= f HATCHRACKS, SALOONS AND ESTATES \\ fog f 1988-1996 ; Ly 6G. 6 reg - P reg in the UK Do pect Ge || Ponren pusuisue FIAT APPROVEDDAW Tipo and Tempra Repair Manual and Service Guide Lindsay Porter and Roy Stenning been taken to ensure that the material in this Book is comect. However, should ‘be clear after reading this book, you are advised ta consult your nearest franchised dealer, Labilty cannot be accepted for damage, loss, accidents or injury, due to falune to follow instructions oF to consult expert advice t this is requireduf 2 =| a) Detailed Contents are shown at the start of each chapter. CHAPTER 1: CHAPTER 2: CHAPTER 3: CHAPTER 4: CHAPTER 5: CHAPTER 6: CHAPTER 7: CONTENTS Safety First! 0... .ecccee Using Your Car Facts and Figures . Getting Through the MoT... .....s0+0006 Repairs and Replacements ........... 60005 Spark Plug Conditions and Recommended Lubricants. .154 Wiring Diagrams 155 Index .. [FACT FILE: LEFT AND RIGHT SIDES OF THE CAR ‘9 Thanh this manval, we fefer tothe el” and right sides ofthe car ‘They Teer tthe ses athe car that you would see if you wee siti inthe seers sat lok! forwardee CHAPTER 1 SAFETY FIRST! ‘You must always ensure that safety Is the first consideration in any job you carry out. A slight lack of concentration, or a rush to finish the job quickly can easily result in an accident, as can failure to follow the precautions outlined in this manual. Raising the Car Safely ALWAY'S ensure that the vehicle is properly supparted when ‘sed of the grourd Dan't werk an, araund, ar underiea 2 raised vehicle unless ane stands are pesitined unc Secu. losd eating underbady areas, or the vehicle driven nto ramps, with the wheels remaining on the ground securely chocked to prevent movement, NEVER work on a vehicle supported on a jack. Jacks are made for iting the vehicle only, not for hoking it aff the ground wile it is being worked an, ALWAYS ensure that the safe working lnad rating af any Jacks, hoists or iting gear used is sufficient for the jb, and that ling gear is used only as recommended by the manwiacturer. NEVER attempt to loosen or tighten nuts that require a lot of fotce to turn leg. a tight ail drain plug) vith the vehicle raised, unless it i safely supported, Take care not ta pull the vehicle off its supports when applying force to a spancer ‘Wherever possible initially slacken tight fastenings before ralsng the ear off the ground, ALWAYS wear eye protection when working under the vehicle and when using power taal, Working On The Vehicle ALWAYS sock spacaiat advice unless you are just iably confident about carrying out each job. The safety of your vehicle affects you, your passengers and ather road users Be sure to consult the suppliers of any materials and equipment you may use, and to obtain and read carefully any operating and health and safety instructions that may be available on packaging or from manufacturers and suppliers. DON'T lean over, or wark an, a tuning engine unless its Strictly necessary, and keep lang hair and! loose clothing well out of the way of moving mechanical parts. Note that it & thenretically possible for fluorescent stipighting to make an ‘appear to be stationary - double check whether it 's spinning or not! This & the sort of error that happens when you've realy tred and not thinking straight, [DON'T work an your car when you're aver ted, ALWAYS ork in a well ventilated area and don’t inhale dust ftmay contain asbestos of other harmful substances, NEVER run the engine indoors. a confined space ar aver apit REMOVE your wrist watch, rings and all ather jewellery before doing any work on the vehicle -and especially When working on the elecircal system DON'T rermave the radiator or expansion tank filler cap when the cooling system is hot, or you may get scalded by escaping coolant or steam. Let the system cool down first and even then, Hf the engine is not completely cold, cover the cap wath ‘ clath and gradually release the pressure, NEVER drain oil, coolant or automatic transmission fhid when the engine ishot. Allow time far it ta com! suificienty to avoid sealing you, ALWAYS keep antifreeze, brake and clutch fhad away froon vehicle paintwork. Wash aff any spills immediately TARE CARE to avoid touching any engine or exhaust system component unless it Eo enough not to burn ys T WaLdVHD j F PT1 aa LdVHO rt) Pd a | a F) “ = Running The Vehicle NEVER start the engine unless the gearbox i in neutral (ar Fark’ in the case ef automatic wansmission) and the hand brat is fully applied NEVER run catalytic converter equipped vehicles without the exhaust system heat shies in place, TAKE CARE when parking vehicles fitted with catalytic converters. The ‘cat’ reaches extremely high temperatures and any combustible materials under the car, such as long dry crass, could be ign Personal Safety (EVER siphon fuel, antifreeze; brake fluid or other such toxic ids by mouth, or allow cantact with your skin. Use 8 suitable hand pump and wear gloves, BEFORE undertaking dirty jobs, use a barrier cream on your hands as a protaction against infection, Preferably, wear suitable gloves, available from DIY outlets WEAR IMPERVIQUS GLOVES for sure when there i a risk of seat engine oil coming into contact with your skin, tt ean ‘cause cancer: ‘WIPE UP any spit nil, grease or water off the floor lenmediately MAKE SURE that sparnners and all ther toals ae the right size ‘or the js and are not likely to sip. Never try ta ‘doubleup’ spanners to gain more leverage SEEK HELP if you nired to ft something heavy which may be bbeyond your capability. Don't forget that when iting & hea ‘weight, you should keep your back straight and bend your knees to-avoid injuring your back NEVER take risky shor-cuts or rush to finish a job, Pan aheoet and allow plenty of time. BE METICULOUS and keep the work area tidy you'll avoid frustration, work better and lose less KEEP children and animals right-away fran the wark ares and from unattended vehicles. ALWAYS tell someone what you're doing at have them regularly check that ali well, especially when working alone fon, oF under, the vehicle esti Fire! Petrol (gasoline) is a dangerous and highly flammable liquid requiring special precautions. When woeking on the fue system, disconnect the vehicle battery earth (grounds terminal whenever possible and always work outside, orn a very well ventilated area. Any form of spark, such as that caused by an lectrical fault, by two metal surfaces striking against each other, by a central heating boler nthe garage tiring up. oF leven by static electncty built up in your clathing ean, in a cantined spice, igote petrol vapour causing an explosion, ‘Take great care net ta spill petrol on to the engine or exhaust system, never allow any naked flame anywhere near the work ‘tea and, above all, don’t smoke. Invest in a-workshop-sized fire extinguishes. Choose the catbon dioxide type or preferably, dry pawder but NEVER a waler ype extinguisher for workshers use DON'T disconnect any fuel pipes on a fuel injected engine withaut following the advice in this manual, The fuel in the line is under very high pressure sufficient to cause serious injury. Remember that many injection systerns have residual pressure in the pipes for days after switching off. I necessary seek specialst advice Fumes Petrol (gasoline) vapour and that given off by mary solvents, thinners, and adhesives are highly toxic and under certain ‘conditions can lead to uncorsciousness ar even death, if inhaled. The risks are increased if such fluids are used in 2 Confined space so alveays ensure adequate ventilation, Abways ‘ead the maker's instructions and foaw them with care [Never drain petrol (gasoline) ar use solvents, thinners adhesives oF other oxi substances in an inspection pit. ti ‘iso dangerous to park a vehicle for any length of time over ‘an inspection pit. The fumes from even a sight fuel leak can ‘cause an explosion when the engine is startedMains Electricity ‘Avaid the Use of mains electreity when werkking on the vehicle, whenever possible. Use rechargeable tools and a DC inspection lamp, powered froma remote 12V battery both are much sales. However, you do use mains-powered equipreant, ensuite that the appliance s wired correctly tits plug. that where necessary i's properly earthed (groundech, and that the {use is othe correct rating for the appliance: Do not use any mains powered eupme conditions-or in the vicinity of fuel, fuel vapaur or the vehicle Battery ‘Alaays use an RCD (Residual Current Bievice) circuit breaker with mains electricity. Then, there i short, the RCD circuit breaker mnimses the sk of electrocution by instantly cutting the power supply Ignition System Never werk nthe ignition system with the ignition seetehed en ot wih the engine being tumed aver en the sta rureing and you ae recommended never to do sa, Touching certain parts of the ignition system, such as the HT leads. dstnbutor cap, ignition col atc, can result ina severe secre shack or physical injury 25a hands pulled sharply away. Voltages produced by elactronic ignition systerns are mach figher than those produced by conventional systems and coud prove fatal. particularly to people with cardiac pacernaker ‘implants, Consult your handbook or main sealer ifn any soutt Cooling Fan (Ohy many vehicles, the electric eacting fan can switch itself on feven‘nith the ignibon turned off, Ths is especialy kel after shiving the car and parking it before turning of, after vhich beat mses tothe top of the engine anc turns the fan on, suddeniy and-without warring. If you intend werking in the ‘engine bay, i's best to do so yhen the engine is ccid, to dsconaect the battery, Or keep aay from the fan, if nether of these are possible Battery Never cause a spark, smcke, or alow a naked light near the vehicle's battery, even ina vel ventilated area Highly explosive hydrogen gas is given aff as pat of the changing process Battery terrinats an the car should be shielded, since a spark cam be caused by anytmetal object which touches the battery's ‘termina or connecting straps. IMPORTANT NOTE: Before disconnecting the battery earth (ground) terrinal read the relevant FACT PLE in Chapter S regarding saving computer and radio settings) When using a battery charger, switeh off the power supply before the battery charger leads are connected or disconnected, If the battery is not of the 'sealed-forife' type, loasen the fer plugs or remove the cover before charging. For best results the battery should be given a low rate trickle charge avernight. Da ot charge at an excessive rater the battery may burst Ahways wear gloves ond goggles when carrying or wher topping up the battery. Acid electrolyte extremely corrosive and must not be allowed 16 contact the eyes, skin or clothes. Obviously, a car's brakes are among its most important safety related items. ONLY werk on your vehicle's braking systern you ar trained and competent ta do $0. you hawe not been trained in this work, but wish ta carry out the jobs deseneed in this book, we strangly recamrnend that you have a garage or ‘ualified mechanic check your work befare using the car. Whenever you work on the braking system components, ar remove front or rear brake pods or shoes: i) weat an efficient particle mask; i wipe of all brake dust from the brakes after Sgr@pg on a proprietary brand of brake ceaner never blow dust off with compressed aii dispose of brake dust and Uiscarded shoes or pads in a seated plastic ban; ri) wash your hands thoroughly after you have finished working on the bales and certainty before you eat or smoke; vi replace shoes and pads only with asbestostree shoes or pads, Note that asbestos brake dust can cause cancer if stated; ¥) abways replace brake pads andi shoes in complete ‘ale sets af four » never replace the padyshoes an one wheel only, Brake Fluid rake fluid absorbs moisture rapid from the air an can baecome dangerous resulting in brake fre. You should change the fluid in accordance with your vehicle marwfactures recommendations or as adwsed in this book. Newer store for use) an opened container of brake fluld. Dispose af the remainder at your Local Authority Waste Dsposal Site, in the designated sisposal unit, nat with general waste ar with waste ail Engine Oils Alvis voor cspasableplisic or rutber gloves when drsining the ol from yourengne i) Note that the dra plug and the oll are often hotter tan you expect, Wlsorglonos the plug is 100 hot to touch and keep yout han to ane ide 0 tha you are not scalded by the spurt of clas the plug cores avy, There are very rel heath hazards assocated wth used eng on the words of cre manactre's handbook "Ptonged and repeated contact may couse serous skin sors, incucing dlermatits and concer," Use a bari cream on your hands and by not to ae al an ther. Aas wear gewes and wash your hands with hand canes soon ater carrying out the wor. Keep of out af the reach of children; ii) NEVER, EVER dispose of led engine alinto the ground or down adr An the UR, and in most EC counties, esory local authority must provide a safe means of ol spas inthe UK, try your oc Environmental Heath opariment for advice on waste disposal facies Plastic Materials Many of the materials used (polymers, resins, adhesives and materials acting 3s catalysts and accelerators) contain dangers in the form of poisonous tures, skin rrtants, and the risk offi eich 5 i F 7 Fl i) =1d explasions. Do nat allow resin or 2-pack adhesive hartiener, i supped with filer or 2spack stopper, ta.came into Contact with skin or eyes. Read carefully the safety notes supplied on the can, tube er packaging and always wear impervious gloves and goggles when working with them, Fluorcelastomers: Fluoroelastemers are commonly used for cil seats, wiring and cabling, bearing surfaces, gaskets, diaphragms, hoses and ©) rings ff they are subjected to temperatures greater than 315, degrees C, they will decompose and can be patently hazardous. Some decomposition may occur at teriperatures above 200 degrees C, and it is obvious that when a.car has been in afire or has been dismantled with the assistance of a cuttng torch ar blew torch, the fluoroelastorners can decompase inthe manner indicated above, or According to the Health and Safety Executive, “Skin contact ‘with this liquat or decomposition residues-can cause painful and genetrating burns. Permanent sreversible shin and tissue ‘damage can occur", Damage can also be caused toeyes or by the inhalation of fumes created a¢ fluormelastomees are burned ‘er heated, ‘After a vehicle has been exposed to Fire or high temperatures: 1, Do not touch blackened or char seals or equipment fluceaelastomers, but if you must, wear goggles and PYC {polyeny chloride) or neoprene protective gloves whilst doing 30, Never handle such parts uniess they ae completely cook 3. Cantaminated parts, residues, materials and clothing, including protective clothing and glows, should be disposed of bby.an approved contractor to landill er by incineration ‘according to national a local regulations, Gi seals, gaskets and ‘O' nngs, along wath contaminated material, must not bebuni WORKSHOP 1. Abnays have a fire extinguisher of the comect type at arm's length when working on the fuel system, i you do have a fire, DON'T PANIC. Use the extinguisher elfectively by directing it at the base of the fre. 2. NEVER use a naked flame anywhere in the workplace 3. KEEP your inspection lamp well away from any sauce of petrol (gasoline) such as when disconnecting a carburette float bbovl or fuel ine 4 NEVER use petrol (gasoline) to «lean parts. Use paraffin ‘kernsene), white spints, or, a proprietary degresser. 5. NO SMOKING. There's. risk offre or ef wanserring dangerous substances to your mouth and, in ary cave, ash falling into mechanical components isto be avoided, FACT-EILE: FOUR WHEEL, DRIVE CARS 19 Whenever you have to rase a whee off the round and turn it by hand, abways ensue that the oppesite-sides whee tothe oe being lite is also of the round and ire to turn and that hath wheels rernining ‘onthe ground are held by the parking brake (fossil are securely chocked in both directions ‘9 ALWAYS have the gearbaxin neta (or'W inthe case of sulomatics). Inthe ease of sume & wheel drive automatics and those ‘with permanent WD, ils necessary to disengage the AWD system bry special means, ‘© Consul your handbook a sek ave from your main dele 6. BE METHODICAL in everything you do, usec and think of safety at al times te St tha The used ol from the sump of just one car can cover an area of \Water the 52e of two football pitches, cutting aff the oxygen supply and harming swans, ducks, fish and other ver lft When you drain your engine oil don't ofl the drain! Pouring ol dovmn the drain wil a pollution, Wis acon offense Don’t mix used ail with ether materials, such as paint and solvents, because this makes ceqycing cicut Take used oil roan ail OIL POLLUTES WATER USE YOUR BRAIN- veeycing tnt |_NOT THE DRAIN! FREE on 0800 663368 to find bbank, or contact you local aut jon of your nearest ol ty necting officerPlea: CHAPTER 2 USING YOUR CAR This Chapter is taken from FIAT’s own official Handbooks ‘on the Tipo and Tempra. It ‘contains important and helpful information for the ‘operation of your FLAT Tipo or Tempra. (4. DOORS AND BONNET DOOR LOCKS Most FIAT Tipas and Tempras have manual lacking, You turn the key in the lock in the normal way ta lock and unlock the daar ‘CHILDPROOF LOCKS 1A. Some madels are fitted with childproof jocks. You wil fing them in the ends of the rear doors, when open. ‘+ lace your ignition key in noteh A, in the end of the door, when open. ‘e Turn to the night to lack the childproof rear door locks; tum to the left to unlloc. REMOTE LOCKING/UNLOCKING 18. A directional signal is emitted when you press buttan ‘Con your remote unit (early motiels}or ‘on your ignition key ater models) IMPORTANT NOTE: The presence of dirt, snow or ice on the side windows may prevent operation. We recommend that you read this chapter carefully, so that you will become familiar with your vehicle's controls and instruments Receiving Unit in C receiving unit can store up to 6 cades, Tag D, supplied with every receiver, has a cade number stamped on tt Keep this tag in asafe place - replacements are very expensive. To Store the Code of Your Transmitter: fe Press and hold down button A with a ball-paint pen The red LED B illuminates, indicating that the receiving Unit is ready to store the code, fe Hold down button Con your remote unit/ignition key The LED at B tums oft, indicating that the receiver has stored the code Release Button A, Red LED B flashes for about 8: seconds to canfirm that the cade has been stored If you press button A again within 8 seconds, the red LED B illurninates indicating that the receiving unit is ready to store another code. Repeat the procedure. I you lose a remote unit there are two ways to store a new code: Using a Remote Unit With Code Already Stored: + Press and hold down button A, After about 2 seconds red LED B flashes once. # Press button € on the remote whose cade has been stored, Red LED B illuminates # Release bution A, Red LED B flashes for 8 seconds indicating new cade has been stored! Manual Operation: Have tag D ready. The four numbers stamped on the tag will be used in this procedure 1 Press Button A twice, Red LED B flashes 3 times and then turns off for about 2 seconds # When LED B lights up again, aress button A the number of times indicated by the first code number on tag B ( 0 do nat press the bution), Two second after pressing button A , LED B will turn off for 2 seconds. Riche AST z € Ma 4 a mI i=} & } a@ Repeat this operation three more times until the compiete code number has been entered, if the code hhas been entered in correctly LED B will start flashing, «Release button A (see illustration 18). Red LED B flashes for 8 seconds indicating the new remate unit's code has been stored IMPORTANT NOTE: If the LED dees net illuminate when remote unit button (illustration 18, button is pressed, change the remote unit's battery. SWITCHING OFF THE ALARM 1C. Some models are fitted with an alarm exclusion switch, which can be found inside the glove compartment. If the alarm is faulty or the remote contral batteries are flat: «Insert the emergency key A into the emergency switch siot in the glove compartment turn the key to the left 10 switch the alarm off see inset Turn the key back towards is original position to Switch the alarm system Back on IMPORTANT NOTE: As the alarm system absorbs energy, if you are not planning on using the car for a long period of time, turn the alarm exclusion key to the off position, so as not to run the vehicle battery down. U2. IGNITION SWITCH AND STEERING COLUMN LOCK IGNITION SWITCH 2. The ignition’steering column lock key, once inserted in the ignition lock, can be placed in any of the following faur postions: ‘* PARK - With the key in this position the side and taillights can be tured on, the steering column locked and the keys can be removed. Press button A to turn the key to PARK 2» UNLOCKING - Rocking the steering wheel gently back and forth whie turing the ignition key to MAR unlocks the stecring wheel ‘= Never remove the key when the car is moving. if you do, the steering wheel will lock the first time you turn it. ‘= If the ignition lock has been tampered with or shows any sign of damage (e.g. attempted theft), ‘have the lock checked at your nearest HAT Service Centre. ye ey O13. PANEL INDICATORS INSTRUMENT DISPLAY PANEL 3. These are the instrument panel warning LED indicators forall FIAT Tipa’Tempra models. Your vehicle will anly have Panel indicators relevant to your particular car. Choke te] Ol pressure warning cer (9) Direction indicators Brake pad wear wamnieg fs) nove kyjection stem | ntarning tage [6 ] pear tx ti EE] etter warning [Bi] teen seat bets nat lights buckled Automatic waramision ass brake waming (O8] fifi searing fal: rs pot properly @ STOP - When the keyis turned to the STOP position the steering column will be locked, and the keys can be removed, @ MAR ~ This is the driving position. When the key is in this position all the electrical devices are energised. # AW - Turning the key to this position starts the engine STEERING COLUMN LOCK # LOCKING - To apply the steering wheel lock turn the Steering wheel sightly to the left or right when the key ts at STOP ar PARK, Turbo pressure warning BD] Front tag tights Diesel heater/glow POE) eas ” = (@S] ester dtection indicators Te] Dic! fet ite condenstate varrung 14. ELECTRONIC CHECK PANEL 4, The electronic check panel isnot titted to models, vaith basic trim IMPORTANT NOTE: The check panel will not indicate if the tail light fuses blow at the same time, or if there is a circuit failure within the panel display. npg ed hoonm ‘SIDE AND HATCHBACK DOORS ‘When the ignition key is at MAR, the check panel LEDs, gh. 1, L, mand n monitor the light bulbs. and fuses. LEDs a, b, ¢, d, and e manitor incomplete closure af ‘the side doors and hatchbackFluid levels (if included) are monitored by LEDs f, © and P, indicating the levels of the fluid reservoirs ‘A red LED illuminates at the position an the check panel corresponding ta. side door or a hatchback/taigate that is not properly closed. SIDE AND TAIL LIGHTS When the side and tail ights are turned on, the check panel monitors the ight bulbs, fuses and circuits. LED g monitors the front side lights. # LED i monitors the taillights. IV one of the two fuses protecting the following bulbs blows, LEDS g, i, and m illuminate NUMBER PLATE LIGHTS # LED m indicates when one or both of the number plate light bulbs have burnt out, REAR FOG LIGHTS # When the fog-guard lights are tumed on, LED h monitors the light bulbs. = When the fuse blows or a circuit malfunction occurs, LED hlluminates, but not the panel indicator STOP LIGHTS fone er beth stop lights burn out, the fuse biows or a Circuit malfunction accurs, LED For i iluminates when braking, # LED n monitors the left stop light. # LED I monitors the right stop light. If both bulbs burn aut at the same time or brake pedal switch malfunction occurs, both LEDs I and n iluminate, ENGINE OIL LEVEL LED #iluminates when the engine oil levels low (key at MAR engine not running) The oil level mionitoring system does not operate when the engine is running, Ifthe ail level warning LED ihuminates when driving, a Grcuit sensor malfunction has occurred When starting the car on a hill ar within 10 minutes of switching off the engine the warning light may luminate (event will be stared in system memary), Start the engine again on level ground to ensure the oil level is sufficient, COOLANT A lon coolant levels indicated by LED @ (key at MAR) The LED also illuminates when a sensor or circuit rmatfunction occurs WINDSCREEN AND REAR SCREEN WASH LEVELS # LED p illuminates (key at MAR) when the level in the windscreen or rear screen wash reservoirs are low \e The LED also indicates when a circuit or sensor malfunction occurs, 15. HEATING AND VENTILATION ‘CONTROLS SA. Air volume contral - Adjust the dynamic air flow tfan OFF) by turning the knot up to 1 Centinue tuning the knob to the right to increase the air ‘ows (Le. fan On, 3A SB. Air temperature contro! - The temperature will increase ‘the further you turn the air ‘temperature knob to the right red zone) The temperature decreases the further you turn the temperature control knob tothe left tblue zone HEATING HEAT DISTRIBUTION 4 5 ‘With the air temperature knab (58) turned to the red zone and the air volume control knob (SA) turned ta the desired fan speed, turn the air distribution knob (50) to: 22 in sunny, cold weather #3 - For heating to footwell vents Demist the windows, Also, turn the air volume contral knab (SA) to level It or VENTILATION ‘# Tum the air distribution control to 5 ‘2 Tuin the air temperature adjustment knab fully anti- Clockwise to the blue zane, ‘© Tuin the air volume control knob to the desired fan speed. ‘© Tuin the air distribution control to § ‘When the car is moving the volume ofthe air entering the passenger compariment can be reduced by turning the fan knob to the left of 4 DUAL TEMPERATURE © Tum the air temperature adjustment knob to an imermediate position © Tum the air distribution control knob to 2. Warmer air is delivered to the footwell vents and caaler air to the dashboard vents a) ra AP Adsl ¢ Ma z a 3 i= rE] ;¢ WaLdV i— My r a PI i-) iS a EI AIR CONDITIONING (EARLY MODELS) ‘Air conditioning is-an optional extra fitted to some models of Tipo and Tempra, ‘AIR CONDITIONING SWITCH SD. When you turn on the air conditioning it will initially operate at the first 4an speed even if set at position 0, AIR RECIRCULATION SWITCH SE. When pressed, no-outuide air enters the passenger compartment. Use the recirculation feature for fast cooling or heating. Select 5E heavy traffic, in.3 tunnel or under any conditions where the air is heavily polluted, recirculation whenever you drive in Use the following settings for maximum cooling: «Turn the air temperature adjustment knob to the blue zone, # Tum the air conditioner switch ON, # Turn the alr volume control knob to position It ‘e Tum the air distribution control knob to 5 AIR CONDITIONER HEATING Tuming the air temperature adjustment knob to the red zone ‘9 Tum the air volume control knob to the desired fan speed ‘= Tum the air distribution contro! knob filustration 50) 10.2 cold, sunniy weather or 3 heating. IMPORTANT NQTE: The air conditioner and heater may be used at the same time during winter or whenever the weather is particularly humid, for optimal demisting DEFROSTING THE WINDSCREEN AND WINDOWS ‘¢ Tum the air temperature adjustment knob (illustration 5B) to the red zone. ‘Select fan speed 3 or 4 ¢ Turn the air distribution control knob to Press the air conditianer swatch far efficient demisting VENTILATION © Tuth the air temperature contral knob (illustration $8) to the blue zone, # Select the fan speed desired. ¢ Tum the air distribution control knob (illustration 5) to position 5 AIR CONDITIONING (LATER MODELS) SF. The air conditioning controls fitted as an optional extra to some later models of Tipa of Tempra are shown in illustration 5F. TEMPERATURE CONTROL « Use the TEMP button to select the cabin temperature « Each time the TEMP button (up or down arrow) is pressed the temperature will inctease ot decrease by 1°C «ifthe temperature displayed exceeds 32°C or is lower than 18°C the words Hi or LO will appear on the display, When the ECON button is selected the temperature will remain static until the outside temperature drops sharply or until the ECON button is switched off AIR VOLUME CONTROL «© Press the AIR left or right arrow buttons to increase or decrease the air flow into the passenger compartment, AIR DISTRIBUTION CONTROL 5G. « Press the demisting button 1 to demist the windscreen and side vweindows. ‘Select button 2 to direct the air flow to the passenger face vent ‘Press button 3 to direct the air flow towards the footwell and face vents. Selecting button will direct the airflow to the floor vents AIR RECIRCULATION SWITCH ¢ When the ait recitculation button (ilustration 56, $) is selected no outside air enters the passenger compartment AUTOMATIC OPERATION ‘* When both LEDs next to the AUTO button light up, ‘the system is fully autornatic ‘»'When only one LED lights up the system is in manual ‘operation '» When the OFF button is pressed the LED next to it will light up and ail of the systems other LEDs wall turn off, indicating that the air control system has been switched off6. LIGHTS AND INDICATORS DIRECTION INDICATORS AND REAR FOG LIGHT SWITCH The lights operate when the key is at the MAR position. 6, The symbols on the stalk all illuminate when the side or headlights column stalk's knurled swatch from 010 €, The pane! indicator sidelight display wall illuminate. LOW BEAM HEADLIGHTS ‘Tum the knurled switch from position € te B, for low beam headlight. HIGH BEAM HEADLIGHTS. When the knurled sivitch pointer is at position B, pull the stalk towards the steering wheel to switch the headlights to high beam, ‘The panel full headlight team LED will ight up. «Flick the stalk towards the steering wheel again to switch off the high beam headlights (the low beam headlights will remain on}, REAR FOG-GUARD LIGHTS Tum the knurled switch ta B (low bear) and then press the rear fog switch JA at the tip of the stalk to. fumm the rear fog-light on, DIRECTION INDICATORS Move the left-hand column stalk (from its centre Position): 6 Up = right turn. « Down = left turn, ‘The panel direction indicator light flashes when the sdrection indicators are operating. The stalk returns to the centre position after compieting the turn. WINDSCREEN WASHER/WIPER CONTROLS 68: WINDSCREEN WASHERAWIPER (FRONT) The washer and wiper anly operate when the key is positioned at MAR, ‘When the windscreen washer stalk is pasitioned at ‘910 The windscreen wiper is off. ‘911 Intermittent operation adjustable by turning switch ¢. ‘rom Mo HM, #2- Continuous high speed ‘operation #3 - Continuous operation (when the stalk is released the wiper turns OFF} WINDSCREEN WASHERIWIPER (REAR) 5G. » Tum switch B fram position 4 to position § to turn on the rear window z wiper. n @ Pull the stalk toward the steering wheel to turn on the rear window washer and wiper (continuous operation} Both the washer and wiper stop operating when the stalk is released REAR WINDOW DEFROSTER The defraster can only be operated when the key is in MAR Press switch A at the tip of the right-hand stalk to turn, ‘on the rear window defroster. The rear defraster LED Panel indicator wil lurninate. HAZARD WARNING LIGHTS 6D. Press the hazard light switch arrowed) to tum on the hazard warning lights. All the directional indicator lights and the panel indicator will flash. The hazard warning lights ‘work whether the key is inserted or not. = 2 FS ) < ) i El) | FRONT FOG LIGHTS Press the front fog light switch (key at MAR, headlights on). The fog light panel indicator will lluminate. PANEL LIGHT DIMMER (DIGITAL INSTRUMENTS) Press the panel light dimmer switch to adjust the panel backlighting level {key at MAR, headlights on). (FUEL CUT-OFF SWITCH ‘GE. Some models are fitted with a fuel cut-off device, ‘which cults the fuel supply off to the engine ifthe car is involved in a collision ‘elf there are No signs of fuel leaks and the vehicle is in| good enough condition to start again, reactivate the fuel feed system by pressing button A (arrowed), which is located underneath the passenger's seat,¢ aa LdVHO = g A 5 i ) € EI 14 7. STEERING WHEEL HEIGHT ADJUSTMENT 7. On some versions the height af the steering ‘wheel can be adjusted - ONLY WITH VEHICLE STATIONARY! «Puller a, positoned L21 under the steering wheel, towards you. ‘When you have acsted the whe to a confortable height push the lever heck (0 its original postion. INDIVIDUAL SETTINGS 8. FRONT SEAT ADJUSTMENT LEGROOM ADJUSTMENT A. Lift lever 1 and exert body pressure in the rection desined to set the seats fore-and-aft position: Release lever 1, ensuring that the seat is locked in the desired positian, FRONT SEAT ANGLE ADJUSTMENT To adjust the angle of the front seats backrest cushion: ‘@ MODELS FITTED WITH A LEVER (ILLUSTRATION BA, 3 lift to recline the seat ‘@ MODELS FITTED WITH AN ADJUSTABLE KNOB (88, 4) rotate to rechne the seat, DRIVER'S SEAT HEIGHT ADJUSTMENT ‘On models with driver's seat height adjustment, depending on which type you have: EITHER, pull up lever 2 illustration 8A): = Move forward to raise the seat fo Move backward 1 lower the seat BC: « OR, pull lever 5 Out so that its at its full extension Move lever § up or down to. adjust the height of the seat. After the seat has been adjusted to the required height slide the extended lever back to its original collapsed position (19. DOOR MIRROR ADJUSTMENT MANUAL TYPE 9A, Move the intemal knob B (attached to the door mirror i) to adjust the mirror Move it from position 41 to position 2 from outside the car if extra clearance is needed. POWER ADJUSTMENT 9B. When the key is at MAR, use the 4-way switch A (near the handbrake) to adjust the rmutror and switch B to select lefvfight mirror Gn some models mirrors are dernsted/te-iced whenever you turn on the rear demister. 0140, ELECTRIC WINDOWS am | we 10. There are faur Buttons in the driver's armrest that operate the front elect windows {fitted} when the key is at MAR A Closesteft window. © B Closes right window @ C-Opens lett window. @ B- Opens right window. @ E-Lorks and uniocks the rear electric windows, # Fand G - Open and close the rear side windows, Some models are fitted with two buttons in the front passenger's armrest to- open and close the passenger- side front window. J). AIR BAG AIR BAG SAFETY DEVICE AS an extra safety device, some modets are fitted with an ai bag, which is stored in the steering wheel. The air bag inflates immediately to protect the drivers chest and face in the event of a head on callision. IMPORTANT NOTE: All diagnosis, repair and replacement of the air bag device is a specialist job and is potentially dangerous. It must only be carried out by your FIAT Service Centre,- Eada stan air bag has been fitted to your vehicie: ne steering ‘operation of the ar bag. . NEVER travel with ‘in interwar cose anything on your lap or O42. INTERIOR LIGHTS COURTESY LIGHT Qn mast models the courtesy light is positioned in the centre of the roof, h the light switch in the central position the light ms on when either of the front doors is opened, ‘eWhen the switch is in the right position the light remains on. ‘#With the switch in the left position the light is ssuatched off 113, SUNROOF OPERATION 1BA, SUNROOF CONTROLS As an optional extra same madels are fitted with a sunroof. To operate the manually operated sunroof. Pullandle A dawn and turn anti-clackwise. The sunroof lifts up and then slides back sunroot with ‘Press rocker soich C either at the front oF back ‘OPENING THE BONNET 4A, Full the bonnet release lever A, toward the steering wheel to release the bonnet catch, 148. Positioned at the front of the bonnet is a release catch B. Lift catch up to release, 146. Lift the bannet and pull the support rod Coutof its alder When the bonnet is fully raised, place the tip of the rod in the recess B located in the bonnet 0115. LUGGAGE COMPARTMENT INCREASING THE CARGO AREA FOLDING THE BACK SEATS - Use the following precedure to fold the rear seat forwards: Pull the strap at the centre of the backseat cushion in ‘an upwards direction to swing up the seat cushion 15A. On models fitted with lever A, pull th release the seat backrest. 158, Models fitted with a lockable lever B, turn the key to positon 2 to unlock (1 to lock), then lift the lever in the direction arrowed ‘Fold the backrest cushion forwards To repositioning the back seats - reverse the order described above. 116. CHANGING THE WHEEL IN AN EMERGENCY CHANGING A WHEEL Whenever possible park the car on firm level ground Put the car into reverse gear and pull on the handbrake. Keep chocks or pieces of wood in the boat of your ear \which can be wedged in front and behind the diaganally-onpasite wheel to the ane being removed to prevent the car from rolling. if you haven't got a piece ‘of wood handy, use large rocks or stones, The location of the spare wheel, jack and tools for most rmadels isin the luggage compartment under the mat. However on some madls the spare wheel and tools are located in a storage container within the side walls of the rear luggage compartment t Wa LdVHO i= “4 A a C4 ) = EJ aBCR ABS le) (3 : s 3 “a Ta release the spare wheel, jack and tool kit; 116A. Undo strap A to release the jack from the support, Unscrew nut B, to remove the spare wheel 1168. Release the jack from the taot stand by lifting tab ©. The arrangement of the tools in their holder might have ‘one of the configurations shawn in dlustration 168, 97. RAISING THE VEHICLE 7A, To raise the vehicle, position the jack under the side member, about 20 cm from the wheel arch. Turn the jack handle until the its grooved head (see inset) fits the flange at the base of the sil [7a] REMOVING A WHEEL a o 178. Loosen all the whee! bolts in the order shown. s Litthe car until the wheel is about | 6 3 25 mm (1 in) off the ground, The hub cap is secured by only three wheel bolts, ‘# Remove the hub cap, then unscrew the fourth wheel bat, and rernave the wheel ‘Put the spare wheel on, making sure that the aligning peg 07 pegs On thé hub fits into the holes in the rim, ‘© Attach the wheel with a single bolt and then put the Wheel cover back on so that the largest hole fits ower the boit holding on the wheel. Screw in the other three bats, which alse hold on the wheel cover «Lower the car and remove the jack. Tighten the whee! balts evenly in a eriss-trass fashion, as shown in ilustration #7C- RAISING THE VEHICLE WITH A TROLLEY JACK 70) # 17C. FROM THE FRONT - Place a hardwaod board between the jack and the car, see inset. The jack must ONLY be positioned under the geartiox case support on the Side of the differential gears 10 17D. FROM THE REAR - Put 2 hardwood board between the jack and the car ONLY at the back of the spare whee! housing (4418. ENGINE STARTING JUMP STARTING YOUR CAR Choose a fully charged battery with the same or higher capacity than the flat battery in your car, then ¢ Make sure that the car with the flat battery's electrical equipment has its ignition turned OFF, and that the Ignition keys are removed 18. « Connect cone of the jump lead lamps ta the positive battery post of your flat battery. Then clamp the other fend of the same lead on to the positive post of the second (charged) battery ‘© Connect one end of the second jug lead te the negative pole of the charged battery, and attach the coher end to the metal terminal {as shown) of the earth cable from your car's flat battery. ‘¢ Run the engine of the car with the charged battery at ‘2 medium to slow speed, «Start the engine of the car with the flat battery, and run the engines of both cars for about three minutes, To reduce voltage peaks when disconnecting the jump leads, turn on the air fan and the heated rear screen of the car that had the flat battery. ¢ Remove the jump leads, starting with the negative clamp connected ta the car with the flat battery's earth, IMPORTANT NOTE: When disconnecting the jump leads DO NOT switch on the headlights in place of the heated rear screen, as the peak voltage may blow the headlight bulbs. BUMP STARTING YOUR CAR IMPORTANT NOTES: 1) Never bump start a car fitted with a catalytic converter, as the sudden rush of unburnt fuel into the catalytic converter could damage the converter beyond repair. 2) On models fitted with automatic transmission bump starting is not possible. 3) Ensure that the key isin the ignition and is turned to MAR while the car is being pushed, or the steering wheel will lock, To bump start a car: Place the key in the ignition and turn to MAR. # Engage a medium gear (2nd or rd), NOT REVERSE. ‘Hold the clutch pedal dawn while someone pushes, «When the pushed car has reached a fair speed, with the car stil in gear, release the clutch pedal # The engine should now tum aver and start running Depress the cluteh and keep the car running.CHAPTER 3 FACTS AND FIGURES This chapter provides you with ail the information you wil ted about your car especially in connection with servicing and repairing it Fist, you'll need to identity the engine type. If you don't knaw it already, see Chapter 6, Repairs and Replacements, IMPORTANT NOTE: Many detail changes have taken place over the years, and there have been many different Special Editions and Options available. The following information will be true of most cases but can only be taken as a general guide, Consult yaur local FIAT dealer for confirmation. PART A: MAJOR MILESTONES (Overview Although the Tipo and Tempra were preseritest as separate models, they are essentially the same cars, with detail tifferences. However, all Tipos are §-door hatchbacks (apart fom some 3-doar 1.4 and the relatively rare 2.04¢. 16y, both ‘tom 1993}; al Tempras are 4-doar salaons (with a boot) oF Shor estates, Apert from the rear bodywork and very sight diferences in rear suspension rates, both models are the: same, although years of production and optians available (including some engine options and came model names) are rot necessarily the same, and changes were nat atways iniraduced to both model names at the same tina -if at all Al medels come with front disc, rear drum brakes, excent the Teo 20i.¢, 16x (but NOT the 2.0 Le. GT), and the Tempra 20 Le Scand SLX models, which have discs front and rear. IMPORTANT NOTE: This manual does NOT cover 1.8 and 2Dlitre Tipo or Tempra models. June 1988 Tipo range introduced, as 1.4, 1.4 DGT, 1.6 GT ed 1.6 DGT SX models wath 1372cc and 1580cc petrol ogines. Also 1 9¥.ds with 1825 turbo diesel engine GT and Ts with digital instruments. All models with galvanised stee! body. € WALdVHO Before buying parts, be sure to. take your vehicle's chassis and engine numbers with you - see Auto-Biography on page and PART G: IDENTIFICATION NUMBERS in this chapter. " 5 I uw Pd < i=} | a ¢ I} i w“ ‘October 1988 Tipo 7.70 diesel version launched, April 1990 Formula and S versions.of Tipo 1.4 intrechuced ‘April 1990 Also 1.6.67 Selecta version introduced with CVT saearbos, July 1880 Tempra #.4 and 1.6 petro) and 9.90, (non-turba diesel), and 1.9 TDS and TOSX (turba diesel) 4-door saloon ‘models introduced. CVT auto-transmission available on 1.6 fhettol models anly -same as Seiecta an Tipe models, but not named as such, Tempra 1.8 fe. 5X with high performance 1756ec dowbie-overnead camshaft (DOHC) fuetinjected engine introduced, Tempra 1.4 and 1.6 basic and 5 models ‘wath regular, analogue instruments; Tempra Sx and SX ie, ‘with digital instruments Tppo 1.8 ie. DGT model, with high perfarmance 1756cc fuel Injected, DOHC petrol engine introduced, June 1991 Tempra Station Wagon introduced, as 1.6 or 1.8 ‘Le. models, with 2-part horizontal split taligate and high- roof styling.€ WALdVH- n 4 Hl “ Po Z L-} a Q € Fr al “a October 1991 2.0.¢. 16y introduced, with 1995cc, 16 valve high-performance DOHC engine, catalytic converter, sports suspension, front and rear disc brakes, ABS available as option January 1992 Existing Tipo model: lightly facelifted and redesignated 1.4 Formula, 1.45, 1,65, 1.65%, 1.97D SK 1.8 Le 5X 1.70 discontinued. 5X versions with digital Instruments Temora 1.9 TDS (turbo diesel) Station Wagan introduced. 1-4 and 1,90 salaans discontinued, May 1992 Tempra 1.8 Le SX Saloon and Station Wagon discontinued June 1992 Tempra 2.0 Le. SX saloon and station wagon models introduced, with high perlormance 1995cc DOHC fue! injected engine, catalytic converter and dsc beakes front and Tipo 7-4 and all Tipo and Tempra 1.6 models (except Selecta) now with a catalytic converter and fuel injection in place af \Weber twin-choke carburettor. Designated i, in badging December 1992 Tipo. 1.8 'e. and 1.6 Selecta discontinued February 1993 Tipo 2.0 ie, GT introduced. Slightly tower performance and spec. version of the 16v model. July 1993 Tpo 1.4 now available as a 3-door or S-doat hatchback. 2.0 Le. 16v now only avalabie as 3-door. Tino 2.0 he. GT replaced by similar spec. 2.0 ie. SLX. Tetipré 2.0 ie. SX'saloans and estates now only available \with euro. gearbox. Otherwise, 5X models became known as SLX. with colour-coded mirrors and ABS brakes. Most Tempras ‘now with body-coloured bumpers. 1.90 {nen turba Diese re introduced), All Tino and Tempra models news with revised tront.ond styling - narrower headlights and revised grite, improved crash protecton. including side impact beams, safety steering wheol and uprated brakes. Power steering, central lacking, elect windows all standard February 1998 Tipo 1.7 non-turbo diesel reintroduced as 4705. May 1994 Tempra 1.905 stavion Wagan introduced September 1994 Nast mogiels wallable wrth divers airbag, fire prevention system and seot belt pre-tersioners December 1994 Tempra 1.6..¢. versions et MP. enepine February/March 1995 All models with ¥IN number window ‘etching and immabiiser standav an all Tempra petrol models ‘October 1995 immobiliser fited te Tempra D and TD made, End of 1995 Tipo discontinued. (Mld-1996 Tempva discontinued PART B: VITAL STATISTICS All Tipo models - $5 litte, except petrol with catalytic converter - 51 es. All Tempra models. 65 ives, except petrol with catalytic converter 62 litres, ‘TYRE PRESSURES (cold) FRONT REAR average load emyload average load heavy load 20 bs29ps Oba ps 19 burps 22 banIz ps) 2.1 bai30 psi 21 baOps 1 9bar 2B psi 2.2 bana? ps 22ba/37Z psi 24 bape 22ba/I2ps 24 ban/35 ps 2.058029 psi 20ba/2Bpsi 18 ber/B psi 2.2 band? ps 2.1 ba/30 psi 2. banf3Ops) 9 ba/2B ps 2.2 ban? ps 22 ba32 ps 24barBpsi 22 ba? psi 24 barr35 psi 2.0 bav29 psi 2.0 ber/25 psi 2.0 bar/29psi 2.2 barr32 psi 2Obav29 ps 2.0 bar29 psi 2.0 bar29psi 22 barP32 psi Z2baBd ps Abas ps 2.2 ba32psi 2.4 bar’35 psi 22bs2 psi 2Abal¥pd 22bw32pH 3.0 bara ps 22bi/32 psi 2A ba/¥S psi 2.2 bav32 psi 3.0 bar/dd ps 42 bab | psi Wheels and Tyres ENGINE PRESSED STEEL RADIAL WHEEL RIM TYPE TUBELESS ‘TYRE TYPE ‘TIPO MODELS Tard 16Petrot S00. 13H 165/708135 1657 Diesel 5.0084 13H 165/708 135 Turbe D 550x148 17565R 147 Vie /16 Le (1983.00) 5 5) 148 165/65R 187 4.70 (1993-an) 55h 18H TOsvESR 147 Option = certain models 55/1 14442 785/608 14H TEMPRA MODELS Early 14 and 1.6 Saloons 5008x134 1687708 1357 55ix 14H 1eS65R 147 and Late 1.6 i. 550K 14H 17865R 14TH 1si1.0r1.870. station Wagons 550K 18H 17565 14H Option for Station 55)» 14h or ANZ. 1aS/GOR 14H Wagons (ally) SPARE WHEEL - ALL TIPO AND TEMPRA MODELS (speed limit 50 mph) ‘Tempra TD Saloon and AULStation Wagons 4.008 Ish twsvoata Allothermodels = 4008 14h 1350814 2 2.8 bana) psi‘Weights and Dimensions. ii weights in kg. All sizes in mm. Al figures are given for 1993 madel-year. Other years may vary. ALLTIRO AND TENIPRA MODELS: Maximum roof load - 20 kg (all models). Maximum weight on towibal, when fitted - 75 kg, VermCLE UNLADEN MAXIMUM TOWABLE UMTS WEIGHT «LADEN WOTHOUT WITH WEGHT BRAKES BRAKES ‘Wo moets 4 030 1530 01100 ‘Smanval 050 1580 401100 ‘Saute. a 1580 01100 19 Turbo D150) 1880 401200 17 Diesel 1060 40010 TEMPRA MODELS. 1.4 Saloon, 17s 1575 00 N00 16 Saloon 180 1380 4001200 16 Auto Saloon 1120 620, 40000 19DSaloon 1170 a70 2001200 1970 Saloon 1210 710 3001300 ‘LB Station Wagon 1140 1705, 00 200 16 Auto Station ‘Wagon 180 1730 000 19D Station ‘Wagon 130 180 801300 19D Station Wagon 120 ve 40 1300 OVERALL OVERALL WHEEL FRONT REAR HEIGHT LENGTH WIDTH* BASE TRACK TRACK (unladen) * nat including mirors All models 398700 8AD 1838S Saloons: asa vin ans 148s Station Wogan: acre was 480142581550 (toot bars ~ act 4d rom) PART C: CAPACITIES ‘See RECOMMENDED FL LUBRICANTS on page 154 ei ei ey All setting in mm, unless stated otherwise. Engine RIG ORDER: All petrol mods 1.3.4.2 INUECTION ORDER: All diesel modes 1-3-4-2 IGNTION TIMING in degrees Before Top Dead Centre - BTDC 350 om: 1372cc-B to 12 degrees, 1SBGMISBIcr - 10 to 1d degees SPARK PLUG TYPES AND GAPS Model nat Champion Gap {mem} 3M (VALS ANBYC F108 istorseice vasise ANTYC = O?toO8 DLE SPEED: Petal: 800 ta 850 rn Turbo Diesal: 880 to 920 rpm Nor turbo Diesel: 740 to 780 rp (CO CONTENT AT IDLE (MAX) Fetral only 0.5 to 1.5% VALVE CLEARANCES {mm) Inlet Exhaust (Checked when engine-cold) Petral engines 044-005 0544005 Diesel engines 034-005 0354-005 Other settings CLUTCH ADJUSTMENT: No pedal frae-tavel, Adjustable pedal heght (see Chapter 5, Jab 20) BRAKE DISC PAD MINIMUM THICKNESS: Frant (all models) and Rear (models with ABS) - Brake pad wear wang light on dash, but also check visually - minimum 1.5 BRAKE SHOE FRICTION LINING MINIMUM THICKNESS: Rear (when applicable) - minimum 1.5 TYRE PRESSURES: See page 18 a} psec A Aas E ; uw PJ 2 1~] mu a =] | m “1580/1581 GHC PR ICAP A: Fe) BORE STROKE 90 REBORE SE (steps of 0.01): 82.6-82.65 PISTON SIZES: Size A 6 4 82.52.82.53 Sze ¢ 4 0 4 82.54.8255 Size € 5 i 82,96-82.57 PISTON PROIECTION AT TDC: nia 667-1132 0.367-0.832 PISTON CLEARANCES IN 003.005 06-0 9.07-0.09 PISTON UNG THICKNESS: | i Tor 1.4784 49 3 o 2.075-2.085 SECOND 7 1.728-1.75 975- 1.978-1.99 BOTTOM 293 2975.2.99 2975-72-93 PISTON UNG CLEARANCES - Tap 0.045-0.077 0080.13 SECOND 0.040.072 .02-0.052 eoTTOM 0.03-0.065 00305, PISTON RING END GAP: Tm 3 0 a A) 2 4 L-} au Oo i=] | a) ) 1820305 1820305 302505 202505 PISTON ING OVERSIZES: (All (CRANK MAIN JOURNAL 0 1:50.79508 52.995-53.004 2: 50.7850 79 52,996-52.995 CRANK, BIG-END DIAMETER: A: 45513-05523 1; 50,796-50.805 8 45.503-45.813 2: 90.787-50.795 MAIN BEARING SHELL THICK 1: 1.841.844 1: 1.839-1.843 2: 1.8d5-1 BA 2 1,803.4 847 MAIN BEARING CLEARANCES: 0.019.005 { 0.027-0.062 ‘MAIN BEARING UNDERSIZES: 5 A:o254 Ao2s4 8.0508 B: 0.508 BIG-END BEARING SHELL THIg om ‘AL1535-1.541 A 1528-1532 B: 1.341.546) B: 1.533-1.537 BIG-END BEARING Cl 0.025-0.063 9 0.028-0.061 BIG-END BEARING UNDERSI 0254 &0508 THAUST WASHER THICKNES! 231-236 THAUST WASHER OVERSIZE: 01271580/1581 OC (CRANKSHAFT END FLOAT: 00055-0265 (0:055-0.305 LdVHO Engine ‘top end’ i 29.989-30.014 “A202 43.02-43.08 47-98-48,005, 25545-2557 98,180-48,205, 24.045-24.07 4a 36-48,405, 43,02-43.04 £4 ae ae fs CAM FOLLOWER DIAMETER: 36975-36.995 36.975-36 995 fa) CAM FOLLOWER BORE CLEA a 0.005-0.05 005 0,005-0.05 Lu INLET VALVE HEAD Size: > 37353765 373.376 8: 392.397 2 EXHAUST VALVE HEAD Size: o A 32.85.3245, 8: 3085-31.15 a VALVE SEAT RE-CUTTING AN oO AS docyens, +15) é VALVE FACE RE-CUTTING. 7 5 dagrees 30°45" a \VALVE SHIM! THICKNESSES: Betsen 3 men in Shi i HY 31,940-39,960 PRECHAMBER PROTRLISON 8 EAD (atenved) NA Cooling system All igures in dearees Celsius THERMOSTAT: (starts aperi THERMOSTAT: (fully open) THERMOSTAT VALVE TRAVE PRESSURE CAP RATING: Al) ‘COOUNG FAN - Switches on: COOLING FAN - Switches of SLOW: 81-85 i FAST. 89-89 WATER TIGHTNESS PRESSURE r 0.78 bar Clutch LUNING, OUTER DIAMETER (1 LINING, INNER DUAMMETER (2),€ HaLdVHO j 4 g z 4 i= P| Vf 1) ABTZOHC = 15BO/1SB1 OHC 1697 Diesel 1923 B 1929 Turbo D Brakes d pa! GAB - SERVO PISTON PLSHROD FROM SUPPORT PLATE (a) 2248-2265 22.45.2265 2285-2265 -22.45-22.65 22.45.2265 MINIMUM ALLOWED FRONT DISC THICKNESS mr NONABS. G2 NOWABS 92 © NONABS:9.2. 10.2 102 ‘ABS: 10.2, ABs: 10.2 (Tox: 1018) MINIMUM ALLOWED REAR DISC THICKNESS «when applicable «(ri 92 92 92 ABs: 92 Ags: 9.2 MINIMUM ALLOWED RAKE DRUM INTERNAL DIAMETER = when applicable »(nm: 181.35 18135 181.35, 230 230 B 230 B 230 Running gear/suspension - front CAMBER (not adjustable}: 20° w 40 20 tw 40 -20' 10 40, +20" to 40 -201040° (TSK: 25° 4-307) FRONT CASTER (not adjustable 1 epee 2 degen SO 1 dope epee S0 Yiepee BD epee | Sere Gores’ epee S02 ea St (180 ps TOE-IN adjustable} ac} fest =) - PV TRE boy teh |e Mite) Te fo) PART C: VEHICLE RAISED OFF THE GROUND Bodywork Structure O11. Ary sharp edgeson the exeral Dayar cused by damage or Comrson al cause te eh fo fo 2, check ati bearing ate for Cowoiin Open the door Sil cect thesis ede nd cu te oak bekae Ay cores hrc Imetahnoe vin 30.0" (12 of seat Feat mou. sing an supercon attachment pits wil case the vehi total Wheels and Tyres 13.1 pass the test, the tread must be at least 1.6 mm deep throughout & continuous band comprising the central three-quarters of the width of the tread. The Tread Wear indicators (Twit will tell you when the limat has been reached, on most tyres, IMPORTANT NOTE: Tyres are past their best, especially in wet conditions, well before this point is reached! 4, Check that the tromt tyres and thatthe rear tyres match each ‘ther «in tars af size and type but ot necessariy make. They must be the correc sige for the vehicle andthe pressures must be comect O15. wath each wheel off the ground ur, check the inside and the outside of the tyre wall for cuts, lumps ‘and bulges and check the whee! for damage. Note that tyres deteriorate progressively over a period of time and Hf they have degraded to this extent, replace them Under the Front of the Car ‘You will need to support the front of the car an axle stands with the rear \wheels firmly chocked in both rections, O16. Have your helper turn the steering fram lack s0 eck and check that the steering tums smoothly and that the brake hasas.or pipes do not contact the wheel, tyre-or any part of the steering or suspension ILLEGAL TYRE. O07. Have your assistant hold dovin the brake pod fil. Check ea brake Retble hose far bulges or leat. a tga tes ae pps underneath the ont the vehi for cometon or ests an as ook fr Signs of fu leas atthe brave calpers fig fs pipes need ta be checked thesare way 8. At each full lack position, check the steering rack rubber gaiters for splits, leaks or loose retaining clips, O10. check the track rod end dust vers to make sure they are in place O11 inspect each constant velocity joint garter - both inners and outers for spits.or damage, You will have to rotate each whee to see the gates at the way round O 1a. check a ofthe suspension upper mountings nuda the ant rolbar mountings then fed) Take a mm grn an each snack spear turn gr bot hands andy io ast ‘the damper to check for deterioratian nine mp and boca renew fsken O13. underneath the front whee! arches, check that the shack absorbers 3r@ not corroded, that the springs have not cracked and thar there are no fad leaks down the body af the shock absorber. O14. While under the front end of the car, check the front af the exhaust system for securty of fixing at the manifold, for corrasion and secure fixing te the mounting points. O15. Preferably working with a helper, grasp each front road wheel at the 12 o'clack and 6 o'clack pasitions and try rocking the wie. Look for Mowernent OF wear at the suspension ball oints, suspension mountings, sleenng mountings and at the wheet bearing -loak for movement between the wheel and hub. Repeat the test by ‘rasping the road wheel at 3 o'clock and o'clock and rocking ance more, 116 Spin each wheel and check fr Tole buch Reriae bearng and ning In ether the wheel beara the brake IMPORTANT NOTE: Don't ferget that on front wheel drive cars, the gearbox must be in neutral. There will be a certain amount of noise and drag from the drivetrain components. O arsteyou suspect wear at any of the spersion pons, wy leven th t sceurdnver ta seevineher or no yOu tan eon ary maven that, Es O18. Vehicles fitted with ather suspension types such as hydraulic suspension, torsion bar suspensian ete need to be hacked in a similar way wath the additional point that there ‘must be no fluid leaks or damaged pipes an wehicles with hydraulic suspension, Underneath the Rear of the Car 018 Irapect thereat springs for seaunt ot el mounted pots end forage, severe corrosion or damage O20, Check the rear shock absorbers in the same way as the checks carried ‘ut for the fronts, O21. Check a rear suspension rounting points, including the rubbers to any locating rods or ant-ribar that may be fitted O22. check all of the flexible and rigid brake pipes and the fue! pipes just as for the front of the vette,(023, Have your assistant press down firnly On the brake pedal while you check the rear brake flexible hases for bulges, splits or other deterioration Oh24. Check the fue! tank For leaks oF cortasion. Remember also to check the fuel filer cap =» correctly sealing filer ‘Gp isa part of the MoT test. ‘O15. bramine the handbrake ‘mechanism. Frayed or broken cables or ‘ween mounting points, either to the Bedywark or inthe linkage wil al be ‘alu points (026. Check each of the rear wheel beatings as forthe froms (027, Spin each rear wheel and check that neither the whee! bearings nor the brakes are binding, Pull on and let off the handbrake and check ance again to ‘make sure that the handbrake mechanism i releasing, O28. While you are out from under the car, but with the rear end still raised off the around, tun the engine. Hold a rag over the end af the exhaust pipe and listen tor blows or leaks in the system. You can now gat back under the cat and investigate further ecessaty. (29, Check the exhaust system mountings and eheck for rust, corrosion ar holes in the rear part of the system, O30. Check the rear beake back plate or calipers fs appropriate} for any signs of fluid leakage: O31. Check the insides and the outsdes of the tyres as well as the tyre treads for damaga, 2: for the front tyres PART D: EXHAUST EMISSIONS ‘Thisis an area that is impossible to check accurately at home. However, the following rule-af.thumé tests will give you @ good idea whether your car 6 key to fall or not Bi side inrormanon: if you feel that your car is likely to fail because cf the eviation tes, hae your MOT testing station cary out money on having the rest of the test carried out. (D). PETROL ENGINES BEFORE 1 AUGUST 1973 AND DIESEL ENGINES BEFORE 1 AUGUST 1879 ony hve 19 ppastsible sake check. Rev the Engine to about 2,500 rpm (about hall ‘uxemum speed for 20 saconds and then low it to retum to ke too ‘much smoke fs emtted inthe prion ‘O)2.DIESEL ENGINES FROM 1 AUGUST 1979 The engine will have to bbe taken up to maximum revs several fumes by the tester, so make certain that your timing belt's in good condition, otherwise severe damage ‘could be caused to your engine. f the latter happens, it will be your responsibilty! co the tester the emission part of the test first so you don't waste we car wl fal FACT FILE: VEHICLE EMISSIONS PETROL ENCINED VEHICLES WITHOUT CATALYSER Vehicles first used before 1 August 1973 «sista spoke check only Vehicles first used between 1 August 1973 and 31 July 1986 ¢154 carbon manocideand 1200 parts per milion, unburned brut. Niebiclesfirst used between | August 1986 and 31 July 1992 © 15% carbon monoxide and 1,200 pats per milion, unburned Iyer. PETROL ENGLVED VEHICLES FITTED WITH CATALYTIC COWERTERS Veils fest used from 1 August 1992 (ermgstration on) a Alt have tobe testedat an MoT Testing Station specially equipped to handle cars ited with catalytic converters whether or not the vehicle isitted with sca. the test, or the gurage's data, shows tat the chile was ao ted witb aca’ by the manfactrer, the overs permitted to take the vehicle toa Testing Station not eauipped for catalysed cars, ifheshe preferto do so (upto 1998: Required avimnare - 3.59% carbon moneuide and 1,200 parts per milion, ‘unburned hydrocarbons. The simgle emissions (est (as above vil be ‘supplemented by aurther check to make sute tht the clas is ‘inane in od and efficent working order 19 The ester also has tocheck thatthe engine ol sup to aspectied termperature before carrying out the test. (Tis is because cls dont wrk propery at wer temperatures - ensure your engine i ally var!) ‘DIESEL ENGINES’ EMISSIONS STANDARDS The Tester will veto rev your engine hard seco times. Its notin geod contin, he is = eat to reset test it. This ithe fll range of| tests, eventhough all may not aml to your a, hile Fat used before | August, 1979 ‘© Engine run at normal running terperature: engine speed taken ta around 2900 rpm (or half governed max. speed, if ower) and hold for ‘2 seconds, FAILURE, if engine emits dense blue or Black smoke fr neat § seconds, a ck-ower (NOTE: Testers are allowed to be more Jenene with pre-1960 vehicles) Vehicles first wsed on or after 1 August, 1979 1 Ator checking engl condition, and withthe engine at nonmal ‘unin temperature, the enlne wil be ran up to fll es betwcen three and sx tims tose whether our engine pases the prescribed smoke density test. (For whal i's worth» 2 5k for orturbo cars 3. for turbo diesels. An opacity meter probe wil be place in your cars exhaust pipe and this i na somthing you can replicate at ame.) Irrespective ofthe meter readings the cat wil al smoke or vapeur cbscures the view of ther rad users, © IMPORTANT NOTE: The diese] engine test putsa lot uf stress on the engine, Is IMPERATIVE that your car's engine is propery serviced, and the carn belt changed on schedule, Before you take it in far the ‘MoT test. The esters entitle to refuse to test the sar if be feels that the engine sot in serviceable coaition and there ae anmumber of pre-Test checks be may carryoutSua. rn) m a = fa) r [3] < [-} ¢ F | 4 CHAPTER 5 SERVICING YOUR CAR Everyone wants to own a ‘ar that starts first time, runs reliably and lasts. longer than the average. ‘And it’s all a question of thorough maintenance! How To Use This Chapter This chapter contains al of the servicing Jobs recammended bby FIAT far all modes of Tipo and Tempra imported inte the UK except cars with 1.8 and 2 litre DOHC petrol engines. To se the schedule, note that: # Each lettor code tells you the Service Interval at whi should carry out each Service Job. # Each Service Job has a Jab number ® Look up the number in the relevant part ef this chapter and you will see a complete explanation of the work you If you follow the FIAT- approved Service Jobs listed here you can almost guarantee that your car will Baad! er We thiok itv making © erty” iran keep things 38 straightforward as possible And where you see this heading, you'll knaw there's an extra tip to help ‘make it easy’ for you! (Qver the years, FIAT, iv common with all other manufacturers, have lengthened their recommended service intervals, For instance, all changes on later FIATS don't have to take place as caten as earlier ones. in the main, these changes have not come about because of specific modifications to the cars themselves. They have came about because of a number of factors: Lubricants, spark plugs. seals and ather components have improved and mechanical parts are better made due to Improved materials and production techniques, ‘Asa nesult, you are recommended to follow the maker's Fecornmendations.on how offen to service your car. I your car lies right on 2 change-aver point, the choice: of which Schedule to follow wil be yours, unless the specific advice given here recommands athervise - as we-said earlier, most change points came about for a number of reasons, seit generally nt necessary to identity with pinpoint accuracy which bracket your car belongs to, if it n't obvious,Thanks are due to the excellent, knowledgeable and helpful staff at AF main dealers, Ryaurte.of Amblecote, in the West ‘Midlands for sunpiying venicles anid for their assistance wath this chapter. in particula, thanks are due to the efficient Maurice Waughs Service Manager, the experienced Foreman, Tony Morris, and young deman mechanic, Matthew Warsfoid. Some ofthe suggested inspectonvreplacernent intervals may not comespand ta thase shown in the original handbook The suggested Schedule, based on RAT'S recommendations, takes nta account the age of the vehicle and the annual MOT testi the UK. Inpractie, because ofthe split between (mainly) 12 mant'v9,600 mile and 18 manth/13,500 rile intervals, you will need to serie your Tipo oF Tempra at most, not every, 6 month inten IMPORTANT NOTE: Each service should be carried out at EITHER the recommended mileage OR the recommended time interval, whichever comes first. Sis ae ag PART A: REGULAR CHECKS PART D: IGNITION AND ELECTRICS. senvice service TERS NTERVALS Job 1. Engine oil - check level A Job 22. Check/clean/aap spark plugs 8 Job 2, Cooling system check level Job 23. Change spark plugs D Job 3. Grakeiclutch fluid - check level Job 24, Check/clean HT leads and Job, Battery - check electrolyte level distributor cap c Job 5. Screen washer fluid - check level Job 25. Check ignition timing ec Job 6. Tyres -check pressures and Job 26. Check/adjust drive belis o € o parm tandition (road wheels} Job 27. Check electric fan operation Jab 7. Check lightsichange bulbs Job 28. Run diagnostic ignition/injection test >> PART 8: THE ENGINE AND PART E: FUEL AND EXHAUST ‘COOLING SYSTEM Job 29. Check fuel pipes for leaks c Job 8 Petrol. change engine oil and filter Job 30. change petrol air filter D Job B Diesel. Change engine oil andfiter Job 31. Change diese! ai fiter c Job 9. Chock crankcase ventilation 4 Job 32. change petrol fuel fiter F dob 10, Checklacustwalve clearances D Job 33. Drain diesel fuel filter 8 Job 41. Check camshaft timing bait F Job 34. Change diese fuel fiter € Job 12. Change camshaft timing belt 1 Job 35. Check/adjust petrol engine idle Job 13. Chack cooling system c and emissions c Job 14, Change engine coolant e Job 36, Check emission/evaparativeEGR systems F Job 37. Check Lambda sensor F PART C: TRANSMISSION Jab 38, Check/adjust diese ile speed c & Job 38, Check/adjust diesel injection timing E Job 15. Check manual gearbox cil level « ob 40. Check inlet and exhaust manifold fixings D Job 16, Change manual gearbox ol 1 dob 44. Check exhaust system c dob 17. Check auto, transmission fluid level c Job. Change ut. rarsmision . PART F: STEERING AND Job 19, Check driveshaft gaiters © SUSPENSION Job 20, Chechladjust clutch c Job 42. Check front wheel bearings. € Job 21. Check auto. transmission selector Job 43, Check front suspension c cable E Job 44, Check steering column, joints and rack —¢ Job 45, Check power steering fluid c Job 46. Check rear whee! bearings c ob 47, Chack rear susnension c Job 48, Check whee! bolts for tightness c LdVHO el w m a H fa} fu] zZ =| nm FE Py Fr fa} Fl F-] a =cum aasl w wn E> fe | ee i [to bP PART G: BRAKING SYSTEM Job 56. Check seat and seat belt mountings Job 57. Check headlight alignment c GEEMIGR, 7058. Check undestiody c job 59. Jobe #8. Chek rn brake Jot 60, Change ple iter ¢ Job 8. Check rear brakes Job 61, Replace airbag gas generator 10 years Job 51. Checktadjust handbrake Job 52. Check brake pipes Job 53. Change brake hydraulic fluid PART & ROAD TEST mannan PART H: BODYWORK & INTERIOR Job 62. Road test and specialist check. AFTER EVERY SERVICE Job 54. Lubricate hinges and lacks © Job 55. Check windscreen © ENGINE BAY LAYOUTS These ae the engine bay layouts comsnon to almost al TipovTempras. Mote that there is no carburettor fitted to fuéling vehicles, 1- PETROL ENGINES 2 - DIESEL ENGINES Tel filer cap 7 = distributor ignition) T2 - al filter location 2+ engine oil dipstick 8- coil ignition) 1 «fuel pump (mechanical) 3- coolant filer cap 9. electronic contro! unit ECU, 14 - diesel injection pump 4 brake fluid reservoir DBigipiex 2 15 - altemator location (behind engine) 5 battery 10 -air filter housing 6 screenvaash reservoir cap 11 fuel fiter PART A: REGULAR CHECKS We commend tat meses af cared out on a weekly 4B. andthe cess basis, aswel a before every ng jour. They conse pte sn ss checks essential for your sfty ond for your eas ea spot located a the - front ede of he OF Job 1. Engine oil «check level iiming covey, behind the ane hand Chick the ennine i eel th the ion level ground the head. tegpne has been unin, lave umd ff for seeral minutes to let the oll drain into the sump IC Lift the dipstick out, wi it dry and re-nsert it. The oil fee scarec en beween oe | MAX MAX and mars i insiDE INFORMATION: The difference beturean MIM and MAX matks is approximately one litee of cil 1A. All petrol engines have the dipstick at the front of the block, towards the timing, belt endTOPPING-UP- 1D. On pete! engines the ail filer cap is pull ‘out reciangular pug at the end ofthe rocker caver adjacent to the dctibutr. Note that en some models, the cap is eicular (On cesel engines, the round cap is near the same end of the ‘am cover. This cap is removed by turning a quarter-ture ta the lft and lifting, 16 Powin the fresh of caretuly, preferably using a funnel, clean Bastc bottle with the bottom cut olf is ideal! IMPORTANT NOTE: Regularly check the ground over which the car has been parked for traces af oil or other {uid leaks. if. leak is found, don't drive the car without first finding out where the feak i from, and idea! repairing it 0 Job 2. cooling system - check level. Never allow the cockant level to fall below the MIN (or LIVELLO |AFREDDO} mark on the expansion tank. Is vitally impeetant that al engines have the correct proportion of ant-freeze in the coolant ail year round to prevent corrosion. 80% mix oF sistled water with FL Paraflu coolant gives the best protection, PETROL ENGINES: 2A, The coolant should be just below the remate header tank filer neck + about 25 mm (1 ink abowe the MN (or UVELLO A FREODO} mack on the tank laroered, This i the header tank (cewron cap, résnoved), on the asenger-side of the engine bay, at the very fsont of the engine yy ‘DIESEL ENGINES oO 28. Check the level as described in Job 2A. Unscrew the ‘coolant filer cap anti-clockwise and remove it DONT confuse the codlant cap ‘with the smaller ‘windscreen washer fluid cap, to one side of SCAR Ad on Top-tip, if necessary using a 50-50 mixture of distiled water and Parafly anti-freeze, 1 Job 3, Brakeictutch fluid - check levels, IMPORTANT NOTE: On later models, a hyetraulic clutch is fitted. The same fluid reservoir serves both brakes and clutch. i> ecl eee hm pet: ee fel (On all models the brake flu reservoir is positioned above the raster ovinder either in the rear sight-hand or rear Seft-hond comer of the engine bay, according to model. The reservoir is semi-transparent so the level can be checked vathout disturbing the cap. 3. brake fac topping-up is required, turn the cap without allowing the centre section ta tum. This section, with twa wares attached, snivels in the cap. Place the cap and float to one side - take care nat to drip fluid from the float = and top up with FL Tutela Top 4 brake and dutch fluid Check that the brake fluid-lewel warning light operating, Tu the ignition key to the MARS$ Wa1LdVHO : F : : ; a a fignitian-ON} position the res \d press down the button between the voir cap - when fitted. The warning light on the dash should light up. Wher no button is fitted, tunscrew and raise the cap (ignition key ON} to check the ‘waening light. Check the bulb, check the fuse, or have-your FIAT dealer repas the warning syste, if faulty, o EACT FILE: DISCO} GTHE == ACTE INNECTING THE: * Many vehicles depend on a constant =] power supply rom the battery with these you find yourself in trouble if your simply disconinect the battery. You ‘might find the car atarm goes off, or thal the engine ‘management system forgets all it ever ‘learned’, making the car feel odd to drive until it has re-programmed itself. You might also find that the radio refuses to operate until its coerect security code is keyed into it, © On cars with engine management systems and! coded radios, you must ensure the car has a constant electrical supply, even with the battery removed, You will need a separate 12 volt battery; put a sel-tapping screw into the positive lead near the batten’ terminal before disconnecting it, and put a positive connection ti your other battery via this screw © Be EXTREMELY CAREFUL to wrap insulation tape around the connection so that no short is caused. The egative terminal on the other battery must be connected to the ear’ bodywork. © The gar given off by 2 battery is highly explosive, Never smoke, use a naked flame or allow a spark in the battery compartment. *© never dlsconneet the battery fit can cause sparking) wlth the barrery caps removed * Ailvehicle batteries contain sulphurke atic if the -acid comes into contact with the skin or eyes, wash immediately with copious amounts of cold water and seek medical advice. *. ‘Do not check the battery levels within half an haur 4. Check the #lectroyte level inthe battery. MAX and MIN lines (arrowed) are ruled into translucent bart v casing. in the case of non-FitT-supplied batteries, the call caps or strip (a) may need ta be removed to s2e the level ‘Onginal FIAT batteries are of the ‘maintenance-tree’ type and usually do not need topping-up, However, if necessary, after prising off the cell sealing stip with a screwdreer, Tog ‘up each cell ONLY with distilled or de-ianised water fluid ~ U1 Job 5. Screen/headlight washer check tevel 5A, Top up with a misture of water & additive, mised acce rsteuctions of the container. FAT recommend ‘Arexons DP. The reservoir for front sereen, reat screen and headlights (as app fate) situated in the engin bay: acfacent ta the left-hand strut, behind the battery ing to 5B. ..and behind the coolant expansion tank on diese! rma, sisted C1 job 6. tyres - check pressures and condition (road wheels), GA. Check the tyre ressures using a reliable and ace gauge, Note th recommended Chapter 3, Facts and Figures) ace given for COLD tyes. Tyres warm up as the ear is used - and warm tyres gree reading. Yau should also-check far weat of damage same tine © if. tyre is worn mare on one side than another, ‘consult your FIAT dealer or a tyre specialist. ft probably ‘means the tracking needs re-setting, though it could “indicate suspension damage, 30 have it checked. — ‘fa tyreis worn mare in the centre or on the edges, ‘this indicates incorrect tyre pressures, * incorrectly inflated tyres wear rapidly, can give dangerous handling. and can worsen fuel ‘consumption, 6B. Every few weeks, examine the tyre treads for wear using a tread-depth gauge. This will help-you keep safe and on the ight side of the lawl Check treads visually ‘every time you check the pressures. Every three months, raise each wheel off the ground and turn it slowly between yourhands. looking and feeling for any bulges, tears or splits in the tyre wall, especially the inner sidewalls, (See Job 59 for spare tyre checks) D1 sid € INFORMATION. In time, rubber deteriorates, Presi the rick ofa blowe out Ketp your eye on the sidewalls of clder tyres. you see any cracking, splits or other damage scrap the tye. you're not sure, conaut, your FIAT dealer or tyre speciale. Hl C1 Job 7. check tights‘change bulbs, san. emyg » * Wherever a light fails 10 mebng EASY ~ work, check its fuse before replacing the bulb. # A blown bulb often causes a fuse to ‘go’ in sympathy. HEADLIGHTS IMPORTANT NOTE: On Diesel models with the air filter mounted behind the right-hand headlight unit, you will fist have to remove the large hose, unscrew the clamp fut and take aff the air filter assembly, See Job 37..0n later models, there Is sometimes an air intake silencer in the same place, 7A Pul aff the headlight mult plug (A) and peel the rubber cover (Bhfrom the back ofthe headlight 7B. Unbook the bub securing sping (from the retention cip by squeering inwards (ameeed) ant withdraw the bull o. Without toucting the bulb glass, fit the new bulb. A jecating tageensues it only goes in in the correct position, Refit and recannectin the reverse order er 7 Apo NGREN a Patopan mating © ensy - 6 otic caving ht ut eid bare Papen as shrtan tf, no bande with apiece of we Pabr 1 e bus touched ioe carey with methylated spin. FRONT SIDE Gers: 6. The side light bob holder is der the main beadlight bulb The bayonet-type holder is pushed in stightly, turned anti-clackwese anc removed, The bull (Bisa push-it wit FRONT DIRECTION INDICATORS - TURBO DIESEL mooets: 4D. Remave the lens inserting a screw driver as shown and pressing down the tab A}. You can easily remove the bulbs with the lens rernoved FRONT DIRECTION INDICATORS: ALL OTHER MODELS TE. From inside the engine bay, turn the bulbhoider Sighty. anti: clockwise, and pull Dut, Remove the bulb (@) and press na new one. Push In and twist clockwise, INDICATOR SIDE REPEATERS - RECTANGULAR TYPE ‘JF. Sie the unit towards the front of the car, then pull out from the panel, Turn the bulbholder (A) anti-clockwise, remove it, and pull out the peess-fit 12V/S4¥ bull INDICATOR SIDE REPEATERS - ROUND TYPE 7G. Test the fens (A) anti-clockwise and remove it The push in bulb canbe pulled out and replaced RCA hs FO) i bp | ee ha Ta bo SS BS he |7TH, Undo screws (A) ad (8), pullout the light unit (0) and ‘undo the connector (). The height ofthe bear ean later be adjusted with sreve (€) 71. Alternatively: Work from under the front of the car, leaving the unit in place, Undo the four scree holding the cover in place. Note that yOu do not need 10 remave the electrical connection fram the cover. On ane version of these bghts, vou have to release the ends of the spring clips (8) and swing them back to remove the bub. 71, On another version, you unhook the butt retainer (6), remove the bulb and connect the bulb cable (U. When refiting, ensure that the cut-out in the bulb base-plate (H) is located correctly. REAR LIGHTS - TIPO 7K. Open the hatchback door and remove the three screws (arrowed) holding the fens in place 7 From the inner side of the light unit, take out the twa screws (arrowed) holding the lens to the wnat. Take care nate stain the wining, As reversing ight bub 21W) Bedrection incator bub (2100 ff C= sop bg bulls ew = tabght bul wy fog light bulb aw 7M. These are the poutions of the bulbs. All of the bulbs are feleased by pushing in slightly, turning anti-clockwase and pulling out when free. REAR LIGHTS - TEMPRA SALOON JN. Open the boot lid and remove the A-taiight bu (5) stop light bub iW C-directn indator bub ava SUT reversing taht bulb (21) E-fog bgt bulb (214) 70. Lit the lens away, The bulbs are removed as described in| 7. REAR LIGHTS - TEMPRA ESTATE 7. Open the tailgate door and remove the two screws (A, From inside the ‘car, remove the spare wheel, fitted, open the side cornpartrent and remave its cavers. Unscrew the knurled rnut (A) vehich fits on to the captive screws (B) mounted on the lens. Use your other hand to prevent the lens from falling. Now, pull off the lens and remove the twe knuled auts (€) to \ghe you access to the bulb holder mabirg G eaty Oye arpa mine tick grease on the end of the screwdriver to prevent the screws fram falling - especially when replacing the lens.D-dual arent stom and fait bull (SW 2940. “Take careful poston af the ‘alte pegs onthe shank of the bubs when retitng E> dieetion inckeatar bub ive F-reresng light bub (2 fog tot mut (2147) TRL Insert a screw river blade in the slat arrowed) on the side of lens depress the tab (A) ard pull the sembly (B) it Remove and tepisce the tubular SW bulb {@) NUMBER PLATE LIGHT - TEMPRA TS Remove the complete urit by acing a serew- hiner under the fight-hand edge. Press the unit 10 lett, in the rection ofthe Sraght araw, whl Iitng t out. The tubular SW bulb is unclipped and Irpidced - see inset, INTERIOR LIGHTS -T1PO ‘Ti. WITHOUT FIAT REMOTE LOCKING: Rerave the interior Aight lens by pacing a screw- sn its sidesnotches Aarowed).nepiace the Sw ‘glial bulb or bulbs (A aii the SW capless bulls (B) ifjour car basa map light ‘WU. WITH FAT REMOTE LOCKING: Pace a screwaiiver in ‘he pesiton shown bythe a0 rte tom the Inseing ure “Pate courtesy Iphris towards “Perecener, then “pal onnards remove 1. Swing the cover lens away (C) and replace the SW cylin drical bulb Yor SW halogen bulb (B) with bayonet fitting. as necessary. INTERIOR LIGHTS - TeMpna 7W. WITHOUT SUNROOF: Remove the ens by evening carefully with a screasdiver Under either ise NOT the front or back. Remove the reflector (©) by pressing gently con the two tabs. The capess la SW bulb (B) can now easily be med pulled out: The SW tubule ag bulb (A) held in place byits REN spting clips 7X. WITH POWER SUNROOF: Remove the lens as described in 7W. The tubular bulbs (Al can be replaced as described in 27. To replace the map light (B) bull you must First remove the plasve cover place a screw driver under the points indicated by the arrows: Now unde the two screws at (C) and the single screw at (D) TY. The entire courtesy light unit 's now removed and the SW capless bulls (E} cannow be removed and replaced trom the rear of the unit TZ. Rear interior light bulbs are replaced in a similar way to the tubular bull deserbed in 7, GLOVE COMPARTMENT LIGHT Ta. Fromm inside the glove compartment, press gently on the side shawn bythe arrow, remove the entire unit and replace the bulb (A PIC W Lud Rel eee ha pb. |LUGGAGE COMPARTMENT LIGHT 7, TIPO: Pull the leas downwards to remove it. Remove and replace the 5¥V tubular bul, Te. TEMPAA SALOON: From inside the boot, lever the light unit aut af it slot with a screw- driver. Remove and replace the SW tubular bub (A), DASH BULBS ‘See Chapter 6, Repairs and Replacements for de\ais of instrument panel removal for access to its ight bulls. The ‘bulbs are @ quarterturn fit in the back of the panel © Td. The fuse box is found to the side of the steering column, Pull the lever marked FUSE, © and lower the fuse box. © Ze. A symbol above each fase tell you which circuit it protects. Four spare fusesare located near the top of the fase bo. 10A Instrument power supply, windscreen ‘washer pump, rear sereen washer pump, reverse lights, steering column switch lights, FIAT CODE system. 10Adnstrument power supply, left tail light, right number plate light, right side light, left. trailer tail ight. 10A Illumination of controls, right tal fight, Jefe number plate light, right tall light. 20A Horns, cigarette lighter, stop lights, 204 Power locks. 7.5A Interior lighting. 20A Rear window heater and indicator light, {door mirror defogging elements (if fitted) 10A Hazard warning lights, 25A Electrical fan for radiator cooling (only for petrol versions without air conditioner). 7.5A Direction indicators, right door power iievor (if fitted). 7.54 Rear fog-guard| indicator, 204 Front fog lights and panel indicator (iffitted), hts and panel 104 Right low beam headlight. OA Left low beam headlight. 10A Left high beam headlight and panel indicator. 10A Right high beam headlight, 20A Windscreen wiper. 204 Read window wiper, power sunroof and Iheated seat (if fited), 20A Heaterventilation fan, ‘Fuses located on the auxiliary panel ‘The fuses protecting special devices (options, features of special versions or devices with high power require- ments) are on an auxiliary panel tothe side of the fuse box under the dashboard. It is much easier to remove and replace auxiliary panel fuses if you first remove the ‘oddment tray and moulding fastened by 5 screws. The panel also houses a number of relays: 204 Intake manifold heater (petral engines). 320A Devel fue iter heater diesel and turbo diesel engines), 20A Headlight washer pump. 254 Front power windows, 25A Rear power windows. 10 Antilock braking system. 7.54 Low beam headlight dimming system (for countries where headlights always need to be on.) 04 Radiator fan (diesel versions), 440A Radiator fan (turbo diesel versions with heater} ‘604 Radiator fan (turbo diesel vérsions with air eondi- tioning). ‘The arrangement of the fuses on the auxiliary panel varies with the number and type of devices present, ‘The amperage is clearly marked on each fuse. ALWAYS replace a blown fuse with one of the correct amperage, NEVER ‘ix’ fault by using a fuse of a higher amperage, nor ‘bridge’ a blown fuse - it could cause a fire! 7f, When a fase is blown its conductor wire (A} has agp init Ifa fuse blows, find out. wi and put i right i before fitting a mew fuse, anFACTFILE: FUSES contd, 1, TEMPRAS WITH AIR CONDITIONING 304 The Air conditioninat system fuse is housed on 2 bracket on the engine compartment bulkhead. ‘The following two fuses are lacated under the frant crnssmember near Gel the right headlight. 3A High-speed radiator fan relay. 5A Electromagnetic air conditioner compressor clutch, ‘The relays housed near the fuses are part ofthe ait conditioner circuit IMPORTANT NOTE: Replace the sealed cover carefully ater changing a fuse. Ensure the gasket is correctly positioned and the screws are fully tightened. 7h. CERTAIN TIPO MODELS: Other fuses are i) a set of three fuses (154,304 (= and 40) protecting the air conditioning, when fitted, located in the engine bay, = hear the horns (A). Press in the two sides. (arrovved) to remove the cover: ‘And ii) there isa 604 fuse, located near the fase box, protecting the fan on Diesel vehicles. Ti. On latest vehicles, there are two 108, fuses (a) protecting the electric petrol pump and the Lambda sensor preheater. Remove the screws (arrowed) and the cover, A. Tre sump drain Bigison the desde of the Sem on perch egies, end on the Bec he sump firing bet end of fgre}on the Gea Te plug has recess Teragora heed and you wil need ether a surep plug ‘Barnes, lage Allen key, or a "Hex headed socket fitted to a fecket wrench INPORTANT NOTE: The plug is.@taper-fit and can become very tight, necessitating the use of lang drive bar fo its removal, tightness of plug has been released. unscrew the last few turns by and, holding the plug in place Unt the threads have cleared, withdranieg t smantly tallow oil ta the receptacie beneath, HB nsibe inFORMATION: On side-mounted drain holes, asthe oll empties. the angle of “spurt” will change, 0 be prepared to move the container. El warm engine -but eat so making t enty - ” hot that the ail can scafd! # Allow the oil to deain for at least ten minutes before replacing the sump plug, * You can use this time by renewing the oil fitter © Only drain the oil froma 8G, On all engines, including diese, the oil fiter ts mounted low on the fran of the engine block, towards the timing belt, Use-a stra o chain wrench to unscrew the oid fer, Note that there may be 2 lot of oil spilt as the Fite seals broken, so keep the drip tray beneath i § WaALdVHD P:R) fe | [= 2 a u eT rH = m =§ WaLdVHO p: oe Bs) a ° =} Ec 2 (>) 7] < a i m E 8D. To prevent the rubber sealing ring on the new fiter fromm buckling or twisting out of shape while tightening, smear it with clean oil BE, Screw the new fiter onto the stub by hand. When the ruber sealing ring contacts its seat, ‘continue to turn the filter 0 further 37 of a tum, ty hand only. Overstight- ening the finer makes it difficult to romewe at the next cl change and can buckle the sea, causing a leak INSIDE INFORMATION: It isn't necessary to Use excessive force when refitting the sump plug. Simply grip. the spanner {no need for an extension, now!) so that the thumb rests on the spanner head, limiting the amount of leverage that can be applied. Use firm pressure anly. Before refitting the plug, wipe around the drain hale with piece of clean cloth to remove any dirt. Ell ‘SF, Pour in the correct quantity of Selenia engine ai sce Chapter 3, Facts and Figures) and check the level against the dipstick Note that the empty i fier will cause the level to drop slightly \when the engine i started and the ol flows into it. Before using the ca, run the engine for two minutes, turn off, leave to stand for a few minutes and recheck and correct the ol level Qo '9. Cheek crankcase ventilation, 9. Check the andition of the breather hose from, thevalve cover or ‘cam caver t0:the air leaner. Ifthe pine has become blocked or damaged, replace a, transferring the flame trap trom inside the old pipe to the naw ane, On sare models, you will have to remave the air fiter mousing the crankcase ventilation pipe beneath. Note this type of spring clip - use pliers to Sacker-off when removing ore Fiting 0 et C1 sob 10, check The valve gear clearances need to be checked at the appro priate intervals, when the engine is cold ALL PETROL AND DIESEL ENGINES WA. Remove the ar cleaner (where 30 then remove the bolts holding the camshaft cover in place. This i the petrol engine with ‘filter removed 108, HB iwsie INFORMATION: If the gasket sticks. which it frequently does DON'T lever the cover or your could or you could easily damage it. Use a spatula to push through the soft joint until the gasket/cover comes free. toc. HM insine INFORMATION The oil level inside the housing is above the level af the bottom of the cover plate on these engines Try:i) raising the front of the car as high as safely possible, so that oll drains out of the back of the housing; ii) stuffing cloths beneath the opening ‘and have more ready, for mopping up; il) being ready to clean off the front of the engine with degreaser, when the job is finished. 100, The vave clearance i measured directly beneath the eam ‘and must be checked when the high point of the cam (arrowed) is Painting directly Upevards and away fram the carn follower. ‘Try different fester gauge thicknesses until you find one that’s a tight sliding fit between cam and follower. Make a written note of each clearance staring with number 1 at the timing belt end of the engine.EACT PILE: VALVE IDENTIFICATION; OF sob 15; check cooting system. Remember that clearances for inlet and exhaust valves differ, See Chapter 3, Facts end Figures. Counting from the timing belt end the valves are: ALdVHD 1.1, 12 8-valve AND DIESEL ENGINES: EXHAUST - 1, 3,6, 8. INLET-2,4, 5, 7. 1372ce AND 1581ce ENGINES: EXHAUST - 1, 4,5, 8, INLET -2, 3,6, 7. 1.2 L6-valve Hydraulic tappets - non-adjustable, at Ia deerance is outside the tolerances shawn in Chapter 3, Facts and Figures, the relevant shir will have to be changed, New shims are avatable fom your FIAT dealer. This work & fuly described in Chapter 6, Repairs and Replacements. Examine the cooling system hoses, looking for signs of splting, chafing and pershing, Squeeze the top and batter radistor hoses. sany hard, britle arews.or crackling sounds tel tif Be ef hee you thatthe hoses are decampasing fram the inside - replace bs - ments needed! Siskel. especially: in vent lee 13, original AT hose cenit clips) are fitted, cut them off (taking great care not to damage the stub beneath!) and replace with serene tight clips, when fitting 2 ew hose, Ensure that hose clips.are secure and firm but ot ever-tightened, and cover faces ant wae the gasket dry 10F.insIOE INFORMATION: The cover is ‘anti- pr 2 EAN: (Check that the wires to the WS.LSAS DNITOO> tighten beyond heh cooling fan switch (b) are in halla” good shape. Also, refer to outhere -50 preyed there's no point tying! 0 tab 14, change engine coolant, Job 11, check camshaft timing belt. femave he carnshaft belt outer cover, See Chapter 6, Repairs and Replacements, PART sA: ENGINE. Peaadan al 1. Berine the betfor wea. tt tere sary caching, oritthe toathed side ape wor, or any'test are resin, replace Seat sight Fae 1A, Remove the expansion tank filler cap. Move the hester ng thet = control (a} to the red (open) pasition a¢,.an automatic brake vanes may collie with the pistons. causing senous systems, press the TEMP buttca (b) on the dash unt Hl tegne damage. Camshaft bot replacement is described in. appears on the dsp (e) Chapter 6 Repairs and Replacements o= you may wish to fave your IAT dealer carryout the work for you, f you can Jw the belt through more than 90 deqrees, it needs re- 1148, Loosen the lwescring, Also see Chapter 6, Repairs and Replacements, —_veorirudrive cip (arrose ard O Job 12. Change camshatt timing belt. pull off the IEisESSENTIAL that you renew the carrshalt drive belt at the Bottom radiator recommended interval, See the Service interval Chart at the "* Sar ofthis chapter. Chapter 6, Repairs and Replacements tppars how to cany out the workCRRA: fe) s 3 4 NOISSIINSNYV4L : AC. Also open the drain plug oF tap (B) at 3 cent flank of the ‘engine block an both petrol and diesel engines, Drain the coolant into a container. On madels with a Separate expansion tank, detach the hose from the exparsian tank and drain the tank of the rear I Insib€ INFORMATION: From time to time its a good idea to flush the cooling system. With the bottom hese reconnected, discannect and remove the top hase from the rachator. inert the end of a garden hose fist into the hose (packing the gap with arag) ang then the ttre faking the pte bth Seton an the water comes out cea. IMPORTANT NOTE: Flush first with the heater contral ‘turned OFF until the engine and radiator are clear, so ‘that you don’t flush sediment into the heater. Then with tthe heater turned ON, flush the heater system out. ‘4D. To prevent ai-locks forming in the cooling fgg ystern a i 8 refied Kall hoses and the drain plug reconnected, of course!) most models have two te-bleed screws strategi- ‘ally positioned in the sytem, These shoutd be revelling, The frst (B 67 ©) hhand ude of the radiator type dependant-on version) PART C: TRANSMISSION 1 Job 15. Check manual gearbox oil level. The combined oi level and filer plug is on the ferward-facing side of the gearbox. Check the level with the car on level ‘grounds 15. From benesth the ca, wipe round the filer plug with a rag te prevent din contamination. Remowe the plug - using a 10 om Alben key’ and top-up if nnecessry, wing the specified Tutala transmasion ol (ote ‘Chapter 3, Facts and Figaresi, unti of just drbbles trom the filler hole. Rit the plug 14E, ond the second (D) - when fited «is found onthe heater hose near the tap af the engine. Only ‘undo the screws by two or three turns. Retighten beth screws when ait-free coolant emerges. “This is the petral engine. 146, and this the diesel engine location. Giwsive INFORMATION: It seems that latest Tipos and Tempras were built without some or all bleed screws, Ryauto recommend removing the highest paint of the tap hose, refilling with coolant, while an assistant refits the hose smartly, losing as littie coolant as possible, Ell fefll the cooing system with 4 50/50 mixture of clean water and fresh Paraflu anti-freeze. Tightes the bleed screves (or hose) when coolant, and nat air, Comes out steadily: Run the ‘engine for a few minutes and bleed again, IMPORTANT NOTE: itis highly likely that more air vill be dislodged when you first use the car, Keep your eye on the coolant level (See Jol 2) - perhaps carrying some 50/50 diluted ceolant with you for the first few journeys. 1 Job 16. Change manual gearbox oil. 16. The combined gearbox and tinal drained at the time shove in the Service Interval Chart. Da so caly after the cat has been used and the {gearbox of is warm, so that it flows veel, Remave the drain plug (on the end-face of the gearbox, accessed from benwa the car - nat much room to get a spanner int) and drain the ai into 2 container, (See page 8 on oil disposal.) Leave for 10 minutes to drain completely, and refill with the coerect grade of Tutela transmission of through the levewfiler plug, as described in Job 15,Wl insIDE INFORMATION: Make sure you have a 10 mm ‘len key that will fit, before you start, There's wery little oom betwoen gearbox and subframe, O Job 17, check auto, transmission fluid level. The automatic transmission fluid level should ibe checked with the car on level ground and the engine at narmal running temperature «the car should have teen driven for about 4 mies, The levels checked by means ofa dipstick next to the battery. IMPORTANT NOTE: j) It especially important that the fluid is athe correct level, Ifthe system needs regular topping up because of leaks, fix them as rapidly as, possible or have your FIAT dealer check the system, i Wipe the dipstick only with a lint-free rag te avaiid dogging up transmission valves. Keep dirt out! 47, Check the level with the lege idling and the gear elector in the 'P* (PARK) postion. Pullout the dipstick (AL wie ft clean with paper kitchen towel, reinsert and check the level. The unger Ind loner marks on the dipstick represent minimum and faceum acceptabie fuid levels. Hncesary tech Tutela. CVT shauld Be poured in through the dosti tube, using a funnel in the tube o by using ATE fom a dssenzer witha imal spout, You moy have to lave the es lt clear the tube before secing a cea dosti rod, O Job 18. Repiace auto. transmission fluid and filter. As well a5 Tutola CVT fuid, you will need a new, sump Basket and a new gearbox al filter, from your LAT dealer. The fher should be changed every time the oil replaced, ABA. Aways dain the Auld when the vane isson swarm, such a aie ann, Rase U font of te car on args, sa the fluid ans wel trom the ian hele (C) at the wear fl Inder-sde of the “box. Fern the drain pug With 2 Allen key or hexagora scket adaptor, and allow the Hild to drain into 3 container benesth the transmission - allow ferminaes for carpet diainage Uedemeath the car, remave the 13 ransmassion sump bolts Bliss neon MATION: Thesump is eatlly ditorted, {Rivtun efttina. tigen al bots progresively and Bs to the ecommonded torque’ see Chapter & ‘facts and Figures. Gl 188. The fiters secured by ane control screw, Undo this and pull ‘the filter dowm, detaching its upper fluid pipe in the rocess, Remove the fiber, discard it and fit the placement. Refit the sump, using a new gasket and ‘hon -setting gasket sealer Replace the drain plug and fill the qearbox through the lipstick tube, (See Job 17.) IMPORTANT NOTE; Take care not te.allaw any dirt or gri to get into the gearbox, Job 19. Check driveshaft gaiters. 119A. Grasp and tun the Inner driveshaft and Gaiters, checking for signs (of gate spitting or damage that could alow ‘grease out or - worse still ‘water in, Ensure the gaiter cis are secure, Giinsipe Inror- MATION: Inners tend to leak, putting an oil stain'on the shaft, as here, You can buy a FIAT repair kit, with bearing and replacement gaiter. to repair the leak. This Involves removing the drive shaft- see Chapter 6, Repairs and Replacements, El . 198. Check the outer ater as well, This moves over a greater range and & mote prone to damage and splits IMPORTANT NOTE: Change a split, or damaged gaiter as soon 2 possible - preferably before using the car again, a > os is) nx a NOISSIINSNVUL *> LHWdWaLdVHO Sy foe B-). /) so1u.LoaTa * Most eartier Tipos and Tempras had a cable-operated clutch, while later anes are hydraulic. © 208. You can easily tell which system your car is fitted with, ‘The hydraulic pipe (if fitted runs almost horizontally, across the hack of the engine bay, © There is no separate clutch fluid reservoir it shares the brake fhuid reservnir, © Clutch cables (when fitted) are inclined to break without warning. © Ih pays to keep the operating mechanism well lubri- cated and renew the cable every few years. HYDRAULIC CLUTCH aed ce meen ON Setar ite (CABLE OPERATED CLUTCH The clutch mechanism i saif-adjusting, although the cable linkage can stretch over a period af te and may need ‘adjustment. The adjuster is on top of the gearbox, reached from inside the engine hay. 206. ‘Work’ the clutch pedal 00) few times, pull back the carpet from under the pedal, then measure the full travel of the pedal, which should be between 140 and 150 mm. 20D. If not, note that after the adjusting nut wards ‘along the theeaded roxi arrowed) wall ncrease pedal travel, Tighten the lock-nut against the inner nut after, adjustment, O Job 21. cheek auto. transmission selector cable. Itshould ony be possible to start the engine when the gear selector isin the 'P' or 'N' postion. Place it in each of the other positions and try to start the car. if it starts, the fault ‘must be put right! Also check that, with the ignition off and the selector lever in ‘D’ (Drive), L'(Low),‘R’ (Reverse) or ‘Ni’ (Neutral) the timed waming buzzer should sound. fit does, the selector cable adjustment may be fauiy. ‘See Chapter 6, Repairs and Replacements, PART B: TRANSMISSION AND CLUTCH, Job 8 for adjustrment details PART D: IGNITION AND ELECTRICS Soe FACT FILE: DISCONNECTING THE BATTERY on page 36 SAFETY FIRST!0 Job 22. checkieleanigap spark plugs. GENERAL On ail Tipe and Tempra peti engines the spark plugs face forwards, lowing easy working access Carefully remove the spark plug cans, being carelul ta pull only en the cap and not the HT lead, f you can't be ‘ure to remember which HT lead beiongs to which spark plua, umber them fram one end ofthe engine to the caher. A Unscrew the plug ting the correct type of spare plug socket. Take care o keep the spanner strety in fine vith the plug 40 as net to crac the 228, the elecirodes ef the us loak rounded and warn, replace the plugs. See page i 154 for details of Reading ¥ Your Spark Plugs. ‘Nip’ the (ap ight wit ples, so that it an'teome loose ae 2G his essential that he plugs geeped correctly See Chapter 3, Facts and Figures. Urea feck blade lite correct thickness sleing it beencen the Gecrates should beafirm siding fit. Uke agapning tool (really wielded pliers to bend the curved elecvade Ionarts or anay from the cenire electrode. Take GREAT CARE fata damage the inculztor near the tip of the plug BINSIDE INFORMATION: The spark plugs screw into Aluinien, which sean damaged i the spark plugs do Getengoge ther threads properly. Screw in the plug by Deed int, say, two oF three tumnd- before iting the pop spanner. A light smear of copper greate on the fos treads wil enable them to turn more freely nd fhomate ther easier to remove next time. Finally. Gent over tighten the plugs - fm hand-pressure on the gone stent Job 23. change spark plugs. ‘Spark plugs tire" and love efficiency over a periad of time, en if they look okay. See Job 22 for information on their }oval and replacement. Use good quality Champion or FIAT plugs of the correct specification D1 Job 24, checkiciean HT leads and distributor IMPORTANT NOTE: On latest models, there is no conven ‘tional distributor and, for those cars, none af the following should be attempted, illustration to Job 28¢ illustrates the type which should NOT be worked on ‘except for wiping off the outer surface, with the engine not running, Remove each plug lead from the spar plugs, pulling only on the plug caps, nat on the HT cables. Also, remove the large HT lead fram the coil and take off the dotributar cap, esther by popping aif its spring retainers if the distributor is on the side 24A. On later cass (Digiplex ignition cdistetstor rounted horizontal end af cinder head) unclip and remove the shoud. Clean the cap and cables of either type with 2 clean rag, applying a litte aerosol water ispellant spray to help shift ail and grime 2248, Check each of the HT posts (a) inside the cap for burning or damage, and the certral carbon brush (b) to ensure that it's ot worn down and that the spring loading i okay. Clean the dust cover (e) and rator arm, and check the tip (dl) for burning, IMPORTANT NOTE: 00 NOT spray water dispellant or apply lubricant to ary part of an electronic ignition distributor. (It's okay to lean the cap, a5 described, however) ie) = y = eI E 7A) be] b= Whe = FC Be Bf |LdVH- bP: ic 3 4 ) 4 5 1 Jeb 25. Check ignition timing. =r FILE IONITION SYSTEM EVES ‘Twordifferent types of electronic ignition systems have been fitted to the petrol engines covered by this manual, ‘The earlier Breakerless Inductive Discharge System can fhe adjusted. Ils distributor is fitted as shovn in illus tration 254, The later, Digiplex 2 system, has an integrated ignition and fuel injection control system and any checks and adjustments will need to be carried out by your FIAT dealership with the appropriate diagnostic equipment. See Job 28, MAGNET! MARELLI BREAKERLESS INDUCTIVE DISCHARGE IGNITION SYSTEM (CHECK VACUUM AND MECHANICAL ADVANCE SYSTEMS 235A. Thisis the location of the break cerless electronic ‘grition components in the car, The distributor (1) 5 fited to the front of the:biock while the tion cod (2) is alongside the bartery 258. This type of distributor can be Identified by the electronic igrition control module (a) and the wacuyen advance unit (b}, not fitted ta cther ignition types IMPORTANT NOTE: Before checking the ignition timing, you must be certain that: * the pipe from the distributor vacuum unit is disconnected from the distributor and plugged. ** the engine must be at its normal operating temper- © the idle speedimisture/CO adjustments must he carrect see dob 35, 25C. To check the ignition timing, conneet up a stiaboscopic lamp, either as shawn on the inset or in accordance with the manufacturer's Instructions. The timing ight should ‘always be connected to No. 1 spark plug lead - the one nearest the timing belt end of the engine, ‘© Start the engine and run it at Between 750 and 850 rpm, ® Point the timing light at the crankshaft pulley ting ena: ‘and ensure that the mark lines up with the 10 dagrses Before p Dead Centre (TDC) mark an the timing belt cower ® Ifthe reading is ‘out stop the engine and slacken the clamp rut en the distrbutor that the dstributor can just be turmd with frm hand pressure. © Turn the distributor a wery small amount, restart the engine and check again. © Repeat the procedure until, with the engine running, the Crankshaft pulley timing mark lines up with the 10 degree BTC mark. Then tighten the nut securing the ds gine block You can naw check the vacuurn advance system 2s follows: * increase the engine speed to approximately 2,000 rpm and, with the timing light pointed at the timing mars, make a rental note of the position of the mark on the crankshaft pulley in relation ta the timing belt cover, H the position is no further advanced than 10 degrees BTOC, the mechanical advance system inside the distributor probably seized * stop the engine, reconnect the vacuum advance pipe and repeat the procedure * you should see a further amount of advance taking place and if not, the diaptragrn inscle the vacuum achance mechanism fs probably punctured # if ether or both of these faults have occured, your engine \willrun unecanomically and inefficiently and it may pay you ta Fit a new distributor MAGNET! MARELLI DIGIPLEX 2 ELECTRONIC IGNITION 25D. This isthe layout af the Digipiex ignition system, viewed! frarn over the engine looking towards the left-side of the ear. ‘The ignition coil (1) is adjacent tw the battery, The electranic control unit (2) is nearer to the engine bay sidewall. The distributor (3) & mounted on the end of the cylinder head and, the rpm and Top Dead Centre (TDC) sensor (4) is located on the crankshaft cover on the flywheel side,‘FACT FILE: DIGIPLEX DISTRIBUTOR REMOVAL ‘25E. If the distributor has to be removed for any reason, it is ESSENTIAL that the PRECISE position of the rotor arm in relation to the distributor bady and the Position of the distributor body (2) in relation to the ‘oflinder head - ia the spacer (1) - are cleafly marked so that they can he replaced in EXACTLY the same position, Note that the locator (arrowed only fives an approx imate, not a precisely correct location of the spacer, as. INSIDE INFORMATION: Use touch-up paint and let it ty before removing the ‘un IMPORTANT NOTE: The slots in the distributor body are NOT used to alter the advance setting, as on a conven- ‘tonal distributor. This operation is eartied aut by the Position of the TDC sensor -see later. CJECKEIG THE IGNITION ADVANCE can be cred out in an Zeproimate ance using the same method as describod in 25¢ However, you must make sure that the folowing steps etaien: # the vacuum pipe between the electronic cantrol unit and Sheet marvotd must remain connected and be in good terion - nite backed ror spt. A he eng mast be at its normal operating temperature 4 the ide soeedimintureiCO adjustments must be correct - we Job 35. “it he engine iting t between 800 and 900 rpm the Atk on the ciarkshat pulley shouldbe at appronmatly 12 degrees STDC PORTANT NOTE: The only marks are for 0,4 and 10 degrees B10C, so you will have to make a quéis atthe ‘iret pasition for 12 degrees. FACT FILE: TIMING MARKS It appears that some earlier engines ‘may be fitted with different types of timing marks. There might be a metal pointer fitted to the timing belt cover, JOther engines may have their timing marks in the Aiywheel housing, so that you need to take out a reetan gular rubber burg and look out for the fixed timing |mark on the fywhee! housing and the timing settings inthe fiywhee itself, # Ut always helps to paint all of the timing marks with "| shite paint or typists’ correction fluid so that they are fasier 1 see when the timing light is operating SETTING THE RPM AND TDC SENSOR POSITION 256. This job can not bbe carried out without the FIAT special too! illustrated. The sence correctly pastioned ‘when the engine is produced and to prevent accidental tampering, one of the ‘wo bolts holding the sensor in place is a shear bott and will have ta be renewed if remaved 1. ine up the mark on the cranisshaft pulley with the 0 egies (TDC) mark on the timing belt cover, See 28€. 2. Without maving the crankshaft fron this position, unda the screws holding the rpm and TDC sensar to the sensor camer plate: Fit the tool na. 1895898000 in place of the sensor, Check that the fiywheel pin or lug (32 must ft in the groove of the taol and the batts must tighten easily. If not, carry out the following procedure: 3, Slacken the bolts securing the cartier plate behind the sensor. 44, Move the plate so that the tool sips freely into the seni’, hole and the bots tighten easily, 5. Tighten the bolts holding the sensor carior plate in place, 6. Remove the tool and refit the sere. (ON BOTH TYPES: As the distributor is sumed (clockwise 10 ‘advance, anti-clockwise to retard), the timing mark-on the fiyvheel will be seen to move relative ta the pointers. Move the distibutor so the timing marks are aligned correctly, and retighten the clamp nut o¢ bolts. U1 Job 26. Check/adjust drive beltis. 26A. Depending on your Tipo or Tempra model, access to the alternator belt and adjustment fixings wil probably be possible fram the engine tay V-BELTS ONLY CCheck the belt, and if there & any sign of cracking, ‘polishing’ fraying or severe wear on the inner face, replace it. The belt should deflect by about 10 mm whee firm thumb pressure is ‘applied to-the belt between the pulleys in the direction of the row. Too litte tension and the belt might si, too much, and belt and bearing wear will increase. WaLdVHD S a Bb E | eT 9 ful Cc m a A 2 ra) u(268, IF adjustment is. necessary, slacken the ‘ensioning nut (Al and ‘the alternator pivot (B), ‘on all models. (These ‘te to typical layouts.) (Use a length of wood to pivot the alternator away from the engine block but take great care not to damage the alternator casing Tighten the rutwbaks \whien the tension comet. RIBBED BELTS ONLY If your vehicle is fitted with a ibbed belt, pivat the alternator 25 described above and tighten it wher you can just tedst the belt by 1 turn in the middie of ts longest run IMPORTANT NOTE: # Belt tension should only be adjusted when the engine iscold. * After adjustment, eu the engine for 15 to 30 seconds to allow the belt to bedi, then check again, * Experience mechanics clam that belts often go slack ‘when the engine heats up, producing belt squeal * if this happens an your vehicle, adjust the belt again when the engine is hat. Wear industria leather gloves and long-sleeved overalls and take very great care not to burn yourself on the hat engine or exhaust. It there is an aunitay Unit, such as an ait conditioning pump, dhiven by 2 separate drive bel, examine and adjust it as desorbed here, 1 Job 27. Check electric fan operation. Drive the ear until it i.at normal operating temperature. Park sutdoors and. with the gearbox in neutral (oF inthe case of an automatic leave the engine running. At just above normal temperature the electric cooling fan should come on, and then go off again when the temperature drops. Refer to your temperature gauge, if fitted. Hf the fan doesn’t behave, check the thermo-switch on the radiator; along with all connections nd wires in its circuit with the fan motor. See Job 13 anch Chapter 6, Repairs and Replacements. Job 28. Run diagnostic ignition/injection test. DIAGNOSTIC Test 2A. Have your FAT dealer ‘cary aut a diagnostic test, plugging hes tester into the diagnostic socket tucked away atthe front of the passenger ‘ide foorwel EMISSIONS TESTS Vehicles fitted with the Mana-etranic fuel injection system #€ nol fitted with adjusiment screws. The system is se ‘equlating. However, specified annual checks cactied ext with an eahaust gas analyser well provide exsertial infarmation on the condition of the injection/grition system, the catalytic -cormerter and the engine itself BB. The checks are carried out tavice: once with the test Seer at least 300 mm into the end section of the exhaust Pipe (a). if the shape of the end section of the exhaust pipe is such that the sensor cannot be completely introduced, special extension pipe must be added ensuring that the joint with the ears tai-pipe is sealed); the second after undaing the cap or nut on the exhaust pipe upstream of the catalytic converter (bi, The fellownng table shows the test limits for carbon monoxide, unburned hydrocarfsons (in parts per milion) and carbon dioxide £0 (%) | HEKp.pm.} |CO, (%) 0441 |= 500600] 12 soa | =90 | 213 (Upatrenm of the cater Downstream oe catalyze (8) * FIAT’s figures vary, IMPORTANT NOTE: The engine must be at its normal operating temperature and normal tick-over speed, # If the percentage concentration af CO upstream of the catalytic converter is not within the limits in the table, check: * the Lambda sensor - see Job 37. ® air penetration around the Lambda sensor housing. * faults in the ignition or injection systems. (First try jenewing the spark plugs, distributor cap and MT leads) at the same time, the concentration af hydracarbons ek less than 5001600 parts per million (FIAT'S figures wary), check: '* the ignition timing (see Jab 25) * the valve clearances (ee Jab 9). '* the valve gear timing (see Job 12) "© the engine compression. (You will need to remove the spark plugs, fit a compresson tester ta each plug. aperture in turn and crank the engine. See the FACT FILE ‘on page 51.)Severe damage can be caused to the ignition ‘gutemn if the engine is ‘cranked with plugs/ remaved - and a etic shack can be caperienced 28C. With very latest ‘distributorless’ system, disconnect the multi-plug fromthe base of the "black bow’. 28D. With the two earlier systems, disconnect the rmulti-plug leading to the distributor/conteol unit, from the ignition ei behind the battery, IMPORTANT NOTE: If the HC reading when measured at the end of the exhaust pipe is outside af the recom fended limit while that measured upstream of the catalytic converter is OX, the cat. Is almost certainly faulty. Have it double-checked by your dealer before replacing it an expensive component! PART E: FUEL AND EXHAUST impervious gloves so that fuel cannot ‘with your skin. It ean induce carter. OF sob 28. check fuel pipes for leaks. Gh the tines orn tank and into the engine farpariment, leaking for signs of chafing, sl Ae ndbber ad plastic pars. Eraure tips used on the connections a O Job 20, change petral air fi Betwo fasteners Bind the to 30€, Pull on the tabs ~ and watch that the speings don't fal on the floor as you release the catches! 20D, Lower the fie 7 ate fier 1 sob a1. Change diesel air filter. 1A. Take out the four screws (arrowed) and lift ff the cover (B). 31B, Ifyou want 19 § WALdVHOD : mi | ij Lut ef P rH | wt % = P=] i wv =1 Job 32. change petro! fuel filter. FUEL INJECTION MODELS 32A. The filter is under the cat, ahead of the fuel tank, Mi insioe inrorwaTion Remove the vibe screws holding the flexible plastic cver in place ‘You can now pul the front down and cut of thewoy. Ml 328, Undo the cama, remove the outer ‘aig and renew the special paper filter, frorn your Fist dealership, There i an arrow on the casing to-remnind you which vray round t must be fitted, Hl INSIDE INFORMATION: Plastic fuel pipes become brittle and snap, Extra care needed! SAFETY FIRST! IMPORTANT NOTES: * wear plastic gloves and goggles and have & lage rag and a suitable {ire extinguisher ready * Place a container beneath the filter to catch fuel spillage * after fitting the new fterin place, refit the casing seruute no traces of fuel ae left, reconnect the battery and ‘restart the engine © Check carefully to ensure th ‘refitting the cover. Fe no leaks before sob 32. orain diesel fuel fitter, IMPORTANT NOTE: Some models are fitted with a water- in-fuel sensor. Drain the filter when the waming light comes on, Unplug the sensor from the base nf the filter, first. 33. The fuel iter is located inthe rear of the engine compartment, Water cae in the fue accumulates in the bottom ofthe fie, and should nat be allowed to bud up. a drain it postion a eeceptacie under the iter, then unscrew the knurled tap at the bottom of the filer by # couple of turas Do so atthe recommenced interval, ofthe pane! indicator cores on. (See Chapter 2. Getting to Know Your Car) IMPORTANT NOTE: All TipovTempra diesel engines are selttbleeding and there should be no need to blged air ut of the system manually 1 sob 34, change diesel fue! filter. Drain the fuel fer. Unscrew the complete filter canister from its head, in the same way that you would an engine oi filter. Fist unclip the sensor plug if fitted from the base of the unit ez Baa Hits too phe mabsvg GC ens * sem by hand, use a0 of fier wrench nthe fer ‘atte zone (0) Wipe the underside ofthe fier hee, fill the mew fitter wth Fk. lubricate its seal with fuel, then screw it onto the Witter head. Once it is ‘nipped up’, dighten itas far as possible by hand, without ‘murdering’ it-s0 that you CAN remove itrnext time!IMPORTANT NOTE: All Tipa/Tempra diesel engines are set-beeding and there should be no need to bleed air aut the system manually. * ifthe engine does not eventually re-start. check all the unions for the fuel inet pipe and: the other unions, feplacing the sealing washers it necessary, to eliminate any ar leaks. 1 Job 35. checkiadjust petrol engine idle and ‘emissions. Seg he ile spend and misture notust 2 mater of aig te carr smoothly and econarncaly ts ao a fpsston cf alowing & to run within the lepal hydrocarbon [HCL Ntrous Oxie tO) and carton mononde(CO} emission Js Is ouside its, he eal fal re annual et Honea vor engine vl al even if the cretion or Inecion ster i conecty set wp) When tuning the engine you should adjust the carburettor (when fitted) last of al, as its settings will be affected ky the state of tune of the vest of the engine. * Ignition dwell ange and timing must be correct, the ar filter should be clean, there should be no air leaks fon the induction system, and all electrical components Be st conthioning (i tt) shold be steed ® Get the engine to full operating tempersture before checking and adjusting. Ifyou warm the engine on tick-over (instead of on a journey), it won't be hot enough until you have heard the electric cooling fan cut in twice. Blasine nrorMATION: These jobs require the use af a Tachometer (rev-counter} and an exhaust gas analyser to: achieve any degree of accuracy. If you don’t awn them - tnd relatively nexpensive tos are rows avalable- you Injen o have the wor caried out by your local PAT tate. ROUGH GUIDE: Wann exch section 3 dessin of how Jil ge te coruning olerab wel without any ‘Petals! equipment, so that you can take it to your FAT ealeship for accurate fand MoT-able!) tuning. CARBURETOR MODELS ONLY TAMPER PROOFING: Al Tipe carburetors originally had 2 tamper roo! sal placed aver the rixtre adjustrant screw rst szas ae to erevent anyone unauthorised orn alterna “Gemini and orhaust omissions. in certain courives these at be retained by aw sea is plastic cap placed over the adjuster screws, it can off with pliers. itis @ plug within the screw recess, ROA With a sharp object BSA. Check the float level with the carburettor it the position shown, Distance (¢) should be Ornen with gasket fitted. Bend tab (2) to adjust but the tab should remain virtually perpen dicular. De NOT achust iter (1) oF (3) 350 IDLE SPCED ADIUSTMENT: Connect a revecounter according 19 the makers instnctions, and check the idle speed. Tunas es ‘sfe speed, ant-ciockwse reduces it Set the idle speed in accordance with Ghapter 3, Facts and Figures. ROUGH GUIDE: Turn the screw until the engine is running at the sfowest speed at which it runs smoothly and ever. MIXTURE ADWUSTMENT: Check thatthe speeds eomeet sd lenny alts a ae a pereta roe tue. Connect an aha ges ana as nse by ‘eke’ a CO rosog casi fe rroe soem Chapter 3, Facts and Figures, adjustment as follows: Simcaneiindipic ernie Bal tr docs clchwie to widish Dalatior anc cocivce than teense) he reading ROUGH GUIDE: Fun the mitre screw inwards (clockwise) ‘As you dose, the tsk-aver speed wi increase, until the point comes where the engine stots tun “ump Back off the screw until the engine runs smoothly again, and then some more unt the speed jst starts to drop. At this point, screw the adjuster back in by a quater tum and you'hbe samevere nes the optimum setting for smooth running IMPORTANT NOTE: After setting the mixture adjustment, re-check and, if necessary, re-adjust the idle speed. 3SC. Thisllustration shows the correct settings for the choke fast idle adjustment (manual ‘choice oniy) and the ‘autornatic ant- flooding device adjustment, See following page, ° ay a =| = a BRS ei Ma Ce eR | |S$ WaLdVH : ia! n i fu] r PJ 2 L-] yt = PS [= co = CHOKE (MANUAL) FAST IDLE ADJUSTMENT ‘Move the choke con ra lever by hand to the end af its travel and hold it there, The main butterfly aperture (A) should now be about 1.1mm, Wnt, slacken the fock-nut (3), regulate the adjustment screw (1), anc tetighten the lock-nust AUTOMATIC ANTI-FLOODING DEVICE ADJUSTMENT With the choke contra! iver stil. atthe end of its travel as described in the prewous paragraph, the strangier butartly aperture (B) should be betvaten 3 and 3.5 mm, tf nat, requlate: the adjustment screw (2) FUEL INJECTION MODELS. The idle speed and mixture settings ate controlled by the Electronic Control Unit (ECL) which is sei-fearning’ and is programmed to adjust itself to gre the ideal settings under all ‘conditions. No manual adjustment is passible, nor provided for. If there 5 problem, see Job-28. You may need to take ‘your car to a RAAT dealer, with the appropriate diagnestic ‘equipment ‘39, . should be br ‘cated with a dab of TUTELA MRMZ- grease. “Th ACCELERATOR UNKAGE must be ‘adjusted correctly if the Mono-Jetrorsc Injection systems to aperate smooth and correctly "© Disconnect the-4od (11 from the lever f2). The pulley (3) should now be against its closed stop, "© Check that the accelerator cable is not loose, bul neither should it be taut, and check that there is no free play in the accelerator pedal © necessary, acfust the accelerator cable by slackening the tock-nut (B) and turning the adjuster rut (€) until the cable is correctly tensioned. Then retighten the lock-nut ca Now reconnact the rod to the lever on the fuel injection unit and let the engine warm up until the cooling fan has cur inat least twice, then turn the engine off. © With the accelerator pedal released check that the ‘clearance between the levers (2) and (4) between 0.2 and 0.5mm, Wf necessary, loasen the lockouts (5) and (6), Live a spanner ‘on the adjuster nut (7) to tighten or loosen the rad (1) until the clearance is between 0.2 and 05 mn, © Retighten the ajuster nuts (5) and (6). Finally, make sure that with the accelerator pedal ‘completely depressed, the buttery in the fuel injection units fully open, © nos, the accelerator cable may be too taut or the ‘dearance between the levers (2) and (@) may be re-adjusied, keeping them within the acceptatie tolerances, 1 Job 36. check emission control systems. PETROL INJECTION MODELS ONLY 36A. On petrol. Injected Tipos ant Tempras, saphist- cated emission control equipment is fitted and must be tested with a proper emissions tester 368. The main features ofthe system are: '* an Electronic Control Module Unit or (ECU) (1) - the ‘computer brain’, which is prograrumed to alter the car's fuel and ignition settings according to information received fram various sensors. + catalytic converter (2) in the exhaust system, to convert CO and other gases to less harmful gases. ‘a Lambda sensor (3) in the exhaust manifold or front pipe (according to model) ta detect the ‘tune’ of the exhaust gases and givea signal ta the ECU. © a petrol evaporation control system, to cut down on Petrol vapour emissions from the fuel tank, © part 4 is the ‘upstream’ emission test paint. See JobELECTRONIC CONTROL MODULE: The ECL is not an item thatequires any servicing, I you think it might be faulty, ask your RAT dealer or fuel injection specialist to check it for you. ‘This must be done by someone with the correct FIAT plugin agnostic equipment and data CATALYTIC CONVERTER: The CAT isnot serviceable. if it {als you will be told at the MoT test. Replacement is ‘@petive, $0 we recommend you obtain a second opinion before replacing the ‘cat LAMBDA SENSOR: For information concerng the senscr se Jab 37, 35C. CHARCOAL CANISTER: This units located behind feoat panel, and does not reed regular servicing, Check the canister one vay vahe (see Chapter & Repairs and Aeplacements, Part F, FUEL AND EXHAUST for ihustration) by discon. necting it and tying ta bow through bath ends. You should only be able to blow air towards the ‘aster, not away from A the valve is faulty, renew, making sure that its fitted the right way round, BE INSIDE INFORMATION: If the canister Is flooded with petrol it is probable that one of the purge walves or purge valve floats is faulty. Get this investigated and rectified by a FIAT dealer. If the engine cuts out and then restarts after a while, it could be the breather hose. valve, fitted under the fuel filler neck. This one-way vralve allows air to enter the tank as the fuel level falls, otherwise an air lock can prevent fuel reaching the ‘engine, To test the valve, take off the pipe clips, remove the valve and test it a5 for the canister one-way valve, above. It should allow air to pass into the tank, but not the ether way, El O Job 37. check Lambda sensor, PETROL INJECTION MODELS ONLY fox a description of hew the sensor works, see fob 36, FACT FALE: ENRSSION CONTROL SYSTEM. It sould be checked at the recommended interval - the ost of checking ard replacing the sensor « far les than that of having to replace the catalytic converter because it has been polluted due to a sensor fault. ap oe _- * Replacement of the mabeng GE enty «ri scimpejob tee Chapter & Repatrs aed Replacements, PART F: FUEL AND EXHAUST), but it car only be etd 2y your FLAT dealer uth te caret if the sensor is faulty, have it renewed by your dealer. © Lambda sensors are very delicate and easily damaged. it is notJkely that you would be able to return one to the supplier if you fitted it yourself. * Lambda sensors are only fitted to cars with a catalytic canverter. C1 Job 38. Checkiadjust diesel idle speed. To accurately check and adjust the diese’s idle speed you eed a dhasel-pecific rev-counter. you're happy with the idle speed, leave well alone, But if you're convinced the idl is Incorrect, i's best to take the-car-to a FAT dealer. tf you wish to-adjust the speed yourself, get the engine to normal operating temperature, and check there is some tree play in the accelecatar cable beface proceeding ADJUSTMENT - BOSCH PUMP 38A. Adjust the ile speed, which should be apgreni- mately 800 epm, by slackening the lock rut of the adjuster serevr (1) then ming the screw inwards to increase the speed «or outwards to decrease. Retighten the lock-nut when the speed is correct ADJUSTMENT . LUCAS/ROTODIESELICAV PUMP. a8 4388, Adjust the ie speed, which should be approximately 800 rpm, by slackening the lock-nut of the adjuster screw Ui) and turning the screw to gue the dased speed, Retighten the lockerut, then nav the engine high and allaw it to return to. Idle. 1 foes below idle speed (Le. it threatens 19 stall, or does stall, or if it decelerates too slawly, slacken the lock-nut of the adjuster screw (B), adjust itand check the deceleration gain. Repeat as necessary to achieve comfortable deceler- ation without stalling, then tighten the lock-nut) Job 39. Checkiadjust diesel injection timing. ‘Although a check of the injection timing is scheduled as a service item, there ks no reason why the timing should have altered if the pump mounting bolts are tight and the pump hhas not heen disturbed. Injection timing is best checked dynamically by a FIAT dealer ar diesel specialist using specialised equipment: f you want to check the timing stat ‘ally, and you have access toa dial gauge and the necessary ‘edaptor to fit t to the pump, proceed as folloves dad VHO Sj 394. Slacken the injection pune flange nuts - one can be seen (A) in illustration 398. and rear support bracket lawer bolt, Make sure that the ‘manual cold start contra! lever lat the dashboard, where fitted) is tully off BOSCH PUMP ONLY 398. Unsceew the plug ils= tration 394, part B) ot the rear of the injection pump, and sceew in a Basch pump dial gauge and adaptor, {he FIAT too! ‘number for this is 90, 1865090000, with the tool fully screwed turn the engine in the opposite direction to normal rotation until the plunger inside the pump reaches its lowest position ~as indicated by gauge mavemént In this pos zera the gauge. Now turn the engine in normal direction until engine piston No. 1is at Top Dead Centre, The dial gauge should read 1 mm ifthe timing is covect. H tint, gently turn the injection pump housing relative to its mounting until the correct measurement is shown onthe gauge. Now lock pump flange nuts and rear support bracket bolt, Remove tool and refit the blanking plug to the back of the pump. ‘Adjust the idle speed if necessary. See dob 38, ; = + pl = La} F > tJ o yl bad F4 ro c “ pe LUCAS/ROTODIESELICAV PUMP ONLY 39C. You wal Find a label attached to the top of the injection pump, quoting the cortect ting measurement in ilimatres, Stacken the pump flange nuts tas in, idlustration 398, part A) and the rear Support bolt (as in, illustration 394, part A}, Reenove the plastic cap from the pure top. Now turn the engine crankshaft inthe opposite direction to normal rotation byy about 20 degrees. Using either FIAT tol No. 11868091000 or, with the the necessary Lucas dial gauge (A), the holder (B) and the probe. (C1 threaded into positicn in place of the plastic cap, position the engine crankshaft at Top Dead Centre. Ensure that the sfal gauge is fitted to itsholde and the pump (©) with a pre Joading of 10-15 mm, then zeros, Slowly turn the pump ‘body, turning the upper part away from engine block, Now. slowly turn the engine crankshaft the normal direction of rotation until the dial gauge indicates the measurement you read off the purnp label (that's the corvect timing po! Tighten the pump nutetct, Tur the crankshaft by two Complete revalutions in the narmal deection of rotation, then re-check the timing, i incorrect, repeat the timing praceduve Remove the tool and refit the plastic plug. Adjust the ile speed i necessary. See Job 38, 1 Job 40. Check inlet and exhaust manifold fixings. Check: that the ine tightened to Figures. nd exhaust manifold nuts and bolts are fe correct torque. See Chapter 3, Facts and 1 Job 41. Check exhaust system. Examine the silencer and exhaust pipes and joints for corraion and signé of leaking, indicated by a “sooty deposit at the paint of the leak 41. Also check the condition of the rubber ‘hangers’ that hold the system to the car. any are missing ar broken, the exhaust system can fracture due to extra stresses, Stretch the ruber, and lock for cracks. ‘if you suspect a leak but its location isn't obvious, mating © ney - * tart the engine ane pressurise the system by holding @ piece of board against the tailpipe, © Under pressure, the leak should be more noisy and obvious. * Don't burn yourself on the exhaust!PART F: STEERING AND SUSPENSION 01 Job 42. Cheek front wheel bearings. In order to check for wear # rae the front of the-car an axle stands (see Chapter 1, Safety First?) # pce the gearbox in neutral * pul the handbrake securely on and chock the rear wheels “Wy spinning each whee! fas far as possible with a ront-drive ‘a feeling for rough rotation. Rock the whee! about its centre, feeling tor excess bearing play. Diinsio€ inroRMaTion: fa wheel bearing is worn. you will nmally hear a noise on the outer, loaded bearing when comering. El 00 Job 43. check front suspension. BOTTOM BALL JOINT Jack up the car underneath the suspension lawer arm (wihibone), so-that the wheels te inches aff the ground See Chapter , Safety Firs BA Foce long, figdba between the ground and the teom ofthe tyre Area, ar carefully Ps the whee! Upsets epeatedy wie a huis locks tan tees the Ipverbaljoin for vertical movement, The helper should NOT Bender the car, and you should be careful not to rock the Carol te jac, Also examine the ball joint quiter for any damage o leakage of grease - a simple, visual examination You will have to replace she wishbane asiembly the gaiter is damaged. See Chapter 6, Repairs and Replacements for inrmaton TRACK CONTROL ARM INNER BUSHES ABB, Further aise the car adsupportit on an axie land uncer the subieame so thatthe suspension on the Sie Bing checked can hang fie. Lever between the edsubtrane, looking for (cessive movernent of the bashes. Some cushioned Boag is normal. See Gapter 6, Repairs and Baplacements for bush Sepbcerent information Geabsn sot the front Tit tndo! the wishbone 43C. , and the other is at the reae af the wishbone. ‘SUSPENSION STRUT/SHOCK ABSORBER 43D, Examine the shock absorber, which is enciased inside the coil spring. for Teaks, looking for signs of a cdamp' ol stain seeping from Underneath the top half of the shock absorber bady The top al the strutshock absorber is mounted in a rubber bush which can be checked for softness, cracking or deterioration from inside the engine bay BOUNCE TEST: Try ‘bouncing’ each front corner of the car in {a rhythmical mation, pressing down as haed.as you ean. When, you let 90, the movernent should continue for ne more ‘one-ancha-alf rebounds. Hf it does so, this i a sute incication that the shock absorber is war and should be replaced. Ifane of the front shock absorbers needs replacing, replace both, for safety reasons. ANTL-ROLL BAR BUSHES ABE, Check the outer mountings, on the suspension, and the body mountings. 4442, Drive the car an to car ps, firmly apply the handbrake and chock the rear wheels. Get your helper twsit inside the car, tum the Ignition key to the ‘MAR’ (ON) postion to release the steering column lock. Now, move the steering wheel repeatedly about 100 enim (4 in. each way while somieane checks for free maverrent inALd VHD su Fe B.\ | NOISN3dSNS/ONIHSaSLS reach track rad end (TRE). Also, look out for a split gater Replace the TAE if the-gaiter is spt, cit wail rapidly ta INSIDE INFORMATION: Try placing your hand ever the TRE as the steering is moved. If there are any signs of wear, replace the TRE. Ell STEERING COLUMN YT Url 4448. The steering column has two universal jaints WAP which reed to be checked for wear, While your assistant is turing the steering whee, check to see if there Is any mowertent in the universal joints AC. The upper joint i alongside the faot pedals, i insive INFORMaTiCN Place your hand over the join’ yeu can usually fee! the mavement better than you ‘an see it. f there is ANY movement at al, play at the steering wheel will be greatly exaggerated - replace the faulty universal joint, STEERING RACK GAITERS 44D. INSIDE INFORMATION: Check the right hand sgaiter from beneath; the left-hand from inside the ‘engine boy, El ‘Turn therignition key to the "MAR" (ON) position but take care otto start the engine, Turn the steering whee! ro ful right lock. From underneath the bonnet, examine the gaier see ilusiration 448, pares B} on the left-hand side, which will nave be fully extended. Check viuay For splits or ail leakage, Turn the steering wheel to the opposite lack and examine the-gaiter }on the other side of the rack, Hf necessary, replace IMMEDI: ATELY « the rack wall rapily be ruined ifthe qaster i spit ‘Aéso, watch the steering rack body (Cl to see if is Firmby ‘tached. If there i any mouement between the rack and its mountings, check the securing holt C1 sob 45. check power steering fluid, 5A. When the engine iscald, the power steering fit should nat drop: below the LIVELLO (level) rrark (B) on the reservoir (Al. ‘458... the mark on the dipstick, as shown. 1's okay tar the level to appear too high when the engine is hot IMPORTANT NOTE: The reservair floats’ around the engine bay - in different places in different models, Jeb 46. check rear wheel bearings. TipavTemars rear wheel besrings are sesled in their hubs and. ‘are usually very lang lived, See the checking procedures deseribed in Jab 42, but remember nat to apply the handbrake! Also nate that the rear wheels will be easier to spin than the frants. Job 47. check rear suspension, ‘Chock the front ‘wheels jack the rear ‘ofthe car, and place stands under the ave, aselose to the wheels as possible, Lower the car ont sands 47. Cheek the subframe mountings (xl), the trailing arm bush, pivot bolts, the shack absorber lower mounting bolts and the ant-rall bar mounting bolts far tightness. Check the condition ff the mounting bushes by levering them with a screwdriver. Replace if excessive maverent or bush deterioration are hoticed. See Chapter 6, Repairs and Replacements.‘REAR SHOCK ABSORBERS Leck for signs of leaks coming fram underneath the top part cf each rear shock absorber and replace if necessary. Check the top and bottom rubber mounting bushes. if any are soft ‘spit they must be replaced. Check that the bump stons are resent and correct BOUNCE TEST: Bounce-test the shack absorbers ain Job 43, Pam Td) ee Ne | jc check: the thickness af the brake pads by lacking the ‘window’ in the caliper. However, this isnt ended unless you are experienced and know what you king for, and you can’t check the caliper ar cea out fated brake dust checking the Tipo’s and Ternpra’s brake pads ms the same amount of work as changing them. For that 1 Job 48. check wheel bolts for tightness. Remove each whet bolt in turn and ensure that they tun smoothly. Clean the threads i necessary Refit and check that all ate tightened to the comrect torque ~ see Chapter 3 Facts and Figures sing a torque wrench pe BS fs 498, This drawing ilustrates the various components of the front brake assembly. 49C, Remove the bottorn caliper bol, Using an open-ended spanner to allow the bolt to tun, ALWAYS refit with NEW FIAT caliper mounting bolts = they are a special ‘ype TERR Uo) Tb eee ey ‘ASD. Slacken the top bolt, swivel the caliper Lp and the pads come free, far ehecking IMPORTANT NOTE: Hfyou remove the top caliper bolt, DO NOT allow the weight of the caliper to hang from the flexible hose - position it to vest on the iiveshaft, or support it fram the road spring using a length of wice, ‘Compare the thickness of the 1we pads - there should be no ‘Sgnaficant diference. The minimum recommended thickness of Bring materials 1-5 rm, but bearing in mind the amount of time before the next service, you may wish to replace the pads before they get to this stage ‘You can now check the thickness of the brake disc, which should nat be below the figure gen for your model in Chapter 3, Facts and Figures, 31 any point.aLdVHD a pe Bh | : e 2 5) wa es wv ba m F ‘EACTFILE: BRAKE DISC WEAR ‘SYMPTOMS There are certain essential checks you should carry out for yourself, with brake pads removed: ® Look for any obvious grooves war into the disc. Slight undulations are acceptable, but anything worse and the disc should be replaced ® Look and feel for any wear-ridge on the outer edges of the disc. The depth will givean indication of weat, ‘© Check for corrosion of the dise surface. If any is found, the brake caliper is probably faulty, and needs, checking © If any surface flaking is found on either side of the disc, replace them both, ® If you are not certain whether any wear is acceptable, ask your specialist or FIAT dealer to check Before reassembling the brake, check the condition of the ‘brake caliper. Have an assistant VERY SLOWLY AND GENTLY apply pressure to the brake pedal while you watch the piston (see illustration 498, part 8), which should move outwards. iteoesn'teasily move, itis seized and the caliper should be replaced, DO NOT allow the piston ta project mare than 10 ‘mm art may be forced from the caliper» use a Geclamp as an “end stop ABE, Check inside the caliper housing for signs.of rearrosion. Hf any 6 found, ar the seal is damaged, the caliper should be exchanged fora new or ‘overhauled unit from your RAT dealership Examine the piston’s protective gaiter (see Illustration 498, part 9) for splitting and fluid leaks. This ane isin poor ‘condition and the caliper requires immediate replacement, =o hae ne ensy - mabig G easy «0 Apcrpitonmin be ete vias © Use an old battery hydrometer to draw akout half of the fluid from the master cylinder. * Push the piston back into the caliper, using a G~ clamp. © Keep an aye on the master cylinder sa that it doesn't overtlow a fluid is pushed back up the pipe, 9F. Before fitting the pasts put alight smear Of brake grease (NOT ordinary ‘rease) on the pads’ metal Dackplates at the points shown, IMPORTANT NOTE: Be very sparing or grease could migeate to the friction linings! WEAR SENSORS ‘496. 1 these are fitted, the contact has to be transferred from the old backing plate ta the nev, Pull off the wire, push out the brass pin, 49H, ..and push out the nivlon bush (arrowed). Reassernble con the new pad and reattach the woe, IMPORTANT NOTE; After fitting the pads, apply the brakes firmly several times to adjust ther. 1 Job 50. Check rear brakes. GENERAL. The majority of Tipa/Tempra models are firted with rear crum-type rear brakes, but models with ABS anti-tock braking have a disc-and-caliper arrangement instead. Stacken the whee! bolts raise the wheel, remove it and support the car with an avle:stand. Make sure that the wheal remaining on the ground are checked in both directions and that the handbeake is off eu nen pmaes . “, If the drum sticks, try: malig CORY 6 creying pai obs inta the two threaded holes in the drum. Eveniy tightening the bolts will force the drum off the shoes * tapping carefully around the drum with 2 hide mailet to help loosen it.—_ bolts (ane or both of s them aso the whes! pastioning stud), 90, ..2nd remove the drum. Clean the ‘rede ofthe drum and the brake with aerosol brake cleaner. ifthe hn is badly scored Or cracked, replace it Examine the brake Shoes for wear oil ‘ontamination. tthe later, the whee cylinder is probably leaking (see S00 and the shoes will have to be scrapped. FIAT recommend a minigun ‘151m shee ining thickness, but it's advisable to replace shoes well before they're this $50 Fold back each of the two rubiters on the wheel eyinder ‘ey huid found inside Feuies anew igleder. However, ‘eis cyinders wil Fhavealitie of their ‘pecal grease still in tere 50D. Take special care fo wash al the brake fist aay from the Automatic athuster feectanism with deroio| brake cleaner. Make sure that itis Pot seined butt ris, orn have to stip doy the asermbly (ee Chapter 6, Repairs and Ieplscements} and tree off or replace. Add brake grease very Jparingly (ROT ondary grease} to the mechanssm, IMPORTANT NOTE: Far information on replacing missing ‘rdamaged springs. brake shoes or wheel cylinders, see Chapter 6, Repairs anc! Replacements. DISC REAR BRAKES With rear ofthe cor rated and safely supported (see Chapter 1, Safety Firsts and the rear wheels remaved, brake Ba inspection can be carried nut by looking through the aerwe in the caliper boxy. However, as or the frant brakes, Jia recommended to remove the calipes. See notes at fesat of Jab 49, The pads shauid be replaced as detailed in {hopier & Repairs and Replacements. Minimum thickness 1615 men- but dont let them get this low! ‘SOE. Using a pair of spanness, as shown, remove the two retaining balts, These bolts are selflocking and FAT recommend that they should be replaced each time they are removed or Hf they became lanse, HLdVHD au On SOF. S0 that you dont have to bleed the syster, release and clsconnect the parking, brake cable (arrowed) and iit the eaiper out of the vay, suspending it.on a piece of wire 50. that no strain &s placed on the flexible hytraulic hose, 506. The brake pads ae simply ited away, IMPORTANT NOTE: * Follow Job 49 ‘carefully for further information such as ‘on checking the ‘caliper seals, the ‘condition of the dise, and lubricating the pad backing plates. © Before fitting new pads, turn the caliper piston clockwise until it goes fully in. ‘= Pump the brake pedal repeatedly to adjust the pad positions and top up with fresh brake fluid IWALSAS ONDIWHE °D Lud Job 51. checkladjust handbrake. “The handbrake is intended to ‘set’ self in use as the rear brake self-adjusters operate. Ifthe handbrake seems nat ta ‘werk, even though lever travel is not excessive, remave the ‘ear drums and examine the brake shoes (soe Jab $0} and the setf-adjuster mechanism, to ensure that it has not seized, The handbrake may need adjusting when, attera time, the handbrake cable stretches or If the rear brake friction materials are replaced IMPORTANT NOTE: On rear disc brake cars, the ‘handbrake-end of the mechanism isthe same as for drum brake cars. At the brakes, the clearance is adjusted automatically, provided that the adjuster, built in to the ‘caliper assembly, has not seized. If it has, replace the caliper.PRC AF AS: fe) 3 | 7 Ls] ° : [-} a rs we z =| a = ° E) 51. Apply the handbrake fever by cone ‘click’ of the ratchet. From inside the car, turn the adjusting nut (ai want the cable is rawr taut, Pll the handbrake up tao more “ccks’ and check that bath rear wheels are now "locked", Check ake that both ear wheels are carnpletey free wher the handbrake is fully OFF, When ererything works, properly, lower the carta the ground, and check again that roving the handbrake through about three notches i su Cent to held the car stabenary, A proper check of handbrake efficiency can anly be carried out by-a garage with walling road’ brake tester C1 seb 52. check brake pipe: FLEXIBLE HOSES Check the fleuible brake pipes that connect the calipers to the ‘metal pines on the body. Try bending back on themselves. those that are nt ¢ontained in a protective col, and look fo any signs of cracking, particularly at the bends. Check thern al for S9ns of rubbing, splitting, kinks and perishing of the rubber. Check hoses for ‘ballooning’ with the brake pedal pressed, RIGID PIPES Check all igi pipes for signs of damage or comesion and check that all of the locating dips are sound and in place Change the brake fluid at the recommended interval. See (Chapter 6, Repairs and Replacements, PART H: BRAKES, Job 15. GE Nsioe inFORMATION: Brake fuid absorbs water from the ai. This corotes brake components and can cause total brake failure, With brakes applied heavy, the id ‘Gn heat to above 100 degrecs Celis, he water Yaporises, and the pedal goes to the floor! El am te tea el ea dled a 54. Lubricate hinges and locks. ‘Apply a few drops of ight oil from either an aerosol or ci can) to the hinges of the bonnet, doors and tailgate. Dip the doontalgate key in graphite powder and insert the key to lubricate the lock barrels. Grease the door and tailgate fatch mechanism (aerosol grease is handy), the bonnet release mechanism fand the tailgate’, if appbcable) and the cable fend, Don't forget the fuel tank flap hinge and the locking cap. it's a stopper when it jams! 1 Job 55. check windscreen, ‘Clzan the windscreen with 3 proprietary glass leaner and ‘examine it for stone chips, cracks and Scoring, While some degree of damage is acceptable, the stnct MoT Test requl tions limit the amount and positian of such detects. Same ‘screen chips.can be repaired and made invisible Job 56. check seat and seat belt mountings. ‘Your car's wat and safety belt mountings and backrest adjustrnent locking mechanism wll be checked as part of the rua test, but it pays to check them beforehand. Also, regularly check that the seat belts a} retract easily and smoothly, and b) ‘hold’ when you snatch them, or under sherp braking, 1 sob 57. Check headlight alignment. ‘Some vehicles are fitted with an automatic headlight leveling device. Gn these vehicles, each of the headlights adjusted according tothe vehicle height and no height leveling adjustment is possible awe RIGHT SIDE 57. On the majority of vehicles, there i a manual height adjuster. When the vehicle & unladen, the lever should be in position (1): when fully laden, in postion (2). The height adjusters are on the inner side of each headlight and are visible with the bonnet open, Make sure that the adusters are set to the ‘unladen’ position before the headlights are adjusted. Dar't confuse the beaen coerectors with the vertical alignment serew (A) ane the harigantal adjuster screw (8) C1 Job 58. check underbody. Chee the condition af the underbady for darnage and corrosion, Take atin of waxy underbady seal and a Brush under the car and replace any missing underbody seal0 Job 58. Check spare tyre, This job should iceally be carried out every month or two - you never know hen you're going to need that spare! But if you havent remembered, do it at the time shown on the Service Imerval Chart at the latest i insiDE INFORMATION: Put in the maxximum recom mended pressure for heavy-duty use - its always easier tolet some air out if necessary, than to put sorne in. Lift the spare out check the ‘hidden’ lower side wall forcracking. See Job 6, EL PART I: ROAD TEST 1 Job 62. Road test and specialist check - after avery service, Before you can claim to have nished working on your car, you must check i, test i, and, if necessary, have 2 qualified Mechanic check it ever for you, Hou are nota qualified mechanic, wre strongiy recommend havea soreone whois 8 propedy qualified mechanic- FAT oraershp perhaps inspect all of the car's safe irs ter they have been worked an at home and befare i he car onthe rad You'l have to remove the toolkit and the wheel to get at the valve - under the bint floor an mast medéls but te.one side of the rear compartment on Estate versions C0 Job 60, change pollen fitter. When fitted to the fresh air intake, seplace it at the scheduled rmigage interval U1 Job 61. Replace airbag gas generator. Have your RAT desir replace the airbag gas generator 10 years alter the carwas bul» see the label inside the car's love compartment dom © Before setting out, check thatthe lights, indicators and ine car controls, 3s well as seat belts and seat adkustrants, all Work correctly, ® Rum the car for several minutes belore setting out then turn ff, check fluid levels and check underneath for leaks, © Check that the steering maves freely n both directions and iat the car does not ‘pul’ one way of the other when driving in. staight line « but do bear in mind the effect af the camber on the road © Make sure that the brakes work effectively, smoothly and without the need for ‘pumping’. Thare sheuld be no juddering oF squealing, © Cheek that the car does not “pull from one side to the tather whien you brake firmly from araund 40 mph. (Don't cause a skid and dom ty this f there ts any following traffic.) \WUNTH PRODUCTS FROM FIAT JA Wurth produce @ huge range et very high quality, fuT- approved products, from zine-rich aerosol paints, fis-proofing products and the safety-related items shown tere Bt eectrical connectors and tools and that wonderful brrkefi’ wire insulation tubing «side ion, heat it up, and it Arnis into place and can't come undone again. See your FAT dealer or other specialist supplier forthe wast range of op-qualty Wurth products. S WHLdVHD BEER eh fe}: me eh fetUP Ihe a A z | i) Fo 2 i=} a m 5 ay ful A m e | Va CHAPTER 6 REPAIRS AND REPLACEMENTS ‘This chapter shows you haw to remove and overhaul all the major ‘wearing’ parts of the cor. We deliberately don't show how te rebuild majar components, such as the gearbox, or differential. You {are much better off, in terms of time, cost and the provision of a guarantee, to buy a replacement unit. ‘The same applies to major electrical components, such as alternator and starter motor. If, as we recommend, you stick to “eriginal’ FIAT replacement parts, you will ‘maintain the original quality of your ear. Mlustration and Section Numbers Boda © inthis chapter, each area ofthe car fs dealt with in 3 differant PART of the chapter, such as, PART A: ENGINE © Each job in each PART has.a separate identitying nurnber For exarnple Job 2. Cylinder head removal © Every lob is broken down into easy-lorillow Steps, ‘numbered from 1-2n. © tiustrations are numbered so that you can see at a glance where they belong * The ilustration Job 1-3 fn PART A} or example, ceates to the test in Job 1, Step 3 FACTEILE:TIPO and TEMPRAENGINETXPES distributor mounted on the side ofthe evlinder block and the 1600 has. distributor which is mounted an the end ofthe £:] PETROL ENGINES: The engines covered by ‘anhalt. whee end ta aulaey binomaloroee DIESEL ENGINES: The Diesel engines covered here are the - found in he UK. There maybe the odd ew with 1627 (171M), the 1029 (1900) a the 1909ec (1900 bo. diferent capacities or specifications which have ben imported would take a trained ey to spot any diferences between the from other countries but even they are usually similar, Heresee ofmally aspirated engines, but the turbo mounted on the are concerned with ane type of OHC (overhead camshaft) exhaust manifold together with its associated extra ‘plumbing PETROL engine, in 1372cc (1400) and 1581cc (1600) capacities, _*asily identifies the most powerful version. They are best identified by the fact thatthe 1400 has itsene erty IMPORTANT NOTE: It false economy to refit a used Aiming belt. ithe belt breaks, it will cause complete engine failure so always fit a new one Distep 1 Decorrect re hatery Beir te Brat coveoen as thee! naarc COOUNG SYSTEM step 2: Take oif He timing test cover. Tisis held bya tot Of four bots (arcowedh, shat pulley ut and remove the paley Job 12. Petro engine. Mountings - replacement. Job 13. Diese! engine. Timing belt - replacement and adjustment. ab 14, Diese! engine. Cylinder head = removal. Job 15. Diese! engine. Cylinder head - refitting. ob 16. Diese! engine. Cylinder head «overhaul. Job 47. Diese! engine, Vale Gerances - adjustment. dob 18. Diese! engine - removal. Job 19. Diesel engine « refitting. Job 20. Dieset engine. Mountings - replacement. ‘Job 21. Diesel enginetransmission (removed from car) sepavation, ‘Job 22. Diesel enginetransmission (femoved from car) = reconnection Jab 23. Diesel engine = dismantling ‘dob 24, Diesel ongine-reaseembiy. | © The crankshaft pulley nut will be difficult to turn, © if the engine is in the car, engage 2 gear for Park’ in the case of an automatic) andi have an assistant hold the footbrake down very firmly. This will stop the engine from turning, © Alternatively, with the starter motor remaved, you Can have a helper prevent the flywheel ring gear from turning with a farge screwdriver step a: Betore removing the bet, put the pu nut back S04 nthe ea and remove the spa plugs You Can now turn the engine ina ck di pulley nut - without the pul using the velitted crank of course! engine timing the cams sprocket lines up with the one.on the front caver. On some engines, cover looks tke this O step se: conde on dh mei tack like this. The top parte the coe backplate ses out thatthe i bee ith the coat sprocket Torn the sproc wath spi, 9 WALdVYHD 5 E Pd m F = F Li9 YaALdVHO 3 4 Pd m Z ey z m O step 6a: You must also check pulley ines with the mark (b) an the et seal hausing. ft will be essential that all of these matks align whan the new belts Fitted! ‘engines rotate the-crankshalt rinng pulley isi line wath TDC reference rark on the front cower. Hf the the reference mark on th O step 2: Slockem off he belt tara step 8: ond remove the camshaft timing bel step 9: the new belt must be fed with the aravs, ponte on theoulsice ofthe be, pointing in the direction of engine rotation, Cl step 10: Engoge the belt with the crankshalt seroctet first, then in turn, the auniiary and camshaft specckets, Final feed it ro tensioner pully. Also, as a daubie-check hat the belts not ‘our’, ensure that the yellaws lines on the belt align exactly with the timing marks en the camshaft sprocket and crankshaft sprocket, 1 step 14: slacken thet onto the Belt unt taut Ch comrecly aligned. Sil pres tighten ts locking nut ener nut and push the pulley that the timing marks are stil the pulley against the be! O step 12: (BF INsIDE INFORMATION! Before finally tightening the tensioner nut wien adjusting the tension, temove't, deon the thread and apply Loctite ‘Threadlocker ta help stop the nut and washer shaking toose. 1D step 13: Tum the engine through two complete tus Slockwie and re-heck he bet tension, Aust apa i rece EB insiDE INFORMATION! Without the special tools used by FIAT, you can make an approximate adjustment by ‘tensioning the belt so that it ean be twisted through 90 degrees (one quarter turn) mid way between the camshatt and aunillary shaft speackets, using your finger and thumb. if you ean’t put enough pressure on the belt ensioner with your fingers, push & pair af bolts into the ‘two holes in the tensioner and lever between therm to ‘turn the tensioner. ELec OM sted 1D step 1: Take note of te parts shown inthis drawing - \which is also relevant to several other jobs an Tipo and Tempra petro! engines. a" Binsin nirorearion! © etore removing the Sjlinder head, make sure the engine is stone cold, ‘Undo the cylinder head bolts strictly in the order laid “outin Step 18. “ditorton, 18. 16 18 Py a 2 3 2. 26 sume sump gastet tus onkee front tsa hein bu lary ah tie gear tate teary suf pocket The new cylinder hesd gasket should stay in its ae 4 8 cs a a a ‘These precautions help to prevent cylinder head craramanerccket ats 51 tae sp ner teoror ploy SD -eesaur manos 5 -aahe ig caer tang bat came At -weaustmanias-non- 5 -athe, ep eae eumnate rece ‘we ‘warher eameat bo heats a she gu adhe Camahat come ie erpne cama end pate ‘fer head gaat lsat fu alte rer nea caminatt Boo. ming bet rar cow 43 topper old inet andes trio 48a separa pl enum amber tbe 49 tappt body bet minoei-rom SO ae, op ca _peékaging url required, to avoid contamination by oil oe * Tis possible to remave and replace the -eylnder head cornplete with the carnshaft housing - ut it is ery dificult without FIAT's special cranleed tov! te fet round the camshaft housing. © You CAN undo the bolts with a ring spanner, hut you ‘CANT torque ther devin praperty again! * Because the gasket between the housing! and the head could also be suspect, we strongly recommend that you doit “aur ‘way, by removing the camshaft housing-even though you will have ta reset the valve clearances. ALIVHO 94 sy rE] a Py m 2 9 r= Llbe GAP Ads Fe) fel stem, if yours i & fuel injection engine see PART F: FUEL AND EXHAUST I step 4: Remove ther cleaner by reeaing the sping eiesto) the fork tw wit weltie eeren weep ce hand sconnect the hoses) Rernove the ol vapour jeer ee le oe bine ih ra of eld omca tistee tot un. 1 Step 5: Disconnect the crankcase vent hase from the cflnder head and the ilet act or the SP injector unit, as ‘appropriate and blanis otf with a bolt of surable size O stop 6 CARBURETOR ENGINES. Disconnect the engine end of he ir eable and inuECTION ENGINES. Disconnect the engine endl of the ‘accelerator cable (a, the idle speed check : ‘actuator fp) and the Hy Injector supply (et. an O step 7: Disconnect the ‘electrical leads trem the following: the (net manitole (arrowed) the manifold cootant temperature sensors {arrowed} and the thrattie position ‘witch and army ther leads which your engine may have U step theaihast tounpipe trom the rant Detach Oi step #: Remove the sist (eros rei cyinder head toclan temperature sense are step 1 distributor ‘Also remove all the HT leads (alana with the p), Place them to.one side 1 Step 14: Undo the brake seria hose from the manifold, CI step 12: Remove she water hoes connected 1 therein step 130: CARBURETTOR ENGINES. Disconnect the fuel pine fromthe cars retior and both pipes from the te! pump (Label bath the pipes and stubs 5a that they vl Be teconneced the taht way roars A step 138: INJECTION. ENGINES, Disconnect the fue supply and return hases feo the 1 Step 14: CARBURETTOR ENGINES. Disconnect the distributor vecuum pipe and el vapour pipes from the carbye retior‘step 148: nECTION ENGINES. Discor buttery valve apening sensor con 2.138, part b) and the © he ction (see lustration Job Uiob 2-138, part O step 15: enone te fing bet. See na 1 O step 16: Uniat nd remove he carat sprocket Moecesiry, we ascrehiver hows the sprocket Boss muting bol behind eso; taming. ining fal ersione bt ete tat iin thee pis O step 18: unbot ana Faroe the timing bet Biciplate. You could leave the Bottom hat in place, if you are {98g no funher than removing the cylinder head, Ostep 19: Take ‘ll these ruts and Sposhers holding the Near cone place fndvenove it U step 20: 12 Gms housing annow be Femoned i order 10 a the cyinder Fi bosSlacken thet2 nowsing Bas progressive, fatet ro sans flton the housing Bough the vave sn D step 24: he camshaft husieg can pow be fed aay. Note the cope and fa new one bitenoertae O step 22: Ginsive INFORMATION: If the cam followers are lonse, you may wis remove them now so that they don't fall out and lose their position. Keep them in the correct order so that they can go back where they came from on reassembly. El A step 23; stat rg the cylinder D step 24: mutered 19 Tor, sockenng them inthe oder 0 step 25: Now slacken the og 10 tots ha 2 turn atone, nthe Jer shown'in ‘Step 24, unt all ‘are loose, and then remove them with thee washers ° <=) - Zz =) ict =] cy 'Ww LuWd ETP ETRICA Ads Fe) 4 | i m FA a FA LT O step 26: Check that nothing remains attached to, or ‘obstructs the oylinder head and block. stuck, i is permissible to tap the head lightly with a soft malt to free it. Never use a wedge between the joint faces and remember that the head will nt side off ast fs located on dowels O Step 27: Remove the old gasket ts Pee eee housing - refitting. IMPORTANT NOTES: * Here, we shaw haw to refit the hhead and camshaft housing, separated. The head complete with housing cannot be torqued down correctly without the use of FIAT's special, cranked spanner for use on the sem|-hididen head bolts. * The valve clearances will have to be re-set. See Job 7. ofer to the illustration te Job 2-4 in connection with the ‘work described here. i sive inFoRsation: FAT recommend that you should not re-use finder head batts which have been refitted more than thre times before, Fit new ones in doubt, so that you can ensure eliilty. Eh step 1: Livia he cinder head bolts and mashes and ear tem to drain for AT LEAST 20 minutes before Ting her Clean the block: anid cylinder head mating surfaces with 2 Straight edge, taking particular care with the light alloy head. ‘ny gouging of the metal could prove very expensive to: have put right! ‘Make sure that al the holes and coolant passages are clear of ‘ary foregn matter, particulaty the evinde head bolt holes which must be clear right down to the battom woe © carburetor deoner~or CNY 7 i curpumenade Lecile “Cir eros ap, vane Hv pas MATa UA tas ree pieces of stuck-on gasket. Oi step 2: win the block face peste ch remove the Oder head eae rn sep nd joel amp trom of or ‘grease, place it on the block with (an FLAT gaskets) this copper-ringed hole above the correct water passage. The gasket only fits correctly one way round 1 step a: Lower the cylinder head into position and locate it an the two dowels (see iustration Job 3-2, arraveed) O step a: the 10 man ejnder etd secuting bots and washers can now be serene by band, Don’ ft the smaller ones (erroneh yt Oi step 5A: ighen the 10 rge ols inh sequence as shown in isto fb 3-4, Alo hes meshownin Chapter 3, Facts ss and Figures ‘ Ci step ss: 20m Tighten the head down tothe fist torque setting, following the correct tightening order. = ) step se: in the sarne onde 401m tighten the bolts tottheir second torque setting, 1 step so: ‘Tighten each bot, once again in the correct ceder, by a further 90 degrees. You could use an angle gauge (2vallabie trom auto-accessory stores) in order 12 be precise Job 3.50) Tighten by another (second) 90 degrees, bolt-by-bolt, again in the correct orderO step de i the four or five smalier bolts, according to tratbon 40b 3-4, attenved) close tothe spark flugholes, and tighten ta thei specified torque. See Chapter 3 Facts and Figures, O step 7: all tems previously remaved in dab 2 can naw be fited in reverse order. When connecting the exhaust always lweamew flange gasket, O step. sure that all connections are sound andl secu. O step 9: all items previously remaved in Jab 2 can naw be fitted in reverse order. Refer to 4ob 1 when fitting the timing belt When connecting the exhaust always use-a new flange gasket O stop 10: Ensure that all connections are sound and seare O step 11: Top up the cooling system with the correct 5050 solution of FL Tutela’ anti-freeze solution. Check the lied Te Oe eT cy ee Fifer 1 the illustration Job 2-1 for the campanents ¢ inthis Jo, 1D stap 1: Remove the camshaft housing from the cylinder ‘head. See Job 2 O step 2: Remove the Ganshaft housing end Bite (othe cstrbutor fared a thesare flae on certain modes) Osstep 3: Remove the Gin folovers and shims from the housing, Beting them inthe (orec order for refting ithe same positions. Ostep 4:sidte the amshalt out, taking (IE not to damage the {amshaft bearings with she cam babes. (O) steps: Clean and check all components for wear and signs of ‘scuffing’ EE insioe ioRBATION! tthe camshafts changed, the follows shouldbe changed as wel the bore in the housing have ‘picked up! these cannot be machined and ‘the housing should be replaced together with new cam followers 9 WHLdVHO (2 Stepp 6: Refit the camshaft to the cam housing and insert the cam followers and shims in their correct bores, using ‘grease ta keep them in place, For adjustment of valve clear: ances see Job 7.

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