Fiat 1996 Brava Service Manual Download Page 190

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Summary of Contents for 1996 Brava

Page 1: ...Fiat Bravo a Service Manual Volume 3 Click here to choose chapter Fuel System Auto trans diff Braking system Electrica Sys Wtfingj file D Volume 203 Vol3 htm l of 2 08 07 2006 16 38 12 ...

Page 2: ...Fiat Bravo a Service Manual Volume 3 file D Volume 203 Vol3 htm 2 of 2 08 07 2006 16 38 12 ...

Page 3: ... 1 50 1 36 1 11 51 69 1 11 28 1 29 6 1 34 1 24 4 1 50 2 Notes Technical data Bravo 1988 HGT 20v Sport Pack Fuel system 1910 TD 100 engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Mid range radio Fuel system 1910 TD 100 engine Removing refitting 1910 TD 100 engine Introduction Technical data Fuel system 191...

Page 4: ... refitting 1910 TD 100 engine Removing refitting 1910 TD 75 engine Automatic transmission and differential Introduction Fuel system 1910 TD 75 Brakes EBD fflp 16V 98 range Fuel system j M 161 98 range Wiring diagrams l j 161 1998 range Technical data 98 range Fuel system TCp 16V 98 range Fuel system M 201 98 range Fuel system i p JTD 98 range Climate control 98 range Control panels 98 range radio ...

Page 5: ...M 16V98 range ABS with active sensors update 98 range Climate control update Additional heater 98 range Electrical equipment update 98 range Fuel system Ifgjji JTD 98 range Removing refitting com ponents Technical data update 98 range Update 1910 TD 100 engine lubrication diagram Technical data update IU3iJ 16V98 range Fuel system update 1 S 16V98 range Fuel system update 20V 98 range Electrical e...

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Page 7: ... 36 1 H 11 51 69 1 1 1 28 1 29 6 1 3 4 1 24 4 1 50 2 Comments Technical data Bravo 1988 HGT 20v Sport Pack Fuel system 1910 TD 100 engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Mid range radio Fuel system 1910 TD 100 engine Removing refitting 1910 TD 100 engine Introduction Technical data Fuel system 191...

Page 8: ...ving refitting 1910 TD 100 engine Removing refitting 1910 TD 75 engine Automatic transmission and differential Algemeen Fuel system 1910 TD 75 Brakes EBD I f l l 16V 98 range Fuel system l f l lev 98 range Wiring diagrams 1 161 1998 range Technical data 98 range Fuel system Kg 16V 98 range Fuel system I M 20V 98 range Fuel system I S JTD 98 range Climate control 98 range Control panels 98 range ra...

Page 9: ...update lltflj JTD 98 range Gearbox and differential l p 16V 98 range ABS with active sensors update 98 range Climate control update Additional heater 98 range Electrical equipment update 98 range Fuel system KHIji JTD 98 range Removing refitting com ponents Technical data update 98 range Update 1910 TD 100 engine lubrication diagram Technical data update lu U 16V98 range Fuel system update I M 16V...

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Page 11: ...11 51 69 1 11 28 1 29 6 1 34 1 24 4 1 50 2 Comments Technical data Bravo 1988 HGT 20v Sport Pack Fuel system 1910 TD 100 engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Middle of the range radio Fuel system 1910 TD 100 engine Removing refitting 1910 TD 100 engine Introduction Technical data Fuel system 191...

Page 12: ...g refitting 1910 TD 100 engine Removing refitting 1910 TD 75 engine Automatic transmission and differential Introduction Fuel system 1910 TD 75 Brakes EBD l p 16V 98 range Fuel system iC3p 16V 98 range Wiring diagrams4 161 98 range Technical data 98 range Fuel system l E 16V 98 range Fuel system te p 20V 98 range Fuel system liEglji JTD 98 range Climate control 98 range Control panels 98 range rad...

Page 13: ...1 Comments Fuel system update l 20V 98 range Fuel system update Egt J JTD 98 range Gearbox and differential I M 16V 98 range ABS with active sensors update 98 range Climate control update Additional heater 98 range Electrical equipment update 98 range Technical data update 98 range Update 1910 TD 100 engine lubrication diagram Copyright Fiat Auto ...

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Page 15: ... 4 2 6 Comments Tech data Bravo 1988 HGT 20v Pack Sport Fuel system 1910 TD 100 engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Mid range radio Fuel system 1910 TD 100 engine Removing refitting 1910 TD 100 eng Introduction Technical data 1910 TD 75 engine fuel system Removing refitting 1910 TD 75 eng Remov...

Page 16: ...iring diagrams lev 98 range Technical data 98 range Fuel system l 16v 98 range Fuel system t 20v 98 range Fuel system JTO 98 range Climate control 98 range Control panels Radio 98 range Wiring diagrams 98 range Wiring diagram update Fuel system update l g 20v 98 range Fuel system update f i JTD 98 range Gearbox and differential l I6v 98 range ABS with active sensors update 98 range Update climate ...

Page 17: ... 6 Comments Tech data Bravo 1988 HGT 20v Sport Pack Fuel system 1910 TD 100 engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Middle of the range radio Fuel system 1910 TD 100 engine Removing refitting 1910 TD 100 eng Introduction Technical data 1910 TD 75 engine fuel system Removing refitting 1910 TD 75 eng...

Page 18: ... 42 1 26 1 16 1 e 11 1 25 1 5 1 6 Comments l I6v 98 range Fuel system lev 98 range Wiring diagrams 1 1 i6v 98 range Technical data 98 range Fuel system l6v 98 range Fuel system 20v 98 range Fuel system 1 1 JTD 98 range Climate control 98 rarfge Control panels Radio 98 range Wiring diagrams 98 range Update wiring diagram Print no 506 670 16 ...

Page 19: ...Notes Tech data Bravo 1988 HGT 20v Pack Sport 1910 TD 100 engine fuel system Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Mid range car radio 1910 TD 100 engine fuel system Removing refitting 1910 TD 100 unit Introduction Technical data 1910 TD 75 engine fuel system Removing refitting 1910 TD 75 unit Removing ...

Page 20: ...ry Bravo Brava Publication no 506 670 14 111 1998 Sections 00 10 55 Page numbers 1 10 1 64 1 37 Notes 101 lev 1998 range Fuel system l i6v 1998 range Wiring diagrams l6v 1998 range Publication no 506 670 14 ...

Page 21: ...5 4 4 Notes Technical data on Bravo 1988 HGT 20v Sport Pack 1910 TD 100 engine fuel system Automatic transmission Wiring diagrams Connector blocks Technical data on 1910 TD and 1581 auto matic transmission Automatic transmission Mid range car radio 1910 TD 100 engine fuel system Removing refitting 1910TD 100 unit Introduction Technical data 1910 TD 75 engine fuel system Removing refitting 1910 TD ...

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Page 23: ...tions 00 10 21 27 55 00 21 27 55 10 10 Page Nos 1 6 1 18 1 50 1 36 1 11 51 69 1 11 28 1 29 Comments Tech data Bravo 1988 HGT 20v Pack Sport 1910 TD 100 engine fuel system Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD and 1581 automatic transmission Automatic transmission Medium range radio 1910 TD 100 engine fuel system Removing ref itting 1910 TD 100 engine Copyri...

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Page 25: ...11 1995 506 670 07 VI 1996 Sections 00 10 21 27 55 00 21 27 55 Page IMos 1 6 1 18 1 50 1 4 36 1 4 11 5 1 6 9 1 11 Comments Technical data Bravo 1988 HGT 20v Pack S Fuel system 1910 TD engine Automatic transmission Wiring diagrams Connector blocks Technical data 1910 TD 1581 automatic transmission Automatic transmission Medium range radio Copyright by Fiat Auto ...

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Page 27: ...rd volume manual is composed of the following booklets Print No 506 670 06 VI 1995 Sections 00 10 21 27 55 Page Nos 1 5 6 1 18 1 4 50 1 36 Comments Tech data Bravo 1988 HGT 20v Pack Sport 1910 TD engine fuel system Automatic gearbox Wiring diagrams Connector blocks Copyright by Fiat Auto ...

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Page 29: ...es for overhauling the individual engines are described in other booklets which have the following print nos Engine 137012V 1581 16V 174716V 1998 20V 1929 D 1910 TD Print No 504 589 19 504 589 20 504 589 18 504 589 22 504 593 11 504 593 13 Part No 604 89 774 604 89 781 604 89 192 604 89 788 604 89 841 604 44 220 The first 4 booklets are inserted in the Overhauling Petrol Engines Manual 3rd volume ...

Page 30: ...rs in line 16 valves running on unleaded petrol and developing a power output of 83kW 113 CV at 5800 rpm 1998 cc five cylinders in line 20 valves running on unleaded petrol and developing a power output of 108 kW 147 CV at 6100 rpm 1929 D cc four cylinders in line 8 valves indirect injection running on diesel fuel and developing a power output of 48 kW 65 CV at 4600 rpm 1910 TD cc four cylinders i...

Page 31: ...Untitled Document introduction T cn Data 1 93 16 introduction Teen Data 199S ffle D Volume 203 intro tech htm08 07 2006 16 38 38 ...

Page 32: ...oo page Planned Maintenance Programme 1 M i ne riannea iviainienance rrogramme wnose operaiions are aescriueo iai W er on is the one in force at the time of printing and replaces and cancels the one in volume 1 of the Manual Copyright by Fiat Auto ...

Page 33: ...arance 1910 TD diesel version Check adjust tappet clearance 1929 D diesel version Checking exhaust gas emissions diesel fumes Check operation of anti evaporation system Replace fuel filter petrol engines Replace fuel filter diesel engines Replace air filter cartridge petrol engines Replace air filter cartridge diesel engines Check top up fluid levels engine cooling braking sys tem power steering w...

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Page 35: ...ditional replacements or further re pairs not envisaged in the Planned Maintenance Programme prior approval must be obtained first from the Customer PLANNED MAINTENANCE OPERATIONS H CHECK CONDITION OF TYRES AND WEAR Check the condition of the tyres making sure in particular that there are no signs of ageing on the tread and the tyre walls that the tyres are not excessively unevenly worn and that t...

Page 36: ...the need to replace or re grind in the case of a brake pad one of the components which has been checked Q CHECK CONDITION AND WEAR OF REAR DRUM BRAKES With one of the rear wheels removed remove the brake drum Check the thickness of the brake linings the minimum permissible thick ness is 1 5 mm Also check that there is no fouling from oil or grease Check the effi ciency of the shoe return device an...

Page 37: ...exible brake pipes in maximum steering conditions Q CHECK CONDITION AND TENSION OF VARIOUS DRIVE BELTS AND ADJUST IF NECES SARY The tension of the various drive belts is checked using tool 1895762000 Engines equipped with auto matic tensioners are exempt from this check Bravo Brava 1581 16v Check that alternator drive belt and power assisted steering drive belt tension measured using the spe cial ...

Page 38: ...olts 1 slack tension and lock the bolts 1 To adjust the tension of the alternator air conditioning cmopressor belt tension act on the special adjustment screw removing the compressor cover if necessary Bravo Brava 1929 D Check that the tension values measured us ing the special tool correspond to the recom mended figures given in the table overleaf If the tension values are not correct act on the ...

Page 39: ... and C TYPE A TYPE B and C 3 ribs 4 ribs 5 ribs 6 ribs 7 ribs TENSION daN 30 40 40 55 40 55 45 i 55 50 65 36 45 48 e 60 60 e 75 72 90 84 105 Poly V type belts In order to determine the number of ribs on the poly v belt in question it is necessary to count the number of teeth or points from 3 7 on the actual belt as illustrated in the diagram below Trapezoid type belts In order to determine whether...

Page 40: ...ft and check the condition of the auxiliary shaft drive belts along the entire perimeter Check the condition of the belts checkin in particular that there are no cracks cuts surface wear of the material which would appear smooth and shiny dry or hard sections with a conse quent loss of grip Also check that the belts have not come into contactwith oil or solvents which could adversely affect the el...

Page 41: ...s necessary to let the clutch operating mechanism bed in by fully depressing the pedal 2 or 3 times to check that the travel X corresponds to the recommended figure The travel is measured using a rule corresponding to the pedal centre line and is equivalent to the distance between the pedal in the end of travel position pedal in contact with the bodyshell and the pedal in the rest position any adj...

Page 42: ...se or decrease the handbrake lever cable travel check that the lever travel is equal to 5 notches on the toothed sector When the adjustment has been car ried out the control lever travel should not exceed 5 notches on the toothed sector With the handbrake lever In the rest posit on the rear wheels should rotate freely If this Is not the case repeat the adjustment m m CHECK ADJUST TAPPET CLEAR ANCE...

Page 43: ...ver to the tappet cover Then proceed with checking the tappet clearance Bravo Brava 1929 D 3 Undo the bolts fixing the tappet cover disconnect the brackets connected to it and remove it Then proceed with check ing the tappet clearance Checking tappet clearance and if neces sary adjusting 4 Rotate the camshaft so that the inlet and exhaust valves are in the closed position With the engine cold chec...

Page 44: ...the idle air flow rate therefore no manual adjustment operations are required However a check on the content of the exhaust gases downstream of the catalyzer can pro vide useful indications on the injection ignition system operating conditions and the engine and cat alyzer parameters The concentration of carbon monoxide CO unburnt hydrocarbons HC and the value X is measured with the catalyzer at o...

Page 45: ... i mV 1000 800 600 400 200 0 GE 0 070 U Sf U RICH I MIXTURES T i 1 1 030 LEAN MIXTURES I 0 7 0 8 0 9 1 0 1 1 1 2 1 3 AIR COEFFICIENT X Factor X is obtained from the ratio between the quantity of intake air and the theoretical quantity of air required to burn all the fuel in jected To achieve an optimum mixture the quantity of fuel injected must be as close as possible to the theoretical quantity r...

Page 46: ... out measurements for five subsequent full accelerations Make a note of the maximum values reached To obtain the figure for the test calculate the arithmetical average of the three closest val ues If there is more than one suitable trio select theone which gives the highest average val ue Compare the values with the limit given on the plate on the vehicle conforming with the EEC directive Where fi...

Page 47: ... Position the vehicle on a lift and check the condition of the pipes under the floo of the vehicle fQ REPLACE FUEL FILTER petrol engines Proceed with removing the fuel filter by car rying out the following operations Raise the vehicle undo the bolts shown in the diagram and remove the protective shield disconnect the rapid fue inlet and outlet connectors from the filter collecting the fu el which ...

Page 48: ...ith the seal from the support 2 When refitting the fuel filter proceed as fol lows lubricate the rubber seal for the cartridge fill the filter cartridge with diesel fuel in or der to shorten the self bleeding time tighten the cartridge in contact with the support close the cartridge by 3 4 of a turn to achieve a tightening torque of 1 3 1 6 P4AMCA02 daNm For the 1929 D version which is equipped wi...

Page 49: ...fecting the operation of the engine fuel system Clean the air filter cartridge container careful ly replace the filter then refit the cover and fix it using the appropriate bolts M H there are traces of oil on the filter f K check for possible penetration throughout the entire air circut NOTE the vehicle is used on dusty roads replace the air filter more often If they ask the Customer should be pr...

Page 50: ...anti freeze us ing the regular test equipment Paraflu Formula Europa is already mixed which means that water does not have to be added P4A16CA02 1747 16v 1998 20v 1910 TD 1929 D Brake fluid level The brake fluid level is checked with the vehi cle on a flat surface Check that the level of the fluid in the tank corresponds to the MAX reference on the tank It is normal for the brake fluid level to de...

Page 51: ... the fluid level is be tween the MIN and MAX references on the dip stick in the tank cap or on the actual tank In order to carry out the check clean the dip stick fully tighten the cap undo it and check the level When the fluid is hot it may exceed the MAX level If necessary add fluid making sure that it has the same characteristics as the fluid already present in the system Start up the engine an...

Page 52: ...been switched off The oil level should be between the MIN and MAX marks on the dip stick The gap be tween the MIN and MAX levels corresponds to around 1 litre of oil If the level of the oil is close to or actually be low the MIN reference add oil through the filler until the MAX reference is reached The level of the oil should never ex ceed the MAX reference When topping up with oil take great car...

Page 53: ...p using distilled water The fluid contained in the battery is poisonous and corrosive Avoid con tact with the skin and eyes Keep naked flames and possible sources of sparks away from the battery as there is a danger of explosion and fire The state of charge of the battery should be checked preferably at the beginning of the cold season to avoid the possibility of the electrolyte freezing This chec...

Page 54: ... to release the spring inside the actual device Then re move the actual belt from the damper fly wheel leaving it fitted on the power steer ing pump pulley it is not necessary to re move the upper shield for the power as sisted steering pump 2 Remove the upper shield for the timing drive belt after having removed the sup port for the coolant pipe 3 Loosen the bolts fixing the damper fly wheel then...

Page 55: ... the crankcase 3 Place tool 1860901000 in position en suring that the opening 1 in the tool co incides with the dowel on the crankshaft gear in this position cylinder no 1 is at T D C 4 Remove the bolts fixing the 1 st 2nd 3rd and 4th timing caps exhaust side loosen the inlet side ones raise the lubrication duct remove the 2nd cap and place tool 1860899000 for timing the camshaft in the housing th...

Page 56: ...it at acute angles in order not to adversely affect the structure of the actual belt The belt should also be fitted with the arrows on it facing in the direc tion of rotation of the engine Tensioning timing drive belt 2 Using tool 1860443000 act at the point shown by the arrow and place the moving index 1 on the tensioner in the maxi mum tension position then lock the nut fixing the tensioner 3 Ti...

Page 57: ... Remove tool 1860901000 placed previ ously on the timing gear and rotate the crankshaft through two revolutions in its direction of rotation Loosen the tension er fixing nut make sure that the moving index 1 coincides with the fixed refer ence 2 then lock the nut fixing the ten sioner and tighten it to the recommended torque Refit the previously removed components taking care to refit the auxiliar...

Page 58: ...rt of the timing belt shield remove the spark plugs and posi tion the dial gauge by cylinder no 1 using support 1860895000 rotate the crankshaft until T D C is found 3 Check that the reference 1 on the damper flywheel is aligned with the refer ence 2 on the timing belt lower shield Also check that the reference on the fly wheel coincides with the reference on the bell housing as shown in the inset...

Page 59: ...874000 for timing the camshafts making sure that the housing 1 for the shaft coincides with the element 2 on the tools engage the element in the housing and fix the tool to the camshaft housing by the covers which were removed previously Repeat this operation both the camshaft inlet shaft and the exhaust one If the tools do not fit perfectly and it is necessary to rotate the camshafts align the pi...

Page 60: ... D C then using the fixing bolt for the timing belt shield fix the fixed reference shown in the diagram in the housing of the bolt used 3 Fit the support base for the graduated disc 1860896000 on the auxiliary shaft drive pulley and fix it to the pulley using a bolt Then fit the graduated disc on the support base ensuring that the 0 on the disc co incides with the fixed reference positioned previo...

Page 61: ...ent value 8 then release the graduated disc from the base position it in relation to the fixed reference without rotating the crankshaft at the value which is the arithmetical aver age for example 9 the average of 10 and 8 then lock the graduated disc once again 3 Rotate the crankshaft pulley in a clock wise direction until the 0 on the gradu ated disc coincides with the fixed refer ence 4 Rotate ...

Page 62: ...w tool 1860876000 for tensioning the timing belt to be positioned Acting on tool 1860876000 place the belt tensioner in the maximum tension po sition then lock the tensioner nut Re move the dial gauge and tighten the camshaft pullies to a torque of 11 5 daNm using tool 1860885000 on support 1860831001 Remove tools 1860874000 rotate the crankshaft through two revolutions in the direction of rotatio...

Page 63: ...release the spring in side the actual device then fit the belt Remove the fixed pulley for the auxiliary shaft drive belt then undo the upper and lower bolts fixing the timing belt shield and remove it 3 Remove the cover for the ignition coils disconnect the connections from the coils the earth cable 1 and the oil vapour re covery pipe from the cylinder head cover Disconnect the connector from the...

Page 64: ...am When the camshaft caps are re moved they must be marked so that they can be refitted in the correct po sition If this is not the case there could be problems with the reliability of the camshafts 3 Position and fix the pair of tools 1860875000 by the previously removed caps The pair of tools 1860875000 should exact follow the profile of the camshaft cams Remove the lower gearbox protective cove...

Page 65: ... the bolt fixing the inlet side camshaft pulley and the exhaust side pul ley using tool 1860831000 These pullies have slots allowing the correct matching of the belt pulley 4 Fit the belt observing the following order 1 Crankshaft drive pinion 2 Fixed pulley 3 Camshaft pulley exhaust side 4 Camshaft pulley inlet side 5 Automatic tensioner pulley 6 Water pump pulley NOTE The belt should be fitted a...

Page 66: ...tool 1860831000 3 Remove the pair of tools 1860875000 and return the camshaft caps marked during the dismantling to their correct position and tighten them to a torque of 1 5 daNm Remove the flywheel lock 1860898000 then rotate the crankshaft through two revolutions in its direction of rotation Loosen the belt tensioner fixing nut and using tool 1860845000 make sure that the moving reference 1 for...

Page 67: ...ndicate Aspirazione and Scarico inlet and exhaust Make sure when refitting that the profile on the tools is perfectly in line with the profile of the camshaft caps To determine T D C for cylinder n 1 po sition a dial gauge with tool 1895879000 for support tightened in place of the spark plug for the first cylinder Rotate the crankshaft until T D C is reached shown by the dial gauge Under these cir...

Page 68: ...t and exhaust side pullies to the recommended figures Remove the tools positioned for timing and locking the camshafts and rotate the crankshaft through two revolutions in its direction of rotation Loosen the nut fixing the tensioner and ensure that the moving reference on the tensioner 1 coincides with the fixed ref erence 2 then tighten the nut fixing the tensioner to torque and proceed with the...

Page 69: ...e compartment undo the bolts for the gear box shield and position the flywheel lock 1860898000 Then remove the damper flywheel auxiliary shaft drive pulley 3 Remove the lower shield for the timing belt remove the reaction connecting rod complete with mounting bracket near the upper timing belt shield then remove the latter as well 4 For the 1910 TD 75 version check that the injection pump timing i...

Page 70: ...e dowel 2 is matched up with the opening 1 In this position cylinder no 1 isatT D C 4 Using tool 1860831000 rotate the camshaft pulley until the following align ments are achieved up to engine n 416499 the reference 1 on the pulley should have moved 7 teeth in a clockwise di rection in relation to the reference 2 on the tappet cover from engine n 416450 the reference 1 on the pulley should be alig...

Page 71: ...r all the pre and post modification engines the new belt can be fitted and timed by fol lowing the alignment of the transverse refer ences A on the back of the timing belt and the references on the pullies NOTE Fit the belt so that the arrow is point ing in the direction of rotation of the engine 3 Exert force at the point shown on the au tomatic tensioner placing the tensioner moving reference 1 ...

Page 72: ...moving reference 2 for the belt tension er Lock the tensioner fixing nut and then tighten it to the recommended torque Proceed with refitting the components previously removed reversing the order of the operations described previously Bravo Brava 1929 D Position the vehicle on a lift then disconnect the negative battery lead remove the right front wheel remove the right wheel arch liner Remove alt...

Page 73: ...e mounting brackets for the engine cooling system pipes 2 Remove the lower timing belt cover 3 Remove the lower flywheel shield from the bell housing 4 Place flywheel lock 1860766000 in posi tion to prevent the rotation of the crankshaft 5 Remove the damper flywheel then re move the flywheel lock 1860766000 Copyright by Fiat Auto 39 ...

Page 74: ...e engine Cylinder no 1 will be at T D C under these circumstances and the camshaft will be timed for the ex plosion stroke in cylinder no 1 NOTE The fixing opening for the camshaft drive pulley has a slot on account of which under these circumstances the reference on it should not coin cide exactly with the fixed reference on the cover 2 Loosen the belt tensioner nut then remove the timing drive b...

Page 75: ...d be per fectly centered on the tool if it is not use a spanner 4 to centre the dowel on the tool using extremely small movements 3 Remove the bolt shown in the diagram which fixes the front cover to the crankcase Then fit the timing drive belton the crankshaft drive gear only 4 Position tool 1860933000 for accurately determining T D C for cylinder no 1 The tool should be perfectly fixed to the cr...

Page 76: ...m and acting on the joint position the milli metric rod on the horizontal plane and lock the joint fixing bolt 3 Tighten the bolt fixing the camshaft drive pulley to the recommended torque Re move the tools positioned previously for determining the timing and T D C and the flywheel lock Let the belt bed in by rotating the crankshaft through two revolutions in its direction of rotation and tighten ...

Page 77: ...GBMSR Champion RC7BMC Only use recommended type spark plugs if the heat rating is insufficient or not guaranteed for the correct peri od problems can arise Also check the condition of the supply cables making sure that there are no cuts cracks or restrictions along the entire length NOTE Carry out the following operations with the engine cold 1 c tS w te SJJC3 S5Z ptajj s J _ Ty Bravo Brava 1370 1...

Page 78: ... great care when extracting the boots and remove and replace the spark plugs using an appropriate spanner Bravo Brava 1747 16v 1998 20v 2 Remove the cover for the ignition coils then disconnect the supply connectors 3 Remove the ignition coils acting on the fixing bolts undo the spark plugs using a special spanner and proceed with replac ing them 44 Print no 506 670 09 ...

Page 79: ... is repaired the light goes out Working with the Fiat Lancia Tester or the SDC or the Examiner it is possible to carry out a complete system fault diagnosis which consists of three stages 1 display of a series of functional parameters 2 display of the errors or their cancellinge 3 activation of certain actuators active diagnosis Unlike the Fiat Lancia Tester the SDC and Examiner equipment use a to...

Page 80: ...a suitable length of time before the check Proceed with checking the gearbox oil level by carrying out the following operations park the vehicle on a flat surface and apply the handbrake with the engine idling gently move the se lector lever from position P to position 1 then return it to P extract the oil dip stick 1 and clean it again completely insert the dip stick in its housing extract the di...

Page 81: ... of be ing scalded Remember that with the engine hot the fan may start working with the danger of injury Raise the vehicle remove the engine com partment lower shield and undo the drain plug and completely drain the oil into a suitable container Work very carefully whilst removing the drain plug because the oil could be very hot Working from underneath the vehicle using the appropriate equipment r...

Page 82: ...ith the laws in force Q3 CHANGE BRAKE FLUID L Q i ffpl O WKA CM sj jj 5 Wi 1 JffiD The brake fluid is hygroscopic i e it absorbs humidity To avoid problems with braking the brake fluid should be changed every two years irrespective of the mileage Raise the vehicle and if necessary remove the wheels connect a flexible pipe to the bleed screws on the brake calipers for rear drum brakes to the bleed ...

Page 83: ...ence Do not reuse the hydraulic fluid drained during the bleeding procedure Restore the level of the fluid in the reservoir and refit the cap check the efficiency of the braking system NOTE For versions with hydraulic clutches Bravo 1998 20v the fluid in the circuit must be drained by connecting a flexible pipe to the clutch operating cylinder bleed screw loosening it and act ing on the pedal to d...

Page 84: ...ng springs in the pollen filter housing extract it and pro ceed with replacing it NOTE Failure to rep ace the filter can con siderably reduce the efficiency of the climate control system If the vehicle is often used in dusty or strongly polluted areas advise the Customer of the need to rep ace the filter element more often it should especially be replaced if a decrease in the flow rate of the air ...

Page 85: ...Untitled Document file D Volume 203 engine htm08 07 2006 16 39 49 ...

Page 86: ...TD 100 CV Typical curves 4 Characteristics 5 Cylinder head assembly and valve gear com ponents 6 Fuel system and supercharging 7 Data for checking Bosch injection pump type VER 679 x 8 Data for phecking Lucas injection pump type FT 09 9 GEARBOX AND DIFFERENTIAL 11 AISIM AUTOMATIC GEARBOX 13 FRONT SUSPENSION 14 N D Data not avaiJaBle at the time of printing Copyright by Fiat Auto ...

Page 87: ... 182 BB 1AA11 182 BB 1AA11B A 182 AB 11A 02 182 BB 11A 12 182 AH 1AA08 182 BH 1AA 17 182 AF1AA06 182 BF 1AA 15 182 Al 1AA 09 182 Bl 1AA 18 BRAVO BRAVA GEARBOX Versions for specific markets Germany A Voluntary Germany A Vehicle type identification code and chassis manufacture number B V I N Plate EEC regulations C Engine type and number Copyright by Fiat Auto Vll 97 Cancels and replaces 1 ...

Page 88: ...al tests and in accordance with procedures laid down by EEC regulations In particular the bench tests measure simulated urban cycle figures whilst consumption at constant speeds of 90 and 120 kph are measured directly on a flat dry road and in equivalent bench tests The fuel consumption figures according tothe 93 116E standards have been defined in the course of homologation tests involving an urb...

Page 89: ...n cycle A 9 3 11 2 Constant speed 90 kph B 5 5 5 8 Constant speed 120 kph C 7 5 Av consumption CCMC proposal A B C 5 9 7 6 _7 7 8 2 7 4 Urban 11 0 Extra urband 11 3 6 5 6 6 Combined 8 2 C02 exhaust emissions g km _8 3_ 194 197 8 3 JI3 8 13 8 8 3 8 3 1 0 10 3 246 246 7 5 4 6 4 7 6 5 A6 _ 02 6 3 J3 5 8 5 2 5 3 6 4 6 5 171 173 7 7 4 5 A4 6 5 6 2 6 23 8 5_ 8 6 5 1 5 2 A 3 6 4 168 171 See specification...

Page 90: ...00 4 5 4 2 4 3 7 a _ TUTELA ZC 75 Synth b TUTELA GI 2 1 1 98 1 8 6 4 3 5 4 3 9 A Distilled water Engine sump only CV kW CEE CEE 85 75 65 55 45 35 25 15J For versions with air conditioning Periodic replacement CV kW CEE CEE P4A04BA01 m TD 75 N m kgm CEE CEE 170n 1000 2000 3000 4000 100 1 90 80 70 60 50 40 30 ou 70 60 50 40 30 n 1 TDIOO N m kgm CEE CEE 210 1 190 170 150 130J 1000 2000 4000 5000 Engi...

Page 91: ... overhead camshaft Indirect mechanical injection Number of cylinders r0 Cylinder liner bore mm 82 Stroke mm 90 4 8 OHM k Capacity cc 1910 Pi 9 Compression ratio 20 7 0 5 Total volume of combustion chamber cc 24 6 kW CV 74 100 Max power EEC rpm 4200 daNm kgm 20 20 4 Max torque EEC rpm 2250 55 75 4200 14 7 15 2750 Copyright by Fiat Auto 5 ...

Page 92: ...g TD 75 CV Values in mm Cam lift e m 8 5 8 5 8 5 8 5 17 20 timing check k clearance for 1 e m operational clearan e m 0 50 0 50 0 35 0 05 0 35 0 05 TIMING DIAGRAMS PI W Timing angles A B C D Inlet Exhaust Q m opens before TDC closes after BDC opens before BDC closes after TDC 6 26 26 6 6 26 26 6 6 Print no 506 670 07 ...

Page 93: ...CD 011R02AA1 LCR 6705344 LUCAS RND 05DC6897 143 150 bar Electronic adjustment 870 930 min 4920 5020 min BOSCH mechanical VER 679 BOSCH BOSCH KCA 30S41 BOSCH DN 0SD 321 150 158 bar 0 92 mm 830 870 min 5000 5100 min Signal injector installed on cylinder no 1 TURBOCHARGING Turbocharger operated by exhaust gases with waste gate pressure valve and air air heat exchanger intercooler Turbocharger type Ma...

Page 94: ...x Max Max Max Max Max Max Max Max Min Min Min 1500 1500 Rotation speed rpm 1000 1500 2100 600 1000 1500 2100 2400 2600 2800 100 400 525 600 2100 425 500 425 Advance check mm 2 4 3 8 5 1 6 3 8 2 9 6 Transfer pressure bar 5 4 6 4 6 8 7 8 8 3 9 3 P MAX 0 2 0 1 Output per element mm cycle 39 3 43 9 40 3 44 9 41 45 41 3 45 9 26 2 36 2 8 4 18 4 3 50 80 52 72 55 65 15 31 l h 20 50 l h 10 5 18 3 3 3 Q MAX...

Page 95: ...ention Supercharging device gradient Op N 1 2 3 4 5 6 7 8 9 10 11 12 Adjust lever pos Max Max Max Max Max Max Max Max Max Max Max Max Rotation speed rpm 0 0 0 1000 2000 1500 2530 2330 2100 1250 750 750 Av capacity per cyl mm3 cycle 19 4 405 4 56 5 2 55 4 2 40 2 2 5 Q12 Q11 11 2 Advance 0 6 7 5 0 5 4 5 0 5 1 5 0 5 0 Max discr btwn flow rates mm3 cycle 4 4 4 4 4 4 Ops or checks to be carried out Fil...

Page 96: ... 5 S a is u X n _ CD J 2 O CD D CO CO CD Q O C ro k_ co n o _ CD a CO 1 o 0 0 H o CN O O X ro 2 LO o 0 X o 5 5 a a s X IS 1 I t o CN H LO co 1 c CD f 1 CO _ CD _CD o o CD Q CO CD n CD CO co CD CD CC rt O C N H O CN O LO c 5 r o u c a J g o cv X u 1 tf o H ST CD a c 5 00 1 1 CD _CD 0_ O l co CD n 5 1 O 0 0 LO o LO C 2 CD 3 a a 3 1 0 s CO CD D 0 co CD a ro c ro _ CO o CD a 3 CO 1 o o sl 1 o o o CN X...

Page 97: ...GEARBOX Q TD 75 M TD 100 Type C 510 5 17 00 Synchronizers spring J ring Porsche type Vis baulk ring type o oo Gears straight toothed helical toothed 3 909 2 238 5 oo 1 444 Gear ratios 1 029 0 815 3 909 3 909 2 238 1 444 1 029 0 767 3 909 Copyright by Fiat Auto 11 ...

Page 98: ...16 13 102 12 313 04 Differential internal casing bearing conical roller bearings ffit o Adjustment of bearing pre loading by shims mm 0 07 1 70 2 89 Thickness of shims Arjtb Interference to obtain exact bear ing pre loading mm Bearings not pre loaded 0 12 bearings pre loaded 350 daN 0 08 AX t Clearance btwn planet and sat gears mm 0 10 4 no adjustment is carried out Adjustment of cirnce btwn plane...

Page 99: ...rter 0 mm 216 Ratio multiplication for engine torque 2 150 Quantity of oil total with gearbox converter radiator and pipes empty GI 2 replacement only 6 litres 5 4 kg 4 3 litres 3 9 kg DIFFERENTIAL II I I l HI H n I I ii n l Hl H II n P r II u u Ratio at the wheels Crown wheel and pinion reduction Final ratio fooooo ooooo ooooo ooooo vooooo 3 565 82 23 3 633 54 53 82 23 10 197 5 373 3 633 2 670 10...

Page 100: ...333 5 height of mm yellow 1 for J those under 354 a load of i 367 333 5 green 1 for J those under 354 a load ot 1 367 height of mm height of mm height of mm height of mm height of mm 12 3 0 05 3 75 clockwise 461 192 192 192 12 5 0 05 3 75 clockwise 461 192 192 s 192 12 7 0 05 3 75 clockwise 454 192 192 1 9 2 1 Springs of the same category must be fitted A With automatic transmission B With automat...

Page 101: ...Bravo i i mHGT20v Introduction and technical data index oo SPORT PACK INTRODUCTION STEERING FRONT SUSPENSION REAR SUSPENSION WHEELS page 1 v2 r 3 L l r A 5 Copyright by Fiat Auto ...

Page 102: ...l of respon siveness and to minimize understeer round tight bends this geometry allows the front wheels to work optimally with consequent improvements to the driving as well special power assisted steering which features a direct steering ratio 60 mm turn or 2 and 1 4 turns lock to lock which makes the steering responsive and precise this direct steering associated with the specific variation in t...

Page 103: ... 41 Type rack and pinion power assisted no of turns lock to lock Ratio rack travel 2 3 128 1 5 mm rrr 0 Turning circle 12m i i Steering angle outer wheel ai inner wheel a2 26 30 34 30 Steering col with 2 universal joints 2 P 7 f no 506 670 06 ...

Page 104: ... load of 358 388 daN m m The springs are subdivided into two categories identifiable by a mark yellow 1 for 350 daN those under 373 daN h e i 9 h t o f m m a load of green 1 for 350 daN u u t those under 373 daN he Qht of mm a load of 13 5 0 05 4 clockwise 355 170 170 170 1 Springs of the same category must be fitted For vehicles with air conditioning Shock absorbers Type telescopic double acting ...

Page 105: ...l Height of spring released mm u n t r a t o a d T 275 303 daN m m The springs are subdivided into two categories identifiable by a mark yellow 1 for __ those under 289 daN height of mm a load of green 1 for those under 289 daN height of mm a load of 11 8 0 05 4 5 clockwise 296 8 194 194 194 1 Springs of the same category must be fitted Shock absorbers Type telescopic double acting low pressure ga...

Page 106: ...30 2 20 30 1 1 mm fcS camber ui U Rear suspension toe in rear wheel thrust angle A 45 30 1 5 mm Angles cannot be adjusted With tyres inflated to the correct pressure and vehicle in running order with 5 litres of fuel A Angular values which cannot be adjusted used for the correct alignement of the vehicle Copyright by Fiat Auto 5 ...

Page 107: ...5 Radial tubeless tyre 205 50 ZR 15 P700Z 115 70 R15 90M Rfjffj Tyre inflation Sun w pressure nS i in bar Front average load 2 5 heavy load 2 7 Rear average load 2 2 heavy load 2 5 4 2 Not to be used with snow chains because they could interfere with the wheel arch 6 Print no 506 670 06 Bravo piHGT20v ...

Page 108: ... curves 2 Cylinder block crankcase and associ ated components Timing system 4 Timing diagrams 5 Fuel system 6 GEARBOX DIFFERENTIAL ELECTRICAL EQUIPMENT Starting 9 Recharing 11 This section contains data relating to cars fitted with a 1581 16v STEP A engine For further information refer to data in section 00 of the first and third volume Copyright Fiat Auto IV 99 Stipf rstcies previous vnrsion ...

Page 109: ...rava 93 116 EC fuel consumption figures were determined during homologation tests an urban cycle i e a cold start foFIowed by a simulated varied urban route out of town cycle i e frequent accelerations in all gears to simulate normal out of town vehicle use with speed be tween 0 and 120 km h Average combined fuel consumption is assumed to be 37 of the urban cycle and 63 of the extraurban cycle Typ...

Page 110: ...100 90 80 70 60 50 40 30 20 10 80 70 60 50 40 20 10 0 1 I Si 16v N m kgm CEE CEE Typical engine curves measured by EEC method The power curves illustrated can be obtained with the engine overhauled and run in without a fan and with a silencer and air cleaner fitted at sea level NOTE The data and curve shown on this page refer to the 1581 16v engine with order num ber 46474405 3000 5000 6000 7000 P...

Page 111: ...es in mm n m 0 Piston 0 onPn 10 2 86 352 86 362 86 359 86 371 86 368 86 378 0 4 m Piston ring grooves 1 2 3 1 520 1 540 1 510 1 530 3 010 3 030 0 1 2 3 Piston rings 0 BOSB 1 470 1 490 1 470 1 490 3 000 0 4 5 3 t Piston rings Piston ring grooves I 1 2 3 0 035 0 075 0 020 0 060 0 010 0 030 Copyright Fiat Auto 3 ...

Page 112: ...ll end bush 24 016 24 041 22 004 22 009 1 Piston pin Small end bush 0 009 0 019 II Valve guide seat on cylinder head 0 12 950 12 977 12a a e Valve seat m 45 20 45 20 about 2 ID Volume of combustion chamber in cylinder head cm 33 35 15 Pi nMSfr Hi T H 2 P2 Internal valve spring H2 8 3 9 3 daN 27 5 17 6 19 6 daN 18 5 4 Publication no 506 670 14 ...

Page 113: ... O FlM Outer valve spring 1 7 a rt 17b Cam lift 12a I Q B Tappet housings P1 Hi P2 H2 HQ 0 Values in mm 23 4 25 6 daN 33 5 46 50 daN 24 5 8 5 8 33 000 33 025 TIMING DIAGRAMS Timing angles A B C D Intake Exhaust 2 Begins after TDC Ends after BDC Ends before BDC Ends before TDC 4 38 28 4 Copyright Fiat Auto 5 ...

Page 114: ...ure regulator Coolant temperature sending unit Top Dead Centre and rpm sensor Throttle position sensor potentiometer Dual relay for electric fuel pump and injection ignition control unit Electric fuel pump Lambda sensor Fuel filter Knock sensor Ignition coil ICpllGV I A W 49 F B4 I A W 49 F L2 M Marelli TPRT 03 SIEMENS EC1 M Marelli 46 SX F2 M Marelli IB 02 M Marelli IWP 064 M Marelli RPM 84 SYLEA...

Page 115: ...ical data Gearbox and differential GEARBOX Type l i 16v C 513 514 26 00 21 27 W Synchronizers ring type Porsche free ring o oo Gears spur toothed helical toothed OO Gear ratios 3 909 2 238 1 444 1 029 0 816 3 909 Copyright Fiat Auto 1 ...

Page 116: ...ifferential internal casing bearing taper roller type o Bearing preload adjustment by shims o 0 05 mm Thickness of shims 0 10 1 70 2 60 a Interference to obtain exact bear ing pre loading mm bearings not pre loaded 0 12 bearings pre loaded 350 dan 0 08 Differential planet gear backlash mm 0 10 4 Adjusting differential planet gear backlash by shims Thickness of shims 0 0 5 mm 0 80 1 25 8 Publicatio...

Page 117: ...ent voltage speed Relay Winding J resistance Lubrication Internal splines and shaft bushes mm A rpm V daNm A V daNm A V rpm pull In Q hold in Q Engagement sleeve and intermediate plate M Marelli M70R 12V 1 3 kW with reduction unit 12 1 3 clockwise 4 series parallel winding free wheel electromagnetic 0 15 0 45 360 380 1150 8 15 1 30 680 700 4 9 3 11 60 80 11 1 4040 0 33 0 37 1 13 1 27 VS SAE 10 W T...

Page 118: ... 55 STARTER MOTOR WIRING DIAGRAM AND TYPICAL CURVES Wiring diagram of M Marelli M70R 1 3 12 starter motor KWNm V 35 1H 2 1 1 8 1 5 m 0 9 0 6 10 0 3 5 J 0 30 25 10 Typical curves for starter motor M Marelli M70R 1 3 12 with epicyclic reduction gear 10 Publication no 506 670 74 ...

Page 119: ...27IR 14V 40 85A Bosch KCB1 14V 45 80A Bosch KCB2 14V 50 90A Bosch KCB2 14V 55 105A 14V 75 40 75 85 50 85 25 87 2 613 80 45 80 2 16 2 64 90A 105 50 55 90 105 2 34 2 86 1 8 2 2 Clockwise Bridge Data obtained at an ambient temperature of 20 C For cars with air conditioner destined for ISRAEL Alternators without cooling system fitted from chassis no 4788901 VOLTAGE REGULATOR Make Alternator speed for ...

Page 120: ... ...

Page 121: ...ristics 7 Typical curves 8 Crankcase and crankshaft 9 Cylinder head assembly and valve gear 14 Counter rotating shaft 19 Lubrication 20 Cooling system Fuel system 21 Components of integrated electronic injection ignition system 22 ENGINE 0i JTD Characteristics 23 Typical curves 24 Crankcase and crankshaft 25 Cylinder head assembly and valve gear 29 Lubrication 33 Cooling system 34 Components of BO...

Page 122: ... 000 182 B3 000 182 B4 000 VERSION 182 AP 1AA 182 BP 1AA 182 AQ1AA 182 AR 1AA 182 BR 1AA 3 Doors 5 Doors GEARBOX NOTE This section deals with the new engine versions in the 1998 range For the remaining engine versions refer to the Bravo Brava manual publication no 506 670 and subsequent updates Copyright Fiat Auto 1 ...

Page 123: ...BI N FOR SPARES D Kg Kg Kg Kg M o N A Name of manufacturer B Homologation number C Vehicle type identification code D Chassis manufacture number E Maximum authorized weight of vehicle fully laden F Maximum authorized weight of vehicle fully laden plus trailer G Maximum authorized weight on first axle front H Maximum authorized weight on second axle rear I Engine type L Bodywork version code M Part...

Page 124: ...er wnn uraKing system j Maximum Without braking system X f k C B I B 1A I4 U l __l _ system 1010 1040 1510 1570 850 850 850 850 80 70 400 1000 1190 1690 970 900 80 70 400 1300 1170 1195 1680 1735 920 920 920 920 80 70 400 1300 Loads that should never be exceeded NOTE FOR VERSIONS WITH ACCESSORIES With special equipment fitted non standard air conditioner sun roof trailer tow hook the unladen weigh...

Page 125: ...e following official tests an urban cycle i e a cold start followed by a simulated varied urban route urban cycle i e frequent accelerations in all gears to simulate normal out of town vehicle use with speed be tween 0 and 120 km h The average combined fuel consumption test involves 37 of the urban cycle and 63 of the extraurban cycle Type of route traffic situations driving style weather conditio...

Page 126: ... 7 Diesel engines SELENIA Turbo Diesel SAE 10 W 40 1242 16v 2 8 2 5 2 55 2 25 1998 STEP A Partial capacity periodic changes 4 8 4 5 4 3 4 0 1910 JTD 4 9 4 3 4 23 3 75 a _ TUTELA ZC 75 SI NT b TUTELA T Gl A Sit m 1242 16v 1998 STEP A 1910 JTD 1 7 1 5 1 8 5 l a TUTELA Gl A b K 854 1 1 0 8 TUTELA TOP 4 270 C without abs 0 38 0 40 with abs Total capacity 0 45 0 54 g 3 AREXONS 1 10 C 20 C 3 50 100 a i9...

Page 127: ...tic fluid F M V S S n 116 DOT 4 ISO 4925 CUNA NC 956 01 Lithium based grease consistency NLGI 000 containing molybdenum disulphide Mixture of alcohol water and tensio active agents CUNA NC 956 11 Mono ethylene glycol based anti freeze for cooling system inhibited mono ethylene glycol CUNA NC 596 16 Additive for diesel fuel with protective action for diesel en gines Usage Temperature 25 C 40 C Temp...

Page 128: ... type Integrated electronic injection ignition BOSCH M 1 5 5 MPI BOSCH ME 3 1 Number of cylinders r0 Cylinder liner bore mm 70 80 82 fi Stroke mm 78 86 75 65 Bffl3 I Capacity cm3 1242 1998 Ft Compression ratio 10 2 10 7 0 15 Maximum power EC kW PS 60 82 rpm 5500 ff Maximum torque EC daNm kgm 11 3 11 5 rpm 4250 113 155 6500 18 6 19 3750 Copyright Fiat Auto 1 ...

Page 129: ...02 Speed when laden rpm 800 1000 1500 2000 Time in minutes 10 10 10 Load at brake no load no load no load Bench test cycles for overhauled engines When bench testing serviced engines it is not advisable to run the engine at top speed but observe the specifications in the table finish running in the engine on the car Engine power curves obtained by eec method The power curves illustrated can be obt...

Page 130: ... 80 63 705 63 718 0 Cylinder bore 0 S A B C 70 800 70 810 82 000 82 010 70 810 70 820 82 010 2 020 70 820 70 830 82 020 82 030 X 12 5 W 70 760 70 770 81 952 81 962 70 770 70 780 81 959 81 971 70 780 70 790 81 968 81 978 Piston 0 0 4 weight difference between pistons 5g Q p Piston 4 Cvlind Cylinder liner _A_ 0 B 0 030 0 050 0 038 0 058 0 039 0 061 0 042 0 062 Copyright Fiat Auto 9 ...

Page 131: ... 530 2 010 2 030 0 U L 1 170 1 190 1 180 1 160 1 175 1 190 1 190 1 170 2 475 2 490 1 990 1 970 Piston rings 0 0 4 5 3 o a P i s t o n r i n 9s _3_ _ Piston ring grooves 0 0 06 0 0 055 0 0 055 0 040 0 080 0 020 0 050 0 020 0 060 Piston ring 5 1 P end Pen n 9 J L in cylinder liner C L Z 0 200 0 400 0 200 0 350 0 250 0 450 0 250 0 500 0 200 0 450 0 250 0 500 i 0 Bush housing or i e m a i l o n r l c ...

Page 132: ...ine crankcase assembly OO io DESCRIPTION 4 7 J I lOl 02 Small end bush m7 q p Gudgeon pin H 44 Small end bush r Small end bush n Bush housing Values in mm 0 014 0 035 23 007 23 027 20 006 20 01 2 0 006 0 020 0 035 0 088 Copyright Fiat Auto 11 ...

Page 133: ...08 L1 23 975 24 025 59 994 60 000 59 988 59 99 59 982 59 98 48 238 48 24 48 232 48 23 48 226 48 23 26 575 26 625 Crankshaft bearings 1 836 1 840 1 836 1 840 1 843 1 847 1 839 1 843 1 848 1 852 1 842 1 846 0 f 0 254 0 508 9 8 ELF Main bearings Journals 0 025 0 040 0 025 0 052 10 Connecting rod bearings _ 1 536 1 540 1 544 1 548 1 539 1 543 1 542 1 546 0 0 254 0 508 12 Publication no 506 670 16 ...

Page 134: ...nkshaft end float 0 055 0 265 0 059 0 161 Diagram showing connecting rod piston assembly and direction of rotation in engine 3 Area where matching cylinder liner number is stamped 4 Engine direction of rotation The arrow shows the direction of rotation of the engine as seen from the timing side Value in mm of offset between connecting rod ax is and piston axis D 0 85 1 15 for 1242 16v D 0 10 0 60 ...

Page 135: ...nd valve gear Bravo Brava 1998 range OO io 18 17 16 15 13 i 1 14 20 19J IfEZEll 16v IQ I 20v STEP A DESCRIPTION Values in mm Camshaft supports on cylinder head j P 20v 0 12 STEP A _ 26 045 26 070 19 100 19 150 14 Publication no 506 670 16 ...

Page 136: ... head 0 9 959 9 989 12 950 12 977 Q 45 20 45 5 a Valve seat m 45 20 45 5 e m 1 5 about 2 DrMl r Volume of combustion chamber in cylinder head c m 12 28 38 2 13 tK QD 0 i n 6 022 6 040 7 022 7 040 Valve guide fHQ 0 2 02 m 10 010 10 030 13 010 13 030 0 2 0 05 0 10 0 25 13 12 h Valve guide Bore in cylinder head Q 0 049 0 051 0 033 0 080 12 Tappet housing on cylinder head 0 33 000 33 025 Copyright Fia...

Page 137: ... A Internal valve spring Pi P7 Ha 11 08 12 07daN 29 5 21 58 23 54 daN 20 16 A Hi Mz External valve spring Pi iTT P2 H2 22 5 daN 31 42 3 23 27 7 29 43 daN 34 48 46 52 38 daN 24 5 Camshaft bearings 01 02 03 a ri p_ _JT jS j i_ wrL _rr u LJBLJ u H L0 jSL I0 _L0 0 i 0 17b MF4 01 02 03 0 35 000 35 015 48 000 48 015 49 000 49 015 26 000 26 015 19 250 19 330 e 7 5 Cam lift m 7 5 12 17a 1 Camshaft journal...

Page 138: ... 2 48 045 48 070 Camshaft bearings in camshaft hous 3 ing 49 045 49 070 18 n r u in_ i_r U r Tappet h o u s i n g s 0 28 400 28 421 n j u inz Tappet 0 28 354 28 370 32 959 32 975 1912 5U Iappet 13 l c w n Bore in cylinder head 0 025 0 066 O p Tappet Bore in cylin 19 18 N h er hoari extension 0 046 0 051 17 20 for timing 1 check Q 0 45 S3 Hydraulic tappets Copyright Fiat Auto 17 ...

Page 139: ...o TIMING DIAGRAMS H W Timing angles A B C D Inlet Exhaust e m start before TDC end after BDC start before BDC end after TDC 0 32 42 32 42 0 9 after TDC 49 40 0 With variable valve timing beginning 9 BTDC With variable valve timing ending 31 after BDC 18 Publication no 506 670 16 ...

Page 140: ...ven gear 27 0 2 i _ Pi 2 0 0 01 19 900 20 000 D 02 46 989 47 000 Ball bearings for counter rotating shaft 10 25 Counter rotating shaft journals t 0 19 980 19 993 Bearing seats in crankcase 0 46 975 47 000 27 1 b Ball bearings Cylinder block seats 0 011 0 025 OK tn C3 P I H bhatt journals Z b _ z 4 k Ball bearings 0 020 0 003 Copyright Fiat Auto 19 ...

Page 141: ...een drive and H driven gears C Z t when idling Operating pressure a t 4 0 0 0 r p m at temperature of 100 C M w P1 9 I Hi Li on pressure relief valve spring n Values in mm forced circulation via lobe gear pump with cartridge filter in line lobe gear via crankshaft forced circulation via gear pump with in line cartridge oil filter gear located in the front crankshaft cover via chain driven by the c...

Page 142: ...and pump casing max opening 103 C 101 C 105 C valve travel 9 5 mm Pressure for checking system water tightness 0 98 bar Checking exhaust valve on supplementary expansion tank 0 98 bar Versions with climate control FUEL SYSTEM Make Pump Output Fuel pressure regulator setting Integrated electronic in jection ignition injection ignition Integrated electronic in jection ignition injection ignition ele...

Page 143: ...our solenoid valve Knock sensor Hall effect injection timing sensor TDC and rpm sensor l p i6l IBS 20v STEP A Bosch 0 261 204 578 Bosch 0 280 750 013 Bosch 0 261 230 013 Bosch 0 280 155 816 Bosch 0 261 204 271 Bosch 0 250 003 052 Bosch 0 280 155 770 Bosch 0 580 313 011 Bosch 0 281 002 199 ELTH 2690350 SYLEA 402 183 01 Bosch 0 258 006 071 Bosch 0 280 142 330 Bosch 0 261 231 007 Bosch 0 281 210 124 ...

Page 144: ...E single overhead cam Direct Bosch Common Rail EDC 15C 0 Number of cylinders r0 Cylinder liner bore mm 82 fifl Stroke mm 90 4 88ft I Capacity cm3 1910 Compression ratio 18 45 0 5 Total combustion chamber volume cm 27 35 kW BHP Max power eec rpm f i daNm kgm Max EC torque rpm 77 105 4000 20 0 20 4 1500 Copyright Fiat Auto 23 ...

Page 145: ...n minutes 10 10 10 Load at brake no load no load no load Bench test cycles for overhauled engines When bench testing serviced engines it is not advisable to run the engine at top speed but observe the specifications in the table finish running in the engine on the car Engine power curves obtained by EC method The power curves illustrated can be obtained with the engine overhauled and run in withou...

Page 146: ...supports L2 0 21 75 22 25 22 30 22 70 21 75 22 25 63 691 63 732 r0 Cylinder bore 0 _A_ T 82 000 82 010 82 010 82 020 82 020 82 030 X IIw Piston 0 8 81 920 81 930 81 930 81 940 81 940 81 950 0 4 3 1 i r Piston projection 0 845 1 105 Weight difference between pistons 5 g 3 1 3 Piston Cylinder bore 0 070 0 090 Copyright Fiat Auto 25 ...

Page 147: ...40 O 0 Piston pin 0 25 982 25 988 4 3 Piston pin Housing 0 004 0 014 0 k Piston rings 0 2 568 2 597 1 970 1 995 2 970 2 990 0 4 0 6 c_3 P Piston rings Piston ring grooves 0 088 0 147 0 025 0 070 0 030 0 070 K 1 q P Pis Jon ring o J 4 end opening cylinder liner S 0 250 0 400 0 250 0 500 0 250 0 500 Measured on diameter of 73 8 mm Measured 1 5 mm from outer edge 26 Publication no 506 670 16 ...

Page 148: ...3 897 53 909 Difference in weight between con rods 2 5 g 01 02 1 Small end bush 29 01 8 29 038 26 006 26 012 4 7 Piston pin Small end bush 0 018 0 030 7 6 Small end bush Bush housing 0 046 0 099 8 Main journals 01 2_ 3 Crank pins 02 _A_ C _L Li 59 994 60 000 59 988 59 994 59 982 59 988 50 799 50 805 50 793 50 799 50 787 50 793 26 80 27 20 25 90 26 10 Copyright Fiat Auto 27 ...

Page 149: ... 1 839 1 843 1 842 1 846 0 254 0 508 9 8 1 Crankshaft bearings Main journals 0 011 0 071 10 jQ Connecting rod bearings 0 1 527 1 531 1 530 1 534 1 533 1 537 0 254 0 508 10 8 f Big end bearings Main journals 0 030 0 056 11 Oil r Thrust half rings 2 469 2 485 0 127 11 8 cy Crankshaft end float 0 049 0 211 28 Publication no 506 670 16 ...

Page 150: ...er head 0 13 950 13 977 G a m Valve seats 45 20 45 20 about 2 7 Camshaft bearing housings in cylinder head 0 _0 1 Lf2 f a Wlfy p_j i_r T_PLjn_j i_JT_rxj i_n_ri j l_TTjnj JT_n_r n j LJ uj t iJ 0 0 0 0 I 1 A JLfl J H L Camshaft supports 0 26 045 26 070 19 100 19 150 __n n n n _ 0 Tappet hous ing 0 37 000 37 025 Cap size Copyright Fiat Auto 29 ...

Page 151: ... b Valve guide Bore in cylinder head 0 033 0 080 0 e 0 a Valve M 02 83 0 0 a 7 974 7 992 35 40 35 60 45 30 15 7 974 7 992 34 40 34 60 45 30 5 14 13 Valve Valve guide 0 030 0 066 16 A Hi Valve spring MxM H H2 H 36 69 39 63 daN 36 55 91 60 82 daN 26 5 0 0 0 02 03 J tj _r _ _rT_ _r unjL _n_n_ 0 0 Camshaft journals 0 0 Li Li 26 000 26 01 5 23 10 23 70 19 25 19 30 30 Publication no 506 670 16 ...

Page 152: ...Values in mm 17 12 p radial axial w 0 030 0 070 0 100 0 230 17 Q Cam lift m 8 5 8 5 n J U U L I _ j LJ i r 1 9 an Tappet 0 36 975 36 995 19 12 p Tappet Cylinder head 0 005 0 050 n _r ir rr L 20 4 Shim A0 05 3 25 4 90 17 20 for timing check J 0 50 0 50 0 30 0 05 0 35 0 05 Copyright Fiat Auto 31 ...

Page 153: ...avo Brava Engine cylinder head and valve gear 1998 range OO 10 TIMING DIAGRAMS Timing angles A B C D Inlet Exhaust Q m start before TDC end after BDC start before BDC end after TDC 0 32 32 0 32 Publication no 506 670 16 ...

Page 154: ...f the gears and the H I pump cover Full flow filter Insufficient oil pressure sender unit V b a r y Operating pressure at temperature of 100 C 4 F I Hi l_l Oil pressure relief valve spring Values in mm forced circulation via lobe pump with in line cartridge filter lobe gears by crankshaft built into front crankshaft cover 0 080 0 186 0 025 0 056 cartridge electrical 3 43 4 9 bar 6 27 7 06 daN 36 C...

Page 155: ...unit Water pump operation a via belt thermal switch for fan activation 1 st speed 2nd speed 93 5 C 99 C stop 97 C 102 5 C opening begins 86 90 C Engine coolant thermostat max opening 101 105 C valve travel 9 5 mm Installation fit between blades of impeller and pump case 0 40 0 75 mm Radiator tightness test pressure 1 bar Checking setting of outlet spring on supplementary expansion tank 0 9 1 1 bar...

Page 156: ...sensor Rpm sensor Timing sensor Turbocharger pressure sensor Fuel pressure sensor Injector Preheating control unit Glow plug EGR solenoid Bosch 0 281 001 928 Bosch 0 281 002 199 Jaeger 402 183 01 Bosch 0 281 002 209 Bosch 0 281 002 214 Bosch 0 281 002 213 Bosch 0 281 002 215 Bosch 0 281 002 210 Bosch 0 445 110 002 Bosch 0 281 003 21 5 Bosch 0 250 202 028 46419651 Copyright Fiat Auto 35 ...

Page 157: ...ng loading daN 0i W Lining 0 02 1 0 2 tx Distance between pedal in end of travel position and rest posi tion Clutch release Values in mm dry single plate with bearing diaphragm spring 400 190 134 155 10 mechanical 485 230 155 500 230 155 140 5 hydraulic 36 Publication no 506 670 16 ...

Page 158: ...0 5 21 00 21 27 JTD C 510 5 17 Synchronizers elastic ring Porsche type ring o oo Gears with narrow teeth with helical teeth i 1 3 909 2 158 OO 1 345 1 480 Gear ratios 0 974 1 121 0 829 0 891 3 818 3 545 2 238 1 520 1 156 0 970 3 909 3 909 2 238 1 444 1 029 0 767 3 909 5D version Brava Copyright Fiat Auto 37 ...

Page 159: ... 14 763 13 107 11 933 fld D Differential internal casing bearing taper roller bearings ffit O Adjustment of bearing pre load using shims 0 05 mm Thickness of shims 0 10 2 00 3 00 1 70 2 60 Interference to obtain exact bear ing pre loading mm bearings not pre loaded 0 12 bearings pre loaded 350 dan 0 08 So T Differential planet gear backlash mm 0 10 L 4 a no adjustment necessary Adjusting different...

Page 160: ... servo Iso Vac 8 vacuum servo acting on all four wheels ISO VAC 8 7 vacuum servo acting on all four wheels Iso Vac 8 vacuum servo acting on all four wheels Distance of hydraulic piston push rod from master cylinder support plate 22 45 22 65 REAR BRAKES Drum allowed 203 10 203 40 180 00 180 25 180 95 181 35 203 10 203 40 204 10 204 70 Shoes allowed 1 5 Cylinders 0 22 00 22 00 fc Load proportioning ...

Page 161: ... type Weight in luggage compart ment kg Load to be applied daN Bravo lG i i6v IGSI 16v 94 85 5 5 5 Brava If 16v IcH 16v 64 55 5 5 Bravo IGZ m16v 85 5 75 5 5 Brava iGp 16v 55 46 5 5 Bravo lei TD75 TD100 JTD 85 5 66 5 5 Brava JCEITill TO75 TD100 JTD 64 46 5 5 Bravo fiS 20v 85 5 75 Weight to be applied for vehicles complete with all accessories Weights referring to 1910 TD 100 and 1910 JTD versions o...

Page 162: ...e v STEP A J JJTD Type rack and pinion power assisted no of turns lock to lock Ratio rack travel 142 1 5 mm i 0 Turning circle 10 4 m offside wheel 0C1 31 30 30 Steering angle nearside wheel 0C2 38 1 5 30 Steering col umn with 2 universal joints Copyright Fiat Auto 41 ...

Page 163: ... Tubeless tyre radial tread type 175 65 R14 82T 175 65 R14 82H 185 55 R14 81H 175 65 R14 82H 195 55 R15 84V 205 50 ZR15 185 55 R15 81 H 185 60 R14 82H 185 60 R14 82H 185 55 R15 81 H 185 60 R14 82H 105 70 R14 84M 115 70 R15 90M ii ll T V r e Bill H I pressure 9 4 in bars Front average load 2 2 2 5 2 3 full load 2 3 2 7 2 3 Rear average load 2 2 2 2 2 2 full load 2 5 2 4 2 5 4 2 Speed limit 80 km h ...

Page 164: ...offset A 7 30 33 30 only for Bravo 1998 2 50 30 1 1 mm 5 camber U Rear suspension toe in rear wheel thrust angle 0 46 30 0 4 0 Angles cannot be adjusted With tyres inflated to the correct pressure and vehicle in running order with 5 litres of fuel A Non adjustable angles used for correct vehicle alignment Copyright Fiat Auto 43 ...

Page 165: ... mm 192 352 382 daN 366 396 daN mm 192 The springs are subdivided into two cate gories identifiable by a mark 319 daN 333 5 daN a height of mm 192 yellow 1 springs loaded to 354 daN 367 daN a height of mm 344 daN 369 2 daN a height of mm 192 367 daN 381 daN height of mm 319 daN 333 5 daN a height of mm 1 9 2 green 1 springs loaded to 354 daN 367 daN a height of mm 344 daN 369 daN a height of mm 19...

Page 166: ...aN 1 286 316 daN m m Spring height under J 275 303 daN load of 286 316 daN mm The springs are subdivided into two cate gories identifiable by a mark 284 daN t 1 301 daN h e 9ht of mm yellow 1 springs loaded 289 daN height of mm lo I 1 301 daN height of mm 284 daN 301 daN height of mm green 1 springs 1 loaded 289 daN height of mm lo 1 301 daN height of mm 11 5 0 05 11 9 0 05 4 75 5 11 8 0 05 4 5 11...

Page 167: ...2V 1 4kW with reduction unit M Marelli A127IR 14V 50 80A M Marelli A127IR 14V 55 100A BUILT IN ELECTRONIC 12V 40Ah 200A 12V 50Ah 250A Built in electronic injection ignition M PI Bosch M 1 5 5 Bosch 0 221 503 407 NGK RDCPR 8EKC CHAMPION RA4HCX 12V 50Ah 250A Built in electronic injection ignition MPI Bosch Motronic ME 3 1 Bosch 0 221 504 014 CHAMPION RC8BY For vehicles with air conditioner For cars ...

Page 168: ...BATTERY PRE HEATING ELECTRONIC CONTROL UNIT ELECTRONIC CONTROL UNIT ENGINE FUEL SYSTEM CONTROL GLOW PLUGS BOSCH DIAM 78 5 12V 2 0 kW M Marelli M70R 12V 1 8 kW with reduction unit M Marelli A 127IR 14V 55 100A Built in electronic 12V 60 Ah 380A BOSCH 0 281 003 215 N D BOSCH 0 250 202 028 Copyright Fiat Auto 47 ...

Page 169: ... M70R 12V 1 4kW with reduction BOSCH DIAM 78 5 12V 2 0 kW with reduction unit M Marelli M70R 12V 1 8kW with gearing unit 12 0 9 1 4 2 0 1 8 clockwise 4 in Iine 6 permanent magnets 4 in line parallel free wheel solenoid 0 1 0 5 180 200 1720 2200 9 5 9 8 10 0 37 0 38 324 440 7 1 7 6 3 0 97 1 25 40 44 48 11 4 11 4 11 5 8500 9000 11400 12300 0 30 0 32 0 32 1 2 1 3 1 09 360 380 1150 8 15 1 30 680 700 4...

Page 170: ...rectifiers M Marelli A115I 14V 38 65A M Marelli A115IM 14V 50 90A M Marelli A127IR 14V 50 85A M Marelli A127IR 14V 55 100A 14 65 38 65 2 4 93 50 93 2 23 85 50 85 105 55 105 2 6 clockwise preconstituted bridge Data measured at environmental temperature of 20 C For vehicles with air conditioner VOLTAGE REGULATOR Type Alternator speed for test p Thermal stabilization current Test current A Regulation...

Page 171: ...imary winding at 20 C Q Ohmic resistance of secondary winding at 20 C Q Bosch 0 221 503 407 0 45 0 55 12000 14600 TOP DEAD CENTRE AND RPM SENSOR make and type Sensor winding resistance at 20 C D Distance gap between sensor and tooth of crankshaft pulley Bosch 0 281 210 124 486 594 0 8 1 5 ADVANCE ON ENGINE With engine idling 850 50 rpm N A SPARK PLUGS Make and type Thread Electrode gap mm NGK RDCP...

Page 172: ... Ohmic resistance of primary winding at 20 C Ohmic resistance of secondary winding at 20 C Q Q Bosch 0 221 504 014 0 4 8500 TOP DEAD CENTRE AND RPM SENSOR Make and type Sensor winding resistance at 20 C Gap between sensor and crankshaft pulley teeth Q mm Bosch 0 261 210 160 774 946 0 8 1 5 KNOCK SENSOR Type Code Bosch 0 261 231 131 SPARKPLUGS Make and type Thread Electrode gap mm CHAMPION RC8BY M ...

Page 173: ...L UNIT Type Code Bosch 0 281 003 21 5 TOP DEAD CENTRE AND RPM SENSOR Make and type Sensor winding resistance at 20 C Q Gap between sensor and crankshaft pulley teeth m m Bosch 0 281 002 214 774 946 0 8 1 5 TIMING SENSOR Type Code Bosch 0 281 002 213 GLOW PLUGS Make and type Engine attachment thread Electrical resistant at 20 C mfi Bosch 0 250 202 028 M 12 x 1 25 700 52 Publication no 506 670 16 ...

Page 174: ... unit Oil sump removal wrench Oil sump removal wrench Wrench 13 mm with 1 2 fitting for removing intake mani fold fastenings Wrench for removing refitting spark plugs Spark plug wrench Wrench with 1 2 fitting for cylinder head bolts Wrench for removing refitting belt tensioner Wrench for variable valve timing Alternator pulley wrench Pliers 0 75 110 for removing and refitting piston rings Installe...

Page 175: ...r half cones cups springs and valves Collar 0 60 125 mm for fitting normal and oversized pis tons in cylinders Tool to hold tappets for replacing plates while adjusting valve clearance to be used with 1860443000 Tool for turning crankshaft at bench Tool for removing springs cups half cones and valves use with 1860786000 1860787000 1860788000 and 1860877000 Tool for fitting valve guide Guide for fi...

Page 176: ...wrench for removing refitting oil sump Hexagonal splined wrench for removing refitting oil sump Extractor for removing oil seal on valve guide Tool for preventing crankshaft from turning Tool to hold flywheel operations at bench Pressure pump pulley extractor Adaptor for removing refitting power unit use with 1860859000 and 1860860000 Support for removing refitting power unit Tool for dismantling ...

Page 177: ... Tool for removing nad fitting piston pin Timing belt tensioning tool Tappet retaining tool Extractor for valve guide oil seal Two way installer for fitting crankshaft and camshaft front cover oil seals Tools for positioning pistons in line Tool for fitting valve guide oil seals Tool for removing and refitting valve guide Bracket to secure engine distribution side on rotating stand 1861000000 Brac...

Page 178: ...ts Valve tightness tester Dial gauge Pressure gauge for measuring electric pump supply pressure Graduated disc for cylinder head bolt angular tightening CLUTCH 1875086000 Clutch disk centering pin GEARBOX DIFFERENTIAL 1842133000 1842134000 1845028000 1845057000 1845062000 Tool for dismantling differential bearing and gearbox gears Tool for dismantling gearbox gears and hubs Reaction block for remo...

Page 179: ...l cover retaining bolts Wrench 12 mm oil sump draining plug Wrench 19 mm for removing and refitting gearbox Drift for removing and refitting gear stiffening ball plug Beam for removing refitting gearbox Adaptor for beam used to remove refit gearbox use with 1860851000 Bracket for removing refitting gearbox Two way fitting for striker use with 1847017001 Universal handle Drift for fitting hubs and ...

Page 180: ...ntial bearing outer race Drift to fit gasket on axle shaft flange Tool to remove and refit differential bearing rings to be used with 1840005003 Drift for fitting main and layshaft bearings Pliers for main and layshaft rear bearing retaining rings Tool to select differential bearing adjusting shims to be used with 1895884000 BRAKING SYSTEM 1856132000 1856133000 1872273000 1895901000 Wrench 10 11 m...

Page 181: ...whe re moving dampers Drift to fit front wheel hub bearings to be used with 1870007000 Installer rear wheel hub caps ELECTRICAL EQUIPMENT 1860893000 1860897000 Tool for removing fuel level gauge ring nut Tool for removing radio BODYWORK 1860890000 1878034000 1878077000 1878080000 1878081000 Wrench for removing refitting door hinges Remover window regulator handles Tool to remove door trim panels o...

Page 182: ...ctions for brackets supporting the engine on rotating stand 1861000000 1861000000 Universal handle Support for measuring depth and protrusion use with 1895881000 Rotary column for servicing gearboxes and differential Mini Hylok Contact terminal extractor MHF dia 2 15 mm Adjustable pliers for pipe retaining collars and tabs Tool panel to be fixed to wall or stand 1882003000 with hooks Stand to hold...

Page 183: ...ming end cover Bolt retaining timing belt guards Bolt retaining camshaft driven gear and rear camshaft gears Screw camshaft caps Belt tensioner retaining bolt Bolt retaining coolant intake pipe to pump Bolt retaining coolant intake pipe to cylinder head Coolant pump retaining bolt Bolt retaining thermostat to cyiinder head M10x1 25 M12 M9 M10 M10 M8 M8 M8 M12x1 25 M16x1 5 left M16 left M6 M6 M12x1...

Page 184: ...t retaining engine to crankcase Bolt retaining bracket to engine mount Bolt retaining alternator to slot Nut retaining lower bracket to alternator mount and fastening Bolt retaining compressor to support Power steering pump retaining bolt Bolt retaining pulley to power steering pump Spark plugs Oil pressure switch Coolant temperature sender unit M6 M9 M6 M8 M6 M18 M6 M10x1 25 M8 M10 M8 M10x1 25 M1...

Page 185: ...tomatic belt tensioner to alterna tor mount Bolt retaining fixed belt tensioner to alternator mount and auxiliary parts Bolt retaining fixed belt tensioner to air condition er compressor mount Bolt retaining tensioner bracket to engine moun t for a c versions Bolt retaining belt tensioner to engine mount Bolt retaining reinforcement between front brack et and rear bracket Bolt retaining alternator...

Page 186: ... to engine block Power steering guard retaining bolt Alternator retaining tensioning bolt Bolt retaining plate to engine block Nut retaining cam cover to cylinder head Bolt retaining cylinder head extension to cylinder head Nut retaining rear cover to cylinder head exten sion Nut retaining intake manifold to cylinder head Nut retaining exhaust manifold to cylinder head Bolt retaining coils to rear...

Page 187: ...nnel on head ex tension timing end Plugs sealing camshaft timing studs Bolts retaining belt guard to steel bushes Plug on head extension with resonator retaining seat Stud with screw for securing resonator Bolts retaining cable channels Heat shield retaining nuts Hexagonal splined bolt retaining dust shield Half axle mount retaining bolt Bolt retaining connector beneath cam cover Bolt retaining re...

Page 188: ...ner shield retaining bolt Adjustment bolt retaining nut Bolt reaction bracket to half axle Nut for bolt between sump and half axle mount Bolt retaining power steering pump to rod mount Bolt retaining power steering pulley to shaft Nut retaining oil vapour separator to intake duct Flanged bolt retaining auxiliary mount to crankcase Injector retaining bracket tightening nut Fastening exhaust manifol...

Page 189: ...nger valve retaining fitting Bolt retaining nozzle assembly to crankcase Bolt retaining front coolant intake union to cylin der head Nut retaining thermostat to coolant outlet union to cylinder head Upper and lower alternator reaction bracket re taining bolt Bolt retaining vacuum pump to cylinder head Nut retaining valve to exhaust manifold Bolt retaining pipe to valve Air pressure sensor Preheati...

Page 190: ...erter Bolt for collar retaining rear section to catalytic converter Flanged bolt retaining brackets with side and rail nut Flanged bolt retaining front pipe to turbine fitting Front section bracket retaining bolt Front bracket retaining bolt Bolt retaining front exhaust pipe half bracket connection bracket to bracket anchored to differ ential mount Bolt with safety washer retaining front section t...

Page 191: ...rbox differential end Bolt retaining bracket to gearbox differential end Bolt retaining connecting rod mount to body Tapered bolt retaining connecting rod mount to body Fastener bracket to block and body engine end Fastener engine mount to body engine end Nut retaining block to engine end mount Flanged bolt retaining mount to gearbox Nut retaining differential mount to gearbox Screw reaction link ...

Page 192: ...oad flanged bolt for automatic fittings retain ing pedal unit to dashboard Self locking nut for retaining and adjusting clutch control cable on gearbox Self locking nut retaining brake and clutch pedal pivot pin to pedal unit M6 M8 M8 M6 M8 0 5 1 5 2 6 0 44 3 EXTERNAL GEARBOX LINKAGE Bolt retaining gear lever mount to floor pan Screw retaining bottom selection and engage ment rod to gear lever Nut...

Page 193: ...r to bell housing Screw retaining gear case to bell housing Screw retaining reversing shaft Lock ring main and layshaft 5th speed gear Screw retaining gear control forks Bolt retaining speed selection and engagement shaft lever Reverse lever support retaining screw Screw retaining bush for gear shaft Screw retaining front drive axle ring gear Screw retaining differential case retaining flange to g...

Page 194: ...rier plate to suspension arm Bolt retaining front brake caliper Bolt with tapered safety washer retaining front brake calipers to pillar Bolt retaining front brake disc rear brake disc rear brake drum with wheel centring function Bolt with tapered safety washer retaining bracket assembly for braking system Fitting connecting hose to front brake caliper Bleed screw on front and rear brake caliper F...

Page 195: ...itting from power steering to tank Flanged bolt retaining box to beam Union for pump power steering outlet fitting on power steering Self locking nut retaining box link to pillar Union for pump power steering outlet fitting on pump Bolt with tapered safety washer retaining fork and universal joint Nut retaining steering wheel to steering column Bolt with tapered end with safety washer for steering...

Page 196: ...ne to beam Flanged nut fastening top of damper to block Screw with broad flange retaining top damper block to body Self locking nut retaining damper to pillar Self locking nut for bolt retaining wishbone pivot head to pillar Screw with tapered and flat safety washer retain ing anti roll bar support plate to beam Self locking nut retaining end of anti roll bar to connecting rod Self locking nut ret...

Page 197: ...ivot pin retaining rear hub Bolt retaining stabilizer bar to rear suspension arm Bolt retaining stabilizer bar support plates to rear suspension arm Wheel stud Nut for bolt retaining square lever to wishbone M12x1 25 M12x1 25 M16x1 5 M12x l 25 M10x1 25 M22x1 5 M10x1 25 M8 M12x1 25 M8 10 8 10 8 15 8 8 6 28 5 6 2 8 8 6 1 5 AIR CONDITIONER Bolt retaining dehydrating filter inlet and outlet ducts Bolt...

Page 198: ... hexagonal splined groove retaining lug gage compartment catch Bolt with tapered washer retaining side door lock Hexagonal socket screw retaining fixed side door hinge Bolt retaining front bumpers Bolt retaining brackets to pretensioner M8 M6 M10x1 25 M6 M6 2 0 75 4 5 0 4 4 6 AIR BAG SYSTEM Bolt retaining air bag control unit Bolt retaining driver module to steering wheel Bolt retaining passenger ...

Page 199: ......

Page 200: ...ents 1 Location of fuel system components 2 A i r intake circuit 3 Fu el feed circuit 4 Fuel circuit diagram r 7 Electric electronic system r 8 Input arid output signals between EGU sehsors and actuators 11 Wiring diagram 12 Blow by gas recireulation diagram 17 Exhaust gas recireulation system E G R 18 Copyright Fiat Auto ...

Page 201: ...ebulised into tiny droplets to facilitate ignition the droplets must possess sufficient kinetic energy to penetrate the mass of compressed air the fuel particles must be diffused as evenly as possible in all directions so that as much of the air in the cylinder as possible can be used for combustion The main features of the 1910 TD indirect injection system are as follows fuel injection advance ma...

Page 202: ...ic socket 3 Electronic control unit 4 Injection pump 5 Fast idle valve 6 Borg Warner modulator valve 7 Heater plugs 8 E G R valve Mitsubishi 9 Pre heating control unit 10 Rpm sensor 11 Preheating control unit fuse 12 Airflow meter debimeter 13 Coolant temperature sensor 14 Injectors 2 Publication no 506 670 06 ...

Page 203: ...5 before compression in exhaust gas driven turbocharger 2 Air then flows through the heat exchanger intercooler 3 The air assumes optimal temperature and density properties and then flows to the intake manifold 7 for distribution to the cylinders 1 Inlet fitting 5 Air cleaner 2 Turbocharger 6 Air temperature sensor 3 Heat exchanger intercooler 7 Inlet manifold 4 Air flow meter debimeter Copyright ...

Page 204: ... properly supplied with fuel in the firing order 1 3 4 2 1 2 3 4 5 Injectors Injection pump Delivery line from tank to filter Return line recirculation Vent pipe Because of the particular shape of the tank an air pocket could form at the bottom during refuelling which would prevent the tank from being completely filled This is prevented by pipe 5 which allows air to flow out from the lowest part t...

Page 205: ... unit Centrifugal mass maximum flow regulator fitted to the pump shaft Pump is lubricated by the fuel used to drive the pump Extra fuel under conditions of fuel engine load or when full power is required Coded electronic fuel flow stop device built into the immobiliser system Fiat CODE 1 Idle speed adjustment screw 2 Fitting for diesel return line to tank 3 Throttle lever position sensor 4 Acceler...

Page 206: ...e into contact with the cams and the plungers are pushed inward to raise the pressure and bring about injection At the end of the injection stage the plungers are pushed outward to lower the pressure Fuel delivery stops and valve 5 seals off the outlet pipe Valve 5 not only closes the delivery pipe but also instantaneously lowers the pressure in the pipe lead ing to injector 10 This quickly shuts ...

Page 207: ...arging control valve 2 Feed pressure regulator valve 3 Engine stop solenoid 4 Pumping element 5 Outlet valve 6 Metering device 7 Feed pump 8 Advance actuator control solenoid 9 Pressurisation valve 10 Injectors 11 Tank 1 2 Filter 13 Speed regulator Copyright Fiat Auto 1 ...

Page 208: ... atmospheric pressure information obtained by a sensor lo cated inside the control unit The control unit uses this data in conjunction with specific programs to implement the following operat ing strategies injection advance control fast idle control exhaust gas recirculation glow plug pre post heating control air conditioning system control Rpm TDC Accelerator lever position _ _ Coolant temperatu...

Page 209: ...nt gases which may be returned to the intake On the basis of engine load coolant temperature and intake air quantity the con trol unit controls the Borg Warner modulator valve which in turn activates the EGR valve via a vacuum signal in order to recirculate the exhaust gas Rpm Coolant temperature Air temperature Accelerator lever position Hfc Battery voltage _ _ _ ECU Glow plug preheating control ...

Page 210: ...f only temporarily and automatically restored after a few seconds even if the power requirement is still high Injector with controls The injector with controls informs the electronic control unit of the true injection advance beginning of injection stage i e when the needle valve begins to move On the basis of the signal the control unit corrects the advance set by the injector actu ator until the...

Page 211: ...ontrol unit 4 Heating ventilation system 5 Glow plug warning light 6 Injection system failure warning light 7 Borg Warner solenoid 8 Diagnostic socket 9 10 11 12 13 14 15 16 _ P4A09EJ04 Rev counter Rpm sensor Battery Injector with controls Air flow meter debimeter Fast idle valve Coolant temperature sensor Air temperature sensor Copyright Fiat Auto 11 ...

Page 212: ...Engine Fuel system 10 WIRING DIAGRAM Bravo Brava ty TO 12 Publication no 506 670 06 ...

Page 213: ...itch 18 Fast idle valve 19 Solenoid for advance adjustment device Rpm and phonic wheel sensor Specifications Gap 0 8 1 5 mm Winding resistance 860 ohm 10 at 20 C 1 Rpm sensor 2 Phonic wheel The rpm sensor is fitted on the crankcase and faces a phonic wheel located inside the crankcase and fas tened to the crankshaft The steel phonic wheel is fitted with two reference dowels on the outer part of th...

Page 214: ...t film sensor A Air intake NOTE This debimeter measures air mass directly not volume and thus eliminates problems of tem perature altitude pressure etc Operating description The Wheatstone bridge R3 R2 Rs Rt R1 format is in equilibrium when Rs is about 120 C more than air temperature The air flowing through the membrane removes heat from Rs and the bridge becomes imbalanced This sitaution is detec...

Page 215: ...TC resistance which alters resistance in inverse proportion to tempera ture as shown in the diagram The control unit records a voltage change proportional to the current intensity flowing through the sensor When fitting the sensor take care not to tighten to more than 15 Nm R NTC 4 0 0 0 _ itnn 10 N TEMPERATURE C 50 100 120 130 C 23 2 6 3 3 4 VOLTAGE V 4 4 Copyright Fiat Auto 15 ...

Page 216: ...on switch 15 4 Electronic control unit pre postheating activation 5 Electronic control unit fault diagnosis 8 Battery positive 9 Glow plugs 10 Glow plugs Air temperature sensor The intake air temperature sensor is separate from the air flow meter in this version It is a normal Negative Temperature Coefficient NTC sensor its electric resistance drops as temperature increases Because the control uni...

Page 217: ...ed blow by or vent gas Vent gases from the crankcase and cylinder head flow through pipe 3 to separator 2 where they lose part of their oil content in the vortex This falls back to the sump through pipe 4 in the form of droplets 4 The remaining gases flow through pipe 5 and are directed to the intake circuit Cylinder head gas outlet pipe 1 contains a flap trap 6 to prevent the pipe catching fire d...

Page 218: ...ion pump and from the rpm and coolant tempera ture sensors It produces an output signal which controls the Borg Warner modulator solenoid and hence the E G R 2 The E G R is connected to the atmosphere through filter 3 According to an imput signal the valve di rects a higher or lower vacuum from the brake servo vacuum pump 4 to the Pierburg EGR valve 5 If the vacuum is sufficient this valve opens t...

Page 219: ...and Pensioning timing drive Belt 15 REMOVING REFITTING CYLINDER HEAD Removing cylinder head 18 Refitting cylinder head gasket 24 Refitting and tightening cylinder head 25 REPLACING WATER PUMP Replacing water pump 26 REMOVING REFITTING RADIATOR Removing refitting radiator 27 Procedure for filling engine cooling cir cuit version with heating and air con ditioning for 75 and 100 cv versions 28 DIAGRA...

Page 220: ...ve terminal Then proceed as follows 1 Remove the upper engine guard 2 Disconnect the battery positive terminal unscrew the nut securing the battery to its cradle and remove from the engine bay 3 Unscrew the retaining bolts shown and remove the air shroud shown in the figure 4 Raise the lift and remove the lower engine bay guard 4 x uSi r i 3 l o X t v AH HP Copyright Fiat Auto 1 ...

Page 221: ...tercooler and air outlet sleeve 2 from intercooler to intake manifold 4 Position the hydraulic jack to support the power unit and remove the engine mount on the body Lower the engine and re move the intercooler with bracket Repo sition the engine mount when the opera tion is complete 5 Position a container to recover the engine coolant then disconnect the coolant in take sleeve from the radiator 2...

Page 222: ... on the intake manifold 2 Remove the coolant intake and outlet pipes from the points shown 3 Unscrew the relay case cover bolt shown in the figure 4 Unscrew the nuts illustrated and place the relay box to one side in the engine bay 5 Unscrew bolts 1 loosen bolt 2 and then remove the battery cradle Copyright Fiat Auto 3 ...

Page 223: ... Loosen clip 1 unscrew screw 2 dis connect electrical connections 3 and then disconnect the second section of the air intake pipe 3 Open both clips and release cable 1 dis connect cable 2 and then move glow plug ECU 3 with its bracket to one side 4 Disconnect the two pipes leading from the heater unit from the thermostat 5 Disconnect both fan electrical connec tions 4 Publication no 506 670 08 ...

Page 224: ...ble from the anchorages on the gearbox 3 Disconnect the gear selection and en gagement cables from the points indicat ed taking care not to damage the cables as the head is removed 4 Disconnect both expansion tank pipes from the points indciated 5 Disconnect fuel outlet and inlet lines 1 and 2 and pipe 3 carrying fuel from the diesel filter to the injection pump Copyright Fiat Auto 5 ...

Page 225: ...ewing the bolts shown 3 Disconnect the accelerator cable from the points shown 4 Disconnect the pipe from modulator valve 1 the pipe from fast idle valve 2 and then disconnect the electrical connections shown and the vacuum pump sleeve for brake servo 3 from the point shown 5 Remove the reaction bracket complete with mount by unscrewing the retaining bolts shown 6 Publication no 506 670 08 ...

Page 226: ... pipe carrying fluid to the power steering pump from the reservoir 3 Disconnect the earth lead from the gear box 4 Remove the front section of the exhaust pipe from the connector and from both vi bration resistant brackets 5 Disconnect the front section of the ex haust pipe from the catalytic converter then remove from the vehicle Copyright Fiat Auto 7 ...

Page 227: ...r 2 Disconnect the return fitting from the power steering pump 3 Remove the wiper arms by prising up the plastic protection and unscrewing the un derlying nut 4 Remove the pollen filter plastic protection 5 Undo the nuts retaining the engine wiring mount bracket to the body 8 Publication no 506 670 08 ...

Page 228: ...m the i e control unit and withdraw the relay from its brack et Then withdraw the engine wiring as sembly and attach to the power unit 3 Disconnect the half axles by undoing the bolts securing the constant velocity joints to the gearbox flange 4 Unscrew bolt 1 and loosen bolt 2 re taining the suspension pillar Then turn the pillar outward to release the drive shaft from its attachment on the diffe...

Page 229: ...asten to the power unit using the tools shown The hydraulic jack must have a ca pacity of at least 1000 kg and it must be sufficiently high to allow the pow er unit to be removed from below When calculating the height consid er the maximum height setting of the lift and the minimum height setting of the hydraulic jack Remove the engine oil heat exchanger from the fastenings shown then secure to th...

Page 230: ...hicle M I Lower the hydraulic jack gradually and check that the power unit is cor rectly positioned and balanced on the mounting tool Position the power unit on a stand using a hydraulic hoist Use a hydraulic hoist to move the power unit once it has been re eased from the mounting tool NOTE To refit the power unit carry out re moval operations in reverse order Prepare the engine bay to fit the pow...

Page 231: ...E BELT AND POWER STEERING PUMP Removing Position the vehicle on a lift remove the right front wheel disconnect the battery negative terminal and then proceed as follows 1 Remove the wheel arch guard by un screwing the retaining bolts shown Use tool 1870077000 to prise up the stud shown Turn the tensioning device in the arrowed direction and release belt tension before removing Check the condition ...

Page 232: ...ning device to the posi tion shown in the figure The preloaded tensioner spring will ensure the belt is cor rectly tensioned after the crankshaft has been turned a few times REMOVING TIMING BELT Before removing the timing belt the auxiliary belt must be removed as de scribed previously 3 Remove the lower power unit guard Remove the gearbox guard by unscrewing the retaining bolts shown and position...

Page 233: ...wheel retainer described previously 2 Remove the lower timing belt guard 3 Unscrew the retaining bolts shown and remove the reaction rod complete with mounting bracket 4 Remove the lower timing belt guard 5 Loosen the tensioner nut release belt ten sion and then remove 14 Publication no 506 670 08 ...

Page 234: ... the pin of tool 1860905000 2 Fit the timing belt onto the crankshaft gear 3 Position tool 1860905000 on the crankshaft gear and pin 3 turn the crankshaft through small movements until dowel 2 fits into hole 1 The first cylin der is set to T D C in this position 4 Use tool 1860831000 to turn the timing belt pulley until notch 1 on the pulley is aligned with notch 2 on the cam cover ...

Page 235: ...ing bolts 2 Turn the injection pump pulley until pin 1860965000 fits into the point shown 3 Finish fitting the timing belt by assem bling components in the following order 1 Crankshaft gear 2 Fixed guide pulley 3 Timing pulley 4 Injection pump pulley 5 Automatic tensioner 6 Coolant pump 16 Publication no 506 670 08 ...

Page 236: ...ening the retaining bolts to the specified tightening torque and remove pin 1860965000 from its housing Turn the crankshaft through two turns in its normal direction of rotation release the belt tensioner retaining nut and align fixed indicator 1 on the tensioner mount with the belt tensioner mobile indicator Secure the tensioner nut and then tighten to the specified torque Refit parts removed pre...

Page 237: ...and then proceed as follows 1 Remove the upper cylinder head protec tion by unscrewing the retaining nuts 2 Disconnect the battery positive terminal 1 unscrew nut 2 raise bracket 3 and then remove the battery 3 Unscrew the retaining bolts indicated to remove the air intake shown 4 Loosen the clip shown and disconnect the air intake sleeve from the inlet manifold 18 Publication no 506 670 08 ...

Page 238: ...wn unscrew the nuts disconnect both fuel fittings and then remove the diesel filter 3 Loosen the clip and disconnect the pipe shown then unscrew the retaining nuts shown in order to position the oil vapour separator to one side in the engine bay 4 Disconnect the accelerator cable from the points indicated 5 Disconnect the air pipe to the brake servo from the vacuum pump Copyright Fiat Auto 19 ...

Page 239: ... bolts indicated separate the EG R valve from the pipe and then remove 3 Disconnect the fuel recovery line 1 from the fuel return sleeve and pipe 2 from the intake manifold 4 Use wrench 1852138000 to unscrew the fittings of the diesel supply lines on the in jectors 5 Unscrew the diesel supply line fittings from the injection pump and then remove the pipes themselves Publication no 506 670 08 ...

Page 240: ...ect the electrical connection of the pulse injector 2 Raise the lift and remove the lower engine bay guard 3 Unscrew the retaining bolts shown and release the exhaust pipe from the vibra tion res stant bracket shown 4 5 Remove both brackets holding the tur bine to the engine block Copyright Fiat Auto 21 ...

Page 241: ... 2 Use tool 1860967000 to unscrew the fit ting on the head unscrew bolt 1 dis connect clips 2 and remove coolant pipe 3 from the cylinder head 3 Disconnect the pipe shown from the cylinder head 4 Disconnect the pipes shown from the thermostat 5 Disconnect the sensor and coolant tem perature sending unit electrical connec tions P4A22FX05 22 Publication no 506 670 08 ...

Page 242: ...ve the timing belt side cover 2 Unscrew the bolts retaining the exhaust manifold to the cylinder head unscrew the nut shown and prise the EGR valve rigid pipe from the manifold then release the exhaust manifold from the pins 3 Unscrew the nuts shown and disconnect the glow plug supply leads 4 Unscrew the bolts retaining the intake manifold to the injection pump mount bracket Copyright Fiat Auto 23...

Page 243: ...d ensure that the wording ALTO TOP is facing the operator Average piston protrusion up to 0 80 mm 0 80 to 0 90 mm more than 0 90 mm Cylinder head gasket thickness 1 6 mm 1 7 mm 1 8 mm No of notches 1 2 Reference notch position The cylinder head gasket is AS TADUR type This type of gasket is made from a special material which undergoes a process of polymerisa tion while the engine is running and th...

Page 244: ...ng order shown in the figure is followed for each tightening stage Oil screws and washers and leave to drain for at least 30 minutes screw in bolts to a torque of 2 daNm then carry out final tightening to a torque of 6 5 daNm using wrench 1852154000 o y v m3l f RSr C w 3 Tighten bolts through an angle of 270 in three different stages 90 90 90 us ing wrench 1852154000 applied to tool 1860942000 Cop...

Page 245: ...ary belt and the tim ing belt as described previously 1 Position a suitable container to collect the coolant and disconnect the coolant sleeves shown from the points illustrated Use tools 1860831001 and 1860831000 to unscrew the camshaft pulley retaining nut 3 Remove the coolant pump from the cylin der head 26 Publication no 506 670 08 ...

Page 246: ...n proceed as follows 1 Unscrew the retaining bolts shown and remove the air intake illustrated 2 Position a container to collect the coolant and then disconnect the pipes shown to drain the coolant 3 Disconnect the fan and thermostatic switch electrical connections 4 Unscrew the bolts retaining the fan to the radiator indicated in figure and then re move the fan P4A27FX02 Copyright Fiat Auto 27 ...

Page 247: ...itting A on the heater outlet sleeve then close the bleed fitting Carry on pouring in coolant until fluid emerges from bleed fitting B on the rigid pipe then close the bleed fitting Continue filling until fluid emerges from bleed fitting C on the radiator then close Close bleed fit ting D at the same time as fitting C for air conditioned versions Complete the operation by filling until the fluid r...

Page 248: ... TD100 Engine Removing refitting radiator 10 Location of engine cooling circuit bleed fittings for 75 bhp and 100 bhp engines heated and air con ditioned version Heated version Version with a c Copyright Fiat Auto 29 ...

Page 249: ...pass into the cooling radiator to lower the temperature and en sure better lubrication A main longitudinal duct in the cylinder block crankcase allows the lubrication of the crankshaft the pistons and the connecting rods A duct allows the lubrication of the cylinder head and all the engine timing system components Two special pipes allow the lubrication of the tur bocharger 1 Oil pump 2 Oil pressu...

Page 250: ...r Knock sensor Ignition coils INTAKE CIRCUIT Throttle body Engine idle speed actuator and throttle position sensor page 1 2 FUEL FEED CIRCUIT Fuel circuit diagram Fuel carrier assembly Fuel manifold Injectors Safety inertia switch Engine Contents 10 page 31 32 32 33 33 34 EMISSION CONTROL DEVICES 35 3 4 5 6 9 10 12 12 13 14 15 15 15 16 17 18 18 22 24 25 26 27 27 27 28 29 30 30 Catalytic converter ...

Page 251: ...ed in this publication is supplied as a guide and may no longer be up to date as a result of modifications made by the Manufacturer at any time for reasons of a technical or commercial nature or to meet le gal requirements in different countries Fiat Auto S p A D M C M D S Servizi al Cliente Post Vendita Largo Senatore G Agnelli 5 10040 Volvera Print n 506 670 20 March 1999 920 Printed by Satiz S ...

Page 252: ...sible engagement of the air conditioning the possible end of travel of the power assisted steering This information usually in analogue format is converted into digital signals by analogue digital A D converters so that they can be used by the control unit The management programme software is stored in the control unit memory and consists of a series of strategies each of which manages a precisely...

Page 253: ...r fan relay s 10 Radiator fan 13 Climate control connection 14 CODE connection 15 Diagnostic equipment connection 16 Rev counter 17 System failure light 18 Speedometer 19 Injectors 20 Spark plugs 21 Ignition 22 Charcoal filter solenoid valve 24 Lambda sensor 25 Power assisted steering sensor 26 Coolant temperature sensor 27 Detonation sensor 28 Engine idle adjustment actuator and but terfly positi...

Page 254: ...s 10 Radiator fan 11 Compressor engagement relay 12 Compressor 14 CODE control unit 15 Diagnostic equipment connection 16 Rev counter 17 System failure light 18 Speedometer 19 Injectors 20 Spark plugs 21 Ignition 22 Charcoal filter solenoid valve 24 Lambda sensor 25 Power assisted steering sensor 26 Coolant temperature sensor 27 Detonation sensor 28 Engine idle adjustment actuator and but terfly p...

Page 255: ...tem fuse 7 Electric pump fuse 15 Diagnostic equipment connection 19 Injectors 20 Spark plugs 21 Ignition 22 Charcoal filter solenoid valve 24 Lambda sensor 25 Power assisted steering sensor 26 Coolant temperature sensor 27 Detonation sensor 28 Engine idle adjustment actuator and but terfly position sensor 29 Engine rpm and TDC sensor 30 Absolute pressure and air temperature sensor 31 Main fuses ma...

Page 256: ...from the Lambda sensor which on the basis of suitable operating strategies ensures that the mixture strength is constant ly around the stoichiometric value The system is known as the speed density Lambda type because the injection time is basically deter mined from these three parameters All the particular operating situations which require adjustments to the ignition advance and injection timing ...

Page 257: ...ement strategies are designed to provide the engine with the correct quantity of fuel at the desired moment according to the engine operating conditions The management of the injection basically consists of calculating the injection time determining the in jection phase and then the implementation by operating the injector The basic injection time is calculated by means of mathematical interpolati...

Page 258: ... figure and in that case the Lambda is X 1 The strategy is designed to correct the basic injection times so that the mixture strength constantly os cillates at a high Hertz frequency NOTE 1 Hz 1 oscillation per second In cut off conditions or in full load engine conditions or with the engine cold coolant and air temperature below around 20 C the strategy is disabled Self adjustment The control uni...

Page 259: ...ake a large number of factors into ac count In general the injection time is increased for positive transitions and reduced for negative ones The extent of the correct basically depends on the variation in the engine load however other factors such as the speed of movement of the butterfly the engine speed the gear engaged obtained from the ratio between the engine speed and the vehicle speed the ...

Page 260: ...th an anti theft function This function is achieved through the presence of a special FIAT CODE control unit capable of conversing 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 the OFF position the Fiat CODE system completely deactivates the engine control unit When the key is turned to the ON po...

Page 261: ...his moment obviously varies in terms of the angle in relation to TDC for the explosion stroke for each cylinder and the greater the advance the greater the engine rotation speed because the time required to saturate the current in the coil primary winding is more or less constant it is determined using suitable coefficient stored in the memory dwell management The moement for the start of conducti...

Page 262: ...In particular the advance is increased if the speed decreases and is decreased if the speed increases in order to ensure the stability of the actual speed P4A12JJ01 Aoc correction of the ignition advance during idling A RPM the speed during idling is higher than the nominal speed ARPM the speed during idling is lower than the nominal speed Control of the detonation This strategy has the task of de...

Page 263: ...ration In deceleration conditions outside of idling the control unit controls the position of the butterfly through a special dash pot curve in other words it slows down the return of the butterfly towards the closed position this produces a reduction in the braking effect of the engine In addition if the vehicle is in deceleration conditions the information concerning its speed correlated to the ...

Page 264: ...the engine is idling the control unit increases the air flow rate altering the position of the butterfly in advance of the engagement of the compressor and conversely it returns the butterfly to its normal position after the compressor is switched off The engine idle speed is also increased the entire time the compressor is activated engine warm 900 rpm As far as point 2 is concerned the control u...

Page 265: ...mperature of the coolant reaches Ti 96 5 C high speed this is switched on when the temperature of the coolant reaches T2 102 C The fan is switched off with a temperature hysteresis of around 3 C According to the condition of the four stage pressure switch Low speed this is switched on when stage II of the pressure switch is triggered high speed this is switched on when stage III of the pressure sw...

Page 266: ...d The detection of a confirmed fault usually in volves the warning light in the dashboard corrj ing on it goes out when the fault conditions no longer exist NOTE During starting the warning light is on for about 4 seconds off for 0 1 seconds kept onIoff permanently according to whether or not permanent errors are present Working with the diagnostic equipment it is possible to carry out a complete ...

Page 267: ...ssor relay if fitted CODE control unit connection control panel connection diagnostic equipment engine side wiring B engine speed sensor absolute pressure and air temperature sensor coolant temperature sensor detonation sensor Lambda sensor power assisted steering end of travel sensor injectors idle speed actuator butterfly position sensor ignition charcoal filter solenoid valve Layout of system e...

Page 268: ...9 Sensor supply 30 Lambda sensor signal 31 N c 32 Engine speed sensor negative 33 N c 34 Operation of charcoal filter solenoid valve 35 Operation of idle speed actuator 36 N c 37 N c 38 Operation of coil for cylinders 1 4 Connector A vehicle side 1 N c 2 Operation of rev counter 3 Operation of fuel pump relay 4 Operation of high speed fan relay 5 N c 6 N c 7 Control unit supply from relay 30 8 Eng...

Page 269: ... 1 5 5 SYSTEM WIRING DIAGRAM Connector A vehicle side 1 2 3 4 5 i 1 8 9 It 11 12 13 14 15 It 17 IB 19 X 7 mmmmmwmmwmwm w c 9 e A 00 0 2KJ 0 i z LZj 10 l i L H o O O O O e o o e o O e o Q o o e o o e o o o o o o o o o o o o 12 13 14 18 Print no 506 670 16 ...

Page 270: ...ectric fan low speed relay 5 Engine control system relay 6 Fuel pump relay 7 Front cable connection 8 Battery 9 Ignition switch 10 Inertia switch 11 Electric fuel pump 12 Air conditioning control unit on button 13 Four stage pressure switch 14 Compressor relay A 30Afuse B 40Afuse C 40Afuse D 7 5Afuse E 7 5A fuse F 7 5A fuse G 7 5Afuse H 15Afuse L 15Afuse Copyright by Fiat Auto 19 ...

Page 271: ...M WIRING DIAGRAM Connector B engine side srt JL 3 J S 5 t l t m I 1 2 3 4 5 i 7 8 9 10 II 12 13 14 15 16 17 II 19 a it i iJ iil iiiii W i II i IDl a lt 5 Mi M fil 6 G U o G G G G O O G G G 2 9 G O O O G O Q G O G G O O Q 1 V k 11 t i 8 IT 3 12 20 Print no 506 670 16 ...

Page 272: ...l unit 2 Active charcoal filter solenoid valve 3 Detonation sensor 4 Coolant temperature sensor 5 Engine idle adjustment actuator butterfly position sensor 6 Absolute pressure and air temperature sensor 7 Front cable connection 8 Lambda sensor 9 Engine speed sensor 10 Coil 11 Injector section Copyright by Fiat Auto 21 ...

Page 273: ...tem 10 Bravo Brava iggi 16v 98 range LOCATION OF FUSES AND RELAYS NOTE For more information see Group 55 Electrical equipment Main fuses maxi fuse A System fuse B Fuse controlled by the ignition 22 Print no 506 670 16 ...

Page 274: ...duced by the magnet 3 oscillations accord ing to the variation in the gap These oscillations create an electro motive force in the winding 2 producing an alter nately positive voltage tooth facing the sen sor and negative voltage gap facing the sensor The peak sensor output voltage de pends all other factors being equal on the distance between the sensor and the tooth gap I 32B I _n JT_ 1 2 1 3 i ...

Page 275: ...c tion time later when the sensor signal is high voltage above 800 mV the control unit rec ognizes a rich mixture and decreases the in jection time This sequence is repeated at a frequency in order of tens of Hertz so that the engine con stantly operates with a mixture strength close to the stoichiometric ratio For temperatures below 300 C the ceramic material is not activated therefore the sensor...

Page 276: ... the temperature in creases The two thermistors are separate and provide information concerning the temperature to the instrument panel A and the engine man agement control unit B respectively The reference voltage for the latter is 5 Volt since the control unit intake circuit is designed as a voltage divider the reference voltage is shared between a resistance in the control unit and the actual s...

Page 277: ... This information is then used to compute injection time and igni tion point The sensor is fitted on the intake manifold Temperature C 40 20 0 10 20 30 40 50 60 80 100 Resistance M 52600 38700 17500 13500 6500 5300 4200 3400 2700 2300 1850 1550 1300 1050 920 750 650 530 360 290 210 160 Connector wiring Checking the resistance The table shows resistance values that the temperature sensor NTC thermi...

Page 278: ... pipe consists of a pressure switch which closes when the hydraulic pressure exceeds a set value corresponding to the steering in the end of travel position the in formation is used to managing the idle speed control actuator in advance of the absorption of power due to the steering DETONATION SENSOR This is a piezoelectric type sensor fitted on the cylinder block crankcase symmetrical in relation...

Page 279: ...s implies that the discharge current in the secondary winding always flows in the same direction and therefore the sparks for the two cylinders connected to the coil strike In the opposite way in the spark plug with the positive centre electrode the spark strikes from the earth electrode towards the centre one in the spark plug with the negative centre electrode the spark strikes from the centre e...

Page 280: ...nents which ensure that the air flow rate required by the engine is correctly directed in different operating conditions P4A29JJ01 1 Inlet vent 2 Air filter 3 Resonator 4 Engine idle speed adjustment actuator and butterfly position sensor 5 Butterfly casing 6 Inlet manifold Copyright by Fiat Auto 29 ...

Page 281: ... ad justment actuator in order to be able to sup ply the additional air required according to the engine conditions The actuator also in cludes the butterfly position sensor ENGINE IDLE SPEED ACTUATOR AAAND BUTTERFLY POSITION SENSOR The actuator fitted on the butterfly casing consists of a direct current motor operated by a circuit inside the engine control unit which regulates the position of the...

Page 282: ...p tray complete with pump filter pressure regulator and gauge Supply pipe Returnless type fuel manifold complete with injectors FUEL CIRCUIT DIAGRAM 1 Air bleed connector 2 Injectors connector 3 Supply pipe 4 Tank filler pipe 5 Drip tray complete with pump filter pressure regulator and gauge 6 Fuel tank Copyright by Fiat Auto 31 ...

Page 283: ...r 3 Fuel gauge with float 4 Pressure regulator 5 Gauze pre filter The pump is fitted with an excess pressure valve which short circuits the supply with the inlet if the pressure in the supply circuit ex ceeds around 5 bar to prevent the electric motor from overheating In addition a one way valve in the supply prevents the entire fuel circuit from being drained when the pump is not working Fuel fil...

Page 284: ... the engine the fuel is injected into the inlet duct immediately upstream of the inlet valve The injectors are the top feed type and there is an electrical winding connected to the connector 3 terminals When the current passes through the wind ing the magnetic field which is created at tracts the shutter causing the opening of the injector and the flow of fuel There are two seals on the fuel manif...

Page 285: ...cone There is a rapid release mechanism which forms a normally closed NC circuit When it is struck by the ball the mechanism changes position into a normally open NA circuit thereby interrupting the electrical supply to the electricpump and causing it to cut out The calibration of the switch causes it to in tervene at acceleration above 1 2 g approx 11 7 m s2 corresponding to an impact at a speed ...

Page 286: ...ected by the fact that the mixture strength with which the engine is operating 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 of the Lambda sen sor Lastly the conversion processes are activated at temperatures in excess of 300 350 C it is therefore vi tal for the catalyzer to reach this temper...

Page 287: ...Engine Bravo Brava i6v Fuel system 98 range 10 ENGINE EXHAUST ASSEMBLY DIAGRAM Key 1 Lambda sensor 2 Exhaust manifold 3 Catalytic silencer 4 Silencer 5 CO intake 36 Print no 506 670 16 ...

Page 288: ...he lightest particles of hydrocarbons which form in the tank from being discharged into the atmosphere 1 vapour supply pipe to the butterfly casing 2 Charcoal filter solenoid valve 3 Charcoal filter 4 Vapour supply pipe from the tank to the charcoal filter 5 Safety and ventilation valve 6 Multi purpose valve 7 Tank 8 Injection ignition control unit Copyright by Fiat Auto 37 ...

Page 289: ...nting the liquid fuel from reaching the active charcoal filter preventing it from being damaged b jf the level of the fuel in the tank decreases the float 2 goes down and rests on the ball 3 open ing the port 1 when the pressure exerted by the fuel vapours on the plate 4 overcomes the spring 5 loading a ring section opens between the actual plate and the valve body allowing the fuel vapours to com...

Page 290: ...s to it remove the rear part of the right front wheel arch liner It consists of granules of charcoal 4 which trap the petrol vapours entering through the intake 5 The scavenging air which enters through the intake 1 through the paper filter 3 comes into contact with the granules and di rects them towards the outlet 2 and from there towards the cut out valve The air having entered through the intak...

Page 291: ...RCULATION OF GASES COMING FROM THE ENGINE CRANKCASE BLOW BY This system controls the emission from the cylinder block crankcase of the breather gases made up of air petrol mixtures and burnt gases which escape through the piston ring seals in addition to the lubricant oil vapours recirculating them to the inlet With the accelerator butterfly open the gases from the upper cover reach the main air i...

Page 292: ... as far as possible CHECKING EMISSIONS CONCENTRATION This system manages the advance the carbon monoxide CO content and the idle air flow rate with no possibility for manual adjustment However a check on the content of the exhaust gases upstream and downstream of the catalyzer can provide useful indications on the injection ignition system operating conditions the engine parameters or the catalyze...

Page 293: ...utside of the recommended limit whilst that measured previously upstream of the catalyzer was correct the engine parameters are correct and the cause of the problem should there fore be sought in the decreased efficiency of the catalyzer CHECKING ENGINE IDLE SPEED If the engine idle speed does not correspond with the one recommended as the system is the self ad justing type no adjustments can be c...

Page 294: ...igure the adaptors as illustrated in the diagram The arrow indicates the the side to insert in the test equipment 1860955000 pressure gauge Discharging the fuel pressure in the supply circuit The fuel supply circuit is kept at a constant pressure of about 3 2 bar even with the engine switched off therefore before carrying out any operations on the supply pipe the pressure in the system must be dis...

Page 295: ...key to the ON position and observe whether the pressure on the gauge e after in creasing to about 3 5 bar settles down at around 3 2 bar the fall in pressure is due to the fact that after operating for several seconds the pump is deactivated if the engine is not started up If there is a fall in pressure to below the values mentioned above check the seal of the section of the sys tem Upstream of th...

Page 296: ...check the seal of the fuel manifold and the in jectors following the procedure described in the paragraph below Injector leakage test 1 Complete electric fuel pump 2 Fuel supply pipe 3 Adaptor A 4 Test equipment No 1860955000 5 Adaptor B 6 Fuel manifold 7 Rapid attachment connector 8 Injectors Keep the test equipment in the same position as described in the previous paragraph place valve b in the ...

Page 297: ... fuel flow from the pipes into the container reconnect the fuel supply pipe H i r v A P Checking fuel consumption using FLOWTRONIC equipment 1866149001 To carry out the check the equipment should be configured with the connectors shown in the diagrams A supply pipe side B fuel manifold side If this has not been done make the adjust ment following the instructions given below cut the end of the FLO...

Page 298: ... FLOWTRONIC equipment 2 Fuel supply pipe 5 Rapid connector 3 Female rapid connector 6 Fuel manifold carry out the fuel consumption road test in accordance with directive 93 116 CE litres per 100 km URBAN CYCLE this includes a cold start followed by a simulated urban journey EXTRA URBAN CYCLE this includes frequent acceleration in all the gears simulating normal out of town usage the speed varies b...

Page 299: ...g using tool 187807700 and remove it then lift up panel cover to gain access to the dust cov er undo the bolts arrow and remove the dust cover disconnect the supply pipe 1 the breather pipe 2 and the electrical con nector 3 using tool 1860893000 remove the ring nut securing the drip tray and extract the drip tray from the tank taking care not to damage the seal When refitting repeat the operations...

Page 300: ...ld as fol lows remove the bands shown arrow then undo the two bolts detail and remove the inlet hose complete with resonator rotating the accelerator lever release the end of the accelerator cable from the lever A then remove the adjuster from the bracket B and move the accelerator cable away disconnect the engine idle speed actuator connector 1 undo the bolts arrow fixing the upper half of the ma...

Page 301: ...the rapid connector 4 undo the fixing bolts 5 then remove the com plete fuel manifold When refitting repeat the operations de scribed for the removal in the reverse order Removing refitting injectors To remove the injectors proceed as follows Disconnect the electrical connection 1 Remove the safety clip 2 Remove the injector 3 which is a press fit M H Never act on the electrical connector M M to r...

Page 302: ...k from bracket B and place the accelerator cable aside disconnect the engine idle speed actuator connector 1 unscrew the four retaining bolts arrowed and remove the throttle body Reverse removal instructions to refit Adjust the accelerator cable as described in the following paragraph NOTE If the throttle body is replaced connect a tester Examiner to the tester con nection and run the required pro...

Page 303: ...OTE If at least one of the parameters is not as specified turn the ignition off and repeat the procedure If the parameter is still not as specified check the test lead is connected properly and the equip ment working properly Turn the ignition off and wait for 30 seconds Start the engine without operating the accelerator pedal and wait for the fan to come on Disconnect the tester Carry out a test ...

Page 304: ...NT ACTUA TOR THROTTLE POSITION SENSOR NOTE The engine idle adjustment actua tor throttle position sensor should be disconnected from the throttle body only in case of rep acement_because removing refitting causes damage to certain components e g internal sealing rings and correct component operation cannot be guaranteed once the component is refitted Removing refitting To remove the actuator disco...

Page 305: ...e ad justment actuator M D S data as de scribed in the THROTTLE BODY paragraph LAMBDA SENSOR Removing refitting Disconnect electrical connection 1 and re move sensor 2 from its seat on the exhaust manifold When refitting spread the threading with lubri cant grease resistant to high temperature Engine RPM and TDC sensor Removing refitting Disconnect the electrical connection Unscrew the retaining b...

Page 306: ...ITION SYSTEM WIRING DIAGRAM Connection between control unit igni tion coils and injectors LOCATION OF INJECTION IGNITION SYSTEM COMPONENTS page 1 1 1 1 2 3 4 4 4 4 4 5 6 6 6 6 7 7 7 8 8 FUSES AND RELAYS DIAGNOSTIC SOCKET INJECTION IGNITION 10 page 17 18 SYSTEM COMPONENTS Injection ignition system wiring Injection ignition electronic control unit Ignition coils Timing sensor Rpm and TDC sensor Deto...

Page 307: ...ir as finely and uniformly as pos sible As far as the optimum metering on the other hand is concerned it is calculated by the control unit after the following measurements have been taken the exact quantity of intake air by the air flow meter the engine rotation speed by the rpm sensor the power request by the accelerator pedal potentiometer the engine coolant temperature by the sensor on the ther...

Page 308: ... System failure warning light 15 Air flow meter 16 Butterfly casing electronic actuator 17 Clutch pedal switch 18 Fuel manifold 19 Injectors 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Phase transformer solenoid valve Brake pedal switch Ignition coils Engine timing sensor Air filter Engine rpm sensor Detonation sensors Coolant temperature sensor Fuel vapour solenoid valve Charcoal fil...

Page 309: ...unit to recognize the cylinder where detonation or the onset of detonation is taking place and only correct the ignition advance for the spark plug of the cylinder concerned d An accelerator pedal potentiometer which transforms the angular value of the actual pedal into an electrical signal allowing the control unit to recognize minimum partial and full load conditions Functions of the injection i...

Page 310: ...rol unit recognizes this condition and corrects the injection time on the basis of the sig nal for the temperature of the coolant the temperature of the intake air the battery voltage and the engine speed The ignition advance depends exclusively on the engine speed and the temperature of the engine coolant During cold starting the control unit controls an initial simultaneous full group injection ...

Page 311: ...perating times of the injectors to prevent the engine from being overloaded also protecting it outside of revs If the engine idle speed exceeds 7 000 rpm the control unit activates the fuel cut off function restoring the operation of the injectors when the speed goes below a certain level Check on combustion using the Lambda sensor The Lambda sensor informs the control unit of the quantity of oxyg...

Page 312: ...ment function which memorizes the reductions in the advance which are continuously repeated to adpat the map to the different conditions in which the engine finds itself Control of the phase transformer The control unit controls the solenoid valve for the phase transformer hydraulic actuator fitted on the camshaft inlet side by means of a relay The transformer has two operating positions A OFF pos...

Page 313: ...at CODE which only allows the injection ignition control unit to be activated by an electron ic code Each time the key is turned to the OFF position the FIAT CODE system completely deactivates the in jection ignition control unit If the ignition key is turned from OFF to ON the following operations take place in order 1 The injection ignition control unit sends the Fiat CODE control unit a request...

Page 314: ...ment of the radiator fan The control unit directly controls the operation of the radiator fan according to the temperature of the engine coolant and the engagement of the climate control system The fan is switchedon when the temperature exceeds 98 C 1st speed and 10VC 2nd speed It is switched off with a hysteresis of 2 C below the temperature threshold AIR INTAKE CIRCUIT The 1998 5 cylinder 20 val...

Page 315: ...ditioning compressor relay 15 Climate control system 16 Electric fuel pump relay 17 Electric fuel pump 18 Accelerator pedal potentiometer 19 System failure warning light 20 Diagnostic socket 21 Variable geometry inlet manifold solenoid valve 22 Phase transformer solenoid valve 23 Fuel vapour solenoid valve 24 Butterfly casing actuator 25 Brake and clutch pedal switch 26 Rev counter signal 27 Injec...

Page 316: ...he fuel supply system is the returnless type in other words with one single connecting pipe between the fuel tank and the engine This system makes it possible to keep the risk of the vehicle catching fire in the case of an accident to a minimum reduce the emission of fuel vapours in the atmosphere The electric fuel pump is enclosed in a casing which also incorporates the fuel pressure regulator th...

Page 317: ...o reach the separator 4 from where when they condense they mainly return to the tank 7 In the case of spillage whilst driving or if the vehicle overturns the float valves 6 close preventing fuel from escaping When the pressure inside the tank reaches approximately 30 40 mbar the multi purpose valve 3 opens and the fuel vapours reach the charcoal filter 2 The valve 3 also allows an intake of air in...

Page 318: ... connector 4 on the air hose upstream of the butterfly valve to be drawn into the manifold With the butterfly closed the vacuum in the inlet manifold draws in the gases through the intake 1 and they reach the connector 3 on the inlet manifold via the pipe 2 which contains a PCV Positive Crank Ventilation relief valve 8 which shutters the inlet The PCV valve can in effect be modulated and the quant...

Page 319: ...eously keep down the levels of the three pollu tant gases present in the exhaust gases unburnt hydrocarbons HC carbon monoxide CO nitrogen ox ides NOx Two types of chemical reaction take place inside the converter oxidation of the CO and the HC converted into carbon dioxide C02 and water H2 0 reduction of the NOx converted into Nitrogen N2 The following would put the catalytic converter out of use...

Page 320: ...Engine Fuel system 10 INJECTION IGNITION SYSTEM WIRING DIAGRAM Bravo 0 i 20v 98 range 14 Print no 506 670 16 ...

Page 321: ...witch 16 Flow meter 17 Air conditioning compressor 18 Radiator fan 1 st speed resistance 19 Air conditioning compressor elec tro magnet coupling relay 20 Radiator fan 1st speed relay 21 Radiator fan 2nd speed relay 22 Coolant overheating warning light 23 Radiator fan 24 Variable geometry manifold fan 25 Clutch pedal switch 26 Injection ignition system relay feed 27 Phase transformer solenoid valve...

Page 322: ...valve 4 Injection ignition control unit 5 General system protective fuse 6 Flow meter air temperature sensor 7 Motorized butterfly casing 8 Coolant temperature sensor 9 Vehicle speed sensor 10 Variable geometry manifold actuator solenoid valve 11 Rpm sensor 12 Lambda sensor 13 Ignition coils 14 Timing sensor 15 Diagnostic socket 16 Detonation sensors 16 Print no 506 670 16 ...

Page 323: ... p 20v 98 range Engine Fuel system 10 FUSES AND RELAYS NOTE For more information see Group 55 Electrical equipment Main fuses maxi fuse A system fuse B fuse controlled by the ignition Copyright by Fiat Auto 17 ...

Page 324: ...enoid valve Fuel vapour cut out solenoid valve Variable geometry manifold solenoid valve Electric fuel pump including filter and pressure regulator Injectors Ignition coils Spark plugs INJECTION IGNITION SYSTEM WIRING The various system components are connected by two distinct sets of wiring The engine side wiring connector M connect the components fitted on the engine to the injection con trol un...

Page 325: ...cted Not connected Not connected Engagement of climate control system compressor Not connected Supply from battery Supply from relay Not connected Not connected Not connected Not connected Not connected Not connected Not connected Connector M 1 Butterfly casing motor 2 Not connected 3 Injector for cylinder 4 4 Variable geometry manifold actuator 5 Fuel vapour cut out solenoid valve 6 Reference ear...

Page 326: ...ed 62 Go ahead to engage radiator fan high speed 63 Reference voltage for flow meter 64 Not connected Bravo 0I 20v 98 range Connector M 24 Butterfly casing potentiometer 1 signal 25 Coolant temperature 26 Butterfly casing temperature sensor po tentiometers 1 and 2 reference earth 27 Not connected 28 Not connected 29 Not connected 30 Not connected 31 Ignition coil for cylinder 5 32 Ignition coil fo...

Page 327: ...nder head supplies a spark plug directly without intermediate cables Checking ignition coil primary circuit resis tance The resistance is checked by connecting an ohmmeter to the connector external pins 1 and 3 Primary winding resistance 0 73 ohm Electrical specifications Primary winding inductance 2 5 mH Primary winding resistance 0 73 Q Anti interference resistance 1 KQ Diagram showing electrica...

Page 328: ...y with an opening passes through tiie sensor As it moves the met al part of the ring covers the sensor blocking the magnetic field with a consequent low output signal conversely when the opening is present and consequently there is a magnetic field the sensor produces a high signal As a result the high signal alternates with the low signal once for every two revoluations of the engine namely when ...

Page 329: ...an alternating voltage whose frequen cy depends on the number of revs The flywheel consists of 58 teeth plus a space equivalent to the size of the two miss ing teeth The reference defined by the space of the two missing teeth constitutes the basis for detect ing the synchronism point TDC Removing refitting Position the vehicle on a lift then working from the lower part of the vehicle disconnect th...

Page 330: ...manifolds and be tween cylinders 1 2 and 4 5 respectively These sensors have a bush to prevent inap propriate torque tightening If they are replaced do not place washers or shims between the cylinder block crankcase and sensor contact surfaces When the engine is knocking detonation vibrations of a certain frequency are pro duced in the cylinder block crankcase This phenomenon produces a mechanical...

Page 331: ...eller and a support cover 3 which contains the electrical and hydraulic connections The electric pump is the single stage type with high performance in low voltage and temperature conditions It has the following advantages compared with pumps which operate on the volumetric principle lighter smaller dimensions FUEL SUPPLY MANIFOLD The fuel manifold is fixed to the inside of the inlet manifold and ...

Page 332: ...until the inlet stroke has already begun The injectors are fixed by the fuel manifold which presses them into their housings in the inlet mani folds In addition they are secured to the fuel manifold by means of safety clips Two rubber seals 10 and 11 ensure the seal on the inlet manifold and the fuel manifold 1 Injector body 2 Needle 3 Magnetic core 4 Coil spring 5 Winding 6 Injector nose 7 Adjust...

Page 333: ...ne main one and one safety one A coil spring on the shaft guarantees the cor rect pressure resistance whilst a second spring ensures the return on release Wiring connector The numbers indicate control unit pins the corresponding BRAKE PEDAL SWITCH There is a switch 1 on the brake pedal which operates the brake lights the same switch sends a signal to pin F27 of the in jection control unit The brak...

Page 334: ... suit able Wheatstone bridge and the signal obtained is sent to the injection control unit 1 Covers 2 Electronic card 3 Sensor 4 Support plate 5 Support 6 Seal O Ring 7 Temperature sensor NOTE This flow meter directly measures the mass of air and not the volume there by eliminating problems of tempera ture altitude pressure etc Description of the operation The Wheatstone bridge made up of resistor...

Page 335: ...ng actuator is fitted with two potentiometers connected in parallel so that one controls the other and viceversa If there is a problem with the two potentiome ters or if there is no supply the control unit re duces the engine torque according to the posi tion of the accelerator pedal If the butterfly casing actuator or the injection control unit are replaced the following self learning procedure m...

Page 336: ...the fuel injected is equal to 1 Therefore X 1 ideal mixture X 1 lean mixture X 1 richmixture The Lambda sensor in contact with the ex haust gases produces an electrical signal whose voltage value depends on the concen tration of oxygen present in the actual gases This voltage is characterized by a sharp varia tion when the composition of the mixture moves away from the value X 1 The heating of the...

Page 337: ...y the left driveshaft coupling and transmits information concerning the vehicle speed to the control unit the signal is also used for the operation of the speedometer The sensor is the Hall effect type see para graph on engine timing sensor and is cali brated so that each impulse corresponds to a distance of one metre it is possible to know the speed of the vehicle from the frequency of the impuls...

Page 338: ...e 40 C and the engine speed below a pre set level with the butter fly angle greater than around 8 the solenoid valve 1 is energized thereby pushing the valve body 2 downwards In this position the oil coming from the duct A enters the piston chamber B and from there flows through a special port into the duct C inside the latter The oil can only leave the above mentioned duct through the upper port ...

Page 339: ... transformer Engine Fuel system 10 1 Solenoid valve 2 Valve body 3 Valve body spring 4 Piston 5 Pinion 6 Camshaft element 7 Piston spring 8 Battery 9 Injection ignition system relay 10 Injection ignition control unit 11 Ignition switch Copyright by Fiat Auto 33 ...

Page 340: ...this voltage is shared between a resistance in the control unit and the sensor NTC resistance As a re sult the control unit is capable of evaluating the changes in voltage and obtaining temper ature information in this way 1 NTC for injection system 2 NTC for gauge in Instrument panel Recovery The last value detected is taken as valid or a fixed values of 80 C if the temperature of the intake air ...

Page 341: ...d opens the normally closed NC electrical circuit interrupting the connection to earth for the electric pump and as a result the sup ply to the injection system To restore the connection to earth for the auxiliary electric pump the seat must be moved backwards and the switch pressed until it is heard to click Even after an apparently slight impact if there is a smell of fuel or there are leaks fro...

Page 342: ...pansion of the mass of granules when the pressure increases Vapour cut out solenoid valve 0 280 142 340 The function of this valve is by means of the electronic control unit to control the quantity of petrol vapours drawn in by the charcoal filter and directed to the inlet manifold If this valve is not supplied it is open by turning the key to the ON position it closes in prepara tion for operatio...

Page 343: ...charging the battery disconnect it first from the system if the vehicle goes into a drying oven after painting at temperatures in excess of 80 C then the injection ignition electronic control unit must be removed first never connect or disconnect the electronic control unit multiple connector with the ignition switch in the ON position a ways disconnect the negative battery lead before carrying ou...

Page 344: ...ANT EMISSIONS Through the self adjusment of the system the Motronic ME 3 1 system guarantees a continuous check on the idle speed and CO percentage thereby making any outside adjustment operations superfluous there are no adjustment screws However a check on the content of the exhaust gases downstream fo the catalyzer can provide precious information on the operating conditions of the injection ig...

Page 345: ...uced a special ex tension pipe which guarantees the seal in the join area must be added 1 Check that the idle CO and HC concentrations are the same as those in the table 2 If the HC value differes from the recommended limit whilst that measured previously upstream of the catalyzer was correct the engine parameters are correct and the cause of the problem should there fore be sought in the decrease...

Page 346: ... frequency counter Classification of the defect If a defect is recognized for the first time or the error state persists for a time t 0 5s the defect is memo rized as permanent If this defect later disappears it is memorized as intermittent and not present If it then reappears it is memorized as intermittent but becomes present The classification of a fault as permanent activates the recovery func...

Page 347: ...ard Bosch communication protocol The diagnostic equipment can supply the following information display of the errors display of the engine parameters active diagnosis List of errors Description Rpm sensor Air temperature sensor Coolant temperature sensor Battery Lambda sensor Injector Butterfly casing actuator Petrol vapour solenoid valve Relays actuators Control unit Flow meter Timing sensor Deto...

Page 348: ...ntrol unit is equipped with a permanent type memory EEPROM i e it keeps a record of the error even when the cause of the problem no longer exists and if the ignition is switched OFF and a volatile memory RAM where the information concerning the error is lost as soon as the cause of the problem ceases This also allows the more effective identification of error of an occasional nature Before ending ...

Page 349: ...ure sensor 14 Heater plugs control unit 15 Accelerator pedal potentiometer 15 Brake pedal switch 16 Clutch pedal switch 16 Excess pressure sensor 16 Atmospheric pressure sensor 16 FUEL SUPPLY CIRCUIT 17 Auxiliary immersed electric pump as sembly and fuel gauge 18 Fuel filter 18 Pressure pump 19 Fuel pressure regulator 19 Multi purpose valve 20 Supply manifold rail 20 Inertia safety switch 21 AIR S...

Page 350: ...nce and duration of the injection reduction in fuel consumption reduction in emissions FUEL SYSTEM MANAGEMENT STRATEGIES There is a management programme software in the control unit memory which consists of a series of strategies each of which manages a precise system control function By using information supplied by the various sensors input each strategy processes a series of param eters using m...

Page 351: ...cess pressure sensor 10 Fuel temperature sensor 11 Fuel pressure sensor 12 Injection system relay 13 Electronic control unit 14 Injectors 15 Heater plugs 16 Rpm sensor 17 18 19 20 21 22 23 24 25 26 27 28 29 Engine coolant temperature sensor Climate control system connector Diagnostic socket Fiat CODE system connector Flow meter Timing sensor Potentiometer on accelerator pedal Switch on clutch peda...

Page 352: ...he following parameters the quantity of fuel introduced into the cylinders for the duration of the injection time the atomization of the fuel injected the penetration of the jet the delay between the electrical operation of the injector and the effective start and end of injection The above mentioned parameters have a considerable effecton the behaviour of the engine especially as far as the power...

Page 353: ...emperature The injection control unit is constantly informed of the temperature of the fuel by the sensor on the re turn manifold If the temperature of the fuel exceeds a certain level about 110 C the control unit reduces the line pressure acting on the pressure regulator and leaving the injection times unaltered Control of engine coolant temperature The injection control unit is constantly inform...

Page 354: ...mperature Control of engine immobilizer function The system is equipped with an engine immobilizer function This function is achieved through the presence of a special control unit Fiat CODE capable of dialogue with the injection control unit and an electronic key with a special transmitter for sending a recognition code Each time the key is turned to the OFF position the Fiat CODE system complete...

Page 355: ...7 3 103 5 3 23 3 9 3 213 8 4 264 37 4 17 4 6 4 7 4 8 3 24 3 1 4 34 4 24 4 13 3 28 3 37 3 50 3 13 4 214 31 2 3 3 204 15 4 3 4 2 2 8 2 13 2 2 1 1 1 7 1 8 3 46 0 CK Kp QO HD O O 3 52 2 1 3 51 3 38 o o o o 1 4 1 5 1 6 5 2 5 9 5 7 5 4 5 5 5 3 4 234 11 4 4 4 1 4 14 1 2 3 4 5 63 SS 6R ...

Page 356: ...tronic control unit 20 Timing sensor 21 Fuse 7 5A protecting injection control unit 15 power supply from ignition switch 22 Fuse 7 5A protecting injection control unit 30 power supply from battery 23 Injection system main relay 24 30A fuse protecting injection system 25 Auxiliary fuel pump supply relay 26 Glow plug preheating control unit 27 Intake air flow and temperature sensor debimeter 28 Brak...

Page 357: ... 1 20 1 1 01 Battery positive 30 from main 1 02 Not connected 1 03 Not connected 1 04 Earth 1 05 Earth 1 06 Earth 1 07 Battery positive 30 from main 1 08 Battery positive 30 from main 1 09 Not connected 2 01 Glow plug timer signal 2 02 Clutch pedal switch 2 03 Climate control system activation 2 04 Not connected 2 05 Not connected 2 06 Not connected 2 07 Not connected 2 08 Brake pedal switch relay...

Page 358: ...ne radiator fan high speed Main relay go ahead Not connected Injection system failure EGR modulating valve earth Heater plugs timer control Auxiliary electric pump relay feed go ahead Flow meter supply Timing sensor earth Timing sensor signal Flow meter earth Not connected 4 4 4 4 4 4 4 4 06 Excess pressure sensor signal 4 07 Excess pressure sensor earth 4 08 Excess pressure sensor supply 4 09 Not...

Page 359: ...control unit Accelerator pedal potentiometer Brake and clutch pedal switches Fuel pressure sensor Intake air temperature and quantity sensor flow meter Engine coolant temperature sensor Fuel temperature sensor 13 14 15 16 17 18 19 20 21 22 23 24 Excess pressure sensor Timing sensor Rpm sensor Vehicle speed Battery Four stage pressure switch Fiat CODE control unit Diagnostic socket Fuel pressure re...

Page 360: ...gnetic flow sufficient to produce an al ternating voltage from the counting of the teeth on the flywheel The peak rpm sensor output voltage depends all things being equal on the distance between the sensor and the flywheel teeth 1 Metal bush 2 Permanent magnet 3 Sensor body 4 Winding 5 Core 6 Flywheel 7 Electrical connection H P 1 rv V I E H Z E j M n rl i O 3 PMflfflllllli To obtain the correct s...

Page 361: ...overs the sensor blocking the magnetic field with a consequent low output signal conversely by the opening where the magnetic field is present the sensor produces a high signal This signal together with the signals relating to the rpm and TDC allow the injection control unit to rec ognize the position of the pistons and determine the injection point AIR FLOW METER The flow meter is located on the ...

Page 362: ...nd valve 5 Operation The operation of the injectors can be divided in to three stages 1 rest position The coil 4 is de energized and the shutter 6 is in the closed position and does not allow the introduction of fuel into the cylinder F o F a where Fc is the force produced by the pressure which acts on the control area 7 of the pres sure rod 1 and Fa is the force produced by the pressure acting on...

Page 363: ...crease in temperature is greater at lower temperatures than at higher temperatures 1 NTC resistance 2 Sensor body 3 Electrical connector FUEL TEMPERATURE SENSOR This sensor is fited on the return manifold and detects the temperature of the fuel through an NTC thermistor which has a negative resistance coefficient For the operation of the sensor refer to the pre vious description dealing with the c...

Page 364: ... 4 Injection control unit pin 3 51 5 Injection control unit pin 2 1 8 Battery positive 30 G Heater plugs only 4 outlets are used ACCELERATOR PEDAL POTENTIOMETER The position of the accelerator pedal is trans formed into an electrical voltage signal and is sent to the injection control unit by the poten tiometer connected to the pedal The accelerator pedal position signal is pro cessed together wit...

Page 365: ...signal is used by the injection control unit to distinguish the gear engaged and gear shift conditions EXCESS PRESSURE SENSOR This sensor is fitted on the inlet manifold and the signal transmitted to the injection control unit is used for regulating the injection pressure regulating the duration of the injection The diagram at the side shows the sensor and the electrical connector with the pin out...

Page 366: ...ure circuit consists of a radiaijet pressure pump supply manifold and injectors 1 Fuel tank 2 Immersed auxiliary electric pump assembly complete with fuel gauge 3 Multi purpose valve 4 Pressure pump drive pulley 5 Diesel filter cartridge 6 Pressure pump 7 High pressure pipes 8 Supply manifold rail 9 injectors 10 Fuel recirculation pipe return for the injec tors 11 Return manifold 12 Pressure regul...

Page 367: ...en the fuel circuit from being drained when the pump is not working the second excess pressure valve 7 which re circulates the supply with the inlet when the pressure exceeds 5 bar FUEL FILTER The fuel filter is located in the engine compart ment fixed to the inlet manifold The filter is the cartridge type with a filter ele ment 1 made up of a pack of paper discs with a filtering surface area of a...

Page 368: ...s lubricated and cooled by the same diesel fuel through ducts and is capa ble of supplying a maximum pressure of 1350 bar 1 Cylinder 2 Cam 3 Inlet valve 4 Supply ball valve 5 Piston 6 Pump shaft 7 Dieselinlet connector low pressure from fuel filter 8 Diesel supply connector high pressure to manifold rail 9 Diesel supply connector low pressure re circulation FUEL PRESSURE REGULATOR The fuel pressur...

Page 369: ...nction of the valve in this case is to restore the pressure inside the tank by drawing in air Any irregularity in this function can cause misfiring or the vehicle to come to a halt through problems with the supply of the electric pump Seal in the case of overturning roll over The roll over function is designed to prevent fuel coming out of the tank if the vehicle turns over or is at an angle Durin...

Page 370: ... opens the nor mally closed N C electrical circuit interrupting the connection to earth for the auxiliary electric pump and as a result the supply to the injection system To restore the connection to earth for the auxiliary electric pump the seat must be moved backwards and the switch pressed until it is heard to click Even after an apparently minor impact if there is a smell of fuel or there are ...

Page 371: ... the torque in the most frequently used range e g low speeds The intake air after having passed through the filter 1 is compressed by the turbocharger 4 operated by exhaust gases cooled by the heat exchanger intercooler 5 and sent to the inlet manifold 6 from where it is distributed to the cylinders Diagram showing air supply circuit P4A22KJ01 4 Turbocharger 5 Air air heat exchanger intercooler A ...

Page 372: ...ngine power torque request 1 Impellers 2 Shaft 3 Lubrication 4 Waste gate valve 5 Actuator To the turbocharger and through a pipe to the ox the bodyshell CATALYTIC CONVERTER The catalytic converter is a post treatment de vice for oxidizing the CO HC and particle mat ter transforming them into carbon dioxide CO2 and water vapour H2O The catalyzer consists of a ceramic honeycomb structure 1 whose ce...

Page 373: ... operation of the engine is not adversely affected by the presence of inert gases in place of the air The recirculation is controlled by the injection control unit 1 which basically according to the signals from the accelerator pedal potentiometer the rpm sensor and the engine coolant temperature sensor supplies an output signal for operating the modulating valve 2 On the basis of the signal recei...

Page 374: ...he forces acting on the disc 3 are in equilibrium the atmospheric pressure in the duct A en ters the chamber B moving the moving element downwards case II so that the valve 5 shutter closes the duct F and places chamber E in contact with chamber C at atmospheric pressure de creasing the value of the vacuum in the duct E The decreased vacuum value or the increase in the absolute pressure in the cha...

Page 375: ...ngs in addition to lubri cant oil vapours They are defined as blow by or breather gases The breather gases coming from both the crankcase 2 and the cylinder head 5 reach the separator 1 In the separator 1 the gases lose some of the oil dissolved in them which return to the sump via the pipe 3 in the form of drops The remaining gases on the other hand are di rected through the pipe 4 to the intake ...

Page 376: ...the rail leading to the injectors and remove them 3 Undo the retaining nuts and remove firstly the bracket and then the injectors NOTE When refitting carry out removal pro cedure in reverse order Tighten the fittings between return manifold and injectors to the specified torque ofi 2 daNm Copyright Fiat Auto j l r ii T lfcrse tfes 5rW lC34as ve il f1 29 ...

Page 377: ...nnect the terminals and remove the battery 1 Disconnect the flow meter electrical con nection 2 Loosen the collars and remove the first pipe section between the air filter case and tur bocharger 3 Loosen the bands and remove the second pipe section between the air cleaner case and turbocharger 30 VII 99 Supersedps prevails veFsion Publication n 506 670 21 ...

Page 378: ... 3 Disconnect the electrical connection from the fuel pressure sensor 4 Unscrew the remaining nut securing the rail and remove NOTE To refit carry out removal instructions in reverse order Tighten the fittings of pipes between return manifold and injectors and of the fuel delivery pipe from the pressure pump to the speci fied torque of 2 daNm Copyright Fiat Auto i S x 4i i i 33 ...

Page 379: ...sconnect the electrical connection for the flow meter 2 Loosen the collars and remove the first sec tion of piping between air cleaner casing and turbocharger 3 Remove the second section of piping be tween air cleaner casing and turbocharger 4 Undo the retaining bolts and remove the upper engine protection cover 34 VH B9 Strpotsectes prev Vjusifr 5rs ir Publication n 506 670 21 ...

Page 380: ...tings of the pipes carrying fuel from the pressure pump to the rail to a torque of 2 daNm Fitting and tensioning timing drive belt 1 Fit the timing belt to the crankshaft gear provisionally and remove the bolt indi cated from the oil pump Position tool 1860905000 on the crank shaft drive gear and pin 3 turn the crankshaft through small movements until locating dowel 2 fits into hole 4 on the tool ...

Page 381: ... to maximum tension Then tighten the tensioner bolt to the mount Remove tool 1860905000 and turn the engine through two revolutions in its normal direction of rotation Loosen the nut securing tensioner 3 and apply leverage with a screwdriver so the tensioner does not go completely slack Then align mobile pointer 1 on the ten sioner with fixed reference 2 Then tighten tensioner bolt 3 to the specif...

Page 382: ...Untitled Document file D A olume 203 Fuel 20System htm08 07 2006 16 45 03 ...

Page 383: ...ctronic control uhit Injection pump management Fast idle management Exhaust gas recirculation management Air conditioning system management Heater plugs pre post heating man agement Instrument injector Signals arriving at and leaving control unit sensors and actuators Wiring diagram Engine rpm sensor and flywheel Air flow meter Coolant temperature sensor Pre heating control unit Air temperature se...

Page 384: ...climate conditions the pump is equipped with an automatic flow rate supplement system which increases the amount of fuel injected The pump comprises a single pumping element made up of two opposing pistons which is an integral part of the distribution rotor The rotor in turn rotates inside a unit known as the hydraulic head Each piston comes into contact with the internal lobes of a cam seal by me...

Page 385: ...ping pistons dictated by the rotation speed of the pump During the injection stage the piston control rollers come into contact with the cam seal cams the pis tons themselves are thrust inwards causing an increase in pressure and consequently injection At the end of the injection stage the pistons are thrust outwards creating a decrease in pressure the fuel is no longer supplied and the valve 5 cl...

Page 386: ...regulator valve 3 Engine cut out solenoid valve Elec trostop 4 Pumping element a front section view b side section view 5 Supply valve 6 Meter 7 Transfer pump 8 Advance actuator solenoid valve 9 Pressure valve 10 Injectors 11 Tank 12 Filter 13 Speed regulator Copyright by Fiat Auto IX 96 Cancels and replaces 7 ...

Page 387: ...w rate 2 Operation with turbocharger not operat ing During normal operation the intake transfer pressure 1 is greater than the opposing force exerted by the spring 2 and this al lows the pistons 5 to move the sliding plates 3 inwards In this way the pistons 4 are in contact with the longer side of the plates 3 with a conse quent decrease in the stroke and conse quently the value of the maximum flo...

Page 388: ...low towards the vehicle tank via the return pipe 8 This causes a de crease in the pressure acting on the piston 2 allowing the spring 5 to extend fully and rotate the cam seal towards the mimini mum advance position by means of the pin 4 In this way by varying the solenoid valve 7 opening closing frequency the electronic control unit modulates the value of the pres sure acting on the piston 2 ther...

Page 389: ... the piston 2 moves it compresses the regulating spring 3 and gradually places the ports 8 and 9 in contact allowing the fuel to return to the transfer pump inlet via the passage 7 By increasing and decreasing the opening for the ports 8 and 9 the valve makes it possible to regu late the transfer pressure value The valve also has the function of filling the transfer pump to ensure priming during t...

Page 390: ...he roller carrier 2 outwards By rotating the rotor interrupts the alignment between the charging and filling ports end of charging cycle By continuing the rotation one of the fuel supply ports coincides with one of the high pressure outlets 1 Roller 2 Roller carrier 3 Small piston 4 Cam seal 1 Cam seal 2 Cam seal bolt Cam seal The internal surface of the cam seal has lobes 1 which are diametricall...

Page 391: ...injection cycle the supply valves recall a certain amount of fuel from the high pressure pipes to ensure the rapid closing of the nozzles and combined with the cam seal profile the maintenance of the residual pressure in these high pressure pipes Cut out solenoid The engine can be made to cut out by completely removing the sup ply This is achieved by means of a solenoid valve 3 bolted onto the hyd...

Page 392: ...plied by the turbocharger On accelerating the engine speed increases and consequently so too does the pressure produced by the turbocharger which reaches the supercharing control valve gradually moving the diaphragms 4 which compress the spring 5 The valve piston 2 moves opening the discharge port 8 producing a drop in pressure behind the sup plementary flow rate device pistons Under these circums...

Page 393: ...een the force exerted by the masses 9 and the force of the spring 14 resting on the idle shaft During acceleration the accelerator lever 1 moves the metering valve 7 via the regulator rod 5 to wards the completely open position The centrifugal force exerted by the masses increases but remains lower than the pre loading of the mini maxi device 2 spring This means that the connection between the met...

Page 394: ...ove compartment right side and is connected to the wiring by means of a 25 pin connector It receives all the information relating to the engine running conditions transmitted by the various sen sors in addition to atmoshperic pressure information obtained by means of a sensor inside the actual control unit Through this data and with the aid of special programmes the control unit is capable of carr...

Page 395: ...l value transmitted by the instrument injector and if necessary it operates the advance actuator solenoid valve so that the start of the injection always takes place at the most appropriate moment for all engine operating conditions The engagement of the fast idle function is implemented by the control unit when at least one of the fol lowing conditions prevail 1 intake air temperature below 25 C ...

Page 396: ...witched on the compressor absorbs power from the engine which when idling tends to cut out In order to prevent this problem the control unit activates the fast idle function described previously Another function carried out by the control unit is that of interrupting the compressor supply if one of the following conditions occurs 1 Coolant temperature more than 110 C 2 Exceeding of a certain rpm l...

Page 397: ...injection advance start of the injection stage or of the start of the movement of the needle valve According to the signal the control unit cor rects the advance set by the injection actua tor until the nominal value is reached The injector is fitted on the cylinder 1 and is equipped with a device for recognizing the exact moment of the start of the injection stage and with wiring for sending a si...

Page 398: ...er plugs control unit 4 Climate control system 5 Heater plugs warning light 6 Injection system failure warning light 7 Borg Warner solenoid valve 8 Diagnostic socket 9 Rev counter 10 Engine rpm sensor 11 Battery 12 Instrument injector 13 Airflow meter 14 Fast idle valve 15 Coolant temperature sensor 16 Air temperature sensor Copyright by Fiat Auto IX 96 Update 19 ...

Page 399: ...Engine Fuel system 10 WIRING DIAGRAM Bravo Brava g TD100 20 IX 96 Update Print no 506 670 08 ...

Page 400: ...18 Fast idle valve 19 Advance adjustment device solenoid Engine rpm sensor and flywheel Features Gap 0 8 H 1 5 mm Winding resistance 860 ohm 10 at 20 C 1 Rpm sensor 2 Flywheel The engine rpm sensor is fitted on the crankcase and is facing a flywheel located inside the crankcase and fixed to the crankshaft The flywheel has 2 reference dowels at 180 from one another on the outer part of the circumfe...

Page 401: ... P4A22EJ01 NOTE This flow meter directly measures the mas of air and not the volume thereby eliminating prob ems of temperature altitude pressure etc Description of the operation The Wheatstone bridge made up of R3 R2 Rs Rt R1 is in equilibrium when Rs is at around 120 C higher than the temperature of the air The air which passes through the diaphragm removes heat from Rs therefore the bridge is n...

Page 402: ...ies in a manner which is inversely proportional to the temperature as illustrated in the diagram The control unit detects the variation in volt age proportional to the current intensity cir culating in the sensor The sensor should be fitted taking care not to exceed the tightening torque of 15 Nm RNTC 4OOO Rftft 40 10 V v TEMPERATURE C uu 80 U 60 40 20 10 0 10 30 20 10 0 80 T 100 120 130 CO 2 2 6 ...

Page 403: ...itch 15 4 Electronic control unit pre post heating activation 5 Electronic control unit fault diagnosis 8 Battery positive 9 Heater pJugs 10 Heater plugs Air temperature sensor The intake air temperature sensor is on this version separate from the air flow meter it comprises a standard NTC Negative Tem perature Coefficient where the electrical re sistance decreases as the temperature in creases Si...

Page 404: ...her gases coming from both the cylinder block crankcase and the cylinder head through the pipe 3 reach the separator 2 where following the vortex action to which they are subjected they lose part of the oil dissolved in them which returns to the sump through the pipe 4 in the form of drop lets The remaining gases on the other hand are directed via the pipe 5 to the inlet circuit There is a spark o...

Page 405: ... control lever on the injection pump and from the rpm and engine coolant temperature sensors and provides an output signal to operate the Borg Warner E G R solenoid valve 2 The latter connected to the atmosphere via a small filter 3 transmits a lesser or greater vacuum ac cording to the signal received coming from the special brake servoc vacuum pump 4 to the Pierburg E G R valve 5 If the vacuum i...

Page 406: ...wheel and proceed as follows 1 Remove the bolts shown and remove the right front wheel arch liner 2 Loosen the bolts shown which fix the auxiliary shaft drive pulley 3 Act on the automatic tensioner to loosen the tension at the auxiliary shaft drive belt then remove the belt 4 Remove the lower protection for the tim ing drive belt Copyright by Fiat Auto IX 96 Update 27 ...

Page 407: ... the fixing band Undo the bolts shown then remove the reaction connecting rod and the mounting bracket engine side Undo the fixing bolts and remove the tim ing belt upper shield Loosen the nut securing the timing belt tensioning device then remove the actual belt 28 IX 96 Update Print no 506 670 08 ...

Page 408: ...Acting at the points shown disconnect the diesel supply pipes from the filter to the pump the diesel return pipes from the pump to the tank and the diesel return pipes from the injectors to the pump 3 Undo the fixing bolts and remove the sound insulation shield 4 Disconnect the electrical connections disconnect the diesel supply pipe be tween the tank and the filter undo the fix ing nuts and remov...

Page 409: ...ng and adjust ment bracket 2 2 Disconnect the electrical connections shown 3 Disconnect the pipe 1 from the oil vapour separator 2 Undo the nuts fix ing the separator 2 a third nut not illus trated is at the lower side of the separator 4 Disconnect the pipe 1 which connects the oil vapour separator to the tappet cov er and move the actual separator towards the engine compartment rear partition 30 ...

Page 410: ...panner and remove the fuel sup ply pipes Remove the injection pump acting on the fixings shown in the diagram To refit the injection pump reverse the order of the operations carried out for the removal with the exception of the timing belt Before refitting the timing belt it is necessary to check the timing and then the tension of the belt as speci fied in the paragraph Replacing tim ing belt in t...

Page 411: ......

Page 412: ...NENTS OF THE FUEL INJECTION IGNITION 25 Wiring of fuel injection ignition 25 Fuel injection ignition electronic con trol unit 25 Engine rpm and TDC sensor 29 Knock sensor 31 Throttle body 32 Throttle position sensor 33 Coolant temperature sensor 35 Engine idle speed actuator Intake air temperature and sensor Electric fuel pump Fuel manifold pressure Charcoal filter and fuel vapour cut valve Multi ...

Page 413: ...sion control systems Via suitable sensors the system can measure the following parameters 1 instantaneous engine rpm 2 the position of each pair of pistons in relation to TDC of cylinder 1 3 air intake temperature 4 angular position of the throttle valve 5 engine coolant temperature 6 actual mixture strength via the Lambda probe 7 pressure in the inlet manifold 8 vehicle speed 9 battery voltage 10...

Page 414: ...otecting fuel injection ignition system 16 Main fuse box 17 Throttle valve position sensor 18 Fuel supply manifold 19 Fuel injectors 20 Air cleaner 21 Spark plugs 22 Ignition coils 23 Coolant temperature gauge 24 Air temperature and pressure sensor 25 Rpm and T D C sensor 26 Knock sensor 27 Coolant temperature sensor 28 Fuel vapour cut off solenoid 29 Activated charcoal filter 30 Air conditioner c...

Page 415: ... the inlet manifold Volumetric efficiency is the parameter relating to the cylinder fill coefficient measured in accordance with experimental tests conducted on the engine throughout its operating range and subsequently stored in the electronic control unit s memory After establishing the quantity of air drawn in the system must provide the quantity of fuel in accor dance with the desired mixture ...

Page 416: ...ted by the Greek letter X lambda quantity of air drawn in by the engine quantity of theoretical air for burning all the injected fuel It is easy to observe that oc ocst X The stoichiometric ratio depends on the type of fuel for the current non ethylated unleaded petrols it is about 14 7 14 8 which corresponds to a Lambda strength 1 ratio 14 8 1 means that 14 8 parts air are required to burn 1 part...

Page 417: ...g conditions The control unit also has a self adaptivity function which corrects the opening of the idle speed actuator at idle speed on the basis of variations due to leaks from the throttle body or natural ageing of the en gine This specific correction is lost if the battery or control unit are disconnected Starting and post starting During starting it is not possible to recognize instantaneousl...

Page 418: ...is decreased proportionally as the temperature increases until the nominal value is ob tained 850 30 rpm when the engine is up to temperature The electronic control unit by driving the stepper motor keeps the idle speed constant even when the electrical and mechanical loads vary Connection with the automatic transmission The control unit adjusts the engine idle speed in accordance with the load wh...

Page 419: ...iation in altitude and will be updated automat ically by the electronic control unit whenever the engine is switched off and under particular conditions of throttle valve position and engine speed typically at low rpm and throttle wide open dynamc ad justment of barometric correction Operation in cut off The fuel cut off strategy is effected when the control unit recognizes the throttle valve in i...

Page 420: ...ed ON engine in transient P4A08IJ01 Over rev protection When the engine speed exceeds for over 10 seconds the value of 6700 rpm or instantaneously the lim it value of 6900 rpm imposed by the manufacturer the engine is in critical operating conditions When the electronic control unit recognizes that the above mentioned speed has been exceeded it in hibits the driving of the fuel injectors When the ...

Page 421: ...ons during starting in transient acceleration and deceleration periods under cut off conditions to stabilize the idle speed if there is engine knocking when required by the automatic transmission control unit gear change In order for the ignition system to function correctly the electronic control unit must recognize the sig nal picture A Rpm sensor signal B Power control C Current circulating in ...

Page 422: ...ion advance a calculated by the computer the advance a varies depending on the rpm The control unit thus manages both the advance of the spark to the various cylinders in relation to top dead centre and the conduction time required by the coil for storing energy alternately controlling the two power stages which permit current to circulate in the primary windings pins 59 and 66 of the coils 6 for ...

Page 423: ...onnected directly two by two by high tension cables to the terminals of the coil s secondary winding and their connection may be considered to be serial as the cylinder head joins them This solution is also called lost spark as the energy accumulated by the coil will be almbsYexclusively discharged on the electrodes of the spark plug located ini the cylinder under compression allowing the mixture ...

Page 424: ... and an electronic key which has a special transmitter for sending a recognition code Whenever the ignition is switched off the Fiat CODE system completely disables the fuel injection igni tion control unit When the ignition is switched on the following operations take place 1 the fuel injection control unit whose memory contains a secret code sends a request to the Fiat CODE control unit to send ...

Page 425: ...ours from making the mixture ex cessively rich this condition remains until the coolant reaches a temperature of 65 C when the engine is up to temperature the electronic control unit sends the solenoid a square wave signal duty cycle control which modulates its opening In this way the control unit controls the quantity of fuel vapours sent to the inlet manifold thus prevent ing significant changes...

Page 426: ...r passing from the idle actuator in advance of the switching on of the compressor and vice versa it returns the actuator to the normal position retarded in relation to the disconnection of the compressor As regards point 2 the control unit automatically controls the disconnection of the compressor for a few seconds time lagged disconnection when there is a high requirement for engine power strong ...

Page 427: ...agnostic socket 9 Spark plugs 10 Ignition coils 11 Engine coolant overheating warning light 12 Fuel injection fault warning light 13 Coolant temperature gauge 14 15 16 17 18 19 20 21 22 23 24 Air conditioner Engine coolant temperature sensor 16 Intake air temperature and pressure sensor Throttle valve position sensor Knock sensor Rpm and TDC sensor Ignition switch Lambda probe Electric fuel pump R...

Page 428: ...ure sensor 3 Connection for fuel anti evaporation sys tem 4 Inlet connection for crankcase gases blow by for recirculation of exhaust gases during idling 5 Brake servo connection 6 Connection for engine coolant outlet pipe 7 Engine idle speed actuator 8 Top resonator 9 Main inlet for crankcase gases 10 Throttle body 11 Connection for engine coolant inlet pipe for heating throttle body 12 Air clean...

Page 429: ... then to the fuel injectors The fuel supply system is of the returnless type i e with only one connecting pipe between the fuel tank and engine This system makes it possible to minimize the possibility of the vehicle catching fire in the event of an accident reduce fuel vapour emissions into the atmosphere The fuel pump is enclosed in the cage which also incorporates the fuel pressure regulator fu...

Page 430: ...ation system is of the closed type This system prevents the petrol vapours which form in the tank or fuel supply system from discharging into the atmosphere and releasing the light hydrocarbons HC they contain thus causing pollution The system consists of a tank 5 a multi function valve 4 for controlling the vapour flow a two way safety and ventilation valve 3 located in the fuel filler an activat...

Page 431: ...nd recirculates them to the inlet With the throttle valve open the vent gases coming from the crankcase reach the connecting duct be tween the air cleaner throttle body 3 through the pipe 2 inside which there is a flame trap 1 to prevent combustion phenomena due to flame returns from the throttle body 4 With the throttle valve closed engine idling the vacuum in the inlet manifold draws in the gase...

Page 432: ...Engine Fuel system 10 WIRING DIAGRAM OF FUEL INJECTION IGNITION Bravo Brava 98 range Connection only present on cars fitted with four stage pressure switch 20 Publication no 506 670 14 ...

Page 433: ... 10 15A fuse protecting lambda probe and fuel vapour cut off solenoid 11 Lambda probe 12 Inertial switch 13 Electric fuel pump 14 Rev counter 15 Engine coolant overheating warning light 16 Air conditioner control unit and relays controlling radiator fan high and low speeds 17 Spark plugs 18 Ignition coils 19 Fuel vapour cut off solenoid 20 Fuel injectors 21 Fuel injection ignition fault warning li...

Page 434: ...simultaneously reduces the three polluting gases present in the exhaust gases unburnt hydrocarbons HC carbon monoxide CO and nitrogen oxides NOx Two types of chemical reactions take place inside the converter oxidation of the CO and HC converted into carbon dioxide C02 and water H20 reduction of NOx converted into nitrogen N2 The causes which quickly and irreparably put the catalytic converter out...

Page 435: ...A general system protective fuse 9 Diagnostic socket 10 Battery 11 Earth at negative battery terminal 12 Connection between injection earth and bodyshell earth 13 Injection ignition control unit 14 Coolant temperature sensor 15 Ignition coils 16 Join between injection cable and front cable 17 Injectors cable coupling 18 Injectors 19 Rpm and TDC sensor 20 Lambda sensor 21 Detonation sensor 22 Spark...

Page 436: ...rotecting 30 supply 4 15A fuse protecting Lambda sensor and fuel vapour solenoid valve EARTH POINTS fig 3 In order to improve electro magnetic compati bility and operational reliability the earth points have been positioned as follows The main earth for the injection ignition sys tem is directly connected to the negative bat tery terminal The earth for the injection ignition control unit housing 1...

Page 437: ...nected to the electrical wiring by means of two connectors the top connector with 52 pins and the bottom con nector with 28 pins _ _ It is a digital microprocessor unit characterized by a high calculation capacity precision reliability ver satility low energy consumption and absence of maintenance The task of the electronic control unit is to process the signals coming from the various sensors by ...

Page 438: ...ator and the angle position of the fully closed throt tle valve It is also assigned to memorizing the engine parameters and adapting them over time this means that the control unit using mainly the Lambda probe s signal modifies and stores in memory a corrective factor of the injection time which influences the mixture strength To be maintained the self adapting corrections of the idle speed actua...

Page 439: ...anged between different vehi cles to check whether they are working During diagnosis before replacing the control unit make sure that the component under exami nation is really not working as when a new control unit is supplied the secret code of the Fiat CODE system is memorized rendering the control unit totally unusable on other cars Voltage may be present on unconnected pins so no connection s...

Page 440: ... Air conditioner compressor relay Not connected Lambda probe cables shielding Not connected Supply 15 Request to switch on air conditioner 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Automatic transmission control unit gear change signal Vehicle speed signal Not connected Fuel vapours solenoid Rpm sensor positive Earth of coolant temperature air ...

Page 441: ...ends oiwhich there is a voltage which is alternately positive tooth opposite the sensor and negative gap opposite the sensor Provided all other factors are equal the peak output voltage from the sensor depends on the distance be tween sensor and tooth gap The phonic wheel has sixty teeth two of which are removed to create a reference the pitch of the wheel thus corresponds to an an gle of 6 360 di...

Page 442: ...e sensor Checking the gap Check the distance between the sensor and phonic wheel teeth gap Gap 0 5 1 5 mm NOTE If work has to be done on the rpm and TDC sensor mounting e g gap outside tolerance limits sensor misaligned etc the procedure must be carried out for correct positioning of the sensor and its mounting and setting its timing as described in the engine overhaul manual publica tion no 504 5...

Page 443: ...on The molecules in a quartz crystal are electri cally polarised Under rest conditions A the molecules are not aligned in any particular direction When the crystal is subject to pressure or im pact B the molecules line up and the degree to which they align is directly proportional to the pressure on the crystal This alignment creates a voltage at the crystal terminals A Rest position B Position un...

Page 444: ...emperature and or high humidity the throttle body is heated by recycling a small amount of coolant from the engine thermostat through a chamber inside the body The throttle valve position sensor and engine idle speed actuator are fitted to the throttle body In the pre modification version the engine idle actuator and throttle valve position sensor are bolted to the throttle body In the post modifi...

Page 445: ... sensor is integral with the throttle body A three pin socket ABC on the container ensures an electrical connection to the elec tronic injection ignition control unit During operation the electronic control unit supplies the potentiometer with a voltage of 5 Volts The parameter measured for injection management is throttle position from idle to full opening The output voltage tells the control uni...

Page 446: ... Strategies to gradually decrease rpm at idle speed dashpot are blocked Idle speedself adaption is blocked Mixture concentration self adaption is blocked Removing refitting Procedure for premodification cars Disconnect the electrical connection undo the two fixing bolts and remove the sensor NOTE The sensor is secured to the throttle body by two tabs with two non slotted holes Sensor angular posit...

Page 447: ...nce voltage is shared between a re sistance in the control unit and the actual sen sor As a result the control unit is capable of evaluating the variations in the sensor resis tance through the changes in voltage thereby obtaining information concerning the tem perature 1 NTC for injection system 2 NTC for indicator on instrument panel Recovery Assumes last temperature reading or a fixed value of ...

Page 448: ... that leaks thorugh closed throttle 4 with the engine idling must be increased while the engine is warming up or when external services or loads are activated e g automatic air conditioner etc by an additional quantity of air Q to allow the engine to maintain a constant rpm To achieve this result the system uses a step motor 1 secured to throttle body 5 and controlled by a drive circuit 6 located ...

Page 449: ...e warm Idle management depends on a signal from the engine rpm sensor The control unit manages sustained idle mode when external loads are activated During deceleration The electronic control unit identifies deceleration stage from throttle potentiometer position It controls step motor position via the idle flow law dashpot law i e it slows the return of plunger 3 to its seat so that a quantity of...

Page 450: ...ompute injection time and ignition point The sensor is fitted to the inlet manifold Self diagnosis and recovery The self diagnostic system monitors both sen sor output signals It identifies the following for both signals Short circuit to earth Short circuit to positive and reference volt age Circuit open broken When the sensor pressure signal is cut off the throttle potentiometer signal and engine...

Page 451: ...red with pumps which operate on the positive displacement principle are its lighter weight and small di mensions Removing refitting electric fuel pump The electric pump is located in the tank to re move it Remove the attachment buttons arrowed using tool 1878077000 Lift the boot carpet Undo the screws arrowed and remove the dust cover Disconnect the wiring connection for the pump and fuel gauge se...

Page 452: ...ur cut off solenoid 2 Charcoal filter 5 3 4 6 T 7 iLJt o Hn oc P3 n 1 Charcoal filter This consists of charcoal granules 4 which retain the fuel vapours entering through the connection 5 The scrubbing air which enters through the con nection 1 passing through the paper filter 3 envelops the charcoal granules removing the petrol vapours and conveying them towards the outlet 2 and then to the cut of...

Page 453: ...l In this way the control unit controls the quantity of fuel vapours sent to the inlet manifold thus avoid ing significant changes in mixture strength In the operating conditions listed below throttle in idle position engine speed below 1500 rpm bottom inlet manifold pressure at a limit value calculated by the control unit in accordance with the rpm the solenoid control is inhibited and the soleno...

Page 454: ...ole 1 preventing the liquid fuel from reaching the activat ed charcoal filter thus preventing damage to the latter if the fuel level falls the float 2 descends and rests on the ball 3 opening the hole 1 when the pressure exerted by the fuel vapours on the plate 4 exceeds the load of the spring 5 a ring shaped gap opens between the plate and the valve casing which allows the fuel vapours to emerge ...

Page 455: ...s the vehicle speed can be obtained on the basis of the pulse fre quency Removing refitting Disconnect the wiring connection and re move the sensor Tightening torque 0 8 daNm Wiring diagram SAFETY AND VENTILATION VALVE This valve is located in the fuel filler and it performs the following functions depending on the pressure in the tank When the pressure inside the fuel tank ex ceeds 0 13 0 18 bar ...

Page 456: ... The injectors are fixed by the fuel manifold which presses them into their seatings in the inlet pipes They are also anchored to the fuel manifold by means of safety stops Two Viton rubber rings 1 and 2 ensure the seal on the inlet pipe and fuel pipe The fuel is supplied from the top 3 of the injector whose body contains the winding 4 connected to the terminals 5 of the wiring connector 6 NOTE Du...

Page 457: ...rical circuit interrupting the earth connec tion of the fuel pump and consequently the feed to the fuel injection system To restore the fuel pump s earth connection push back the seat and press on the switch until you hear it engage Removing refitting 1 Push the driver s seat back fully undo the bolts indicated and remove the plastic cover 2 Undo the bolts indicated disconnect the wiring connectio...

Page 458: ...ic mechanical and ther mal properties as they can withstand high temperatures The vicinity of the primary to the magnetic core reduces magnetic flow losses ensuring maximum connection to the secondary 1 H T connector for cylinder 1 plug 2 H T connector for cylinder 2 plug 3 H T connector for cylinder 3 plug 4 H T connector for cylinder 4 plug 5 L T connector for control unit connection 6 Primary c...

Page 459: ...er between the two high tension output terminals The resistance of the secondary circuit read on the instrument must be between 4500 and 5500 ohm at 23 C Recovery Inhibition of the injectors corresponding to the cylinders where there is no ignition Open loop check of mixture strength If there is a short circuit to positive the com mand in progress is disabled and there is a retry In the case of op...

Page 460: ...xpresses the excess or shortfall of air supplied to the engine in relation to the value theoretically required the air petrol mixture is a ratio between these two sub stances which combined together react chemically For today s engines this means that they require 14 7 14 8 parts of air to burn 1 part petrol The probe is mounted upstream of the catalytic converter This consists of a ceramic casing...

Page 461: ...ient constantly fluctuating between about 0 980 and 1 020 For temperatures below 300 C the ceramic material is not active so the probe does not send usable sig nals and a particular circuit present in the control unit blocks the closed loop adjustment of the mixture strength during the warming up of the probe To ensure that operating temperature is quickly reached the probe has a heating element 4...

Page 462: ...ve cable Disconnect the wiring connector installed against the rear wall of the engine compart ment Remove the Lambda probe from its seating on the exhaust pipe E When refitting smearANT ISEIZE MA TERIA BORON NITRIDE N G K SPARK PLUG CO L TD grease on the threaded part Tightening torque 3 5 4 5 dalUm 50 Publication no 506 670 14 ...

Page 463: ...electronic control unit do not connect or disconnect the control unit s multi connector with the ignition on always disconnect the battery negative before carrying out electric arc welding on the car Remember that this system has a permanently supplied memory which stores the learnt self adaptivi ty values of the engine idle speed actuator Disconnecting the battery will lead to the loss of this in...

Page 464: ... section of the inlet manifold to the engine block and remove it 3 Remove the fuel pipe and remove the man ifold complete with fuel injectors 4 Then remove the fuel injectors as follows Disconnect the electrical connector 1 Remove the safety clip 2 Remove the fuel injector 3 which is a press fit Never pull the electrical connector to remove the injector Before refitting check the condition of the ...

Page 465: ...878077000 Remove the protective cover shown in the insert by undoing the attachment screws Disconnect the wiring connections from the pump and fuel gauge sender unit Dis connect the vent pipe 1 by undoing the retaining nut and the fuel return pipe 2 and delivery pipe 3 by undoing the re taining clips Undo the ring nut securing the electric pump to the tank using tool 1860893000 together with a rin...

Page 466: ... fuel filler to the bodywork 2 3 Open the clips shown by the arrows and release the handbrake cables from the attachments on the fuel tank 4 Place a suitable hydraulic jack under the tank to support it during removal refit ting Then remove the bolt and front plugs securing the tank to the bodywork 54 Publication no 506 670 14 ...

Page 467: ...and rear plugs securing the tank to the bodywork 2 Gradually lower the hydraulic jack check ing that the tank is correctly balanced then disconnect the fuel vapour recovery pipe 3 If necessary also disconnect the vent pipe 2 on the tank 4 Fuel tank Copyright Fiat Auto 55 ...

Page 468: ... accelerator pedal 2 In the engine compartment rotate the throttle valve lever 1 and disconnect the throttle cable Then withdraw the cable 2 from the mounting bracket 3 Withdraw the rubber buffer from the an chorage hole on the bulkhead wall and withdraw the complete throttle cable 4 Complete throttle cable When fitting adjust the throttle cable as described in the Adjusting throt tle cable sectio...

Page 469: ...m of the catalytic converter To check the concentrations of carbon monoxide CO and unburnt hydrocarbons HC upstream of the catalytic converter proceed as follows 1 Undo the plug or nut located on the exhaust pipe upstream of the catalytic converter and screw in the tool 2 Connect the probe of a suitably calibrated CO tester to the tool 3 Start the engine and bring it up to temperature 4 Check that...

Page 470: ...pe of the end of the exhaust pipe will not allow the probe to be inserted fully add an appropriate extension tube which seals properly at the join 1 Check that the CO and HC concentrations during idling are as specified in the table 2 If the HC value is outside the specified limit while the measurement upstream of the catalytic con verter was correct the engine parameters should be considered to b...

Page 471: ...connect injectorsupply connec tor 2 NOTE Tool 1860955000 comes with adaptors for connection to various types of injection system Before connecting the system set up the equipment using the appropriate adaptors start the engine and check that the reading on the pressure gauge remains stable at 3 5 bar 0 2 bar then turn off the engine operate the fuel pump with the engine off using a tester and runn...

Page 472: ...ctor supply connector as described in the previous paragraph on fuel supply pressure testing 0 the fuel supply circuit is maintained at a constant pressure of 3 5 bars even with the engine off Before disconnecting the delivery pipe it is therefore necessary to drain pressurised fuel as de scribed below obtain a suitable container 5 and insert pipe 4 into it connect the other end of pipe 4 to the f...

Page 473: ...evice 4 carry out a fuel consumption road test in accordance with the Directive 93 116 CE litres x 100 km URBAN CYCLE includes one cold start followed by a simulated varied urban journey OUT OF TOWN CYCLE includes frequent accelerations in all gears simulating normal out of town use of the vehicle the speed varies between 0 and 120 km h AVERAGE COMBINED CONSUMPTION includes 37 urban cycle and 63 o...

Page 474: ...en an error is detected this is checked for a certain period of time to avoid possible interference on the diagnostic line If the fault passes this stage it is considered to be present and is stored in RAM fil tered error It is then checked that the error remains present for a further period of time called validation time if this stage is also passed the error is finally memorized validated error ...

Page 475: ... counter Ignition coil charging time Dwell Battery voltage Number of open close steps of the speed actuator Advance Rpm sensor Throttle potentiometer Absolute pressure sensor Air temperature sensor Coolant temperature sensor Battery Lambda probe Fuel injectors Ignition coils Idle speed actuator Fuel vapours solenoid Actuators relays Control unit engine idle List of Petrol vapours solenoid Start co...

Page 476: ...id Rev counter Air conditioner relay Fuel injection fault warning light Coolant overheating warning light Engine idle speed actuator Fiat CODE Method of activation Activation of the relay for 30 s Activation for 4 ms per s 5 times Activation for 2 ms per s 5 times Deletion of validated errors Activation for 20 ms per s 7 times Activation at 125 Hz for 2 s Activation of the relay for 30 s Activatio...

Page 477: ... position signal Engine coolant temperature signal Wiring diagram Diagnosis page 1 3 3 4 5 5 6 3 9 13 15 16 19 26 27 27 28 29 29 30 30 30 30 31 32 DRIVE SHAFTS Removing refitting Dismantling reassembly Refitting Transmission components VALVE ASSEMBLY Removing refitting valve assembly Kick down switch page 63 64 65 66 67 69 SERVICING AND ADJUSTMENTS Changing gearbox oil 39 Checking oil level 39 Gea...

Page 478: ...unit of the fuel injection ignition for exchanging information relating to the en gine and the instrument panel for displaying the operating conditions The mechanical unit of the automatic transmission comprises an oleodynamic torque converter with a lock up clutch which locks the converter in the higher ratios two epicyclic gears located on the main shaft a band brake B1 a multiple disc brake B2 ...

Page 479: ...iple disc clutch C3 Multiple disc clutch D Clutch carrier drum E Motion input shaft FO Free wheel F1 Free wheel P4A02ABOI 11 Main shaft motion output gear 12 Layshaft gear K1 Epicyclic gear set P1 crown wheel K2 Epicyclic gear set P2 crown wheel 51 Epicyclic gear set P1 sun gear 52 Epicyclic gear set P2 sun gear ST1 Epicyclic gear set P1 planet gear ST2 Epicyclic gear set P2 planet gear ST3 Epicyc...

Page 480: ...al position the engine can be started D Drive Automatic operation of the gearbox on all four ratios 3 3rd gear Automatic operation of the gearbox on the first 3 gears the change to 4th gear is in hibited 2 2nd gear Automatic operation of the gearbox on the first 2 ratios the change to 3rd and 4th gears is inhibited 1 1st gear Operation only in 1st gear with engine braking effect TORQUE CONVERTER T...

Page 481: ...io of 1 1 corresponding to a turbine speed of 85 90 of the pump speed When the turbine and pump speeds are almost the same the stator is enveloped by an oil flow directed at an angle which makes it change its direction of rotation and as it is not blocked by the free wheel it rotates in a clock wise direction without impediment and the torque converter behaves like a simple hydraulic joint LOCK UP...

Page 482: ...lubricate the moving components of the gearbox to circulate oil in the cooling system Structure of the oil pump 1 Inlet side 2 Delivery side EPICYCLIC GEARS The AISIN automatic transmission uses two epicyclic gear sets for obtaining the five trans mission ratios 4 forward gears reverse gear The rear gear set P1 is a simple epicyclic gear set comprising a sun gear ST four planet gears ST1 and a cro...

Page 483: ... valve assembly located in the gearbox hydraulic control system When engaged the clutch C1 couples the gearbox input shaft E to the clutch carrier drum D When engaged the clutch C2 couples the gearbox input shaft E with the shaft E on which there are the two sun gears S1 and S2 of the gear sets P1 and P2 When engaged the clutch C3 couples the clutch carrier drum D with the crownwheel K1 of the epi...

Page 484: ... disc type B2 and one band brake B1 They are activated by the valve assembly located in the gearbox hydraulic control unit The band brake B1 blocks the rotation of the sun gears S1 and S2 connected to each other which form part of the gear sets P1 and P2 The multiple disc brake B2 blocks the rotation of the crownwheel K2 of the gear set P2 Copyright Fiat Auto 7 ...

Page 485: ...e gear set P1 when the clutch C1 is active and the motion comes from the gearbox input shaft The roller clutch F1 prevents the anti clockwise rotation of the crownwheel K2 of the gear set P2 P4A08AB03 HYDRAULIC CONTROL SYSTEM The operation of the automatic transmission is made possible by the operation of the clutches and brakes via hydraulic actuators driven by valves which move in accordance wit...

Page 486: ...ic gear set P1 Crownwheel epicyclic gear set P2 Sun gear epicyclic gear set P1 Sun gear epicyclic gear set P2 Planet gear for epicyclic gear set P1 Inner planet gear for epicyclic gear set P2 Outer planet gear for epicyclic gear set P2 P1 and P2 epicyclic gear train carrier Relay shaft The table below gives the conditions of activation of the components depending on the gear engaged and the positi...

Page 487: ... the vehicle from moving First gear selector lever on posi tion 1 The gearbox input shaft E rotates in a clockwise direction The crownwheel K1 is coupled to the input shaft E by the engage ment of the multiple disc clutch C1 the clutch carrier drum D and the clutch C3 already engaged with IM or P selected The clutch C3 locks the free wheel FO The crownwheel K2 is locked to the gearbox casing by th...

Page 488: ...s the crownwheel K2 can rotate freely in a clockwise direction allowing the gear train carrier T1 to rotate at a higher speed than that imposed by the transmission ratio Second gear selector lever on position D 3 2 1 selected manually recovery The gearbox input shaft E rotates in a clockwise direction The crownwheel K1 is coupled to the input shaft E by the engagement of the multiple disc clutch C...

Page 489: ...clockwise direction The crownwheel K2 is coupled to the input shaft E by the engagement of the multiple disc clutch C1 the clutch carrier drum D and the clutch CO The free wheel FO allows the crownwheel K1 to rotate in a clockwise direction The sun gear S2 is locked on the gearbox casing by the engagement of the band brake B1 The planet gears ST2 driven by the crownwheel K2 via the planet gears ST...

Page 490: ...3 rotating clockwise shift onto the locked crownwheel K2 thus making the gear train carrier T1 and gear II rotate anti clockwise obtaining reverse gear P4A13AB01 SAFETY CONTROL UNIT The safety functions of the AISIN automatic transmission are managed by a special electronic control unit and may be divided into two categories 1 warning functions which cause a buzzer to sound when the selector lever...

Page 491: ... Starter motor relay 13 PARK position additional switch 14 15A fuse protecting STOP lights 15 STOP lights switch 17 Automatic transmission safety electronic control unit 20 5A fuse protecting control module 23 Ignition switch 25 Speedometer signal generator 26 Ignition switch solenoid 27 Shift lock solenoid 28 STOP lights 29 Front left button controlling courtesy light and door open indicator 30 F...

Page 492: ...module also sends signals to the instrument panel and exchanges information with the fuel injection ignition control unit and diagnostic socket Location on the car of the control system components of the AISIN AW 596 Y024 automatic trans mission 1 Transmission control module 2 NORMAL SPORT mode switch 3 ICE mode switch 4 Kick down switch 5 Stop lights switch 6 Instrument panel 7 Main shaft rpm sen...

Page 493: ...mbly located at the front of the automatic transmission and to the fuel injection ignition electronic control unit for reducing the driving torque under particular operating conditions Control module functions In accordance with the commands received from the driver via the various switches and also the signals coming from the sensors concerning the operating conditions the control module ensures ...

Page 494: ...de switch 4 Kick down switch 5 Stop lights switch 6 Main shaft rpm sensor 7 Vehicle speed sensor 8 Gearbox oil temperature sensor 9 Selector lever position sensor 10 Gear engagement solenoids S1 and S2 11 Lock up clutch solenoid SL 12 Pressure control solenoid STH 13 Instrument panel 14 Gearbox oil cooling fan relay 15 Fuel injection ignition control unit 16 Diagnostic socket Copyright Fiat Auto 1...

Page 495: ...it pin 32 Input for engine coolant temperature signal fuel injection ignition control unit pin 5 Main shaft rpm sensor Vehicle speed sensor NC ICE mode switch NC Selector lever position sensor PA Pin L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 L25 L26 Connection Pressure control STH solenoid Earth on car Selector lever position sensor A NC Gearbox oil tem...

Page 496: ...to be engaged and the converter to be locked The control module has two specific programs for locking the torque converter memorized for the NOR MAL and SPORT driving strategies while for the ICE strategy the torque converter is not locked These programs are described on the following pages in the section concerning the driving modes The converter is not locked under the following conditions 1 whe...

Page 497: ...f the operating strategy used and the selector lever position The behaviour of the AISIN automatic transmission in accordance with the driving mode NORMAL SPORT or ICE used is described below The characteristic curves of change between the four ratios and the locking of the lock up clutch are shown both during progression and during reduction of the ratio scaling expressed as a function of the per...

Page 498: ...ches to SPORT mode when the NORMAL SPORT pushbut ton located on the left of the selector lever is pressed This mode of use of the gearbox is designed to make full use of the power so as to obtain maximum performance from the vehicle for the same aperture of the throttle valve the changes to the higher ratios are automatically shifted to a higher engine speed The SPORT mode does not use 4th gear cr...

Page 499: ...0 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 Gear change program The ICE mode is excluded in the following cases 1 if the NORMAL SPORT button is pressed 2 if the selector lever is at a position other than D 3 if the engine is switched off 4 if the transmission fluid temperature is over 150 C 5 operation under recovery conditions The table below illustrates the ...

Page 500: ...dule de pending on the aperture of the throttle valve and the vehicle speed Control of gear change times Comparing the ratios between the input and output speeds provided by the main shaft rpm sensorsand vehicle speed sensor respectively with the memorized values of the transmission ratios of the different gears the control module assesses the time used for the gear changes Controlling gear change...

Page 501: ... 5 km h selector lever position other than R Self test The electronic control system constantly monitors the sensors control solenoids and all the other elec tronic components in order to detect faults and malfunctions immediately these errors are memorized in the control module and can be read using the FIAT LANCIA Tester Error detection conditions The control module can detect errors in the vari...

Page 502: ...rror e g pressure control solenoid the classification of the error Present or Intermittent the type of error A C D C GND D C Vbatt etc Error deletion The errors memorized by the control module can be deleted by active diagnosis with the FIAT LANCIA Tester or by disconnecting the battery for over 10 seconds Recovery strategies If the control module detects a fault the red warning light on the instr...

Page 503: ...wn switch In the case of error it is considered ON if the throttle valve aperture is greater than 73 5 OFF if it less than 70 51 nin 8 7 6 5 o D a 3 16 15 14 13 12 11 10 a a n n n p 1 n 4 9 L26 L13 Gearbox sensors actuators connector view of contact side The resistance of the gear change solenoids S1 and S2 can be measured by disconnect ing the connector and connecting an ohm meter as shown in the...

Page 504: ...4 3 2 1 a n 16 15 14 13 12 11 10 9 D D D D D D D D i_r L24 The resistance of the lock up clutch control solenoid SL can be measured by disconnect ing the connector and connecting an ohm meter as shown in the figure P4A27AB04 Gearbox sensors actuator connector view of contact side PRESSURE CONTROL SOLENOID The line pressure control solenoid STH is lo cated at the front of the gearbox and it man age...

Page 505: ...hich it is connected mechanically and informs the control module via an appropriate electrical signal The module lights up the warning light on the instrument panel The sensor also switches on the reversing lights when reverse is engaged and enables the starter motor only when the selector lever is at position N or P The combination output sig nals present on the various ter minals of the sensor i...

Page 506: ...duction sensors located on the gearbox casing allow the control module to check the correct operation of the gearbox with regard to transmission ratios and gear change times and to conduct diagnoses on the operation of the sensors The main shaft rpm sensor detects the speed of rotation of the gearbox main shaft conneted to the torque converter turbine via a 20 tooth phonic wheel on the outer surfa...

Page 507: ...TS SWITCH The switch mounted on the pedal assembly is closed when the brake pedal is pressed causing the STOP lights to come on and supplying the L9 terminal of the control module to exclude the torque converter lock up function when the brake pedal is pressed THROTTLE VALVE POSITION SIGNAL The throttle valve position signal is acquired by the fuel injection ignition control unit which detects it ...

Page 508: ...n automatic trans mission Selector lever position sensor Vehicle speed sensor Kick down switch Gearbox oil temperature sensor Main shaft rpm sensor Rear earth Reversing lights NORMAL SPORT and ICE mode switches Starter motor relay 15A fuse protecting STOP lights STOP lights switch Fuel injection ignition electronic cont drol unit P N position signal Automatic transmission safety elec tronic contro...

Page 509: ... the engine idling gently move the selec tor lever from position P to position 1 then re turn it to P withdraw the dipstick 1 and clean it insert the dipstick fully into its seating withdraw the dipstick again and check that the oil level lines up with the notch on the side of the stick marked HOT If the oil level is low identify and eliminate the leaks then top up the level Also check the conditi...

Page 510: ...coustic signal and displays a message relating to the error A list of the possible causes of the error is then displayed After all the necessary repairs or replacements have been carried out and all the faults eliminated the er rors will be automatically deleted by the F L Tester Guided diagnosis can also be carried out by checking step by step the efficiency of the circuits and oper ation of the ...

Page 511: ...ot move the selector lever to position D press the accelerator pedal down fully with the right foot and quickly read the maximum speed reached by the engine Stall speed 2300 150 rpm Repeat the sequence of operations but moving the selector lever to position R Stall speed 2300 150 rpm Stall speed Lower than specified value in both D and R Higher than specified value in D Higher than specified value...

Page 512: ... warm it up to temperature and check that the idle speed is correct move the selector lever from position N to D using a chronometer measure the time elapsing between the movement of the selector lever and per ception of engagement of 1st gear IM D engagement time less than 0 7 s Repeat the sequence of operations except moving the selector lever from position N to R N R engagement time less than 1...

Page 513: ...rom under the vehicle remove the gearbox oil screw plug and screw in its place the con nector 1860870000 pass the pipe 1895411000 from the top of the engine compartment so as to connect one end of the pipe to the connector 1860870000 and connect the other end to the pressure gauge 1895424000 Position it so that it is visible from the driver s seat P4A36AB03 36 Publication no 506 670 06 ...

Page 514: ...speed test must not exceed 5 seconds in duration Repeat the last two operations with the selector lever on position R Speed Idling Stall Position D and 1 2 3 3 7 4 3 bar 3 8 4 4 kg cm2 10 8 12 5 bar 11 0 12 8 kg cm2 Position R and IM P 5 4 6 3 bar 5 5 6 4 kg cm2 14 1 16 9 bar 14 4 17 2 kg cm2 Line pressure Higher than specified value in both D and R Less than specified value in both D and R Less t...

Page 515: ...on position D fully press the accel erator pedal to close the kick down switch and check that the limit speeds for the changes 2 1 3 2 and 4 3 conform to the gear change program F Engine brake Driving in fourth gear move the selector lever sequentially from position D to positions 3 2 and 1 and perceive the engine braking effect at each of these gear changes Tests in position 3 2 and 1 with NORMAL...

Page 516: ...box oil level must be checked with the engine and gear box at normal operating temperature gearbox oil temperature 70 80 C so the vehicle must be driven for an appropriate period of time be fore the check To check the gearbox oil level proceed as follows park the vehicle on flat ground and apply the handbrake with the engine idling gently move the se lector lever from position P to position 1 then...

Page 517: ...may be oil leaks from the veni pipe Contamination of the oil wilh water 01 the use of an oil with different characteristics from the recommended oil causes higher consumption and malfunction of the transmission GEAR CHANGE CABLE Removing Disconnect the battery s negative cable then proceed as described below 1 Remove the air intake duct by undoing the bolts shown in the figure which secure it to t...

Page 518: ...rol unit mounting bracket then remove the control unit from the engine compartment The nuts indicated also secure the starter motor supply wiring and the front cable fuel injection cable connection Remove the bolts 1 and slacken the bolt 2 securing the battery cage to the body shell Before removing the cage disconnect the cable clip underneath Remove the split pin and washer shown in the figure li...

Page 519: ...upwards then remove the selector lever position indicator panel Release the driving mode switch panel discon nect the electrical connectors and withdraw the panel Remove the plastic trim from the handbrake lever slacken the tension from the relevant cable and dis connect the wiring connector for the handbrake on indicator Place the car on ramps and carry out the following operations from under the...

Page 520: ...from the exhaust manifold 2 Remove the first section of the exhaust pipe by undoing the attachments to the catalytic converter 3 Undo the bolts securing the gear change internal linkage mounting and handbrake to the body shell 4 Withdraw the internal gear change linkage mounting downwards 5 Internal linkage assembly 4 llSs Xf P f I y L iSk o jr T Z k PI SsM _ fe P4A43AB04 Copyright Fiat Auto 43 ...

Page 521: ...e the mounting 3 Disconnect the gear change cable from the selector lever mounting then replace the cable Dismantling selector lever 4 Undo the bolt securing the clip retaining the supply cables to the shift lock device and additional PARK position switch 5 Undo the nuts securing the additional PARK position switch 1 if the shift lock device 2 has to be worked on undo the bolts shown in the figure...

Page 522: ...be adjusted adjust the head 1 by screwing it or unscrewing it on the threaded part of the cable then lock it with the nut 2 Finally fit the washer and split pin operate the selector lever and check that at each position you can hear the gear change lever clicking into position Complete the assembly by securing the bat tery cage i e control unit battery and air in take duct Finally carry out the fo...

Page 523: ...ge cable position the selector lever at P then carry out the follow ing operations 1 Disconnect the wiring connector from the gear change lever position sensor 2 Remove the split pin and washer so as to disconnect the gear change cable from the lever on the sensor 3 Undo the nut securing the lever to the sensor then remove the lever 4 Release the central nut from the washer and remove the nut then...

Page 524: ...ition N rotating the pin two notch es in an anti clockwise direction 3 rotate the sensor so that the projection on the top surface 1 lines up with the side machining on the pin 2 then lock the sensor in this position by tightening the two side screws It is advisable to position the sensor using an ohmmeter connected be tween terminals 6 and 10 of the sup ply connector Rotate the sensor to the cent...

Page 525: ...ushion on the right Before proceeding with removal disconnect the battery s negative pole then iff A J v 1fl P 1 Remove the rear seat cushion by undoing the bolts securing the retaining brackets to the body shell 2 Lift the trim under the rear seat cushion then remove the bolts and nut securing the control unit mounting bracket to the body shell 3 Rotate the control unit mounting bracket disconnec...

Page 526: ...ntrol unit to the body shell disconnect the sup ply wiring connector then remove the control unit REMOVING REFITTING GEARBOX OIL COOLING RADIATOR AND FAN Place the car on ramps disconnect the bat tery s negative pole remove the front left wheel drain the gearbox oil and then pro ceed as described below 2 Remove the air intake duct by undoing the bolts shown in the figure securing it to the front c...

Page 527: ...hen 3 Remove the left wheelarch trim in order to gain access to the sensors 4 To remove the main shaft rpm sensor 1 black disconnect the relevant supply con nector 2 then undo the bolt securing the sensor to the gearbox casing and remove the sensor by pulling it upwards To remove the vehicle speed sensor 3 grey disconnect the supply connector 4 then undo the bolt securing the sensor to the gearbox...

Page 528: ...ke duct by undoing the bolts shown in the figure securing it to the front cross panel 2 Remove the air inlet pipe by undoing the clips shown in the figure then remove it from the engine compartment complete with resonator 3 Left the cover protecting the battery s po sitive pole and disconnect the cable undo the nut securing the battery to the cage then remove the battery from the engine compartmen...

Page 529: ...en remove the control unit from the engine compartment The nuts indicated also secure the starter motor supply cables and the front cable fuel injection cable connection 4 Remove the bolts 1 and slacken the bolt 2 securing the battery cage to the body shell Before removing the cage disconnect the cable retaining clip underneath 5 Remove the split pin and washer shown in the figure lift the gear ch...

Page 530: ... 2 Disconnect the earth cable shown in the figure from the gearbox 3 Disconnect the connectors shown in the figure of the selector lever position sensor and solenoids gear change lock up clutch control and pressure control after releasing them from the retaining clips 4 Disconnect the connector shown in the figure 5 Disconnect the speedometer drive cable P4A63AB05 Copyright Fiat Auto 53 ...

Page 531: ... undoing the central fixing nut after removing the protective cap 3 Remove the plastic covers from the space under the windscreen to allow the engine support tool to be installed during removal and refitting of the gearbox 4 Remove the gearbox top mountings 5 Fit a suitable supporting eye at the point shown in the figure to hook up the power unit during removal of the gearbox P4A54AB05 54 Publicat...

Page 532: ...ests on the front cross member b Rear mounting fit the tool level with the central reinforcement of the fire proof bulkhead c Secure the cross member hook to the eye positioned previously near the thermostat a e r J 4 v o i s z k r s v K jS Au y y lJj VB 1860851001 w v P4A66AB03 b y yyjlh L X k b Remove the starter motor by undoing its bolts then move the starter motor to one side securing it taki...

Page 533: ...retaining button shown in the figure To remove the trim also disconnect the brake pad wear sensor connector repeat the operation on the other side 3 Remove the nut securing the track rod end to the vertical link then remove the latter from the vertical link arm using the puller 1847038000 repeat the procedure on the other track rod end 4 Remove the bolts securing the vertical link gearbox side and...

Page 534: ... on the anchorage point and move it away from the working area 3 Disconnect the drive shaft on the timing gear side from the differential levering on the anchorage point 4 Differential oil seals When withdrawing the drive shafts take care not to damage the differen tia sea s Withdraw them perfectly horizontally Remove the connectors shown in the fig ure in order to disconnect the oil pipes from th...

Page 535: ...aft to gain ac cess to the remaining bolts total of 6 3 Undo the bolt shown in the fibure from the valve assembly cover to allow the gearbox support tool to be installed 4 5 Place the gearbox support tool 1860873000 on a hydraulic jack then secure it to the gearbox at the points shown in the figure To fit the tool cor rectly also fit a bracket 1 to be manu factured on site of the dimensions shown ...

Page 536: ...ing on the gearbox side by undoing the bolts shown in the figure 3 Remove the bottom bolts securing the gearbox to the engine 4 Gently separate the bellhousing from the engine then manoeuvre the converter back into its seating For greater safety fit a bracket to be manufactured on site screwing it into the seat of the bolt secur ing the gearbox bottom guard to prevent the converter falling out of ...

Page 537: ...rain plug tighten to 2 35 5 49 daNm 0 vi J y k p V A 7 f f Wi 1 P R F JHs i l_ Js PRECAUTIONS After releasing the cable from the support tool do not place it directly on the floor to avoid damaging its structure and the external components Interpose a suitably shaped wooden wedge If the gearbox is replaced before fitting the new transmission remove the bracket 1 in the converter seating and the pl...

Page 538: ...n make sure that the converter is fitted properly on the oil pump If it is not fitted properly the bush and oil pump gearing could be damaged Make sure that the distance between the holes of the bolts securing the converter to the flywheel and the gearbox front surface is 29 4 mm P4A61AB02 P4A61AB03 When fitting the gearbox check that the cen tring pins are positioned correctly and also check that...

Page 539: ...the other end of the converter and deform the clutch seal 2 Bolts which are too short may not with stand the input torque and could break O 1 1 1 X E C M n i r H W 1 11 P4A62AB02 When fitting the drive shafts take particular care not to damage the differential oil seal 2 on the splined part 1 of the drive shaft In sert the drive shaft perfectly horizontally If the seal is damaged it could cause oi...

Page 540: ...ic trim on the gearbox side by undoing the bolts and re taining button shown in the figure To re move the trim also disconnect the brake pad wear sensor repeat the procedure for the other side 3 Remove the nut securing the track rod end to the vertical link the remove the latter from the vertical link arm using the puller 1847038000 repeat the procedure on the other track rod end 4 Remove the bolt...

Page 541: ...connect the drive shaft on the timing gear side from the differential levering on the anchorage point NOTE When refitting reverse the procedure for removal tightening the wheel hub nut to the specified torque To remove and refit the drive shafts bear in mind the warnings mentioned under removing refitting the gear box DISMANTLING REASSEMBLY 4 Place the drive shaft in a vice then remove the clips r...

Page 542: ...ase the inside of the constant veloc ity joint Using tools 1847017001 and 1860889000 and holding the circlip in side the joint at the same time remove the joint from the drive shaft 4 Check that the drive shaft is not deformed or out of true and that the surface in con tact with the seal is not worn REFITTING When refitting reverse the procedure described for removal Whenever a gaiter is removed i...

Page 543: ... coupled to the shaft as indicated in the table Conduct a final check on the joint to make sure that there are no signs of seizure or scoring TRANSMISSION COMPONENTS 1 Constant velocity joint 2 4 CJips retaining constant velocity joint protective gaiter 3 Constant velocity joint protective gaiter 5 Drive shaft 6 8 Clips retaining sliding joint protective gaiter gearbox side Sliding joint protectiv...

Page 544: ...ks REMOV1NG REFITTINGVALVE ASSEMBLY Place the car on ramps disconnect the bat tery s negative pole drain the gearbox oil then proceed as described below working from under the vehicle 1 Place a hydraulic jack under the bellhous ing then remove the power unit mounting on the gearbox side to allow the valve as sembly cover to be removed 2 Undo the bolts securing the valve assem bly cover and remove ...

Page 545: ...ition the valve assembly and tighten the fixing bolts Connect the solenoid supply connectors and fit the gearbox oil temperature sensor on the mounting bracket _ _ The valve assembly bolts are of different lengths M J f l Arrange the bolts as shown in the figure 5 Using solvent clean off any sealant residues from the valve assembly cover Apply a bead of silicone sealant 1 1 5 mm thick along the ed...

Page 546: ...9 daNm Top up the oil level then check that there are no oil leaks from the valve assembly cover or drain plug Finish refitting the valve assembly by revers ing the procedure for removal KICK DOWN SWITCH The kick down switch is located on the ac celerator pedal To remove this switch re lease the lugs which secure the switch to the mounting bracket Disconnect the supply connector 1 then replace the...

Page 547: ...tial 98 range Removing refitting 21 27 page REMOVING REFITTING Removing 1 Refitting 1 Drive shafts 7 EXTERNAL CONTROLS 8 Diagram showing external gearbox controls 8 Removing refitting 9 Dismantling at the bench 12 Copyright by Fiat Auto ...

Page 548: ...ect the negative battery lead re move the protective cover for the positive pole disconnect the terminal and separate the latter from the starter motor supply leads undo the nut securing the battery to the drip tray then remove the latter from the engine compartment 3 Undo the bolt securing the relay casing cover and remove it then undo the nuts fixing the casing to the battery drip tray and place...

Page 549: ... nut 2 disconnect the clutch cable from the con trol lever 3 Disconnect the end of the gear engage ment cable and undo the bolts fixing the mounting bracket 4 Disconnect the end of the gear selection cable then move the selection and en gagement cables to the side of the engine compartment 5 Undo the upper bolts 1 fixing the gear box to the engine and the bolt 2 fixing the starter motor to the gea...

Page 550: ...e cross member 1860851000 for supporting the engine at the points il lustrated a Front support fit the tool in the housing in the bonnet lid lock so that it rests on the front cross member b Rear support position the tool by the cen tre reinforcement for the flame partition c Fix the hook for the cross member to the heater water supply pipe so that the en gine is resting in the centre P4A03BB05 Co...

Page 551: ... steering knuckle and rotate the steering knuckle towards the inside releasing the brake pipe from the shock absorber Repeat the operation on the other side 3 Undo the fixing nut the steering track rod end to the steering knuckle then using tool 1847038000 disconnect it from the steering knuckle Repeat the operation for the steering track rod end on the other side 4 Position a container for recove...

Page 552: ...ve it away from the work area 2 Disconnect the timing side drive shaft us ing leverage at the engagement point then move the driveshaft away from the work area 3 Undo the lower bolts fixing the starter motor to the gearbox disconnect the elec trical connections then remove the actual starter motor 4 Remove the engine flywheel shield acting on the fixing bolts 5 Undo the bolt fixing the gearbox to ...

Page 553: ...upport from the bodyshell and the gearbox 2 3 Position the tool illustrated for support ing the gearbox during the removal oper ation 4 Remove the power unit mounting gear box side from the bodyshell and the gear box 5 Undo the remaining bolt fixing the gear box to the engine P4A06BB04 6 Print no 506 670 77 ...

Page 554: ...below Check that the thrust bearing is correctly matched with the gearbox main shaft con trol lever checking that the teeth on the thrust bearing mesh with the control lever as shown in the diagram Fix the clutch release lever in a fully re tracted position on the bell housing then using the hydraulic jack move the gearbox differntial unit near the clutch centre it on the special references and fi...

Page 555: ...NTROLS 2 7 s 9 W t f i i V j 5 X o 6 1 4 W 7 2 Jir ull j 1 External controls support 2 Gear lever 3 Selector linkage on lever 4 Engagement linkeage on lever 5 Gear engagement cable 6 Gear selector cable 7 Cable mounting bracket 8 Selector linkage on gearbox 9 Engagement linkage on gearbox 8 Print no 506 670 17 ...

Page 556: ...ct the terminal and separate the latter from the starter motor supply leads undo the nut securing the battery to the drip tray then remove the latter from the engine compartment 2 Remove the gear lever cover from the ve hicle interior 3 Remove the handbrake protective boot then disconnect the electrical connection underneath 4 Undo the bolt securing the relay casing cover and remove it then undo t...

Page 557: ...ment cable and undo the bolts fixing it to the mounting bracket 3 Disconnect the end of the gear selector cable then move the gear selector and en gagement cable assembly to the side of the engine compartment 4 Raise the vehicle and disconnect the handbrake cables from the support and re lease them from the bracket 5 After having disconnected the electrical connection for the Lambda sensor undo th...

Page 558: ...converter then remove the pipe 2 Release the exhaust pipe from the rubber mounting shown in the diagram 3 Undo the bolt fixing the exhaust pipe front mounting bracket 4 Undo the bolt fixing the exhaust pipe rear mounting bracket then extract it from the vehicle 5 Remove the heat shield acting on the fix ings illustrated P4A11BB04 Copyright by Fiat Auto 11 ...

Page 559: ...om its housing then re move the cables from the engine compart ment and extract the assembly from the ve hicle DISMANTLING AT THE BENCH 2 Remove the gear lever assembly undoing the bolts then remove the rubber cable cover 3 Remove the two clips securing the cables to the lever support 4 Disconnect the cables from the lever sup port the engagement one is a press fit and the selector one is fixed by...

Page 560: ...3BB02 1 Remove the gear lever mechanism undo ing the bolts fixing it to the support 2 Using tool 1870668000 remove the knob from the gear lever the internal spring and the reverse gear inhibitor outer sleeve 3 Remove the circlip 1 and dismantle the gear lever mechanism Copyright by Fiat Auto 13 ...

Page 561: ......

Page 562: ...tern with ABS 3 f I 8 1 Description of the EBD function Elec tronic Brake force Distribution 3 f I EBD operation 4 I ABS system failure warning light 5 1 EBD function failure signal 5 Wiring diagram of ABS system inte I grated with EBD function 6 j Fault diagnosis 6 VARIANTS FOR 98 RANGE Wheel rpm active sensors Copyright by Fiat Auto ...

Page 563: ...n addition the optimum exploitation of the rear brakes is ensured as the device is capable of con stantly sending the ideal braking pressure to prevent the rear wheels from locking The diagrams overleaf illustrate the location of the device components the majority of which are the same as on the ABS system Key for diagrams showing braking system with ABS integrated with EBD function Hydraulic circ...

Page 564: ...Braking system EBD device Bravo Brava 33 Diagrams showing braking system with ABS system integrated with EBD function P4A02BD01 2 Print no 506 670 13 ...

Page 565: ...d proportioning valve acting on the rear axle load superfluous so it has therefore been removged from the braking circuit The graph below illustrates the operation of the EBD device curve D in relation to the pressure in the braking system curve A the ideal braking pressure for the rear axle curve B and the reduction in the braking pressure for the rear axle normally implemented by the conventiona...

Page 566: ... with poor adhesion The graph below illlustrates the braking pressure implementation strategy operated by the electronic control unit according to the input data represented by the signal for the rotation speed of the wheels of the two axles V Km h P bar i JEJ Controllo EDB JF i V Controllo ABS H E Rear wheel speed F Front wheel speed G Front wheel pressure H Rear wheel pressure Operation of the E...

Page 567: ...EBD function is signalled simultaneously by the braking system failure warning light 1 in the dashboard and the ABS system failure warning light 2 both coming on P4A05BD02 The warning light 1 in the dashboard coming on without the ABS warning light 2 coming on means that there is not an EBD malfunction but that there is a different fault low brake fluid level handbrake applied Conversely the ABS w...

Page 568: ... front rpm sensor FR 5 Right rear rpm sensor RR 6 10A protective fuse 7 60A protective fuse 8 Braking system failure warning light 9 Protective fuse 40A for consumers con trolled by ignition 10 Battery 11 Ignition switch 12 Diagnostic socket 13 Brake lights switch 14 ABS warning light 15 Junction unit Fault diagnosis It is possible to search for and identify any faults in the ABS system components...

Page 569: ...re positioned in such a way as to form different magnets with alternating North South polari ties around the circumference The multi polar ring can be fitted on the wheel bearing seal or on the rear wheel hub The sensor is supplied by the ABS electronic control unit and produces a square wave signal whose range is almost constant and whose frequency is proportional to the rotation speed of the whe...

Page 570: ...els This distance cannot be adjusted therefore if the gap measured is outside of the tolerance check the condition of the sensor and the multi polar ring NOTE Each time an rpm sensor is fitted it should be lubricated with water repellant grease to avoid the effects of heat variations over a period of time causing deterioration and making it difficult to extract Positioning of front wheel sensor Po...

Page 571: ...stributor assembly Location of climate control system components SCROLL compressor SCS08 Operation of the electronic control unit for the compressor Maintenance and service operations Draining the system x Compressor 1 1 2 3 4 6 11 13 16 17 19 20 24 25 ADDITIONAL HEATER Introduction 27 Location of components on vehicle 29 For anything not dealt with refer to the previous edition print no 506 670 0...

Page 572: ...e climate control system In effect it automatically manages the following according to the desired temperature requested for the passenger compartment air temperature at the vents fan speed continuous variation Manual operation on the other hand is required for fixed fan speed 4 speeds engaging the compressor air refrigeration circuit engaging the air recirculation MAX DEF function Lastly the adju...

Page 573: ...g the thermo dynamic parameters to ensure a comfortable climate temperature and humidity for the vehicle occu pants P4A02CH01 According to the requests received and the temperature conditions detected the control unit carries out sets certain functions aimed at adjusting the temperature of the passenger compartment to meet the requirements 2 Print no 506 670 16 ...

Page 574: ...th the compressor on the fanis always forced at the first speed even with the knob at 0 NOTE There are two different maps inside the control unit which correlate the air flow rate and the speed of the fan the pollen filter on the outside air inlet ensures that the flow rate is lower in relation to the fan speed in the dynamic air condition compared with the recirculation condition The right knob 3...

Page 575: ...low 4 C and switches on again above 6 C temperature detected by the frost sensor switches off below 3 5 C and switches on again above 5 C P4A04CH02 It should be rememebered that the compressor can also be switched off through the intervention of the four stage pressure switch or the engine control unit This logic dependson the different engine jnan agement control units as detailed below CONNECTIO...

Page 576: ... JTD Engines 1 Injection control unit 2 Climate control controls 3 Climate control control unit 4 Four stage pressure switch 5 Compressor relay 6 Compressor Case B the signal a to engage the compressor is sent from the control switch 2 via the climate con trol control unit 3 the four stage pressure switch 4 and the thermal swrtch 7 to the compressor engagement relay 5 If the conditions for disenga...

Page 577: ... P4A06CH01 TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 FUNCTION MAX DEF Compressor engagement Earth NOT USED Ventilation potentiometer Requested temperature po tentiometer Treated temperature sensor Engagement of recirculation Diagnostic line K Diagnostic line L Potentiometer supply 5V 30 from battery Earth for sensors TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FUNCTION Earth NOT USED Passenger compa...

Page 578: ...stream of the distribution flaps for the air flows to the various vents It consists of an NTC sensor R at 25 C 10 kOhm with an operating range of between OX and 80 C Requested temperature potentiometer This potentiometer is connected to the tem perature knob and detects the various angu lar positions sending a signal to the electron ic control unit for a total of 15 different posi tions one for ea...

Page 579: ...g nal corresponding to the position of the knob Rl R7 1500Ohm l Recirculation function switch Pressing this switch engages the recircula tion function which is managed completely manually Compressor enablement switch air refrig eration circuit Pressing this switch enables the operation of the compressor air refrigeration circuit Passenger compartment temperature sen sor This is located in the clim...

Page 580: ...ugh which the hot water coming from the engine passes through A motor with a 12 V supply controls the ro tary movement of a drive pin which acts di rectly on the mixture flap A potentiometer detects the actual positionand acts as feed back to the control unit Total rotation angle between max hot and max cold 62 Ratio u U for max hot 0 707 Ratio u U for max cold 0 26 Electrical recircuiation actuat...

Page 581: ...lectric fan with electronic speed regulator This fan which sends the outside or recircula tion air towards the duct distributor receives a 12 V supply and is operated at different speeds continuously by an electronic regula tor positioned nearby 1 Electric fan 2 Electronic regulator 30 15 C G N D 21 fe m S Wiring diagram The electronic regulator receives an input signal from the control unit and t...

Page 582: ... The control unit has two methods for reading errors it is storing by means of the diagnostic equipment through the display in the on board panel enabled by reading the outside temperature As an error detected by the control unit occurs even an occasional type error the words Error Cli ap pear on the on board panel display to indicate that the system has memorized a fault By pressing the outside t...

Page 583: ... C to mixture earth feedback C A or C C indistinguishable mixture feedback Fan operation malfunction C C to 5 V supply earth C C to battery supply 5V DISPLAY CODE 12 14 32 34 42 44 52 54 65 82 84 92 94 B2 B4 D5 E2 E3 If several errors are present they are displayed every 3 seconds Having concluded all the rrors the milometer is displayed once again If the codes differ from those mentioned above be...

Page 584: ...is directed by a special actuator which can take up a position between closed and one of the above mentioned two openings There is an electric fan 4 fitted inside the duct in the lower part by the above mentioned openings which when supplied at different voltages can rotate at different speeds The heater distributor assembly basically consists of a casing which houses the following in order a mixt...

Page 585: ... LO position the flow of air drawn in by the fan is distributed to the various vents without under going any variation in temperature because it is impossible to come into contact with the heater radiator R finned surface When the mixture flap is in the limit position HI the entire flow of air introduced by the electric fan has to come into contact with the heater radiator fins with hot air at the...

Page 586: ...deograms i e starting from to the front vents only ending with the windscreen vents as il lustrated in the diagrams below P4A1SCH01 View of positioning of the various distribution flaps when the knob is rotated completely in an anti clockwise direction P4A15CHQ2 W View of positioning of the various distribution flaps when the knob is rotated completely in a clockwise direction P4A15CH03 Copyright ...

Page 587: ...y an expansion valve which is fitted on the evaporator inlet duct various rigid and flexible pipes which connect the various system components a threee stage pressure switch which is fitted on the drier filter There are two small pipes fitted to the high and low pressure pipes with a needle valve which is de signed to drain and repressurize the system P4A16CH01 1 Compressor 2 Condenser 3 Drier fil...

Page 588: ...lley produces a chamber in which the volume decreases during rotation allowing compression The adoption of this compressor consisting of only two moving parts has resulted in the following ad vantages no seals are required there are no leaks either radial or axial low load losses through the absence of internal valves and pipes the wear of the spirals produces an improved seal of the side panels o...

Page 589: ...e gas un der pressure The volume defined by the two scrolls decreases determining the compression mechanism for the gas stored The pressure gradually increases until the gas arrives at the centre zone where operating pres sure is reached at this point thegas is released through the outlet connector to the condenser P4A18CH01 The sequence illustrates the different gas compression stages the compres...

Page 590: ...These control operations are carried out by the fuel injection control unit 15 INT A V J 1 Air conditioning on switch 2 Air temperature sensor on the evaporator 3 Compressor electronic control unit elec tronic thermostat 4 Four stage pressure switch Air temperature sensor on the evaporator The temperature sensor is an N T C resistance and is kept in place by means of a retaining spring on the evap...

Page 591: ...d with nitrogen to prevent dampness and impu Q rities from entering therefore when refitting remove the inlet and outlet connector plugs slowly with the compressor positioned exactly as illustrated in the diagram below with the cover fac ing upwards 1 Pour the quantity of oil in the compressor which is being replaced into a graduated test tube C tak ing care to let it drain well 2 Pour the quantit...

Page 592: ... or black coloured seals making sure that they are current production ones which are resistant to R134A fluid Do not under any circum stances use old production black seals because they are permeable NOTE If the system pipes are dismantled it is advisable to seal the disconnected ends of the pipes with suitable plugs if they are not going to be refited immeidately to prevent dampness or for eign b...

Page 593: ...ravo Btava 98 range Attach the connector for the red flexible pipe to the needle valve on the four stage pressure switch connector IMOTE Move the ring nut shown by the ar row completely upwards before fit ting the connector on the needle valve 22 Print no 506 670 17 ...

Page 594: ... the engine running rotation speed of around 1500 rpm and the outside temperature 20 28 X after having connected the pipes as illustrated on the previous page under these circumstances the pressure gauge readings should be low pressure circuit pressure gauge A 1 5 3 0 bar high pressure circuit pressure gauge B 11 1 6 bar NOTE The radiator condenser cooling fan is switched on at a high pressure cir...

Page 595: ...hich connectors the evapo rator to the compressor 2 Undo the plug for the needle valve high pressure side which is at the end of a pipe which is an integral part of the connector at the end of the pipe which connects the condenser to the drier filter 3 4 Fit the rapid attachment connector for the ends of the blue low pressure side and red high pressure side flexible connecting pipes for the Cleane...

Page 596: ...ont wheel remove the clip and undo the bolts shown in the diagram fixing the wheel arch liner to the bodyshell 3 Undo the bolts shown in the diagram and remove the lower shield from the engine compartment 4 Acting on the belt tensioning device loosen the tension of the single engine components drive belt release the belt from the pullies and remove it IMOTE Avoid the belt coming into contact with ...

Page 597: ... and the com pressor duct using suitable plugs undo the bolt shown and release the pipe from the compressor supply duct seal both the end of the pipe and the com pressor duct using suitable plugs P4A26CH02 undo the bolts shown in the diagram and remove the compressor Refitting To refit simply reverse the order of the opera tions carried out for the removal P4A26CH03 26 Print no 506 670 17 ...

Page 598: ... three relays are connected by the diesel filter on a special bracket fixed to the engine compartment bulkhead The system control unit is located under the dashboard behind the glove compartment Operating logic The operation of the heater plugs is controlled by an electronic control unit which operates one two or three heater plugs thereby giving a supply 200W 400W or 600W This control logic depen...

Page 599: ...t the operation of the heater plugs with the engine switched off the enabling takes place at around 660 rpm The supply of one two or three heater plugs is operated by two relays 1 st level is activated by the first relay 2nd level is activated by the second relay 3rd level is activated by both relays There is a third relay remote control safety switch which interrupts the supply for the heater plu...

Page 600: ... compart ment coolant 351 Safety relay for heating passenger com partment coolant 352 Relay for heating passenger compart ment coolant P4A29CH01 353 70A protective fuse for passenger com partment coolant heater plugs 355 Passenger compartment coolant heater plugs 357 Passenger compartment coolant heater plugs control unit Copyright by Fiat Auto XI 98 Update 29 ...

Page 601: ... frequency range 3 Tuning automatic search r 3 Tuning manual search 3 Manual memorization of a station 4 Listening to a memorized station 5 Automatic memorization of 5 stations in the FM RDS band Autostore 5 Cassette player 6 Fast forward winding of cassette tape 7 Fast rewind of cassette tape 7 Autoreverse function 8 Equalization t 8 Clock function 8 Display information T 10 Care and maintenance ...

Page 602: ...utton for preselecting transmitter no 1 selection of priority of indication of time radio frequency on display 7 Button for preselecting transmitter no 2 adjustment of hours in decreasing order 8 Button for preselecting transmitter no 3 adjustment of hours in increasing order 9 Button for preselecting transmitter no 4 adjustment in increasing order of minutes 10 Button for preselecting transmitter...

Page 603: ...G TONE P4A048L06 Emphasize high tones O Emphasize low tones Decrease volume P4A048L07 Press the button again after completing the adjustment ADJUSTING BALANCE Press the button P4A048L09 Withdraw the button until it clicks Emphasize sound from right loudspeaker O Emphasize sound from left loudspeaker Press the button again after completing the adjustment 2 Publication no 505 670 07 ...

Page 604: ...tation in question in the area you are passing through The name of the station transmitting in RDS appears on the display MEMORIZATION OF LAST STATION LISTENED TO This takes place automatically for each frequency band which is tuned when you switch on the radio or change frequency band TUNING AUTOMATIC SEARCH Briefly press the button several times until you select the de sired frequency band Brief...

Page 605: ...one of the buttons illustrated below and identified by the numbers 1 to 5 you pass from automatic tuning mode and the letters MAN flashing on the display disappear If one of the five buttons is pressed the radio is tuned to the station previously memorized with that but ton NOTE When the frequency band is selected you change from manual to automatic search MANUAL MEMORIZATION OF A STATION You can ...

Page 606: ...itched off and the letters AST are displayed The buttons numbered 1 to 5 see figure at bottom of preceding page automatically memorize the stations which have a strong sig nal at that moment in the selected band A maximum of two re scans of the entire range of frequencies are executed with increasing search sen sitivity and this operation is concluded when tape is switched on again and the letters...

Page 607: ... tape the tape will automati cally stop temporarily and Will resume automatically when the message tias finished Point c You can receive traffic information even if you are not listening to the radio After tuning to an RDS TP transmitter and setting the volume to zero if that transmitter transmits traffic information it will be heard at a pre set minimum volume In some countries there are stations...

Page 608: ...buttons shown in the figure which cause the cassette tape to be ejected from its compart ment The word TAPE disappears from the display and the radio is switched on The cassette tape can be ejected even if the ra dio is off FAST FORWARD WINDING OF THE CASSETTE TAPE To close the cassette compartment press verti cally on the arrows at the top of the door until the lock clicks FAST REWIND OF THE CASS...

Page 609: ...y of onceM second The dock is still displayed when the radio is off P4A08CL01 Display modes When the radio is on two display modes are possible with these characteristics Mode1 M1 The clock is displayed instead of the radio meassages priority to clock function When the radio is switched on without a cassette being inserted or when a radio station is selected or a cassette is inserted with the radi...

Page 610: ...the display as follows to decrease the hours press button 2 to increase the hours press button 3 to decrease the minutes press button 4 to increase the minutes press button 5 If the buttons 2 3 4 5 are pressed briefly the hours and minutes are increased decreased by one unit Press the buttons for longer to change the hours minutes display quickly Once the correct time has been set press the button...

Page 611: ...function 8 Distinctive letters of wave band 9 Numbers indicating tuning frequency with decimal point of frequency 10 Hours and minutes in clock function CARE AND MAINTENANCE Never expose the cassettes to heat or to direct sunlight and always put them back in their boxes after use It is recommended that you use high quality tapes and not longer than C 90 in order to ensure ex cellent reproduction a...

Page 612: ...g Supply 30 Earth CONNECTOR B SEATING N 3 4 5 6 Connection Right loudspeaker Right loudspeaker Left loudspeaker Left loudspeaker NOTE The terminals not mentioned in the tables are not connected Wiring diagram 30 5 3 0 30 lb GN BN SN NZ RG SN NZ m 1 2 3 4 5 6 7 7 6 5 4 3 2 1 J 5 D GL3 I IO 2 1 Earth on right dashboard 2 Radio 3 Loudspeaker on left door 4 Loudspeaker on right door 5 Battery supply 3...

Page 613: ...Bravo Brava TD Electrical system Contents 55 page Wiring diagrams Connector blocks K e y 1 31 36 Copyright Fiat Auto ...

Page 614: ...Rear window wash wipe Electric horns Heated rear window and warning light Headlamp washer Air conditioner Fuel level gauge and reserve warning light Handbrake on law brake fluid level warning light Speedometer Trip recorder mileage counter and relevant reset button Water temperature gauge Lew engine oil pressure warning light Front brake pade wear warning light Heater plugs warning light Rev count...

Page 615: ...re 120 Km h a fe Choke starter Water in fuel filter Plug preheating Turbo compressor pressure Rear fog lamps Front fog lamps Brake pad wear Turbo compressor pressure Auto transmission fluid temperature Speed limits Fuel gauge Coolant temperature 30 IS 1 Ign switch discharge ID Dipped headlamps Indicators with central door locking Electric horns O H Left indicator Right indicator Engine cooling sys...

Page 616: ...ture 00 I a 5 T D Button open Coil controlled switch Relay Engine Rear window wiper Headlamp washer Windscreen wash wipe Rear window wash wipe SPORT ANTI LOCK STOP sp Doors open Door locking Sport function con trolled damping sus pension Transistor Air Bag A B S Japan version Car stop fault Windscreen wiper dm D Temperature Anti theft device Electric windows Earth No plate lights JT Pulse Timer ge...

Page 617: ...l speedometer _ E b illinium Ex3 P a t iniiiiiiiii Digital rev counter Digital fuel gauge Analogue fuel gauge Analogue coolant tem perature gauge Econometer Digital coolant tempera ture gauge 3 Eb Engine oil temperature K Ms Engine oil pressure gauge 5 Voltmeter Copyright Fiat Auto 3 ...

Page 618: ... CB 40 STOP A R N U RN RN RN L R N R U 95 B C RU RNl ubM Effl 12 AR N D AR AR RU 17 13 m 1 c n G 10 178 179 COJ n B 96 181 RU R II R N B R 15 1 6 4 17 5 1 8 E 20 8 21 9 22 10 23 11 24 12 25 i 13 r 176 NZ NZ N D 174 u n 180 OJ Key to references A Component number B Connection number C Connector identification on component D Connecting pin number E Ultrasound soldered joint taped into wiring loom 4 ...

Page 619: ...5D 1 U1312 0 6 5 4 AR AG N CB 22 a N D I fcB H 12 238 129 E 154 H 23 S 7 0 S 1 2 3 A E 172 XI XI L BN ifr R L 1 I AN H 122 L L IBN 121 Ijiywpj ill infraite pre I f iaiti31 L See air conditioner diagram I ip t N 126 N AG N N D I BN 86 as 3d a N D L IBM L 1 m n N N AG N O HE N D r f 236 f l f i A R N D n n 123 LN AG ANH LN AG lm flfi IR 127 B H 1 1 5 8 55 HB NZ AR 17 14 1 bad Location of components ...

Page 620: ...123A Engine cooling fan high speed control relay 126 Front air conditioner cables connection 127 Connection between front left cables cable on relay bracket 128 Front air conditioner cables connection 129 40A power fuse protecting engine cooling fan 154 Engine cooling fan 158 Coolant temperature sensor for instrument 170 Engine cooling fan limiting resistor 172 Two stage thermostat 236 Front air c...

Page 621: ...gine oil pressure warning light Heater plugs warning light Fuel injection fault warning light Fiat CODE system fault warning light Rev counter See key following dia grams See air conditioner wiring dia Not present on versions with heater Variant connection for S version Not present on S version grain 4A0SZL Copyright Fiat Auto 7 ...

Page 622: ...switch 121 Three stage pressure switch 124 Air conditioner compressor control relay 127 Connection between front left cables cable on relay bracket 131 Fiat CODE electronic control unit 139 Diagnostic socket for fuel injection 142 Low oil pressure warning light switch 143 Alternator 145 Starter motor 152 10A fuse protecting fuel injection 157 Water temperature sensor for fuel injection 192 Air tem...

Page 623: ...rning light Heater plugs warning light Fuel injection fault warning light Fiat CODE fault system warning light Rev counter See key following dia grams 4 fHl HHl l 145 m 142 143 H 201 E 222 229 251 252 223 See air conditioner diagram Not present on versions with heater Variant connection for S version Not present on S version Copyright Fiat Auto 9 ...

Page 624: ...engine cables connection 56B Fuel gauge sender 57 Inertial switch 127 Connection between front left cables cable on relay bracket 131 Fiat CODE electronic control unit 139 Diagnostic socket for fuel injection 142 Low oil pressure warning light switch 143 Alternator 145 Starter motor 157 Water temperature sensor for fuel injection 200 Inertial switch control relay 201 Plug preheating control unit 2...

Page 625: ...8 um BUs 4 HZ15D ClJ i 3 MI312I1103 8 7 6 5 4 5 m t fft fB AR flG N CB G m 11 22 N D c a _ j i p i _ i p i 3 0 M M iitttifaitg FE 129 XI A N A N N D CB AG See side lights diagram 1 2 SI 154 1 T R N R RN N D i p 170 N D 1 N 1 L j N D 171 E 1 2 2 i n m n 172 Ttl RN I L RN N N i H N D HB 55 H 158 HB NZ AR 17 U 1 I N D N D iUGlRB 206 J 202 Z N D GR UG 1N B l H N d 42 207 208 Copyright Fiat Auto 11 ...

Page 626: ...h 22 Left dashboard earth 42 Right dashboard earth 55 Front engine cables connection 122 Engine cooling fan low speed relay 129 40A power fuse protecting engine cooling fan 154 Engine cooling fan 158 Coolant temperature sensor for gauge 170 Engine cooling fan limiting resistor 171 Heater unit 172 Two stage thermostat 202 Bulbs for heater air conditioner unit 206 Heater air conditioner electric fan...

Page 627: ...D 70 i fi H R N 14 13 1 5 5 6 7 e 10 3 STE UU H H H L H L N D n J l J a a lnt iittfa 5to rMS ffl 1 2 S N D 7 is4 x 6 4 7 n H i T BN BN 2 I Z N E 9 C B 25 97 iT l 9 m m m S SN UN N ETT N I HL pL m 127 N CB HL Tit irh Lit J u HJ LN CN i C B iffl I J V i i I E s g g g Not present on S version Single connector for Bravo version Not present on versions with heater N D N N u 71 Mil 5 IffTTTT ttl C B fl ...

Page 628: ...h 24 Windscreen wiper motor Electric horns Heated rear window and warning light Headlamp 25 Windscreen rear window wash pump 26 Rear window wiper motor 27 Rear connections contact assembly with built in boot light switch 28 Dashboard longitudinal cables connection 34 Switches control unit A Alarm on warning light B Rear fog lamps switch C Rear fog lamps relay D Rear fog lamps warning light E Heate...

Page 629: ... 237 JHN 128 ft f4 154 f ll TS sr BN L R L L BN 170 123A nl R LRN RN L L AN njn N D N D ftR 121 N D 122 172 fif Jf AG N D HC 236 AG ffl AG flG W ft N H h AG I JN 13 123 124 I AN AN 127 mm LNIARII AN N fri M ARIAG AN ns N AN BN m 209 120E N G UG il 210 b RN AN 203 241 13 AJ i T10 11 R T J 120 B I d rril HI j G CUIHR pS IBNI L 2 0 8 Ptf PHI U ANI C N p G R 1 4 l Pfi ftj 202 cu fN D N D i T 2Q7 N D 2...

Page 630: ...154 Engine cooling fan 170 Cooling fan limiting resistor 1 72 Two stage thermostat 202 Bulbs for lighting heater air conditioner unit 203 Air conditioner controls A Switch for switching on air conditioner B Switch controlling air conditioner recirculation 204 Relay controlling air conditioner electric fan 1st speed 205 Air conditioner fan relay 206 Heater air conditioner electric fan 207 Switch co...

Page 631: ... C15D s 123 1 3 5 9 7 6 5 4 3 2 1 1713 D D G N II CB E EH AN IAG J fae 122 172 a Ti n N U AG N All f 236 M ffi AG ffi T A N A N N D 123 L w 124 I Hi KNINI iff 441 J I 253 ffl 8 37 85 B6 d HN I IIG I 211 X 203 tl HW 120S RH AH Lb 203 N D 249 1 2 3 i 5 6 7 8 3 1011 120 22 12 US K j i i ri h CULBT 208 a i rf fill Hll C N cu tH Dj cvLN D p G B UsJ N f 202 ran U tM U 1 I N I N i H J C I N TjT N 206 55 ...

Page 632: ...ngine cooling fan 170 Engine cooling fan limiting resistor 172 Two stage thermostat 202 Bulbs lighting heater air conditioner unit 203 Air conditioner controls A Switch for switching on air conditioner B Air conditioner recirculation switch 204 Air conditioner fan 1 st speed relay 205 Air conditioner fan relay 206 Heater air conditioner electric fan 207 Heater air conditioner speed control switch ...

Page 633: ...ileage counter and relevant reset button Water temperature gauge Lew engine oil pressure warning light Front brake pad wear warning light Heater plugs warning light Rev counter See key following diagrams eg f o_ m 4Hlllllhi 3 MM MM 600 400 600800 YY YY 560 56B 19 Not present on S version Variant connection for soft versions 75cv 1 Variant connection for S version Copyright Fiat Auto 19 ...

Page 634: ... Z1 Trip recorder reset button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front left cables connection 19 Rear right earth 22 Left dashboard earth 28 Dashboard longitudional cables connection 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge sender assembly A Fuel level sensor B Electric fuel pump 70 Dashboard front...

Page 635: ... reserve warning light Handbrake on low brake fluid level warning light Speedometer Water tem perature gauge Low engine oil pressure warning light Front brake pad wear warning light Heater plugs warning light Rev counter See key following diagrams P4A37ZL01 4A37ZL Copyright Fiat Auto 21 ...

Page 636: ... V1 Speedometer W Rev counter X Coolant temperature gauge 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 19 Rear right earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge sender assembly A Fuel level sensor B Electric fuel pump 88 Low bra...

Page 637: ...ront brake pad wear warning light Heater plugs warning light Rev counter See key fallowing diagrams N 8 9 L a K HIIIII 89 EC 60A 40A 60A80A 137 J L TOT C B C B N D CB 91 4 C2J C10J i 2 3 5 111213U 1 1 2 3 i 5 6 7 a 3 aiL 4 4 B 70 A 223 158 241 e 15 9 iu N HG 44 N D H H H BN HR 28 I j 90 1 2 O HG L HR BN R BR CL H n CHlHB GN BN NZ HR 1 2 3 4 5 6 7 8 31011121314151617181920 1 2 3 4 5 5 7 8 910111213...

Page 638: ...rip recorder reset button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 19 Rear right earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge controller A Fuel level sensor B Electric fuel pump 70 Dashboard front cables connection 88 Low bra...

Page 639: ...ng diagrams 55 Version S SX Instrument panel connections See key following diagrams ft 4 ffif 14 1 1 0 a n I 8 9 Not present on S version Variant connection for soft versions 75cv Variant connection for SX version Copyright Fiat Auto 25 ...

Page 640: ...tch H Direction indicators switch 10 Battery earth on body shell 11 Battery 12 Ignition switch 22 Left dashboard earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge controller A Fuel level sensor B Electric fuel pump 53 Lighting brightness adjustment rheostat 70 Dashboard front cables connection 88 Low brake fluid level sensor ...

Page 641: ...Q i l l l 5 J 3 M 6S H G R 6 L M D N D j f N D fflM 1 2 S I fyrrl By H V m Q5 ED N D L HB CBI HRl IK HNlftS t t f 1 3 5 5 CHI Htll LN HHfCL N D MJ HHJLN GRJCL HGI CN HB fiU UrlJGrl BhiI H FINI N NZ HRlLG 58 ED Ml 2 3 4 5 6 7 3 3 lQnm3l l5l6l7lS13Zrj 1 2 3 1 5 6 7 8 S 101112133 151517IB EF S 0 1HT1 U K M 1 9 K 1 7 1 5 H L i b 4 f s I l m 117 suJf 95 g B I J I 7T I 1 31 5 5 6 3 7 56A 568 DE Copyrigh...

Page 642: ...d beam main beam headlamps switch F Side lights switch H Direction indicators switch 10 Battery earth on body shell 11 Battery 12 Ignition switch 22 Left dashboard earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge controller A Fuel level sensor B Electric fuel pump 58 Lighting brightness adjustment rheostat 88 Low brake fluid...

Page 643: ... Brava B 7B Electrical system Wiring diagrams 55 Version EL ELX Instrument panel connections See key following diagrams m Variant connection for versions without alarm see door locking Copyright Fiat Auto 29 ...

Page 644: ... Dipped beam main beam headlamps switch F Side lights switch H Direction indicators switch 10 Battery earth on body shell 11 Battery 12 Ignition switch 16 Rear left lights cluster 17 Rear right lights cluster 22 Left dashboard earth 28 Dashboard longitudinal cables connection 40 Stop lights switch 42 Right dashboard earth 55 Front engine cables connection 56 Fuel gauge controller A Fuel level sens...

Page 645: ...pretation of the codes on the connector blocks 58 Wiring colour code 58 Connector blocks 59 With regard to the 1910 Turbo D engine the connector blocks have been added from the previous publication for aspects not cov ered refer to the Bravo Brava publication no 506 670 02 Copyright Fiat Auto 31 ...

Page 646: ...Yellow Grey Blue Brown Black Red Pink Green Purple Light blue Light blue Light blue Light blue Light blue White Yellow Black Red Green BG BL BN BR BV BZ CA CB CIM GIM GL GR GV HG HN HR HV White Yellow White Blue White Black White Red White Green White Purple Orange Light blue Orange White Orange Black Yellow Black Yellow Blue Yellow Red Yellow Green Grey Yellow Grey Black Grey Red Grey Green LB LG...

Page 647: ...onal engine cooling fan 2 3 8 use Protect n 9 engine cooling fan 2 3 9 Heated diesel filter control relay R127 NZ127 2 4 H 20A fuse protecting heated diesel filter control relay 2 4 2 Fuel injection control relay Rn d N222 2 4 3 Engine advance adjustment solenoid 2 4 4 Fast idle adjustment solenoid Copyright Fiat Auto 33 ...

Page 648: ...ol unit SB 244 245 E G R solenoid HV249 HV241 Variant connections for 100 BHP version 246 Heated fuel filter 247 Heated fuel filter thermal contact 2 4 8 Potentiometer on fuel pump G n d G249 V241 V249 AR241 A R 2 4 9 Variant connections for 100 BHP version 34 Publication no 506 670 06 ...

Page 649: ...48 VG 157 B n d R n d _ _ f BR 139 V 2 4 8 iflF lr EKBtHEIig 131 1 Elm AR 248 MG55 Iffi T _ HV 245 N222 Cn d 2 5 0 Water temperature sensor for preheating control unit 251 Thermal switch for K S B 252 Earth for K S B device C251 2 5 3 Re av f r switching off compressor Copyright Fiat Auto 35 ...

Page 650: ...meter W Rev counter X Water temperature gauge Z Trip recorder mileage counter Z1 Trip recorder reset button 7 Stalk unit A Windscreen wiper speed switch B Windscreen wash headlamp wash rear window wash switch C Rear window wiper switch D Headlamp flasher button E Dipped beam main beam headlamps F Side lights switch G Indicators hazard lights intermittent switch H Direction indicators switch I Horn...

Page 651: ...elay 205 Air conditioner fan control relay 206 Heater air conditioner fan 207 Heater air conditioner speed control switch 208 Heater air conditioner limiting resistor 209 Actuator controlling exterior air recircula tion 210 Electronic thermostat cables connection 211 Electronic thermostat N T C 222 Earth for fuel system 223 Wheel speed sensor 224 Instrumented fuel injector 225 Flowmeter 226 Diagno...

Page 652: ...Bravo Brava Electrical system Contents 55 page Electrical symbols 1 How to read the wiring diagrams 4 Wiring diagrams 5 Key to wiring diagrams 37 Copyright Fiat Auto ...

Page 653: ...ooling system Water temperature gauge Car interior ventilation Direction indicators and warning lamp Hazard warning lights and warning lamp Stop lights Reversing lights Fuel level gauge and reserve warning light Hand brake on low brake fluid level warning light Speedometer Trip recorder total mileage counter and trip recorder reset button Water temperature gauge Low engine oil pressure warning lig...

Page 654: ...starter Water in fuel filter Heater plug Compressor turbo pressure Rear fog lamps Front fog lamps Brake pad wear 3D 15 1 1 Switch discharge to Dipped headlamps Indicators flashing with central door lock ing Electric horns O Left indicator Right indicator Engine cooling 1 1 Compressor turbo I pressure Q 120 Km h Auto transmission fluid temperature Speed limits a A Fuel gauge Engine coolant temperat...

Page 655: ...RAKE SPORT flNTI LOCK STOP sp Electronic injection Engine oil level Brake fluid level Japan version Doors open Central locking Sport function on elec tronic suspension sys tem Transistor Air Bag A B S Japan version Car stop fault Windscreen wiper Differential lock Auto transmission fluid temperature 00 m a n Temperature Anti theft device Electric windows Earth No plate lights Pulse generator Timer...

Page 656: ...IIIIIIIIII Digital speedometer Digital rev counter Digital fuel gauge L Analogue fuel gauge hMA RC I Uiy mini K LEJ 5 Analogue coolant tem perature gauge Econometer Digital coolant tempera ture gauge Engine oil temperature Engine oil pressure gauge Voltmeter Copyright Fiat Auto 3 ...

Page 657: ... 179 OJ n B R p R N R U 95 B R U R N 96 N D B 3r r tttists pos miftJ 12 AR A R AR RU i 1 7 1 9 1 c I r n G D3 BD BEI 181 RU R f i n 8 R 16 I 6 1 20 I 21 9 22 10 23 11 2 RN M 25 13 176 NZ NZ N D 174 N f O 178 u n 11 G3 180 OJ Key to references A Component number B Connection number C Identification of connector on component D Connecting pin number E Ultrasound soldered joint taped in wiring loom 4 ...

Page 658: ...late lights Location of components 01 Oi Mi TS MIIIII y I A IB c I D 30A40A 60A80A nt h 1 li M 0 ID J 2 9 I N GR V U L 1 3 5 6 7 3 2 4 5 6 7 S 3 2 1 ID 3 R T p S GN ai N D L L N D R R 5 I ID I G LR HR IGR GN GN J D A G Nj M CBGV ifi JGV 286 LR AG L m E S S N GN VN N N 16 e 18 u t Variant connections for Bravo versions N GR Ls 1f s l V WSJL M WD ii Copyright Fiat Auto 5 ...

Page 659: ...7 Stalk unit D Flasher button E Main beam dipped beam headlamps stalk F Side lights stalk 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 1 3 Connection between front right left cables 14 Left number plate light 15 Right number plate light 16 Rear left lights cluster 17 Rear right lights cluster 18 Rear left earth 19 Rear right earth 22 Left dash...

Page 660: ...s 55 Front fog lamps and warning light Rear fog lamps and warning light N V s 4 m il I 30A40A 60A80A U L N D N D M 7 N N D 29 E f cl 70 33 18 h N Not present on Bravo N dH 19 Location of components WElMMMm30 16 T m SJ EEE o IT r i i Copyright Fiat Auto 7 ...

Page 661: ...31 Front right fog lamp 32 Front fog lamp relay 33 20A fuse protecting front fog lamps 34 Switch controls unit A Alarm on warning light B Rear fog lamps switch C Rear fog lamps relay D Rear fog lamps warning light E Heated rear window switch F Heated rear window warning light G Switch controls unit symbol light H Front fog lamps warning light I Front fog lights switch 70 Dashboard front cables con...

Page 662: ...B L i t 283 fi I A N f5 i J AR J AB B N D i BN n I jpr AR CB CB N D j CB CB i4 I5 5 IS rt M f top ffllJ i Bh I R i l 120 VG J I C N D f c c c 1 127 N D 279 H B 55 1 H B 4 H ARI HB NZ A R 11 B t f o E j J I 5 17 U 17 1 2 m See air conditioner wiring diagram Variant connections for EL ELX versions vSJx m 1 9 5 f 42 Copyright Fiat Auto Location of components 51 ii 7yA 1 f j A_ lliiifl 3 X r Xl 8 v f ...

Page 663: ...ir conditioner 121 Three stage pressure switch 1 22 Engine cooling fan low speed control relay 123A Engine cooling fan high speed control relay 127 Connection between front left cables cable on relay carrier bracket 1 28 Front air conditioner cables connection 1 29 50A power fuse protecting engine cooling fan 154 Engine cooling fan 170 Engine cooling fan limiting resistor 195 Ignition fuel injecti...

Page 664: ... 2 3 5 5 7 8 910 1112 U M CB AR A R H 94 r 10AM L c c BNBN N bi c c N D f N D 4 0 N D RN rRN RN 1 L RN BN clRV h 95 0 J H PTfjr 12 SS N D AR _ AR RV BN Eft gift Bit 1 7 I 0 178 Variant connections for EL ELX versions N D k 179 M B R N R N N D 181 R V B N f 15 3 T 7T 17 M N R 6 1 1 1 10 11 11 e 3 6 i 1 176 NZ 55ZJU 174 180 da l M X 7 kJ rJ i Wff YWQ H Mr JffiggPS STL M M5 j n T f a y d X M J8ify If...

Page 665: ...ng electrical system 174 Power earth for anti lock braking system A B S 176 Diagnostic socket for anti lock braking sys tem A B S 177 Sensor on front left wheel for anti lock brak ing system A B S 178 Sensor on rear left wheel for anti lock brak ing system A B S 179 Sensor on front right wheel for anti lock braking system A B S 180 Sensor on rear right wheel for anti lock brak ing system A B S 181...

Page 666: ...0 4H11 Hill 2 3 4 5 6 7 G 91011121 AR AR N D C CB m N D f 1 2 m 40A30A 60A80A 131 I I I I I I i 2 3 4 5 6 7a A Al l il ml w r I I UN N S C N M R I I I W E UN I N S C N N N D N N 282 N D 1 Si sr R R RN I I 280 HM w S a 4 m Variant connections for EL ELX versions N D i 199 in 195 s N D 1 N 1 N f t N N S Hl Copyright Fiat Auto 13 ...

Page 667: ...t 139 Diagnostic socket for fuel injection 195 Ignition fuel injection electronic control unit 1581 199 Aerial for Fiat CODE system 280 7 5 A fuse protecting ignition switch 282 7 5 A fuse protecting Fiat CODE electronic fuel injection N D Ultrasound soldered joint taped in wiring loom 55 Fuse and relay unit Applies only to S SX version Applies only to EL ELX version 131 Fiat CODE electronic contr...

Page 668: ...e warning light Fuel injection fault warning light Rev counter HvfliiiiiF 8 iH KZ C fri f t LQJJ ajr 1 2 m I 1 3 I 5 7 IC111JIJt4 51 l lll 20 201911171 51 Mi NZ NZ 1 7 6S i 1 2 I 13 1 138 137 l N 1 I I 194 MB m NR RV 162 163 164 165 7J N N I 56A 56B 57 g 1 ZI See air conditioner diagram See Fiat CODE diagram Not present on S versions Copyright Fiat Auto 15 ...

Page 669: ...Fiat CODE electronic control unit 132 Petrol vapours cut off solenoid canister 136 Knock sensor 1 37 Car speed sensor 138 Idle adjustment actuator 139 Diagnostic socket for fuel injection 141 Heated Lambda probe 142 Low oil pressure warning light switch 143 Alternator 144 Rpm and T D C sensor 145 Starter motor 146 Potentiometer on throttle valve 150 Fuel injection control relay 155 Ignition coils ...

Page 670: ...III 129 r W 3 30A40A 60A8OA E 1 I S f U C15D i i 1413121110 9 B 1 6 b 4 5 T T f f f B AR AG N CB G SI i G N m ca N D L5L M CB M 5 H i eslpcc hr 12 O A N A N N D S 154 284 H HA G C N D c 55 E m 171 CB AG N HB NZ AR ARl N D T N D 1G n 195 206 202 GR N D 1VG RB VGlAN 6 d 42 207 208 Variant connections for EL ELX versions See side lights diagram Copyright Fiat Auto 17 ...

Page 671: ...rol connection 129 50A power fuse protecting engine cooling fan 154 Engine cooling fan 1 71 Heater unit 195 Ignition fuel injection electronic control unit 1581 202 Heater air conditioner light bulbs 206 Heater air conditioner electric fan 207 Heater air conditioner speed control switch 208 Limiting resistor for heater air conditioner 279 Engine coolant temperature double sender unit 284 Engine co...

Page 672: ... range Electrical system Wiring diagrams 55 Version S SX Direction indicators and warning lamp Hazard warning lights and warning lamp Stop lights Reversing lights N Hi 19 7 Not present on Bravo Copyright Fiat Auto 19 ...

Page 673: ...rth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 16 Rear left lights cluster 17 Rear right lights cluster 18 Rear left earth 19 Rear right earth 20 Front left side repeater 21 Front right side repeater 22 Left dashboard earth 23 Hazard lights switch unit A Hazard warning lights warning lamp B Hazard lights control switch C Hazard lights unit sy...

Page 674: ... range Electrical system Wiring diagrams 55 Version EL ELX Direction indicators and warning lamp Hazard warning lights and warning lamp Stop lights Reversing lights N H 19 Not present on Bravo Copyright Fiat Auto 21 ...

Page 675: ...arth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 16 Rear left lights cluster 17 Rear right lights cluster 18 Rear left earth 19 Rear right earth 20 Front left side repeater 21 Front right side repeater 22 Left dashboard earth 23 Hazard warning lights switch unit A Hazard warning lights warning lamp B Hazard warning lights switch C Hazard warni...

Page 676: ... Rev counter Front brake pad wear warning light j B9 m 4 H I IIII B9 B 3 3 Q A 40A 60A80A CB AR 2y 1 2 3 5 1T 2I3M 1 io I 2 3 4 5 6 7 6 9 a frR 70 CB N D j CB BN HR 1 G3 279 137 N BN J L LN MG N BN N D BN N D HB LN M G L HG CN M HG L BN R BR N CN H B 3 28 90 iBN 12 See side lights diagram P 55 NZ HG L HB 2 195 R NZHR N Z N N D 1 2 3 5 6 7 fi 9 I01H213U1S1S1718I970 44 I 1 3 4 5 6 7 8 9 1011121314 1...

Page 677: ...Z1 Trip recorder reset button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 19 Rear right earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front cables fuel gauge control connection 56 Fuel gauge control unit A Fuel gauge sensor B Electric fuel pump 70 Dashboard front cables con...

Page 678: ...el gauge and reserve warning light Hand brake on low brake fluid warning light Speedometer Trip recorder total mileage counter and reset button Water temperature gauge Low engine oil pressure warning light Front brake pad wear warning light Rev counter P4A45EL01 Copyright Fiat Auto 25 ...

Page 679: ...reset button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 19 Rear right earth 22 Left dashboard earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front cables fuel gauge control connection 56 Fuel gauge control unit A Fuel gauge sensor B Electric fuel pump 70 Dashboard front cab...

Page 680: ... AB GN N O N D L R N f i i a K153 1 2 3 8 1 6 S O 2 I7 6 AG N GN B R 9 G i BN L B I ce Q_ f I 1 2 m CB CB 1 N D I CB AG N D RN RN N D C f C c N D f AN f 127 N N N D N D 209 I 120 H 210 L r RN AN Lb rt v GR RN vl l 203 120 M ANIC I N CVIHRI BNI L 208 f f i 202 cv fN D I H IHRI R b A N N 206 207 205 Rv N ifcz J J 204 124 K Bi JO a I KG KG I MN RN AN 232 235 MNWC 147 Z 195 P4A49EL01 Copyright Fiat Au...

Page 681: ...n limiting resistor 195 Ignition fuel injection electronic control unit 1581 02 Heater air conditioner light bulbs 203 Air conditioner controls unit A Switch for switching on air conditioner B Switch for air conditioner recirculation 204 Air conditioner fan 1st speed control relay 205 Air conditioner fan relay 206 Heater air conditioner electric fan 207 Heater air conditioner speed control switch ...

Page 682: ... 98 range Electrical system Wiring diagrams Courtesy light Symbol illumination 55 4 llllll JUJL M 30A40A 60AB0A 107B u KM Variant connections for S SX versions Not present on Bravo P4AB3EL01 Copyright Fiat Auto 29 ...

Page 683: ...witch controls unit symbol light H Front fog lamps warning light I Front fog lights switch 42 Right dashboard earth 48 Radio with clock 58 Lighting brightness adjustment rheostat 59 Courtesy light button on front left pillar 60 Courtesy light button on front right pillar 61 Courtesy light button on rear left pillar 62 Courtesy light button on rear right pillar 64 Glove compartment light with built...

Page 684: ...Bravo Brava 98 range Electrical system Wiring diagrams 55 Version S SX Instrument panel connections Not present on S versions Copyright Fiat Auto 31 ...

Page 685: ...attery earth on body shell 11 Battery 12 Ignition switch 13 Front left right cables connection 22 Left dashboard earth 28 Dashboard longitudinal cables connection 42 Right dashboard earth 55 Front fuel gauge control cables connection 56 Fuel gauge control unit A Fuel level sensor B Electric fuel pump 70 Dashboard front cables connection 88 Low brake fluid level sensor 89 Left brake pad wear sensor...

Page 686: ...i 98 range Electrical system Wiring diagrams Version EL ELX Instrument panel connections 55 4B9IH RN BR N D i P ttUMMR n Variant connections for versions without alarm See central door locking Copyright Fiat Auto 33 ...

Page 687: ...ght earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 16 Rear left lights cluster 17 Rear right lights cluster 22 Left dashboard earth 28 Dashboard longitudinal cables connection 40 Stop lights switch 42 Right dashboard earth 55 Front fuel gauge control cables connection 56 Fuel gauge control unit A Fuel level sensor B Electric fuel pump 58 Li...

Page 688: ...ng diagrams 55 Diagnostic socket connections Location of components Mlllll 0 I 12 3 5 6 7 3 3 2 1 N S 131 SI N D N N N D H 12 l B r E 130 E 114 Y 176 103 NZ N NZ N N N i N M N D 174 N N D ffl N N 100 Kl j N D H 195 T f 139 Copyright Fiat Auto 35 ...

Page 689: ...n 174 Power earth for anti lock braking system A B S 176 Diagnostic socket for anti lock braking sys tem A B S 181 Anti lock braking system ABS electronic control unit 195 Ignition fuel injection electronic control unit 1581 N D Ultrasound soldered joint taped in wiring loom 55 1 O Front right left cables connection 1 0 3 Diagnostic socket for alarm 1 J Q Diagnostic socket for Air bag system 1 4 Q...

Page 690: ...er rear window wiper stalk C Rear window wiper switch D Flasher button E Dipped beam main beam headlamps stalk F Side lights stalk H Direction indicators stalk I Horn button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 12 Ignition switch 13 Front right left cables connection 14 Left number plate light 15 Right number plate light 16 Rear left lights cluster 17 Re...

Page 691: ...B S 177 Sensor on front left wheel for anti lock braking system A B S 178 Sensor on rear left wheel for anti lock braking system A B S 179 Sensor on front right wheel for anti lock braking system A B S 180 Sensor on rear right wheel for anti lock braking system A B S 181 Electrohydraulic control unit for anti lock braking system A B S 194 Injection injector flange cables connection 195 Ignition fu...

Page 692: ...tesy VARIOUS DEVICES Location of additional fuses relays Power steering pump sensor Control buttons on facia Engine oil level control unit 33 34 35 35 35 55 page RADIO SYSTEM Cassette radio AD 182 H2 36 General description 37 Operation 38 Switching on radio 38 PAUSE function 39 Bass and treble adjustment 39 Adjusting balance between right and left speakers 39 Adjusting balance between front and re...

Page 693: ...NIT Integrated service electronic control unit 83 Operating the front electric windows 84 Door lock release 84 Central door locking release 85 Door open close remote control unit 85 Receiver 85 Simplified programming 86 Protected programming 86 Opening the memory and storing a new remote control unit 86 Timed passenger compartment lighting 87 Timed heated rear window operation 88 Publication no 50...

Page 694: ...vehicles to reduce high currents overloading or short circuits The size of all the system fuses is based on the nominal absorption of the simultaneous loads and is de signed to guarantee operation in the case of a short circuit Through the adoption of a fuse box containing four maxi fuses plus other located outside it is possible to protect all the supplies with the sole exception of the cable whi...

Page 695: ... Power fuse protecting engine cooling fan See air conditioning engine cooling wiring diagrams for relevant engine types 143 Alternator 145 Starter motor 201 Heater plugs control unit 238 Power fuse protecting engine cooling fan See air conditioning engine cooling wiring diagrams for relevant engine types Exists only for the Turbo Diesel versions 60A fuse for Turbo Diesel versions 2 XI 98 Cancels a...

Page 696: ...mp washer intermittent device 122 Engine cooling fan low speed relay 123A Engine cooling fan high speed relay 124 Air conditioning compressor relay 129 Power fuse protecting engine cooling fan 150 Injection system relay feed 290 Electric fuel pump relay feed 307 I E system protective fuse 1242 1 6v 308 15A fuse protecting canister solenoid valve 335 1 5A fuse protecting Lambda sensor Copyright by ...

Page 697: ... sun roof control unit all versions and engine types 96 Power fuse protecting A B S system 98 Preparation for headlamp washer intermittent device 122 Engine cooling fan low speed relay 123A Engine cooling fan high speed relay 124 Air conditioning compressor relay 129 Power fuse protecting engine cooling fan Bravo Brava 98 range 4 XI 98 Cancels and replaces Print no 506 670 17 ...

Page 698: ...d relay 124 Air conditioning compressor relay 129 50A protective power fuse for engine cooling fan 238 Protective power fuse for 2nd engine cooling fan 239 Diesel preheating protective relay 1910 JTD 240 Diesel pre heating protective fuse 1910 JTD 282 Fiat CODE I E control unit 30A pro tective fuse 350 Passenger compartment coolant heat ing relay 351 Passenger compartment coolant heat ing safety r...

Page 699: ...ainte nance relay C Spare D 25A fuse protecting central locking control unit E 20A protective fuse current socket cigar lighter electric seats F 10Afuse protecting EURO BAG 296 Fuse carrier base on front cable A 7 5A fuse protecting cooling sys tem I E alarm automatic transmis sion B 20A fuse protecting windscreen wiper C 7 5A fuse protecting Fiat CODE cooling system I E D 10A fuse protecting anti...

Page 700: ... sun roof F 10Afuse protecting EUROBAG 296 Fuse carrier base on front cable A 7 5A fuse protecting cooling system I E alarm automatic transmission 307 308 315 317 330 B 20A fuse protecting windscreen wiper C 7 5A fuse protecting Fiat CODE cooling sys tem I E D 10A fuse protecting anti lock braking system A B S E 7 5A fuse protecting climate control system F 7 5A fuse protecting electronic injectio...

Page 701: ...unit 103 Diagnostic socket for alarm 139 Diagnostic socket for injection system 1 76 Diagnostic socket for anti lock braking system A B S 181 Electro hydraulic control unit for an ti lock brakes A B S 190 Injection ignition unit 1998 20v 195 Injection ignition unit 1581 16v 294 Injection ignition unit 1242 16v electronic control electronic control electronic control 8 XI 98 Cancels and replaces Pr...

Page 702: ...iesel ver sions 100 Alarm device electronic control unit 181 Electro hydraulic control unit for an 103 Diagnostic socket for alarm ti lock brakes A B S 139 Diagnostic socket for injection system 201 Heater plugs control unit 1910 JTD 1910 JTD 176 Diagnostic socket for anti lock braking system A B S Copyright by Fiat Auto XI 98 Cancels and replaces 9 ...

Page 703: ...onic control unit 1747 16v 272 Automatic transmission diagnostic socket 273 Automatic transmission control unit 295 297 299 330 349 357 Injection ignition electronic control unit 1910 JTD Climate control control unit Diagnostic socket for climate control system A B I control unit Alzacristalli Blocca porte Integrato Inegrated Central locking electric windows Engine oil control unit Passenger compa...

Page 704: ... particular shape The iden tification letters for the connectors are the same as those used in the wiring diagrams o y 1 4 J i 12 6 1 9 i ir u 0 E2 TL4 H 10 E3 5 8 n 4 14 it Ji l l fj 1 D 0 n 5 1 B E1 0 Rear view of the junction unit and Location of relays E1 Ignition discharge relay dur ing starting E2 Heated rear windscreen relay E3 Horn relay Copyright by Fiat Auto XI 98 Cancels and replaced 11...

Page 705: ...lamp alignment Fuse No 6 7 8 9 10 11 12 13 14 15 Amp 10 10 20 10 10 30 30 20 20 20 Ideo gram ID ID 0 A SERVIZI SERVICES m ft hy V Circuit protected Right main beam headlamp Left main beam headlamp Main beam headlamps warning light Rear fog lamps Hazard warning lights flash er Interior light Luggage compartment light Clock supply Remote control re ceiver supply where fitted Radio supply Glove com p...

Page 706: ...ng Fiat CODE cooling system I E F E D C B A 17 5 SMI 17 5 S i I Mo oil 17 5 S i 120 031 17 5 S i 110 Oil 120 0Z 125 S3 25 S 115 SH 17 5 SYI 296 293 296 293 D 10A fuse protecting anti lock braking sys tem A B S E 7 5A fuse protecting climate control sys tem F 7 5A fuse protecting electronic injection DIAGRAM SHOWING CONNECTIONS INSIDE THE JUNCTION UNIT TTTTTTT B 4f TTTTTTTTTTTTTTTTTT 1 2 3 4 5 6 7 ...

Page 707: ...h air condi tioning air conditioning control unit Electric fuel pump operation inertia switch Heating air conditioning system speed control switch Right dipped headlamp Left dipped headlamp headlamp washer go ahead Left main beam headlamp Right main beam headlamp CONNECTOR E Term No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Cable colour RN RG M N MB AG AN GR GR RG RN R Circuit concerned Right rear brake li...

Page 708: ...o 1 2 3 4 5 6 7 8 9 10 Cable colour A CZ A RN AN AN AN A BR MB Circuit concerned Right direction indicator warning light Central door locking control unit Hazard warning lights operation Instrument panel device signalling brake lights failure Right direction indicator control Hazard warning lights control Left direction indicator warning light Left direction indicator control Instrument panel devi...

Page 709: ...rol unit aside disconnect the connec tors from the rear and remove the control unit from the dashboard Suitably reverse the operations car ried out for the removal Refitting control unit shield 3 Position the shield in the housing in the dashboard inserting the centering tabs lo cated on the lower part 4 Turn the shield upwards until it is contact with the dashboard Complete the refitting proceedi...

Page 710: ...n indicator warning light 7 Side lights warning light 8 Right direction indicator warning light 9 Main beam headlamps warning light 10 Handbrake applied insufficient brake level warning light 11 Rev counter 12 Engine coolant temperature gauge 13 EURO BAG system failure warning light fluid 14 Odometer 15 Low engine oil pressure warning light 16 Battery recharging warning light 17 Injection system f...

Page 711: ... warning light D Right direction indicator warning light E Side lights warning light F Instrument panel ideogram light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Petrol Diesel injection system failure warning light 0 Glow plug warning light only f...

Page 712: ...warning light F Instrument panel ideogram light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Petrol Diesel injection system failure warning light O Glow plug warning light Q Front brake pad wear warning light R Handbrake applied insufficient brake f...

Page 713: ...rning light 7 Side lights warning light 8 Right direction indicator warning light 9 Main beam headlamps warning light 10 Handbrake applied insufficient brake level warning light 11 Rev counter 12 Engine coolant temperature gauge 13 EURO BAG system failure warning light 14 Brake lights failure warning light fluid 15 Doors open warning ilght 16 Odometer 17 Low engine oil pressure warning light 18 Ba...

Page 714: ...symbol light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Petrol Diesel injection system failure warning light O Glow plug warning light only for JTD Q Front brake pad wear warning light R Handbrake applied insufficient brake fluid level warning lig...

Page 715: ...e of the ABS and AIR BAG device warning lights The caps must therefore be replaced with the releavnt warning lights if one or both devices are present Location of caps on VEGLIA BORLETTI instrument panel Location of caps on NSI instrument panel Location of caps on VEGLIA BORLETTI instrument panel with automatic transmission 18 4 x s ppdie Publication n 506 670 21 ...

Page 716: ...ed Speedometer signal 30 battery Speedometer generator supply Engine coolant temperature Outdoor temperature serial signal Speedometer signal Rev counter signal Connector B No pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Wiring colour RG BR LG AN A GN VN BN RN GR N HR VB AR NZ HM on facia lead Circuit involved Left car brake light failure Brake light Not connected Euro ...

Page 717: ...warning light 7 Side lights warning light 8 Right direction indicator warning light 9 Main beam headlamps warning light 10 Handbrake applied insufficient brake fluid level warning light 11 Rev counter 12 Engine coolant temperature gauge 13 EURO BAG system failure warning light 14 Odometer 15 Low engine oil pressure warning light 16 Battery recharging warning light 17 Injection system failure warni...

Page 718: ...g light C Left direction indicator warning light D Right direction indicator warning light E Side lights warning light F Instrument panel ideogram light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Injection system failure warning light O Glow plug ...

Page 719: ...ning light 7 Side lights warning light 8 Right direction indicator warning light 9 Main beam headlamps warning light 10 Handbrake applied insufficient brake level warning light 11 Rev counter 12 Engine coolant temperature gauge 13 EURO BAG system failure warning light 14 Brake lights failure warning light 15 Doors open warning ilght 16 Odometer 17 Low engine oil pressure warning light 18 Battery r...

Page 720: ...t 8 Right direction indicator warning light 9 Main beam headlamps warning light 10 Handbrake applied insufficient brake level warning light 11 Rev counter 12 Engine coolant temperature gauge fluid 13 EURO BAG system failure warning light 14 Brake lights failure warning light 15 Doors open warning ilght 16 Odometer 17 Low engine oil pressure warning light 18 Battery recharging warning light 19 Inje...

Page 721: ...ts warning light F Instrument panel ideogram light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Petrol Diesel injection system failure warning light 0 Glow plug warning light only for JTD ver sions Q Front brake pad wear warning light R Handbrake ap...

Page 722: ... Speedometer generator power supply Engine coolant temperature Outdoor temperature serial signal Speedometer signal Rev counter signal Connector B No pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Wiring Colour RG BR LG BL AN A GN VN BN RN BH NR GR N HR VB AR NZ HM on facia lead Circuit involved Left car brake light failure Brake light Not connected Euro Bag device failur...

Page 723: ...warning light 10 Fiat CODE system failure warning light 11 Brake pad wear warning light 12 Handbrake applied insufficient brake level warning light Bravo Brava 1998 range 13 Doors open warning ilght 14 Brake lights failure warning light 15 Automatic transmission warning light 16 Low engine oil pressure warning light 17 Battery recharging warning light 18 Injection system failure warning light 19 M...

Page 724: ...panel ideogram light G Main beam headlamps warning light H EURO BAG system failure warning light I Anti lock brakes failure warning light J Fuel reserve circuit control module J1 Fuel reserve warning light K Fuel gauge L Fiat CODE failure warning light M Petrol injection system failure warning light P Automatic transmission failure warning light P1 Automatic transmission circuit control mod ule Q ...

Page 725: ...V on left front lead Circuit involved Generator Brake fluid level Injection failure 30 battery Not connected Not connected Not connected Brake lining wear Fiat CODE Not connected Not connected Insufficient engine oil pressure Speedometer signal Not connected Speedometer generator supply Rev counter signal Engine coolant temperature Not connected ABS system failure Not connected power 26 X 9D Super...

Page 726: ...nnected No pin 10 11 12 13 14 15 16 17 18 19 20 Wiring Colour AN A ZN NZ HR AR LG Circuit involved Left turn signal Right turn signal Not connected Automatic transmission signal Electronic earth Not connected Fuel level 15 Euro bag device failure Not connected Not connected Connector C No pin 1 2 3 4 5 6 7 8 Wiring Colour BH RG RN AR N BR Circuit involved Boot open Left brake light failure Right b...

Page 727: ...5 9 Electrical operating diagram Fuel gauge 1 Left dashboard earth 2 Junction unit 3 Instrument panel 4 Fuel gauge 5 Fuel gauge control module 6 Fuel reserve warning light 7 Fuel level gauge 8 Right rear earth A R N 9i 1 2 112 rh 1 15 L J T Y N B22 B23 H R B20 4 a r N Z HR C3L f COOLANT TEMPERATURE GAUGE ENGINE COOLANT Temperature of Coolant C 50 8 0 100 130 Sensor Value Ohms 820 36 2 7 3 1 4 3 62...

Page 728: ...ing light fluid 9 14 Passenger side EURO BAG system failure warning light Warning lights for turbo diesei and petrol versions with outfit ELX v u CODE 1 2 4 5 6 O 3 BD 0 O Q 7 8 9 10 11 12 13 v 1 Glow plug warning light only for turbodiesel 7 versions 8 2 Fiat CODE failure warning light 9 3 Injection system failure warning light 10 4 Battery recharging warning light 11 5 Low engine oil pressure wa...

Page 729: ...ght 13 Doors open warning ilght 14 Passenger side light EURO BAG off warning Warning lights for 1581 version with automatic transmission and oufits SX ELX 1 2 3 4 6 7 ISTOPI 8 9 10 O 11 CODE 12 0 13 1 Automatic transmission system failure warning light 2 EURO BAG system failure warning light 3 Side lights warning light 4 Main beam headlamps warning light 5 Injection system failure warning light 6 ...

Page 730: ...te for 20 sec onds and then the outside temperature is flashed for 10 seconds The sequence described above is known as the warning cycle This takes place only once after the detection of an outside temperature below 3 C and can only be re peated after the outside temperature goes above 6 C and then below 3 C With the ignition ON and the outside temperature below 3 C the instrument displays the war...

Page 731: ... Undo the outer bolt fixing the instrument panel frame 2 Undo the outer bolts fixing the instrument panel frame 3 Extract the frame from the dashboard after having disconnected the connector for the headlamp dimmer shown by the arrow 4 Undo the bolts fixing the instrument panel to the dashboard 5 Disconnect the two electrical connections for the instrument panel and remove it from the vehicle 32 X...

Page 732: ...OUR TESY LIGHT AND REPLACING BULB Using a screwdriver in the side slit remove the courtesy light from its housing disconnect the connector and remove the courtesy light P4A33HL02 release the bulb from the flexible tabs and remove it P4A33HL03 Copyright by Fiat Auto XI 98 Update 33 ...

Page 733: ...3 0 m V _fi l 2 disconnect the electrical connector and remove the glove compartment from the vehicle behind which the additional re lays and fuses are located INERTIA SWITCH 3 The inertia switch is located inside the ve hicle under the dashboard on the driver s side POWER ASSISTED STEERING PUMP SENSOR 4 Location of power assisted steering pump sensor valid for 1242 versions only 34 XI 98 Update P...

Page 734: ...erated by a control unit located behind the glove compartment The warning lights in the instrument panel carry out a self test lasting about 2 seconds when the igni tion is switched on If the engine oil level is below the minimum level the electronic control unit switches on the warning light for 30 seconds at a frequency of 2 Hz In the case of a sensor short circuit or open circuit there will be ...

Page 735: ...n 12 Switch for programming station N3 selecting TRACK RANDOM function setting time hour in troducing secret code figures 13 Switch for programming station N4 selecting TP function volume setting minutes deactivating clock syncrhonization with R DS Tl M ER signals selecting LN R function setting on volume select ing radio suppressing function when HANDS FREE phone is fitted adjusting telephone inp...

Page 736: ...MW and LW bands Automatic programming of transmitters through Autostore function at buttons 1 2 3 4 5 6 on FM1 FM2 FM3 MW and LW bands DX automatic function Distant maximum sensitivity in searching for radio stations Automatic programming Autostore Audiocassette function Autoreverse Tape fast forward or rewind Music Search System function automatic search for previous next track DOLBY B noise redu...

Page 737: ...To activate this logic keep the button 5 for selecting stations 1 with the radio switched off pressed until the words IGN ON appear on the display then switch on the radio using the VOL control 2 The logic is only activated whenthe radio is switched on via the VOL control To deactivate this logic keep the button 4 for selecting stations 3 with the radio switched off pressed until the message IGN O...

Page 738: ... and TREB Select the BASS or TREB function by pressing the AUDIO button 2 briefly once or more Having selected the function adjust the de sired sound using the VOL control 1 To restore the basic adjustment press the AUDIO button 2 for about 3 seconds until the message 00 or appears on the dis play BflL L R Adjusting the BALANCE between the left and right speakers The balance is the volume ratio be...

Page 739: ... button 1 this func tion is activated and the message LOUD appears on the display To deactivate the function activated previ ously simply press the LOUD button 1 again MUTE function By pressing the AUDIO button 1 for about 3 seconds the MUTE function is selected and the message MUTE ON appears on the display diagram below To deactivate this function the AUDIO but ton has to be pressed again The me...

Page 740: ...nction Using the BAND button 1 select the F M 1 FM2 or FM3 range Press the IS button 2 briefly for the intelli gent automatic search At the end of the search the RDS pro grammes are memorized first and then the transmitters according to their transmission power in the radio IS memory The IS memo ry is capable of storing up to 30 transmitters If reception is not possible it remains con stantly acti...

Page 741: ...sitivity with which to search for radio transmitters With the DX function activated the radio only selects stations above a certain power level With the DX function deactivat ed radio stations with lower power levels are also selected To activate the DX function press the button 1 the function is then de activated if the same button is pressed again Automatic memorizing of transmitters AUTOSTORE F...

Page 742: ...frequency selec tion buttons or if no buttons are pressed for sixty seconds Listening to programmed stations Proceed as follows 1 Select the desired band using the BAND control 1 2 Briefly press one of the frequency selec tion buttons 1 2 3 4 5 6 The display will show the button pressed and the transmitter code if it is an RDS transmit ter If the transmitter selected offers an RDS ser vice and the...

Page 743: ...ng to acti vate the TP function Point b If you wish to receive traffic news before inserting the audio cassette or Compact Disc tune into an RDS TP transmitter If whilst listening to a cassette or a Compact Disc there is a traffic news flash the reproduction of the tape or the Compact Disc will be temporarily halted and then resumed automatically afterwards Point c It is possible to receive traffi...

Page 744: ...refer to the paragraphs be low Programming desired types of programmes using the station selection buttons Press the TP button 1 in the diagram above for about 6 seconds until the display shows the message PTY ON Select the type of programme desired using the k 2 T 3 buttons Having identified the type of programme desired for example classical music CLASSICS press the station selection button 1 2 ...

Page 745: ...he type of pro gramme desired press one of the but tons for about 2 seconds to start the auto matic search The search stops when the ra dio tunes into a transmitter broadcasting the type of programme selected The display will show the type of programme for example CLASSICS WEATHER Weather forecasts FINANCE Financial news CHILDREN Childrens broadcasts SOCIAL A Social information RELIGION Religion p...

Page 746: ...audio cassette Open the protective flap for the cassette play er by pressing the button 1 Fully insert the audio cassette by hand until the radio automatically switches to playing it To close the audio cassette housing press the button 1 vertically closing the flap until the retaining spring can be heard clicking Changing the side of the tape listened to When the audio cassette housing contains a ...

Page 747: ...tion press the MSS but ton 1 during operation of the cassette The message MSS ON will appear on the dis play To move onto the next track press the A 2 button whilst to move to the previous track press the T 3 button By pressing the A button or the T button repeatedly the same number of tracks as the number of times the buttons has been pressed are skipped To deactivate the MSS function press the M...

Page 748: ...io operates tuned into the last sta tion listened to The audio cassette cannot be ejected with the radio switched off Temporary halt whilst listening to a cassette It is possible to temporarily stop listening to a cassette by pressing the MODE button listening to a cas sette can be resumed by pressing it again Never expose audio cassettes to heat or direct sunlight always store them in their conta...

Page 749: ...h can hold up to 6 Compact Discs Filling the Compact Disc loader Extract a support for each Compact Disc that you wish to play insert the Compact Disc with the label or the printed section facing the support P H If the Compact Disc has been posi Z f l tioned incorrectly it cannot be played Inserting the loader in the Compact Disc player NOTE The player cannot play 8 cm Com pact Discs unless a spec...

Page 750: ...rrow on the Compact Disc player Removing Compact Discs from the loader Remove the discs and supports from the loader in order Compact Disc reproduction To play Compact Discs CD already inserted previously in the player press the MODE button 1 repeatedly until M C D appears on the display If this function is selected after each inser tion in the loader the words CD CHECK appear on the display whils...

Page 751: ...the word MECHANIC will appear on the display If the Compact Disc player has overheated the words TOO HOT will appear on the display the last condition mentioned above occurs it is advisable to switch off the CD player for a while Disc selection Press the station selection button 5 1 or 6 2 briefly and repeatedly until the number of the desired CD appears on the display Using station selection butt...

Page 752: ...e TRK ON will appear on the display By pressing the station selection button 1 1 again the TRACK REPEAT function selected previously will be disabled The message TRK OFF will appear on the display Repeating tracks from the CD selected REPEAT function To repeat the CD being listened to press the station selection button 2 1 The message RPT CD will appear on the display To end the repetition of the ...

Page 753: ... player and the radio is ended and the RADIO configuration is restored Display of the CD player state By pressing the EXP button 1 briefly any special function activated for example TRK ON is displayed Never expose discs to sources of heat or direct sunlight always place them back in their con tainer after use Compact Discs should be protected from dust and the surface of the discs should never be...

Page 754: ...RT Selezionare mediante i tasti A T 2 3 la regolazione che si desidera effettuare Premendo i tasti opportuni di selezione delle frequenze e possibile impostare il livello de siderate I tasti di selezione delle frequenze interessati dipendono dalla regolazione che si desidera effettuare Per la loro identificazione si rimanda ai para grafi successivi relativi alle singole regolazio ni possibili Per ...

Page 755: ... between these transmissions selecting the one with the strongest signal The frequency selection buttons needed are button 5 1 for switching the function on and button 4 2 for switching it off The messages displayed are RES ON when the function is switched on and RES OFF when the function is switched on see diagram Limiting the switching on volume It is possible to select the level of the volume w...

Page 756: ...m the dashboard if it is stolen Secret code The 4 digit secret code is on the Security Code Card which is given at the same time as the Fiat Code Card The secret code should be kept in a safe place for example together with the vehicle documents but not in the vehicle Press the EXP button 2 and press the A T 3 4 buttons until the message SAFE or CODE ap pears on the display SAFE if the code is act...

Page 757: ...ectronically protected In order to be used again the code must be introduced following the procedure described below Switch on the radio using the VOL control 1 the message SAFE will appear on the display followed by I Key in the code following the previous exam ple Confirm the code by briefly pressing the EXP button 2 After around 3 seconds the radio will start to work If an incorrect code is int...

Page 758: ...T10A Supply voltages Contacts at blade A A8 Connection for earth Connect to terminal 31 earth of the vehicle A7 Connection for 12V supply voltage Connect to terminal 30 continuous positive of the vehicle A6 Connection for instrument lights Contact not connected no lights with radio switched off if the instrument lights are switched on A5 12 V switching voltage output max 0 5 A Present at the conta...

Page 759: ...ed speaker C1 Left rear speaker C2 Right rear speaker C3 Earth C4 Left front speaker C5 Right front speaker C6 Switching voltage for power amplifier on off max 0 3 A Steering remote control C8 Earth C9 Remote control Telephone input Possibility of connection for car phone or receiver transmitter listening through radio C7 Telephone NF C12 Telephone earth NF Disc change connections C13 CD bus contr...

Page 760: ...assettet fast forward button BN button for selecting FM1 FM2 FM3 MW LW frequencies for starting IS automatic search for selecting AUTOSTORE function For recalling IS memory for RDS transmitters automatic search for manual tuning into transmit ters for setting the type of programme for selecting the type of adjustment from the EXPERT menu TP button for selecting the TP function for selecting AF alt...

Page 761: ...ystem with TP Traffic Program EON functions Automatic manual station tuning Manual programming of 5 stations on FM1 FM2 FM3 bands and MW and LW band Automatic programming of transmitters via the AUTOSTORE function with buttons 1 2 3 4 5 on the FM1 FM2 FM3 MW and LW bands Automatic IS search tuning Audio cassettte section Autoreverse Tape fast forward and rewind Audio section Loudness function Mute...

Page 762: ...or about 3 seconds until the message EXPERT appears on the display Select the on off adjustment via the ignition switch using the A 2 a n d V 3 buttons Press frequency selection button 5 4 to ac tivate the function or if activated previously press frequency selection button 4 5 to de activate it The messages IGN ON and IGN OFF re spectively will appear on the display when the function is activated...

Page 763: ...he AUD button for about 3 seconds until the message 00 or appears on the display Adjustment of balance between left and right speakers BALANCE The balance is the volume ratio between the left and right speakers The adjustment can be made by pressing the AUD button 1 several times briefly to select the BAL ANCE function The message BAL L R will appear on the display The VOL control 2 can be used to...

Page 764: ...he display When the Mute function is selected the radio no longer sends any signals to the speakers RADIO FUNCTION K M Reception conditions vary constantly whilst driving Reception can be interfered with by the Q presence of mountains buildings or bridges especially when the broadcasing transmitter is far away NOTE When the RADIO function is activated the last station listened to before switching ...

Page 765: ...ppears on the display followed by IS ON By pressing one of the A buttons briefly it is possible to recall the transmitters pro grammed To deactivate the IS function press one of the A T buttons briefly until the message IS OFF appears on the display RDS transmitters automatic search tuning Select the FM or A M frequency desired using the BN button 1 The IS function should not be activated for this...

Page 766: ...ncy selection buttons or if none of the buttons has been pressed for 60 seconds Listening to programmed stations Select the desired band using the BN button 1 Press one of the frequency selection but tons briefly The display will show the button pressed and the transmitter code if it is an RDS transmit ter If the transmitter selected offers an RDS ser vice and the reception is not good the radio w...

Page 767: ...inserting the audio cassette tune into an RDS TP transmitter If traffic news is broadcast whilst listening to a cassette the reproduction of the tape will be temporarily halted and resumed automatically when the news flash is over Point c Even when not listening to the radio it is possible to receive traffic news After having tuned into an RDS TP transmitter and set the volume at zero if this tran...

Page 768: ...of programme de sired in the station selection buttons Press the TP button 1 for about 6 seconds until the message PTY ON appears on the display Select the type of programme de sired using buttons k T 2 3 Having identified the type of programme de sired for example classical music CLAS SIC press the station selection button 1 2 3 4 5 desidered for more than 2 sec onds The type of programmed select...

Page 769: ...he automatic search The search is halted whtn the radio tunes into a transmitter broadcasting the type of pro gramme selected WEATHER Weather forecasts FINANCE Financial news CHILDREN Childrens programmes SOCIAL A Social information RELIGION Religion and philosophy programmes PHONE IN Phone ins TRAVEL Travel news LEISURE Leisure hobbies and pastimes JAZZ Jazz music COUNTRY Country music NATIONAL N...

Page 770: ...he message TAPE A or TAPE B appears on the display briefly press buttons 1 and 2 simultaneously The player will play the other side of the tape The messages TAPE A and TAPE B mean the upper side and the lower side of the audio cassette respectively P4A71HL01 Fast forward and rewinding Whilst listening briefly press button 1 or 2 to fast forward or rewind the audio cas sette respectiv ely The messa...

Page 771: ...witching the clock RDS tuning on off 3 Traffic news minimum volume 4 LRN on off 5 Regional programme automatic change on off 6 LOC on off 7 MONO on off 8 LOUDNESS on off 9 FADER on off 10 Limiting volume when switching on 11 BDLY delay in switching BOOSTER connected on off 12 Switching on off via ignition 13 Audio mute during operation of car phone 14 Telephone input sensitivity Selecting and modi...

Page 772: ...quency selection button 4 3 is pressed the message SYNCH OFF will appear on the display Minimum volume for listening to traffic news The desired level can be set using frequency selection buttons 4 1 and 5 2 to increase or decrease the volume respectively During the adjustment the message TAVOL YY will appear on the display where YY re fers to the volume level set Switching LIMR on off radio funct...

Page 773: ...cted the search is also extended to less powerful transmissions To activate the LOC function press the fre quency selection button 5 1 until the mes sage LOC ON appears on the display To deactivate the function selected previously press frequency selection button 4 2 until the message LOC OFF appears on the dis play MONO function The MONO function makes it possible to set the radio equipment to st...

Page 774: ...e the LOUDNESS function press frequency selection button tasto 5 1 until the message LOUD ON appears on the dis play To deactivate the LOUDNESS func tion activated previously press frequency selection button 4 2 FRDER ON FADER function By selecting the FADER function it is pos sible to alter the distribution of the volume between the front and rear speakers To select the FADER function press frequ...

Page 775: ...ensitivity The telephone input sensitivity can be adjusted using frequency selection button 4 or 5 The messages PHONE 00 or PHONE 03 respectively are displayed for lesser or greater sensitivity TECHNICAL INFORMATION Aerial The vehicle has an aerial located on the roof Electrically operated aerial and external amplifier available on request The radio is prepared for an automatic electrically operat...

Page 776: ... 20 W or 2 x 15 W Connection for 4 x 20 W Front speaker Rear speaker B3 right B1 right B4 right B2 right B5 left B7 left B6 left B8 left Connection for 2 x 1 5 W B3 right B2 right B5 left B8 left When operating with 2 x 15 W the FADER should be switched off in the EXPERT Menu A4 Connection for voltage of 12 V Connect to terminal 15 of the vehicle if the radio is going to be switched on and off via...

Page 777: ...mplifier Booster or speaker activated C1 Left rear speaker C2 Right rear speaker C3 Earth C4 Left front speaker C5 Right front speaker C6 Switching voltage for power amplifier on off max 0 3 A Steering remote control C8 Earth C9 Remote control Telephone input Possibility of connection for car phone or receiver transmitter listening through the radio C7 Telephone NF Btavo Brava 98 range s 78 XI 98 ...

Page 778: ...l 11 volume print no 506 670 01 On the version in question as a result of a differenti CODE system software configuration the specific procedure described below must be followed At least two main keys are required in addition to the MASTER key Insert the wine MASTER key in the ignition switch in the OFF position Turn the MASTER key to the ON position 15 the CODE warning light should come on for 0 ...

Page 779: ...sition 15 the CODE warning light should come on for 0 7 sees When the CODE warning light goes out turn the key 1 to the OFF position and extract it Repeat the operations as for the key 1 for the second key and for all the keys to be pro grammed Within 10 seconds insert the MASTER key once again in the ignition and turn it to the ON position 15 the CODE warning light should come on for 0 7 sees 80 ...

Page 780: ... than 10 sees because all the codes pro grammed will be cancelled Turn the MASTER key to the ON position 15 the CODE warning light should come on for 0 7 sees When the CODE warning light goes out turn the MASTER key to the OFF position Repeat the two previous operations until when the MASTER key is turned to the ON position the CODE warning light rather than coming on for 0 7 seconds remains on co...

Page 781: ...s placed in the ON position the CODE warning light will go out after coming on initi cally for 0 7 seconds otherwise it will start to flash in rapidly 1 6 Hz if this is the case the program ming procedure must be repeated If a mistake is made at any time during the programming procedure place the ignition key in the ON position for longer than 2 seconds or in the OFF position for longer than 10 se...

Page 782: ...raise 9 Supply to driver side window motor lower 10 Driver side window motor control raise 11 Driver side window motor control lower 12 Lock control from remote control unit 13 Release control from remote control unit 14 N C 15 Power supply 30 16 Power supply 30 17 N C 18 Passenger side window control from driver s side raise 19 N C 20 Driver s side window earth Connector B 1 Timed ear courtesy li...

Page 783: ...l unit deactivates the system within a maximum time of 500 milliseconds This interruption occurs when the controlled current taken up by the electric window motor drops to less than 0 8 A If the control buttons are faulty short circuit or keys stuck down control operation is inhibited at the time of control unit activation until the defect disappears or the key is released for longer than 60 milli...

Page 784: ... the receiver in the courtesy light 1 Control button 2 Repeater led 3 Password code card 4 Transponder used by invisible Fiat CODE 4PA83HL01 NOTE Each key with remote control unit has a plate 3 with a 4 figure password to protect against un authorised programming protected programming The Dealer must remove the plate at the time of sale and place it on the back of the Code Card refer to the Fiat C...

Page 785: ... and press remote control unit key 3 3 Then release key 3 when the light of led 4 on the receiver should become fixed 4 Then release button 5 on the courtesy light at the end of the cycle 5 The remote conrol unit is now programmed NOTE Repeat the operations below to store the next remote control units 6 If the receiver led stops flashing and goes off when the remote control ke is pressed the recei...

Page 786: ...t until the light on the green LED 4 on the courtesy light becomes fixed 9 Then release key 3 of the remote control unit when the light on LED 4 on the courtesy light be comes fixed 10 then release button 5 on the courtesy light when the programming cycle is concluded 11 The remote control unit is then programmed The memory closes again after storing the new remote control unit TIMED PASSENGER COM...

Page 787: ...y ceases if the key is turned to STOP or taken out a deactivation signal is received from the switch on the facia a MAX DEF function deactivation signal is re ceived If one of these two signals is not received the timer keeps the coils activated for 20 MINUTES but a spe cific system is applied the power supply stays on AT ALL TIMES for the first 10 MINUTES During the SUBSEQUENT TEN MINUTES the pow...

Page 788: ...Chapter 1 Click here to choose chapter intro TachDataj Engine Braking system Auxiliary Untts i Electrical Equipment I Bodywork 1 Sack file D Volume 203 rhdrive htm08 07 2006 16 53 11 ...

Page 789: ...ava manual COMPOSITION OF RIGHT HAND DRIVE VERSION Publication no 508 876 Sections 10 18 33 41 50 55 70 Number of pages 1 4 5 7 1 8 9 11 1 12 13 17 1 7 1 4 1 7 1 15 Notes 1370 12v engine fuel system 1910 TD 75 engine fuel system Components and operation 1370 12 clutch operation 1910 TD 75 clutch operation 1370 12v clutch operation 1910 TD 75 clutch operation Operation Heater with manual controls R...

Page 790: ...urfaces to be machined After machining Interference Press fit Dimension to measure Measurement Check Thickness Clearance Rolling torque e 83 T o 4 O Q a Intake Exhaust Operation Tolerance Weight difference Preload Rotate Compression ratio Select categories Oversized Undersized Oversized to Undersized to Maximum Minimum t Ib ep Rpm Ratio Pressure Temperature Temperature 0 C Cold Winter Temperature ...

Page 791: ...Contents 10 page FUEL SYSTEM i Q l 12v Removing refitting accelerator cable 1 Removing refitting accelerator pedal 3 0 TD75 Removing refitting accelerator cable 5 Removing refitting accelerator pedal 7 Copyright Fiat Auto ...

Page 792: ... the clip then withdraw the cable from the bracket 2 Working from inside the car remove the left foot rest then disconnect the control cable from the anchorage on the accelera tor pedal 3 Remove the pipe connecting the air clean er to the butterfly valve case 4 Remove the relay unit protective cover 5 Unscrew the relay bracket retaining bolts and position unit to one side P4A01DA03 H B I 1 sic ujr...

Page 793: ... Also remove the underlying rubber block in order to free the hole and allow removal of the cable 3 Release the accelerator cable from the re taining clip located beneath the injection control unit 4 Withdraw the cable through the hole in the bulkhead between engine bay and passenger compartment and remove from the engine bay When refitting adjust the cable as described in the paragraph Adjust ing...

Page 794: ...e cable from the bracket This operation is necessary to facilitate removal of the accelator cable from the control pedal 2 Working from inside the car remove the left foot rest by undoing the retaining bolts shown in the figure 3 Disconnect the control cable from the an chorage on the accelerator pedal 4 Disconnect the clutch pedal reaction spring attached to the accelerator pedal bracket by remov...

Page 795: ...Engine Bravo Brava ii2v Fuel system 10 P4A04DA01 P4A04DA02 1 2 Unscrew both nuts retaining the accel erator pedal bracket then remove from the car 4 Publication no 508 876 ...

Page 796: ... the engine bay release the accelerator cable by taking out retaining clip 1 and unscrewing nut 2 3 Working from inside the car remove the left foot rest and unscrew the bracket re taining the air hose shown Disconnect the pipe from below to allow access to the cable anchorage on the accelerator pedal 4 Disconnect the control cable from its an chorage on the accelerator pedal P4A01DA02 Copyright F...

Page 797: ...n remove the stud retaining the lining of the bulkhead be tween engine bay and cabin and move the lining to one side 4 5 Unscrew the bolts retaining the diesel filter bracket disconnect the connections shown and position the bracket to one side Move the lining of the bulkhead between engine bay and cabin further to one side then unscrew the nut retaining the accele rator cable to the bulkhead remo...

Page 798: ...EFITTING ACCELERATOR CONTROL PEDAL 1 Proceed as described for the 1370 12v en gine but remove the air pipe bracket shown in the figure in order to release the pipe and gain access to the accelerator ca ble anchorage on the pedal Copyright Fiat Auto 7 ...

Page 799: ......

Page 800: ...refitting clutch pedal 2 Removing refitting clutch pump 3 Removing refitting pipe connecting clutch pump slave cylinder 6 Removing refitting master cylinder 7 Bleeding 8 J TD7S Removing refitting clutch pump 9 Removing refitting pipe connecting clutch pump slave cylinder 10 Removing refitting slave cylinder 11 Copyright Fiat Auto ...

Page 801: ...n is also smoother and less jerky particularly when high torques are transmitted The car is more comfortable to drive because fewer vibrations are transmitted to the power unit due to the damping effect of the fluid The adoption of this device eliminates the need for periodic adjustment because play is eliminated and wear on the driven plate is taken up automatically The clutch is single dry plate...

Page 802: ...move the car brake light switch to facil itate access to the clutch and brake pedal retaining bolt 3 Unscrew the bolt retaining the clutch and brake pedal withdraw in the arrowed di rection until the clutch pedal is released If brake pedal removal is not required do not take the bolt retaining the clutch and brake pedal any further out 4 Release the clutch pedal from the clutch pump rod and remove...

Page 803: ...return spring 4 Roll pin and bush retaining spring to clutch pedal 5 Bush 6 Clutch pump 7 Roll pin and washer retaining clutch pump rod to pedal REMOVING REFITTING CLUTCH PUMP 1 Remove pipe connecting air cleaner to butterfly valve case by undoing the fas tenings shown in the figure P4A01 DA03 Copyright Fiat Auto 3 ...

Page 804: ...osition the bracket to one side 3 Remove the stud retaining the lining of the bulkhead between lining to one side 4 Drain the brake and clutch fluid from the reservoir after disconnecting the level gauge connector and removing the reser voir cap 5 Disconnect the central line connected to the clutch pump marked FRIZ from the reservoir P4A12DA06 4 Publication no 508 876 ...

Page 805: ...he clutch pump rod to the pedal 4 Unscrew the nuts retaining the clutch pump to the body take out slightly in order to release the rod from the clutch pedal then remove complete with connection pipe leading to the reservoir 5 Working on the bench separate the clutch pump from the pipe connected to the reservoir Reverse disassembly instrutions to assemble To refit the pump connec tion line to the r...

Page 806: ...screw the fitting of the line connecting the pump to the slave cylinder on the clutch pump 2 Disconnect the leads from the battery negative terminals then remove by un screwing the nut securing the retaining bracket 3 Remove the relay box cover then unscrew the nut retaining the box to the battery cradle and position to one side 4 Release the electrical leads shown in the figure from their retaini...

Page 807: ...e slave cylinder and then remove the pipe REMOVING REFITTING SLAVE CYLIN DER Remove battery relay box battery cradle as described for removal of the clutch pump connection pipe slave cylinder Also dis connect the pipe connecting clutch pump slave cylinder on the slave cylinder 3 4 Unscrew the bolts retaining the slave cylinder and remove from the engine bay Copyright Fiat Auto 7 ...

Page 808: ...ed screw and insert the opposite end in a suitable container Fill the brake and clutch fluid reservoir then bleed the clutch system by loosening the bleed screw on the slave cylinder Simultaneously press down the clutch pedal and allow it to return slowly Repeat the operation until all air bubbles have been removed With the clutch pedal pressed to the floor tighten the bleed screw and remove the p...

Page 809: ...ed and po sition the bracket to one side without dis connecting the diesel lines 2 Drain the brake and clutch fluid from the reservoir 3 Disconnect the pipe connected to the clutch pump from the brake and clutch fluid reservoir 4 Disconnect the fitting of the line connected to the slave cylinder from the clutch pump 5 From inside the car remove the left foot rest and disconnect the air pipe from t...

Page 810: ...voir REMOVING REFITTING PIPE CONNECT ING CLUTCH PUMP TO SLAVE CYLINDER Remove the upper cam cover protec tion and the guard in front of the brake and clutch fluid reservoir then unscrew the bolts retaining the diesel filter bracket and drain the brake and clutch fluid from the reservoir as de scribed in the previous paragraph 3 Unscrew the fitting of the pipe connecting the pump to the slave cylin...

Page 811: ...ch the pipe from the retaining clips and remove from the car REMOVING REFITTING SLAVE CYLIN DER Drain the brake and clutch fluid re move the battery the cradle and the relay box as described in the previous paragraph Undo nuts retaining bracket 1 and re move disconnect the clips indicated and remove the flow meter in order to gain ac cess to the underlying slave cylinder Disconnect the fitting of ...

Page 812: ......

Page 813: ...refitting brake pump Removing refitting servo brake Removing refitting pedal unit Removing refitting brake servo vacu um inlet pipe Removing refitting one way valve 10kTO 75 Brake clutch fluid reservoir Removing refitting brake pump Removing refitting servo brake Removing refitting brake servo vacu um inlet pipe and one way valve 1 2 3 4 6 10 12 12 13 14 15 17 Copyright Fiat Auto ...

Page 814: ...e fluid reservoir 2 Pipe connecting brake fluid reservoir to pump 3 Brake pump 4 Brake servo vacuum pipe 5 Servo brake 6 Complete pedal mount According to the version the brake fluid reservoir may be connected to the pump by pipes or may be fit ted directly to the brake pump Copyright Fiat Auto 1 ...

Page 815: ...e the roll pin retaining the brake servo rod transmission on the brake pedal 2 Remove clutch and brake pedal retaining bolt completely and then remove the ped al from the car Brake pedal fastening details 1 Pedal unit 2 Brake pedal 3 Brake servo rod P4A22DA03 4 Transmission connecting brake pedal brake servo rod 5 Device for anchoring brake servo rod and transmission to brake pedal 2 Publication n...

Page 816: ...oir 1 Disconnect the connector of the fluid level sensor and remove the reservoir cap then drain the brake fluid from the reservoir us ing a syringe 2 Disconnect both brake pipes and the hy draulic clutch pipe from the reservoir 3 Unscrew the bolt retaining the reservoir to the body and remove from the vehicle Take care the fluid remaining in the reservoir does not leak out NOTE Carry out removal ...

Page 817: ...ings indicated in figure 2 Remove the relay cover 3 Remove the relay bracket by undoing the bolts retaining it to the body disconnect connector indicated and move the bracket to one side 4 Remove the retaining stud of the lining of the bulkhead between lining to one side 5 Remove the cap from the brake and clutch fluid reservoir after disconnecting the fluid level sensor connector Then drain the f...

Page 818: ...h 1856132000 to disconnect the brake pipe fittings from the brake pump f Bleeding brake system 3 Unscrew both nuts retaining the brake pump to the brake servo then remove the pump from the car Reverse removal instructions to refit making sure that the brake pump is properly fitted to the brake servo rod and washer P4A25DA03 P4A26DA04 Copyright Fiat Auto 5 ...

Page 819: ...proceed as follows Working from the engine bay remove the sleeve connecting air cleaner and butter fly valve case Remove the protective relay cover located ortteu I khealdetweeeng i rteaeyrdabibyndoi ntipe bolt indicated Remove the relay bracket by undoing the bolts retaining it to the body disconnect connector indicated and move the bracket to one side Remove the retaining stud and move the linin...

Page 820: ...on wiring bundle from the retaining clip then disconnect the va cuum intake line from the brake servo 3 Working from inside the cabin remove the left foot rest located beside the clutch pedal 4 Remove the bolt retaining the lower steer ing column to the power steering box pin ion 5 Remove the steering column reinforce ment bar by unscrewing the retaining bolts indicated in the figure Copyright Fia...

Page 821: ...h nuts retaining the accelera tor pedal retaining bracket and release the clutch pedal return spring from the bracket 4 Disconnect the control cable from its an chorage on the accelerator pedal then re move the accelerator pedal from the vehicle 5 Remove rubber fitting 1 from the bonnet opening lever and then release the end of the opening cable from its seat and take out through the housing hole ...

Page 822: ...e from the pedal mount 3 Remove the roll pin retaining the brake servo rod to the control pedal transmis sion 4 Remove nuts retaining the pedal unit to the body then remove the pedal unit and servo brake from the body by releasing the clutch pedal from the clutch pump rod 5 At the bench unscrew the four bolts re taining the brake servo to the pedal unit P4A29DA03 P4A29DA05 Copyright Fiat Auto 9 ...

Page 823: ...ITTING PEDAL UNIT Proceed as described for the brake servo removal to remove the pedal unit Note that the brake pump need not be removed from the brake servo and vacuum intake pipe Before re moving the pedal assembly unscrew the nuts retaining the brake servo to the pedal mount as shown in the fig ure 3 Unscrew nuts retaining the brake servo to the pedal mount and remove the roll pin securing the ...

Page 824: ...2 Pull out the bolt retaining the clutch and brake pedals until the clutch pedal comes off then remove 3 Pull the bolt out further until the brake pedal comes off too 4 Unscrew bolt retaining the brake pedal transmission anchoring the brake servo rod then remove the pedal View of pedals 1 Clutch pedal 2 Brake pedal P4A31DA03 vT U RN 1t C Tv11 5 _ Lr Sh Copyright Fiat Auto 11 ...

Page 825: ...injection wiring bundle from the retaining clip then disconnect the vac uum intake pipe from the brake servo 2 Unscrew clip retaining the vacuum intake pipe to the engine and remove the pipe 4J REMOVING REFITTING VALVE ONE WAY 3 Remove the pipe connecting air cleaner at butterfly valve case by undoing the clip in dicated in figure 4 Remove the one way valve from both parts of the brake servo vacuu...

Page 826: ... connector and remove the reservoir cap then drain the brake fluid from the reservoir using a syringe 4 Disconnect the hydraulic clutch line from the reservoir then separate the reservoir from the brake pump and lift out Ensure fluid remaining in the reser voir does not leak out NOTE Carry out brake and clutch fluid reservoir removal operations in reverse order to re fit M I Ensure the reservoir i...

Page 827: ... the hydraulic clutch and placing the reservoir to one side Use wrench 1856132000 to disconnect the brake line fittings from the brake pump u Bleeding brake system 2 3 Unscrew both nuts retaining the brake pump to the brake servo then remove the pump from the car Reverse removal instructions to refit taking care to fit the brake pump properly to the brake servo rod and washer 14 Publication no 508...

Page 828: ...re by undoing the retaining bolts 3 Unscrew bolts retaining the diesel line re taining bracket 4 Disconnect the brake and clutch fluid level sensor then remove the stud retaining the lining of the bulkhead between engine bay and cabin then move the lining to one side 5 Unscrew the bolts fastening the diesel fil ter bracket disconnect the connections shown and position the bracket to one side Copyr...

Page 829: ...disconnect the vacuum inlet pipe from the brake servo Undo nuts securing the brake pump to the brake servo then take the pump out slightly without disconnecting the brake lines 4 il x ir v Continue by removing parts from in side the car and then removing the brake servo as described for the 1370 12v version Note that the air line shown in the figure alongside must also be disconnected for the 1910...

Page 830: ... the brake pump from the brake servo 1 Disconnect the vacuum inlet pipe from the brake servo 2 Disconnect the clip retaining the vacuum inlet pipe from the vane vacuum pump 3 Disconnect the pipe indicated in the figure from vacuum inlet pipe then remove the pipe 4 Separate the one way valve from the vac uum inlet pipe When refitting position the valve with the wording LATO MO TORE turned toward th...

Page 831: ......

Page 832: ...eel Removing refitting 1 Stalk unit release Removing refitting 1 Steering column Removing refitting 2 Rack and pinon power steering box Removing refitting 3 Components of power steering system 6 IP TD75 Components of power steering system 7 Copyright Fiat Auto ...

Page 833: ...tion take care NOT TO STRIKE THE STEERING WHEEL The clock spring is fitted with a safety clip to prewent the lower and upper plates turning in relation to one an other when the steering wheel is not fitted in the car This is achieved by springs 1 which close as shown in the figure Remove the clock spring as described in Section 55 STALK UNIT RELEASE Removing refitting Remove the stalk unit release...

Page 834: ...ot rest located beside the clutch pedal 2 Unscrew bolt retaining the lower steering column shaft to the power steering box pinion 3 Disconnect the ignition connector 4 Remove the lower junction unit protec tion 5 Remove the steering column reinforce ment bar by unscrewing the retaining bolts indicated in figure 2 Publication no 508 876 ...

Page 835: ...ND PINION POWER STEERING BOX Removing refitting 3 Disconnect the negative battery terminal lead position the car on a lift then drain the power steering fluid from the reservoir using an appropriate syringe 4 Remove the left foot rest located along side the clutch pedal 5 Unscrew bolt retaining the lower steering shaft to the power steering box pinion Copyright Fiat Auto 3 ...

Page 836: ... extractor 1847038000 2 Release the reverse inhibition lead from the retaining clip then lift clip 1 and dis connect the gear selection bowden cable head 3 Disconnect electrical connection of the lambda probe 4 Remove the bracket retaining the first ex haust pipe section to the crankcase 5 Unscrew bolts retaining the first exhaust pipe section to the catalytic converter Publication no 508 876 ...

Page 837: ...unt working from the lower rear of the engine bay Unscrew the nuts and bolt shown in the figure which retain the power steering fluid return line brackets to the reservoir Disconnect the fitting for the inlet line for fluid under pressure from the pump and the fitting of the fluid return line to the reservoir Unscrew the bolts fastening the power steering box to the front beam P4A43DA04 P4A43DA0B ...

Page 838: ...wn in the figure 2 Power steering box 1 Fitting for pipe carrying fluid under pressure from the pump 2 Fitting for fluid return line to reservoir COMPONENTS OF POWER STEERING SYSTEM i 9l 12v 1 Pump 2 Fluid delivery line to pump 3 Power steering fluid reservoir 4 Fluid return line to reservoir 5 Power steering box 6 Pipe carrying fluid under pressure from pump P4A44DA03 6 Publication no 508 876 ...

Page 839: ...ONENTS OF POWER STEERING SYSTEM 41 mt TO 75 1 Pump 2 Fluid delivery line to pump 3 Power steering fluid reservoir 4 Fluid return line to reservoir 5 Power steering box 6 Pipe carrying fluid under pressure from pump Copyright Fiat Auto 7 ...

Page 840: ......

Page 841: ...Auxiliary units Bravo Brava Contents 50 page HEATER WITH MANUAL CONTROLS Distributor heater assembly Re moving refitting 1 Removing refitting cabin fan 3 Copyright Fiat Auto ...

Page 842: ...ntra tunnel trim as described in Section 70 1 Working from the lower rear of the engine bay loosen both clips arrowed in the figure and disconnect both rubber pipes from the metal ends of the heater radiator 2 Release the air bag lead from the retaining brackets 3 Disconnect electrical connection located alongside the clutch pedal 4 Disconnect electrical connections located alongside the cabin fan...

Page 843: ...ary units Heater with manual controls Bravo Brava 50 Unscrew bolts indicated in figure which secure the heater distributor assembly to the body then re move the assembly from the car 2 Publication no 508 876 ...

Page 844: ... 50 View of the heater distributor unit REMOVING REFITTING CABIN FAN 1 Disconnect the battery negative terminal then work from the lower left part of the facia to disconnect the supply connector and remove the fan cover retaining bolt Copyright Fiat Auto 3 ...

Page 845: ...Auxiliary units Bravo Brava Heater with manual controls 50 1 Remove the cabin fan from the lower left hand side of the facia P4AS0DA01 4A50DA 4 Publication no 508 876 ...

Page 846: ...ent Contents 55 page LOCATION OF WIRING Perspective view of facia wiring 1 INSTRUMENT PANEL Instrument panel 3 Removing refitting 4 AIR BAG Removing refitting driver s air bag 5 Removing refitting clock spring 6 Copyright Fiat Auto ...

Page 847: ...ol unit 19 Dashboard front cables connection 20 Front right cable 21 Courtesy lights front right switch 22 Dashboard front right door cable connection 23 Front right door cable 24 Right dashboard earth 25 Dashboard rear cables connection 26 Fuse and relay unit 27 Fuses on auxiliary bracket 28 Stop lights switch 29 Fiat CODE antenna 30 Ignition switch 31 Rear cables driver s heated seat connection ...

Page 848: ...L 55 1 6 Bravo Brava 1370 12v Bravo Brava 1910 TD 75 1 Fuel reserve warning light 2 Fuel level gauge 3 Rev counter 4 Turn signal warning lights 5 Speedometer and dual mileometer total and trip counter 6 Coolant temperature gauge 7 Warning lights Copyright Fiat Auto 3 ...

Page 849: ... Remove the upper steering column trim in order to allow removal of the lower control panel frame screws 3 Unscrew the bolts fastening the outside of the control panel frame 4 Remove the junction unit protective cov er Unscrew the outer control panel frame retaining screw Remove the frame from the facia and disconnect the lighting dim mer and headlamp beam alignment con nectors 4 Publication no 50...

Page 850: ... air bag modules must be re moved and refitted with the ignition key turned to STOP and removed and the battery positive and negative terminal and properly insulated Wait for 10 minutes before continuing TAKE CARE TO OBSERVE ALL THE SAFETY RULES SET OUT IN THE CHAPTER ON AIR BAG And PRE TENSIONERS IN THE MANUAL FOR THE LEFT HAND DRIVE VER SION Unscrew both hexagonal headed socket screws indicated ...

Page 851: ...shows how the module should be positioned NOTE Carry out removal operations in re verse order to refit DO NOT CONNECT THE BATTERY UNTIL INSTALLATION IS COM PLETE NOTE After the operation check the system using a Fiat Lancia Tester REMOVING REFITTING CLOCK SPRING Remove the driver s air bag as de scribed on the previous page and ob serving the SAFETY REGULATIONS described All the following operatio...

Page 852: ...n guards 3 Disconnect the connection connecting the clock spring to the Air Bag lead yel low Undo the three clock spring bolts and then remove Once the steering wheel has been re moved the clock spring is blocked so that the lower and upper plates can not turn If the upper plate of the clock spring should turn in relation to the lower for any reason so that the position upon removal is lost the CL...

Page 853: ... 707 page INTERIOR TRIM Dashboard General exploded view 1 General view of retainers 2 Removing refitting dashboard 3 12v Removing refitting bonnet opening cable 11 TD7S Removing refitting bonnet opening cable 13 Copyright Fiat Auto ...

Page 854: ... Glove compartment 9 Car radio 10 Central panel 11 Hazard warning switch 12 Switch unit 13 Panels 14 Fan control knob 15 Ashtray cigar lighter unit 16 Control panel frame 17 Protecting 18 Gear lever boot 19 Handbrake lever boot 20 Tunnel cover console 21 Instrument panel 22 Junction unit protection 23 Door sill trims 24 Left ventilation outlet 25 Upper grille Copyright Fiat Auto 1 ...

Page 855: ...Bodywork Interior trim Bravo Brava 70 GENERAL VIEW OF RETAINERS 2 Publication no 508 876 ...

Page 856: ...he protective gear lever boot 2 Lift the luggage compartment trim shown in the figure and unscrew the bolt under neath 3 Remove the rear ashtray by lifting out and unscrew the underlying central tunnel re taining bolts 4 Undo the retaining tabs to lift the door mirror control panel 5 Disconnect supply connector for the elec tric door mirrors and remove the panel P4A61DA03 Copyright Fiat Auto 3 ...

Page 857: ...unction unit protection by undoing the fastenings shown in the fig ure 3 Working from inside the junction unit housing compartment unscrew screw re taining the instrument panel frame 4 Unscrew the bolts indicated then move the instrument panel slightly to one side disconnect the headlamp alignment ad juster and instrument light dimmer con nections and then remove the frame P4A62DA03 4 Publication ...

Page 858: ... the left and carefully fit right hand part R of tool 1860897000 until it clicks into the radio clips Use right hand part R to pull out the right hand side of the radio slightly move it to the right and carefully fit the left hand part L of tool 1860897000 until it clicks into the radio clips Grasp both sides of the tool and pull the radio out partly then release both parts of tool 1860897000 from...

Page 859: ...ghter light ing and remove the ashtray 3 Use a screwdriver to prise up panel 1 Unscrew screws 2 and pull switch unit 3 out slightly 4 Disconnect connectors 1 and remove the switch unit Proceed as described in the figure to remove hazard warning light switch 2 and disconnect both connec tors 5 Unscrew the bolts fastening the heater and control panel P4A64DA03 P4A64DA04 P4A64DA05 6 Publication no 50...

Page 860: ... Unscrew the bolts fastening the instru ment facia located in the ashtray com partment 3 Unscrew the bolts fastening the instru ment facia to the heater and screw 1 4 Work from inside the glove compartment to undo clips 1 and remove the com partment lining 5 Unscrew the bolts indicated which retain the glove compartment and pull out slightly P4A65DA03 4 V l n Tf v V 1 ___ _ P4A65DA04 Copyright Fia...

Page 861: ...e bolts fastening the left venti lation outlet then remove 3 Unscrew the screw indicated which se cures the left hand side of the instrument facia 4 Unscrew the screw indicated and move the door sill trim away on both sides of the car 5 Unscrew the lower bolt retaining the in strument facia to the body on both sides 8 Publication no 508 876 ...

Page 862: ...peakers by unscrewing the retaining bolts and dis connecting the connectors 3 Unscrew screw located in the right and left speaker compartment which secures the instrument facia to the body 4 Remove the bolt retaining the instrument facia to the body on the left side 5 Remove the central bolt securing the in strument facia to the body P4A67DA05 Copyright Fiat Auto 9 ...

Page 863: ...djustment lever 3 Remove the instrument facia retaining screw on the rihgt hand side near the junction unit 4 Loosen the bolt retaining the steering wheel adjustment lever in order to facili tate removal of the instrument facia 5 Remove the instrument facia with the aid of a second operator Reverse removal operations to refit P4A68DA03 P4A68DA04 10 Publication no 508 876 ...

Page 864: ...e relay unit protective cover 3 Unscrew the bolts fastening the relay bracket and position to one side 4 Remove the stud shown in figure and move the lining of the bulkhead between engine bay and cabin to one side 5 Unscrew nut retaining the bonnet open ing cable to the bulkhead between en gine bay and passenger compartment Re move the underlying guide block P4A69DA03 P4A69DA04 P4A69DA05 Copyright...

Page 865: ...3 Working from beneath the steering wheel remove cap A from bonnet opening lever B then release the end C of the opening cable from seat D Release opening cable fastener E from seat F on the body Fasten the opening cable to a probe in order to facilitate refitting through the bulkhead between engine bay and cabin Withdraw and disconnect the bonnet opening cable NOTE Reverse order of removal operat...

Page 866: ...ines from the retaining clip 3 Remove the bolt retaining the fuel line connection bracket 4 Disconnect connector of the brake and clutch fluid level sensor then remove the stud retaining the lining of the bulkhead between engine bay and cabin then move the trim to one side 5 Unscrew the bolts fastening the diesel filter bracket disconnect connections shown and place the bracket to one side Copyrig...

Page 867: ...the bonnect opening ca ble to the above bulkhead 2 Remove the air duct by undoing the fas teners indicated in figure 3 Disconnect the bonnect opening cable from the retainer seats and the retaining clip 4 Disconnect the air sleeve from the filter 5 Open the cable duct and remove the bon net opening cable P4A72DA03 P4A72DA0S 14 Publication no 508 876 ...

Page 868: ... Release opening cable fastener E from seat F on the body Fasten the opening cable to a probe in order to facilitate refitting through the bulkhead between engine bay and passenger compartment Withdraw and disconnect the bonnet opening cable by releasing from the retaining clip NOTE Reverse order of removal operations to refit Bravo Brava Copyright Fiat Auto 15 ...

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Fiat 1996 Brava, Service Manual

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