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Table Of Contents - Fiat Brava Service Manual

Volume 2

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Table of Contents

Service Manual Composition2

Workshop Manual Composition4

Graphic Representations And Symbols16

Electrical System18

Location Of Components Of Alarm System19

Remote Control20

Emergency Key Switch21

Switching Off The Alarm21

Simplified Programming22

Programming Country Code22

Closing The Memory23

Programming With Closed Memory24

Opening Memory And Memorization Of A New Remote Control24

Replacing Alarm Control Unit24

Analytical Charts25

Electrical Equipmentfault Diagnosis25

Fault Diagnosis28

Wiring Diagrams28

Parking Lights And Warning Lamp - Dipped Beam Headlamps - Main Beam Headlamps And Warning Light - Parking Lightsnumber Plate Lights28

Location Of Components29

Components Key29

Trim Level: S - Sx46

Electric Front Windows46

Table Of Contents48

At The Electric Windows Relay48

Bridge The N Coloured Cable Ok51

Check For Voltage At The R Not Ok51

Coloured Cable At The Elec51

Fault Diagnosis Analytical Charts51

Trim Level: El - Elx - Gt - Hgt54

Check For A Short Circuit In The System And Replace The Fuse56

Restore The Continuity Of The R Coloured Cable Between56

Restore The Continuity For The56

Check For Voltage At The R56

Coloured Cable For The Left56

Electric Window Control57

Trasound Welding57

Restore The Continuity Of The N Coloured Cable Between57

Bridge The Bg Coloured Ca Ok58

Bridge The Zg Coloured Ca Ok58

Control Panel 73 And The Ul59

Window Motor 7760

Trim Level: El - Elx62

Electric Rear Windows62

Extract The Connector For The Ok68

Version Without Alarm: S - Sx - Gt72

Central Locking72

Tween The Control Unit 11274

And The Ultrasound Welding74

Restore Continuity Of The N74

Coloured Cable Between The74

Ultrasound Welding74

Bridge The Rv/Zb & C/Br76

Version: El - Elx - Hgt84

Central Door Locking And Car Doors Not Shut Warning System84

Check The Condition Of The Not Ok87

The Control Unit 112 And The91

Restore The Continuity For The H/G Coloured Cables Be96

Trim Level: El - Elx - Hgt100

Direction Indicators And Warning Light - Hazard Warning Lights And Warning Light - Braking Lights - Reversing Lights100

Vehicle Interior Lights - Ideogram Lights124

Electrical Equipment146

Electrical System: Contents147

Electrical Symbols149

Explanation To Reading Wiring Diagram152

Key To References152

Connector Blocks153

Instrument Panel Connections153

Model: 1910 75 Bhp166

Air Conditioner166

Model: 1910 100 Bhp168

Windscreen Wash/Wipe - Rear Window Wash/Wipe - Electric Horns - Heated Rear Window And Warning Light - Headlampwasher170

Version Without Air Conditioner172

Engine Cooling System - Water Temperature Gauge - Car Interior Ventilation172

Version: 1910 75 Bhp174

Tarting System - Recharging System And Warning Light - Low Engine Oil Pressure Warning Light - Heater Plugs Warninglight - Fuel Injection Fault Warning Light - Fiat Code Fault System Warning Light - Rev Counter174

Starting System - Recharging System And Warning Light - Low Engine Oil Pressure Warning Light - Heater Plugs Warninglight - Fuel Injection Fault Warni176

Interpretation Of The Codes On The Connector Blocks180

Cable Colour Codes180

How To Read The Wiring Diagrams191

Side Lights And Warning Lamp - Dipped Beam Headlamps - Main Beam Headlamps And Warning Light - Parking Lights - Number Plate Lights192

Front Fog Lamps And Warning Light - Rear Fog Lamps And Warning Light 7 7 7 7 7194

Version With Air Conditioner196

Engine Cooling System - Water Temperature Gauge196

Version With Air Conditioner Engine Cooling System - Water Temperature Gauge197

Anti-Lock Braking System (A.b.s.) And Fault Warning Light - Hand Brake On/Low Brake Fluid Level Warning Light 11 11 11 11 11198

Fiat-Code System And Fault Warning Light 13 13 13 13 13200

Tarting - Electronic Ignition And Fuel Injection - Recharging And Warning Light - Low Engine Oil Pressure Warning Light - Fuel Injection Fault Warning202

Model Without Air Conditioner204

Ngine Coaling System - Water Temperature Gauge - Car Interior Ventilation204

Ersion: S - Sx206

Direction Indicators And Warning Lamp - Hazard Warning Lights And Warning Lamp - Stop Lights - Reversing Lights 19 19 19 19 21206

Courtesy Light - Symbol Illumination 29 29 29 29 29216

Diagnostic Socket Connections 35 35 35 35 35222

Electrical Equipment: Contents226

Instrument Panel228

Removing-Refitting228

Instrument Panel For S, Sx Versions229

Front Of Control Panel229

Wiring Diagram229

Rear Side (Showing The Connector Sockets)230

Instruments For El, Elx Versions231

Instrument Panel For Gt Version233

Instrument Panel For Hgt Version236

Fuel Level Gauge239

Fuel Level Gauge Wiring Diagram239

Engine Coolant Temperature Gauge239

Warning Lights For S, Sx Versions240

Warning Lights For El, Elx Versions240

Warning Lights For Gt Version240

Warning Lights For Hgt Version240

Fuse, Relay And Control Units241

Front View Of Fuse And Relayunit And Identification Of Fuses242

Rear View Of Fuse And Relayunit And Location Of Relays242

List Of Fuses And Main Protected Circuits243

Diagram Of Fuse And Relay Unit Internal Connections244

Location Of Fuel Injection/Ignition Control Unit245

Location Of Elecrohydraulic Control Unit For Anti-Lock Braking System245

Front Lights Cluster With Direction Indicator246

Replacing Bulbs On Front Lights Cluster247

Side Light Bulbs247

Direction Indicators Bulb247

Replacing Rear Lights Cluster Bulbs248

Removing-Refitting Rear Lights Cluster249

Replacing Rear Light Cluster251

Replacing Tail Light Cluster252

Additional Stop Light255

Front Fog Lamps256

Replacing Front Fog Lamp Bulb257

Number Plate Light258

Courtesy Lights258

Replacing Courtesy Light Bulbs259

Removing-Refitting Glove Compartment Light And Replacing Bulb259

Removing-Refitting Windscreen Wiper Motor260

Replacing Windscreen Wiper Blades261

Rear Window Wiper Motor262

Replacing Rear Window Wiper Blade262

Windscreen/Rear Window Washer Pump263

Wiring Diagram Of Stalk Unit265

Front View Of Stalk Unit265

Rear View Of Stalk Unit265

Identification Of Connector Terminals266

Stalk Unit Right Lever266

Windscreen Washer267

Rear Window Wiper267

Rear Window Washer267

Headlamp Washer267

Ignition Switch268

Removing-Refitting Ignition Key269

Removing-Refitting Ignition Switch Contact Block269

Tailgate Electrical Contacts270

Removing-Refitting (On Tailgate)270

Removing-Refitting (On Body Shell)270

Stop Lights Switch271

Removing-Refitting Radiator Fan272

Fuel Gauge Sender Unit273

Grunding Ad 182 L Radio And Cassette Player275

Rear View Of Radio276

Codes Relating To The Various Wave Bandsor Ranges276

Adjusting Digital Clock277

Radio Cassette Model Ad 182 H278

Radio Section278

Cassette Section278

Compact Disc Section278

Description Of The Controls279

Description Of The Operation Of The Radio Model Ad 182 H280

Switching On / Off With Engine Started /Stopped280

Pause Function281

Adjusting The Volume281

Adjusting The Tone281

Adjusting The Balance (Between Right And Left Speakers)282

Adjusting The Fader (Balance Between Front And Rear Speakers)282

Loudness Function283

Mute Function283

Radio Function284

Selecting The Function284

Selecting The Band284

Manual Search Tuning284

Rds Function (Radio Data System)285

Programming The Last Station Listened To285

Automatic Programming In Rds2 Band (Autostore)285

Manual Station Programming286

Listening To Stations Programmed286

Tp Function (Traffic Programme)286

Pre-Setting Volume Level For Tp Function (Traffic Programme)287

Eon Function (Enhanced Other Network)288

Scanning Programmed Stations (Scan Function)288

Stereo Transmitters288

Cassette Player289

Automatic Equalizing Selection289

Cassette Reproduction289

Changing Cassette Side290

Fast Forward / Rewind291

Listening To The Radio Whilst Fast Fowarding / Rewinding The Tape291

Searching For Previous / Next Track (Music Search System Function)291

Dolby B Function292

Ejecting The Cassette292

Compact Disc Player Function293

Filling The Compact Disc Loader293

Inserting Loader In Compact Disc Player293

Operation Of The Cd Player294

Extracting Loader From Compact Disc Player294

Extracting Compact Discs From Loader294

Possible Error Messages295

Selecting Disc295

Track Search (Forwards/Backwards)295

Scanning Tracks On The Compact Disc (Scan Function)296

Track Repetition (Repeat Function)296

Cd Repetition (Repeat Function)297

Random Playing Of Tracks (Rrandom Function)297

Clock Function298

Display Modes298

Selecting Display Modes298

Setting The Exact Time299

Switching Priority - Time/Frequency299

Disconnecting From The Supply299

Anti-Theft Protection300

Entering The Secret Code300

Initial Entering Of Secret Code300

Re-Entering The Code301

Eliminating Anti-Theft Protection301

Checking The Activation State Of The Code301

Technical Information302

Partial View Of The Rear Of The Radio302

Location Of Radio System Components For Model Ad 182 H303

Removing Radio Model Ad 182 L304

Radio Equipment305

Removing Radio Model Ad182H305

Refitting Radio Models Ad 182 L - Ad 182 H306

Replacing Radio Models Ad 182 L - Ad 182 H306

Opening/Closing Cassette Housing Flap307

Refitting Cassette Housing Access Flap308

Speakers In Dashboard309

Rear Speaker309

Loudspeakers On Front Door310

Engine Control Unit312

Fiat Code Control Unit313

Perspective View Of The Fiat Code Control Unit And Relevant Connectors314

Identification Of Connector Pins314

Electronic Keys314

Warning Light Of The Fiat Code System316

First Key Memorization316

Key Memorization With Unused System316

Key Memorization Procedure With Used Fiat Code And Electronic Fuel Injection Control Units321

Connection Between Fiat Code Control Unit And Engine Control Unit324

Unused System And Ignition On325

Fault Diagnosis With Fiat Lancia Tester326

Unused Fiat Code Control Unit And Ignition On326

Emergency Starting Procedure327

Emergency Starting With Fiat Lancia Tester327

Emergency Starting Procedure Using Accelerator Pedal327

Replacing Transponder329

Flow Charts Of Fault Repairs On Fiat Code System331

Loss Of Main Key331

Mechanical Breakage Of Main Key (Not In Notch)332

Electronic Fault (Transponder) Main Key332

Mechanical Breakage Of Main Key In Door / Bonnet Lock Notch333

Mechanical Breakage Of Main Key In Ignition Switch Notch334

Aerial On Ignition Switch Faulty335

Loss Of Code Card335

Code Warning Light Not Working335

Fuel Injection Fault Warning Light Not Working335

Wiring Diagram Of Fiat Code System (Petrol Versions)336

Wiring Diagram Of Fiat Code System (Diesel Versions)337

How Wire Safety Device339

Diagram Of Hot-Wire Device340

Noise Detector Safety System341

Location Of Components And Wiring Loom343

Electronic Control Unit348

Fault Memory350

Crash Memory350

Driver's Side Air Bag Module352

Passenger's Air Bag Module356

Device With Spiral Cable (Clock Spring)356

Diagnosis Using A Fiat/Lancia Tester358

Interventions On Vehicle360

Replacing An Air Bag (Due To Defects Or Warranty Expiry)362

Replacing Control Unit362

Action Following An Accident364

Accidents With Or Without Activation Of The Air Bag System364

Accidents Involving Activation Of The Air Bag System364

Painting Operations364

Danger To Health366

Effects Of Over-Exposure366

Safety Regulations For Handling Air Bag Modules366

Disposing Of Used Air Bag Modules370

Foreign Markets370

Ordering Procedure370

Removing Driver's Side Air Bag374

Operation Sequence374

Removing Clock Spring376

Preliminary Operations376

Removing The Steering Wheel378

Removing Watch Spring380

Refitting Clock Spring384

Refitting The Steering Wheel386

Completing Assembly390

Refitting Air Bag392

Side Repeater394

Rear Lights Cluster394

Wiring Diagram Showing Connection Of Headlamp Alignment Device395

Electric Headlamp Adjuster396

Location Of Components And Wiring Loom For Electric Headlamp Adjuster396

Headlamp Alignment397

Vertical Alignment397

Horizontal Alignment397

Manual Adjustment Of Front Fog Lamps397

Removing-Refitting Passenger Side Air Bag398

Safety Measures398

Replacing Passenger Side Air Bag Trim400

Removing-Refitting Control Unit Air Bag System401

Operation Sequence For Fitting Control Unitearth Lead Braid402

Removing-Refitting External Rearview Mirror404

Checking Current Intensity406

Checking Voltage406

Removing-Refitting (137012V)407

Checking Diodes409

Checking Inductor (Rotor) Winding Resistance At The Slip Rings410

Checking Stator Winding Insulation410

Removing-Refitting (1580 16V Version)411

Removing-Refitting (1747 16V Version)413

Removing-Ref Itting (1998 20V Version)415

Removing-Refitting (1370 12V Engine)418

Removing-Refitting (1580 16V Engine)419

Overhauling At The Bench420

Starter Motor Components422

Removing-Refitting (1747 16V Engine)423

Removing-Refitting (1998 20V Engine)425

Starter Motor Operational Fault Diagnosis426

Emergency Key427

Switching On - Switching Off428

Excluding The System428

Surveillance428

Start Of Simplified Programming (First Remote Control)432

Protected Programming-Manual Closing Of The Memory436

Entering The Password436

Checking That The Memory Is Closed439

Programming Codes With Manual Access440

Start Of Manual Opening Of The Memory (Entering A Known Password)440

Electronic Auto-Switching On Function444

Notes And Special Features444

Location Of Alarm System Diagnostic Socket444

Fault Diagnosis With The Fiat-Lancia Tester444

Autodiagnosis Display445

Signalling Cause Of Alarm445

Manual Diagnosis445

Main Wiring Diagram446

Input And Output Signals From The Anti-Theft Device Control Unit447

Alarm Control Unit Input And Output Signals447

Receiver Connector449

Removing-Refitting Alarm Control Unit449

Location Of Preheating Components In Car450

Preheating Electronic Control Unit450

Changes In Preheating Time Of The Glow Plugs451

Preheating Control System452

Checking Glow Plugs452

Main Operating Faults In The Preheating System452

Copyright Fiat A U T O S452

Engine Cut-Out Solenoid453

Checking Operation Of Engine Cut-Out Solenoid (On Fuel Injection Pump)453

Front Bumper455

Rear Bumpers (5D)456

Rear Bumpers (3D)457

Adjusting Front Door458

Adjusting Position Of Door Lock Striker458

Removing-Refitting Front Door458

Removing-Refitting Door Panel And Protective Lining459

Removing-Refitting Outer Door Handle460

Replacing Door Lock Barrel460

Removing-Refitting Door Opening Mechanism461

Removing-Refitting Lowering Window Glass462

Removing-Refitting Window Opening Device462

Removing-Refitting External Rear View Mirror463

Removing-Refitting Door Rear Pillar Trim464

Removing-Refitting Bonnet Lid467

Adjusting Bonnet Lid Position467

Adjusting Bonnet Lid Closing Device467

Removing-Refitting Bonnet Lid Striker468

Removing-Refitting Front Grille468

Removing-Refitting Windscreen Washer Pipes468

Rear Tailgate469

Removing-Refitting Tail-Gate (5D)469

Removing-Refitting Tail-Gate (3D)470

Adjusting Position Of Tailgate Buffers471

Adjusting Horizontal Position Of Tailgate471

Adjusting Position Of Tailgate Lock Striker471

Removing Refitting Tailgate Lock472

Replacing Lock Barrel ( 5 D )472

Replacing Lock Barrel (3D)473

Removing-Refitting Seat Front474

Dismantling-Fitting Front Seat Covers475

Removing-Refitting Front Seat Guides478

Removing-Refitting Seat Raise Device479

Removing-Refitting Rear Seat480

Dismantling-Fitting One-Piece Rear Cushion481

Dismantling-Fitting One-Piece Rear Squab481

Removing-Refitting Rear Side Panel ( 3 D )483

Interior Fittings484

Roof Panel Trim For Versions With Sun-Roof488

W I T H Sun-Roof488

Removing-Refitting Dashboard490

Removing-Refitting Rear Seat Belts496

Seat Belt Pre-Tensioner497

Removing Bracket498

Fitting Seat Belt With Pretensioner499

Safety Rules For Handling Seat Belt Unit With Pretensioner500

Bodywork Operations501

Ordering Instructions501

Composition Of Kit505

Window Glasses505

Thermal Knife506

Vibrating Knife507

Instructions For Using Wire Contained In Kit508

Replacing Front Window Glass (Windscreen)509

Removing Vehicle Trims And Protection509

Preparing The Windscreen Housing510

Preparing The Windscreen510

Replacing Rear Window Glass (Rearscreen)513

Replacing Rear W I N D O W Glass (3D)513

Replacing Rear W I N D O W Glass (5D)513

Replacing Third Fixed Winsow517

Removing Trim And Protection From Vehicle517

Removing Trim520

Removing-Refitting Complete Roof521

Dismantling-Reassembling Complete Roof522

Adjustments During Refitting523

Adjustment Of Opening Device523

Adjusting The Window523

Adjusting The Spoiler523

Replacing Body Panels524

General Instructions For The Repair524

Graphic Index525

Protection Of Repaired Parts538

Preparation And Painting Procedure538

Replacing Rear W I N G (3D)541

Replacing Rear W I N G (5D)541

Removing Off Cuts And Preparing Edges Of Bodyshell542

Adjusting The Replacement Part542

Preparing The Spare Part And Checking That It Is Correctly Positioned On The Bodyshell543

Welding The Spare Part543

Finishing Operations544

Adjusting Replacement Part And Finishing The Edges Of The Bodyshell546

Replacing Vehicle Roof Panel549

Positioning The Replacement Part551

Replacing S T R U C T U R A L Panels554

Replacing Structural Body Panels565

Replacing Front Pillar577

Replacing Rear Wheel Arch593

Typical Measurements597

Measuring Windscreen Housing And Engine Compartment Dimensions597

Measuring Dimensions Of Centre And Rear Pillar Housing (5 Door Version)598

Measuring Door Housing Dimensions599

Measuring Dimensions Of Centre Pillar Housing And Door Housings (3 Door Version)600

Measuring Rear Tailgate Housing Dimensions (5 Door Version)602

Figures For Adjusting Moveable Parts (5 Door Version)603

Squaring Body605

Diagram For Checking The Floorpan605

Diagram For Checking The Underbody606

Partial Replacement Of A Side Member618

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