieving the following objectives 1 Managi...

Page 369: ...ed 24 Engine earth 25 Not connected 26 Not connected 27 Supply 15 54 28 Lambda sensor 29 Detonation sensor 30 Supply for various sensors 31 Not connected 32 Climate control go ahead relay 33 Not conne...

Page 370: ...nit The operations of fitting and remov ing the multiple connector should be carried out with the ignition switched off I G N I T I O N C O I L S 0 221 504 006 The static advance electronic ignition h...

Page 371: ...pply via ignition switch 2 Single coil 3 Electronic control unit 4 Spark plug Checking coil circuit resistance A Primary circuit The resistance is checked by connecting an ohmmeter to the connector ou...

Page 372: ...r When it moves the metal part of the ring covers the sensor blocking the magnetic field with the consequent low output signal viceversa by the opening and therefore where the magnetic field is presen...

Page 373: ...8 teeth plus a space equiv alent to the two missing teeth The reference defined by the space for the two missing teeth constitutes the basis for detecting the synchronism point TDC For a more detailed...

Page 374: ...et manifolds and be tween cylinders 1 2 and 4 5 respectively These sensors have a bush to prevent incor rect torque wrench tightening If they are replaced do not place washers or shims between the eng...

Page 375: ...c pump The fuel flows in the empty housings and is compressed in the supply duct 3 A one way valve 4 prevents the supply pipe from being drained with the engine switched off An excess pressure valve 5...

Page 376: ...re of around 3 bar The pressure regulator is made up of a metal casing which houses a moving element comprising a metal casing 8 and a diaphragm 4 loaded by a spring 5 When the pre set force made up o...

Page 377: ...nsion stroke until the inlet stroke has already begun The injectors are fixed by the fuel manifold which presses them into their housings in the inlet manifolds In addition they are anchored to the fu...

Page 378: ...t interference with the sur rounding duct this screw is not used for adjusting the idle as it is adjusted by fluxing in production and should not be tampered with under any circumstances The flow of e...

Page 379: ...gth With the butterfly closed an elecrical voltage signal of around 0 5 Volts reaches the control unit which recognizes the idle and cut off conditions distinguishing them on the basis of the engine s...

Page 380: ...n near the idle air flow rate for short circuit battery V at opening or closing winding or opening and closing winding open circuit at opening or closing winding or at opening and closing winding shor...

Page 381: ...t assumes air T 20 4 C as a fixed parameter Additional provisions Locking the self adjustment of the mixture strength at current values Wiring connector N O T E The numbers indicate the corre sponding...

Page 382: ...gh Rh to heat Rs and therefore restore the balance for the bridge The circuit IC2 measures the current which passes through Rh This current makes it possible to keep the bridge balanced and therefore...

Page 383: ...g to the temperature of the engine in order to correct the information concerning the air flow rate from the flow meter so that according to the signal received by the sensor the control unit can cont...

Page 384: ...inciple is as follows with the temperature of the coolant below 40 C and when the engine is idling or the speed exceeds 4800 rpm the electro magnet 1 is de energized therefore the valve 2 thrust by th...

Page 385: ...net is discharged through the drainaqe duct E Recovery If the solenoid valve fails the final stage driver in the control unit is deactivated 1 Solenoid valve 2 Valve 3 Valve spring 4 Piston 5 Pinion 6...

Page 386: ...rical connection under the butterfly casing Raise the vehicle Remove the Lambda sensor from its hous ing When tightening do not exert force on the component or it will be irreparably dam aofid If the...

Page 387: ...tion if the key is turned to the ON position it closes preparing for operation In effect if en ergized the solenoid valve 6 attracts the shut ter 4 which overcoming the spring 3 load ing closes the po...

Page 388: ...ponding control unit pins INERTIA SWITCH In order to increase the degree of safety for the occupants of the vehicle in the case of an impact the vehicle is equipped with an inte ria switch located ins...

Page 389: ...s electrical system if the vehicle is going in a drying oven after painting where the temperatures are in excess of 80 C it is necessary to remove the injection ignition electronic control unit never...

Page 390: ...ical connectors from the injectors Undo the fixing bolts 7 Extract the injector manifold assembly To remove the injectors from the fuel mani fold remove the clip 9 1 Fuel manifold P 4 A 3 9 F J O 2 2...

Page 391: ...r activating the fuel pump test the pressure reading on the pressure gauge should stabilize in these test conditions at around 3 bar If the pressure is insufficient carry out the 2nd test 2nd Test Che...

Page 392: ...sure then op erate the electric pump with the engine switched off When the regulation pressure is reached close the control lever B and at the same time restrict the fuel return pipe to the tank a pai...

Page 393: ...HC is measured with the cat alyzer at operating temperature 300 350 C it is advisable to drive hard for around 5 1 0 minutes to make sure that the catalyzer reaches operating temperature then insert...

Page 394: ...ation of the defect If a defect is recognized for the first time and the error state persists for a time t 0 5s the defect is me morized as permanent If this defect then disappear it is memorized as i...

Page 395: ...e Tester takes place via a two direction serial line line K using the standard Bosch communication protocol The Tester can supply the following information display of the errors display of engine para...

Page 396: ...r will signal the error for the sensor concerned and the Recovery value will be displayed Permanent memory The control unit is equipped with a permanent type errors memory EEPROM i e the error indicat...

Page 397: ......

Page 398: ...itting injection pump 6 Final check 7 Possible adjustments on injection pump fitted to engine 7 Anti stall speed adjustment 7 Checking antistall screw setting 8 Adjusting engine top speed 8 Bleeding p...

Page 399: ...container 2 Remove the following parts from the pump 1 Fast idle cable 2 Accelerator cable 3 Electrical connection for engine stop solenoid electrostop 4 Fuel delivery line 5 Fuel return line to tank...

Page 400: ...ated on the rear end 2 Loosen the screw retaining the mobile belt tensioner 3 Remove the timing belt 4 Prevent injection pump pulley turning us ing tool 1860765000 and unscrew the pulley retaining bol...

Page 401: ...aining bracket from the support beam fastened to the en gine block 2 Use tool 1850167000 to unscrew the nuts shown 3 Unscrew the socket screw retaining the injection pump to the mount 4 Disconnect the...

Page 402: ...coolant pump are properly aligned 3 Cheek that the notch on the timing drive gear is aligned with the hole on the rear timing belt cover 4 Also check that the notch on the gearbox bell housing corresp...

Page 403: ...sioner to the specified final torque LUCAS FT05 injection pump 1 Maximum rpm adjustment screw 2 Anti stall adjustment screw 3 Fitting for adjusting pump timing on en gine 4 Fast idle adjustment screw...

Page 404: ...ines but do not tighten nuts retaining pump to mount fully Remove aluminium cap with fitting for socket wrench from fitting on top of pump Turn crankshaft against direction of rotation through about 2...

Page 405: ...ining screws fully Final check Turn crankshaft in its direction of rotation by a few revolutions at least 2 until piston no 1 is exactly at TDC The dial gauge reading should correspond to the reading...

Page 406: ...positive result is obtained Checking antistall screw setting Accelerate engine to maximum speed then release accelerator completely speed should drop steadily to idle level without fluctuations or ju...

Page 407: ...te pump self priming unscrew fittings fastening delivery lines to injectors A start engine and run until fluid emerges from open injector fittings keep engine running and tighten injector fittings If...

Page 408: ...change lubricate rubber cartridge seal fill filter cartridge with diesel in order to reduce self bleeding period tighten cartridge until it touches the mount tighten cartridge by 6 8 turn to obtain t...

Page 409: ...ehicle is used under heavy conditions mainly town driving continuous mountain driving towing of trailers or caravans routes through dusty areas change oil more frequently particularly when the tempera...

Page 410: ...check and or re place Restore correct injection pump timing and adjust advance Check injection pump timing at bench When cold engine does not start or starts with difficulty Tank empty ventilate bloc...

Page 411: ...e Incorrect injection pump setting Check injection pump setting at test bench Tank ventilation defective Check tank ventilation Fuel delivery and return lines on in jection pump changed over Fit fitti...

Page 412: ...mum rated speed Adjust top speed by means of screw on injection pump Injectors defective Check and or replace injectors Incorrect injection pump timing delayed Restore correct injection pump timing an...

Page 413: ...Replace filter White smoke at exhaust Fuel and injection lines blocked or restricted Check lines repair or replace Injectors defective Check and or replace injectors Incorrect injection pump timing de...

Page 414: ...e exhaust pipe Connect and adjust equipment as instructed by the Manufacturer Pump accelerator pedal three times quickly to the floor until rpm limiter threshold speed is reached Carry out measurement...

Page 415: ...Check valve clearance and or timing P4A17DJ05 Check injectors are perfectly clean Numbers at top of illustrations indicate order of operations 10 P4A17DJ02 Check injection pump timing and or output 4...

Page 416: ...ing properly filled Line 4 allows air to flow form the lower part to allow the tank to be completely filled 1 Injection pump 2 Fuel delivery line from filter to pump 3 Excess fuel return line from pu...

Page 417: ...Bravo Brava ft Engine Fuel system AIR INTAKE CIRCUIT DIAGRAM 10 1 Inlet manifold 2 Upper resonator 3 Air cleaner 4 Lower resonator 5 Inlet fitting Copyright Fiat Auto 19...

Page 418: ...t...

Page 419: ...ads Bleeding REAR BRAKES Drum brakes 15 Automatic adjuster assembly for recov ering shoe drum clearance 19 Brake drums Shoes 20 Wheel cylinders Bleeding 21 Diagram of hydraulic braking system front an...

Page 420: ...C V L U o c 00 o C O o o c s UJ H 0 o o c 00 C C U J OH C O U M O X C O 3 o C D c C D T3 c C D Q o TD c Q Q T3 c cc o t c w 5 2 co o 1 C D 5 O O IB 00 li ce to D C O T3 2 2 C O m x rr u m C O C D C D...

Page 421: ...l lows remove the split pin and withdraw the ser vo unit pushrod from the pin on the brake pedal raise the clutch pedal undo the bolt and remove the brake pedal NOTE To refit the brake pedal reverse t...

Page 422: ...uld come on Removing refitting To remove the brake fluid reservoir proceed as follows disconnect the sensor connector and undo the cap remove the brake fluid from the reservoir using the special syrin...

Page 423: ...ake pump proceed as fol lows undo the brake pipe connectors using tool 1856132000 so as not to damage them P4A004D01 When overhauling the brake pump replace the sealing rings if there are traces of fr...

Page 424: ...d on the car Checking hydraulic pushrod recess using a depth gauge NOTE The servo unit is adjusted using the adjustment screw located on the end of the rod At the rest position the end of the adjustme...

Page 425: ...OTE The arrows shows the sound proof ing panel To facilitate dismantling remove the accelerator pedal whose attachment plate rests on the sound proofing panel P4A006D03 disconnect the accelerator cabl...

Page 426: ...ing the plate 3 a new button should be fitted A The sound proofing panel need not be fully removed it is sufficient to move it over to the right to permit ac cess to the servo unit s attachment nuts w...

Page 427: ...ithdraw the brake pump complete with reservoir from the servo unit and rest it in the engine compartment to facilitate the re moval refitting of the servo unit P4AOO8D02 disconnect the vacuum connecti...

Page 428: ...embly mounting P4A009D01 22 45 22 65 mm P4A009D02 Longitudinal section of Iso Vac 8 servo unit 22 45 22 65 mm Distance between hydraulic piston pushrod and brake pump contact plate If nec essary adjus...

Page 429: ...one way valve located on the vacuum unit 1 and the servo unit con necting pipe 2 as shown in the drawing opposite start the engine after running the engine at idling speed for 20 seconds the vacuum re...

Page 430: ...fitting the brake hose check that the mounting rubber is posi tioned correctly to prevent the pipe coming into contact with the whee larch or mechanical parts of the car whatever the travel or turning...

Page 431: ...c tion or seizure if they do the caliper com plete with piston should be replaced It is nevertheless always necessary to replace the dust excluder 1 and seal 2 and to check that the bleed screw 3 is n...

Page 432: ...e table if the measured value is less than the value in the table the disc should be renewed In the case of damage or deep scoring the brake disc surfaces can be skimmed after skimming the brake disc...

Page 433: ...are fitted to each pair of wheels BLEEDING 2 Manual bleeding The old brake fluid should not be reused Top up the level with fresh brake flu id Bleeding with Jollyfren device 3 Connect the device s pip...

Page 434: ...rakes 33 DRUM BRAKES Removing refitting To dismantle the rear drum brakes proceed as follows undo the two bolts and remove the brake drum NOTE Before removing the brake drum eliminate any traces of ru...

Page 435: ...Braking system Bravo Brava ftiavft ft Rear brakes 33 sheath from the brake backplate 16 Publication no 506 670...

Page 436: ...Bravo Brava piizvVBk ift16v Braking system Rear brakes 33 remove the lower shoe return spring remove the left self adjuster spring withdraw the shoe hold down pins Copyright Fiat Auto 17...

Page 437: ...ter refitting adjust the handbrake by following the procedure described on page 32 Rear brake components 1 Shoes 2 Lower shoe return spring 3 Shoe hold down pin 4 Self adjuster 5 Upper shoe return spr...

Page 438: ...eturn spring 6 the ratchet wheel 3 stops at the angle assumed during braking This stop dur ing rotation is caused by the friction between the frame 4 and the ratchet wheel 3 With the ratchet wheel 3 l...

Page 439: ...s are deeply scored or are unevenly worn they must be skimmed The maximum permitted diameter increase on the brake drums is 0 8 mm I Location on brake drum of hole for inspect ing thickness of shoe fr...

Page 440: ...f the cylinder barrel or pistons show faults replace the assembly Make sure that the bleed screw is not blocked BLEEDING Do not re use the old fluid The level should be topped up with fresh brake flui...

Page 441: ...Braking system Bravo i g j j u o v...

Page 442: ...tle the rear disc brakes proceed as follows withdraw the retaining clip 1 undo the hose connector using tool 1856132000 P4A023O02 undo the screw arrowed to slacken the tension on the handbrake cable i...

Page 443: ...brake remove the brake pads NOTE Before fitting the new brake pads make the caliper piston go in fully by turning it clockwise using tool 1856133000 Also adjust the handbrake undo the caliper support...

Page 444: ...protections then proceed as described below undo the connector and re move the brake hose undo the bleed screw and remove it NOTE The hose must not be swollen or cracked otherwise it must be replaced...

Page 445: ...e pads 7 Shim Refitting Fit the piston in the caliper case using tool 1856133000 A Before fitting the piston in the caliper case fit the dust excluder on the rear end of the piston Lubricate the parts...

Page 446: ...ing secured to the piston by the retaining ring 3 and Belleville washer 4 If the brake pads are excessively worn the endfloat A even if recovered is not sufficient to absorb by itself the entire trave...

Page 447: ...ring disc thickness The minimum permissible brake disc thick ness after wear is 9 20 mm if the value is lo wer the disc should be replaced In the case of damage or deep scoring the brake disc surfaces...

Page 448: ...whenever they are slackened or un screwed A NOTE When refitting make the caliper pis ton go back in before fitting the brake caliper Checking brake pads The brake pads must be renewed when the thickn...

Page 449: ...tion mounting 3 undo the bolts and remove the heat shield from the exhaust pipe to facilitate access to the brake pressure proportioning valve 4 uncrew the brake hose connections and disconnect the sp...

Page 450: ...ch 2 Raise the car on the ramps and remove the heat shield illustrated 3 Undo the bolts arrowed lower the car and remove the lever from its seating A Refit the dismantled parts in reverse or der to re...

Page 451: ...ear brake which involve dismantling the cables the cables must be adjusted to ensure the correct operation of the automatic adjuster Proceed as follows Undo the handbrake cable adjustment nut two or t...

Page 452: ...the car on the ramps and remove the heat shield illustrated 3 Undo the bolts arrowed lower the car and remove the lever from its seating Refit the dismantled parts in reverse or der to removal and the...

Page 453: ...he rear brake which involve dismantling the cables the cables must be adjusted to ensure the correct operation of the automatic adjuster Proceed as follows Undo the handbrake cable adjustment nut two...

Page 454: ...ket 1 is also connected to the automatic adjuster assembly for recov ering the clearance caused by shoe wear so the handbrake does not require adjustment The bracket 1 homes on the shoe 2 via the lug...

Page 455: ......

Page 456: ...ol unit 7 Fault diagnosis 8 Wheel rpm sensor 10 Stop lights switch 11 A B S fault warning light 12 Electrohydraulic control unit 12 Hydraulic diagram of TEVES MK20 A B S 13 Description of hydraulic op...

Page 457: ...ion to the driving weight and normal grip coefficients It is therefore necessary to prevent the wheels locking by means of an electronically controlled anti lock braking system which is incorporated i...

Page 458: ...ous and very rapid comparison between the wheel s deceleration acceleration values and those of the memo rized band the rolling of the tyres during braking is monitored When the driver presses the bra...

Page 459: ...st stability of the trajectory NOTE During the intervention cycle the brake pedal moves slightly depending on the increase or re duction of the controlled pressure If a wheel is rolling with a flat ty...

Page 460: ...king light stays on The system is completed by the hydraulic pipes specific electrical wiring and a diagnostic socket for the F L Tester or Computerized Diagnostic Station The presence of a fault caus...

Page 461: ...Bravo Brava Braking system Anti lock braking system 33 P4A05AD02 Copyright Fiat Auto 5...

Page 462: ...11 4 1 1 7 2 1 0 1 Wheel speed sensors 2 Wheel speed sensor connector viewed from insertion side 3 Control unit ground 4 F L Tester diagnosis socket 5 Fuse A 60A 6 Brake pedal switch 7 Fuse B 10A 8 I...

Page 463: ...omplete assembly is supplied as a spare part so the connector B must never be disconnected A Socket for connector on cables between control unit and system B Connector for cables connecting recy cling...

Page 464: ...signals If there is a logic discrepancy between input signals and output response over a certain period of time the safety system detects the fault and the A B S is de activated The electronic contro...

Page 465: ...g pump motor State of brake pedal switch State of fault warning light Detection of faults Memorization of the error Deletion of the error Input solenoids 4 Output solenoids 4 Fault warning light Recyc...

Page 466: ...flow lines which close through the teeth of a metal toothed wheel facing the sensor which rotates with the wheel The passage from full to empty due to the presence or absence of the tooth causes a cha...

Page 467: ...s to pin 12 P4A11AO03 reaches the control unit by the connection of the This information is useful not only for controlling braking but also under particular conditions for example if sudden accelerat...

Page 468: ...porated in the electronic control unit Its purpose is to vary the pressure of the brake fluid in the brake caliper cylinders in accordance with the control signals coming from the electronic control u...

Page 469: ...inlet solenoid 12 Rear right outlet solenoid 13 Front left inlet solenoid 14 Front left outlet solenoid 15 Front right inlet solenoid 16 Front right outlet solenoid 17 Rear left inlet solenoid 18 Rear...

Page 470: ...liper The pressure is maintained by closing this valve i e supplying it electrically When de activated not earthed by the control unit the outlet solenoid 10 is in the closed position and does not all...

Page 471: ...solenoids 9 and 10 of the hydraulic unit are not earthed by the electronic control unit When the braking force increases the wheel deceleration consequently increases this causes faster de celeration...

Page 472: ...t being connected to earth is already closed The hydraulic connection between the brake pump 6 and brake caliper 11 is interrupted waiting position The pressure in the brake caliper 11 is kept constan...

Page 473: ...s thus hydraulically connecting the brake caliper 11 to the low pressure accumulator 2 and recycling pump 4 in order to remove some of the fluid from the brake caliper 11 and reduce the pressure on th...

Page 474: ...mit complete lock ing of the wheels with the car stopped NOTE The recycling pump is of the dual circuit free piston type and is driven by an electric motor which is always turning during recycling The...

Page 475: ...ly the risk of damaging the pipe protection but also the transmission of noise during operation of the A B S If connecting pipes have to be slackened or removed leak tests must be conducted on the A B...

Page 476: ...ohydraulic control unit To remove the electrohydraulic unit proceed as follows 1 undo the clips securing the inlet pipe 2 undo the clip securing the oil vapour recir culation pipe and remove the compl...

Page 477: ...nscrew the cap remove the brake fluid from the reservoir using the special syringe A Take care should residual fluid in the reservoir come out undo the bolts and move aside the brake fluid reservoir A...

Page 478: ...lt securing the connector block bracket and move aside the connec tor block with the fuses undo the brake pipe connections using a 13 mm wrench and tool 1856132000 A Take care not to damage the pipe c...

Page 479: ...bolt 2 2 disconnect the connector pulling the hooking device 3 upwards and remove the electrohydraulic unit 3 undo the screws shown and detach the mounting bracket from the electrohy draulic unit NOT...

Page 480: ...ndo the bolt and remove the sensor 0 645 1 305 mm Checking gap between wheel speed sensor and phonic wheel on front wheel constant velocity joint A The gap is not adjustable since no shims are supplie...

Page 481: ...he rear wheel speed sensor pro ceed as follows 1 remove the rear seat and lift the sound proofing trim 2 disconnect the sensor s connector Raise the vehicle then 3 undo the bolts securing the fuel fil...

Page 482: ...6v D mBjt TD Checking gap between wheel speed sensor and phonic wheel on res wheel hub 20V The gap is not adjustable since no shims are supplied for the purpose If the value measured is outside the sp...

Page 483: ...ariable ratio rack and pinion steering gear 5 Operation 6 POWER ASSISTED STEERING Description and operation 9 Front wheel toe in 11 RACK PINION POWER STEERING GEAR Rack and pinibn power steering gear...

Page 484: ...s fol lows 1 use a screwdriver to remove the horn cov er 2 disconnect the horn wiring connectors 3 undo the nut securing the steering wheel to the steering column then remove the steering wheel To rem...

Page 485: ...o the bolts arrowed and remove the steering column bottom shroud 2 undo the bolts arrowed and remove the steering column top shroud 3 using an Allen key undo the screw on the attachment collar of the...

Page 486: ...ering system 4 1 STEERING COLUMN Removing refitting To remove the steering column proceed as follows 1 remove the bolt securing the lower steer ing column to the steering pinion P4A003F01 P4A003F03 P4...

Page 487: ...h block proceed as follows 1 use a punch to undo the shear bolts lock ing the ignition switch block mounting 2 remove the ignition switch block 3 dismantle the ignition switch and lock from the block...

Page 488: ...r col umn to the steering gear pinion P4A003F01 P4A005F02 2 disconnect the transfer linkage from the gearchange control linkage Raise the vehicle remove the front wheels then working from both sides 3...

Page 489: ...ava Steering gear 41 prise off the gearchange control lever from the head on the steering gear P4A006F01 undo the bolts securing the steering gear to the steering subframe P4A0O6F02 P4A006F03 6 Public...

Page 490: ...e tie rod until you can remove it 3 undo the clamps on the dust gaiter and lu bricating seal and remove the gaiter NOTE Check that there is no stiffness or ex cessive play on the ball joint other wise...

Page 491: ...and the force transmitted to the wheels de pending on the position assumed by the rack in relation to the pinion The rack teeth are cut with module and pressure angle varying from the centre towards...

Page 492: ...in the engine compartment a vane pump driven by the engine with flow regulating and pressure relief valve a set of connecting pipes between pump distributor valve actuating cylinder reservoir a hydrau...

Page 493: ...inal section of power assisted rack and pinion steering gear Checking operation Check the steering wheel s rolling torque with the car stopped and the engine running The torque should be between 0 6 d...

Page 494: ...e to slipping of the pump pulley belt or to a low flu id level If there is a fault in the pump actuating cylinder or distributor valve the power steering will function as an ordinary mechanical steeri...

Page 495: ...op up the level with fresh fluid To remove the rack and pinion power steer ing gear proceed as follows remove the bolt securing the shaft to the power steering pinion Raise the vehicle remove the fron...

Page 496: ...the power unit mounting bracket differential side disconnect the Lambda probe wiring con nector also undo the two nuts on the clamp securing the front exhaust pipe 3 undo the nuts securing the front...

Page 497: ...ng bracket to the gearbox 3 undo the nuts securing the gear engage ment lever rod 1 and the reaction rod 2 remove the split pin securing the gear selector lever rod 3 then release the rods from their...

Page 498: ...t the gearchange lever with the gear selector lever rod 3 2 rotate backwards the pin securing the re lay mounting and withdraw the mounting downwards 3 undo the bolts securing the fluid delivery and r...

Page 499: ...1 slacken the nut locking the tie rod then un screw the tie rod until you can remove it NOTE Check that there is no stiffness or ex cessive play on the balljoints Power assisted rack and pinion steeri...

Page 500: ...ws 1 empty the fluid reservoir using a syringe NOTE The old fluid should not be reused Top up the level with fresh fluid 2 undo the clamps and remove the air intake pipe 3 undo the bolts indicated and...

Page 501: ...ce the vehicle on ramps remove the front wheel then undo the bolts release the button and re move the right wheelarch cover P4A019F01 slacken the pump pulley bolts slacken the belt tensioner and remov...

Page 502: ...g Power steering pump 4 1 undo the bolts and remove the pulley undo the bolts securing the pump to the bracket and remove the pump NOTE To refit the power steering pump re verse the procedure for remo...

Page 503: ...uid should not be reused Top up the level with fresh fluid To remove the power steering pump proceed as follows 1 remove the alternator cooling pipe 2 undo the three bolts arrowed and re move the plas...

Page 504: ...Bravo Brava fti Steering Power steering pump 4 1 1 undo the bolts and remove the pulley and belt P4A022F01 verse the procedure for removal Copyright Fiat Auto 21...

Page 505: ...be reused Top up the level with fresh fluid To remove the power steering pump proceed as follows 1 undo the pump pulley bolts Place the vehicle on ramps remove the front right wheel then 2 undo the bo...

Page 506: ...1 undo the two bolts securing the link to the engine and the bracket and remove the link 2 undo the bolts securing the bracket and link to the bodywork and remove the bracket 3 disconnect the wiring c...

Page 507: ...curing the inlet manifold reaction bracket and remove the bracket undo the bolts securing the alternator mounting bracket and remove the bracket undo the bolts securing the power steering pump and rem...

Page 508: ...s follows disconnect the fluid inlet pipe from the power steering pump after slackening and removing the belts in accordance with the procedure described in Sec 10 undo the bolt and remove the pulley...

Page 509: ...move the circlip and fit tool 1860888000 as shown in the figure then tighten the nut until the bearing is fully withdrawn 2 fit tool 1860888000 as shown in the fig ure then tighten the nut until the b...

Page 510: ...yringe NOTE The old fluid should not be reused Top up the level with fresh fluid 2 undo the bolts arrowed and remove the belt guard also undo the pulley nut 3 disconnect the fluid inlet and outlet pip...

Page 511: ...nut and remove the pulley Be careful with the washer during both removal and refitting of the pul ley 3 undo the bolts indicated and remove the rear bracket also undo the nut 1 on the front bracket 4...

Page 512: ...ng pump 4 1 The documentation relating to this engine was not yet available at the time of going to print The procedure for removing and refitting the power steering pump will be published in a subseq...

Page 513: ...NE The documentation relating to this engine was not yet available at the time of going to print The procedure for removing and refitting the power steering pump will be published in a subsequent up d...

Page 514: ...Vertical linLand wheel hub 8 Components of the front suspension supplied as spare parts 14 REAR SUSPENSION Diagram of rear suspension assembly 16 Removing refitting 17 Dismantling refitting 22 Stub ax...

Page 515: ...Bravo Brava DIAGRAM OF FRONT SUSPENSION ASSEMBLY Suspension and wheels Front suspension 4 4 Copyright Fiat Auto 1...

Page 516: ...e and the steering subframe place the car on ramps remove the front wheels and the front section of the exhaust pipe then carry out the following opera tions 1 undo the bolt securing the wish bone bal...

Page 517: ...Bravo Brava Suspension and wheels Front suspension 44 P4A003G02 Copyright Fiat Auto 3...

Page 518: ...ndi svitare le viti di fissaggio della traversa alia scocca frecce abbassare lentamente il solleva tore e rimuovere la traversa anteriore Riattacco NOTA Per il riattacco della traversa anteriore e del...

Page 519: ...body shell The subframe should be se cured temporarily then cen tred on the bodywork using two studs of a diameter of about 1 2 mm then it should be secured finally BB B A Components of the front sus...

Page 520: ...damper top plate to the bodywork 2 undo the bolts securing the damper to the vertical link and remove the coil spring and damper assembly Assembly with offset coil spring Dismantling refitting Detach...

Page 521: ...er undo the nut securing the top plate to the damper stem and remove the plate then withdraw the spacer spring and end of travel stop 1 0 daNm NOTE The coil springs are divided into two categories ide...

Page 522: ...heel hub proceed as follows undo the nut securing the front wheel hub to the stub axle P4A008G02 undo the bolts securing the brake caliper assembly to the vertical link P4A008G03 withdraw the brake ca...

Page 523: ...Bravo Brava Suspension and wheels Front suspension P4A009G05 Copyright Fiat Auto 9...

Page 524: ...ls Bravo Brava Front suspension 44 undo the bolts securing the spring damper assembly to the vertical link P4A010G01 1 0 P4A010Q03 Front and rear views of vertical link complete with hub P4A010G04 Pub...

Page 525: ...ntle the hub from the vertical link us ing a press using a chisel separate the bearing inner ring from the hub then withdraw the bearing using the tools shown Longitudinal section of front wheel hub a...

Page 526: ...e bearing outer race from the vertical link using a press Checking front vertical link Check that the inner surfaces do not show signs of seizure and that the arms have not sustained visible impact an...

Page 527: ...can be refitted on the verti cal link either using a press or using the handle 1870007000 Then fit the bearing circlip Fit the hub in the bearing on the vertical link using a press supporting the bear...

Page 528: ...NOTE The coil springs are divided by means of a yellow or green paint strip on the central coil Coils of the same category should be fitted Wishbone Check that the wishbone is not deformed that the b...

Page 529: ...d the threaded end of the half shaft using paper towel moistened with ethyl alcohol or hep tane apply Loctite 270 or an equivalent prod uct on the entire threaded part of the half shaft end tighten th...

Page 530: ...Suspension and wheels Rear suspension Bravo Brava 44 DIAGRAM OF REAR SUSPENSION ASSEMBLY 1 Anti roll bar 2 Trailing arm 3 Spring 4 Torsion bar 5 Damper 16 Publication no 506 670...

Page 531: ...section of the exhaust pipe Fuel tank To remove the fuel tank proceed as follows 1 remove the luggage compartment shelf trim and remove the plastic cover 2 disconnect the two wiring connectors 3 undo...

Page 532: ...Suspension and wheels Bravo Brava Rear suspension 44 1 8 Publication no 506 670...

Page 533: ...P4A019G04 1 place a column jack under the tank undo the bolts and remove the attachment but tons shown then gently lower the fuel tank 2 open the clip and disconnect the petrol vapour pipe 3 fully low...

Page 534: ...Suspension and wheels Bravo Brava Rear suspension 44 P4A020G05 P4A020G04 20 Publication no 506 670...

Page 535: ...sconnect the brake pipe connections 2 slacken the handbrake cable assembly and disconnect the cables 3 unscrew and move aside the A B S sensor 4 place a hydraulic jack under the suspen sion crossframe...

Page 536: ...i roll bar is not damaged or deformed otherwise it will have to be re placed Check that the rubber grommets are not dam aged NOTE Whenever the brake pipes are removed check with com pressed air that t...

Page 537: ...ension 4 4 Dismantling damper from anchorage on trailing arm To remove the damper compress the rear suspension with a hydraulic jack Dismantling damper from anchorage on rear torsion beam Dismantling...

Page 538: ...stub axle and wheel hub Whenever the hub nut is removed it should be replaced with a new one NOTE The hub nut should be tightened to the correct torque wiht the rear tor sion beam fitted to the car Ch...

Page 539: ...r worn on the surface on the wheel side otherwise it will have to be replaced If the bearings and spacer arrowed are re placed because of noisiness or excessive play the trailing arm must be replaced...

Page 540: ...tening damper top mounting bolt A and bottom mounting bolt B securing damper to rear suspension assembly A To secure the damper to the trailing arm compress the rear suspension with a hydraulic jack 5...

Page 541: ...4 10 8 daNm Refitting rear suspension Tightening bodywork attachment bolts to correct torque 28 daNm P4A027G02 Also Bleed the brakes Check the rear wheel geometry Tightening nut securing stub axle and...

Page 542: ...Wheel hub If the wheel bearing has to be replaced because of noisiness or excessive play the hub complete with bearing will have to be replaced Stub axle The stub axle must not be cracked deformed or...

Page 543: ...in Sec 00 P4A029G04 If when checking the toe in the values measured are not as speci fied slacken the steering tie rod nuts and adjust the steering tie rods If the wheel camber angle is not as specif...

Page 544: ...fter the following checks have been carried out tyre pressures the eccentricity and out of true of the wheel rims must not exceed 3 mm wheel bearing endfloat If the rear wheel angles are not as specif...

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Fiat 1995 Brava, Service Manual

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