Page 1 Fiat Bravo/a Service Manual Volume 3 Click here to choose chapter rmmary [Intro & TachData Fuel System B r a k i n g s y ^ t e m j ^ Auxiliary Units 9ft tiectnca Sjattm file:///D|/Volume%203/Vol3.htm(l of 2)08/07/2006 16:38:12...
Page 2 Fiat Bravo/a Service Manual Volume 3 K i g M h . n . r j U M V C ^ Bach file:///D|/Volume%203/Vol3.htm (2 of 2)08/07/2006 16:38:12...
Page 3 3rd volume manual is composed of the booklets indicated below: Page Print N° Sections Notes Nos. 1 - 6 Technical data Bravo 1988 HGT 20v Sport Pack Fuel system 1910 TD 100 engine 1 - 18 506.670/06 506.670/06 506.670/06 506.670/06 (Ml/95)
Page 4 Summary Bravo-Brava Page Print N° Sections Notes Nos. Removing - refitting 1910 TD 100 engine 506.670/11 506.670/11 506.670/11 Removing - refitting 1910 TD 75 engine ( V I / 1 9 9 7 ) ( V I / 1 9 9 7 )
Page 5 Summary Bravo- Brava Page Print N° Sections Notes Nos. Fuel system update l ^ ^ ) 20V 98 range Fuel system update l ^ ^ ) 20V 98 range 35 - 36 Fuel system update KEUji) JTD 98 range 21 - 22 Gearbox and differential M&Z£)
Page 7 T E C H N I C A L S E R V I C E M A N U A L COMPOSITION As of May 1999, the Bravo-Brava volume 3 manual is composed of the parts indicated below Page Print N°...
Page 8 Summary Bravo- Brava Page Print N° Sections Comments Nos. Removing - refitting 1910 TD 100 engine 506.670/11 506.670/11 506.670/11 Removing - refitting 1910 TD 75 engine (VI/1997) (VI/1997) (VI/1997) Automatic transmission and differential 21-27 506.670/12 Algemeen (VII/1997) Fuel system 1910 TD 75 506.670/13...
Page 9 Summary Bravo- Brava Page Print N° Comments Sections Nos. 20V 98 range Fuel system update 35 - 36 Fuel system update l u ^ ) JTD 98 range 21 - 22 Gearbox and differential iGp) 16V 98 range 21 -27 1 - 13 506.670/17...
Page 11 Page Print N° Sections Comments Nos. 1 - 6 Technical data Bravo 1988 HGT 20v Sport Pack 1 - 18 Fuel system 1910 TD 100 engine 506.670/06 506.670/06 506.670/06 506.670/06 (Ml/95)
Page 12 Summary Bravo- Brava Page Print N° Sections Comments Nos. Removing - refitting 1910 TD 100 engine 506.670/11 506.670/11 506.670/11 Removing .- refitting 1910 TD 75 engine ( V I / 1 9 9 7 ) ( V I / 1 9 9 7 )
Page 13 Summary Bravo- Brava Page Print N° Sections Comments Nos. 35 - 36 20V 98 range Fuel system update 21 - 22 JTD 98 range Fuel system update 21-27 1 - 13 16V 98 range Gearbox and differential 506.670/17 506.670/17 506.670/17 506.670/17...
Page 15 At present, January 1999, the B r a v o - B r a v a 3rd v o l u m e manual is composed of the f o l l o w i n g booklets: Page Print N° Sections Comments Nos. Tech. data Bravo 1988 HGT 20v Pack-Sport 1 - 6 Fuel system 1910 TD 100 engine 1 - 18 506.670/06 506.670/06 506.670/06...
Page 16 Summary Bravo-Brava 4A06SV Page Print N° Sections Comments Nos. 1 - 10 l6v 98 range 506.670/14 506.670/14 506.670/14 I6v 98 range 1 - 64 Fuel system (111/1998) (111/1998) (111/1998) Wiring diagrams ^p) I6v 98 range 1 - 37 1 - 77...
Page 17 At present, September 1998, the B r a v o - B r a v a m a n u a l 3rd v o l u m e is composed of the f ol lowi ng book- lets: Page Sections Print IM° Comments Nos. 1 - 6 Tech. data Bravo 1988 HGT 20v Sport-Pack 1 - 18 Fuel system: 1910 TD 100 engine 506.670/06 506.670/06 506.670/06 506.670/06 (111/1995)
Page 18 Summary Bravo-Brava Page Sections Comments Print N° Nos. 1 - 10 0 1 lev 98 range 506.670/14 506.670/14 506.670/14 1 - 64 Fuel system @ l lev 98 range (111/1998) (111/1998) (111/1998) Wiring diagrams l@t X6v 98 range 1 - 37...
Page 19 As of March 1998, the B r a v o - B r a v a volume 3 manual is made up of the following parts: Page Notes Publication no. Sections numbers Tech. data: Bravo 1988 HGT 20v Pack-Sport 1 - 6 1910 TD 100 engine fuel system 1 - 18 506.670/06 506.670/06 506.670/06...
Page 20 Summary Bravo-Brava 4A06SV Page Publication no. Sections Notes numbers 1 ± 10 lev 1998 range 506.670/14 506.670/14 506.670/14 Fuel system 0 t i6v 1998 range 1 ± 64 (111/1998) (111/1998) (111/1998) Wiring diagrams'®! lev 1998 range 1 ± 37 Publication no.
Page 21 Summary Bravo-Brava WORKSHOP MANUAL COMPOSITION As of July 1997, the Bravo-Brava manual, volume 3 is made up of the following parts: Number Publication no. Sections Notes of pages Technical data on Bravo 1988 HGT 20v 1 - 6 Sport-Pack 1 - 1 8 1910 TD 100 engine fuel system 506.670/06...
Page 23 Summary Bravo-Brava SERVICE MANUAL COMPOSITION At present, September 1996, the Bravo-Brava 3rd volume manual is composed of the following booklets: Page Print No. Sections Comments Nos. Tech. data Bravo 1988 HGT 20v Pack-Sport 1 + 6 1 + 18 1910 TD 100 engine fuel system 506.670/06...
Page 25 At present, June 1996, the B r a v o - B r a v a 3rd v o l u m e manual is composed of the following booklets: Page Comments Print No. Sections Nos. Technical data Bravo 1988 HGT 20v Pack-S- 1 - 6 port 1 - 18 Fuel system - 1910 TD engine 506.670/06 506.670/06...
Page 27 Summary Bravo-Brava SERVICE MANUAL COMPOSITION At present, April 1996, the Bravo-Brava 3rd volume manual is composed of the following booklets: Page Print No. Sections Comments Nos. Tech. data Bravo 1988 HGT 20v Pack-Sport 1 + 18 1910 TD engine fuel system 506.670/06...
Page 29 Preface Bravo-Brava This manual contains the main instructions for repairing and maintaining the Fiat Bravo and Fiat Brava. The manual is divided into sections distinguished by t w o digit numbers which appear in the parts m i - crofiches and the flat rate manual.
Page 30 It is produced with 5 different engine types. The engines are the same as those fitted on the Fiat Bravo w i t h the exception of the 1998 cc. Ill 96 - Cancels and -epldais Print no.
Page 31 Untitled Document file:///D|/Volume%203/intro&tech.htm08/07/2006 16:38:38...
Page 32 Planned Maintenance Programme The Planned Maintenance Programme whose operations are described lat- er on is the one in force at the time of printing and replaces and cancels the one in volume 1 of the Manual Copyright by Fiat Auto...
Page 33 Check operation of front disc brake pad wear sensor • • • • Check condition of rear disc brake pads (Bravo 1998 20v) • • • • Check rear drum brake linings condition and wear Visually inspect condition of: underbody exterior and pro- tection, pipes (exhaust, fuel system, braking system), rub- ber elements (boots, hoses, bushes, etc.)
Page 35 5 mm. If the tread wear is uneven, check the tyre in- flation pressure and inform the Customer of the possible need to balance the wheels. P4A01CA01 Copyright by Fiat Auto...
Page 36 C H E C K CONDITION OF REAR D I S C BRAKE PADS (Bravo 1998 20v) Remove one of the rear wheels and check the thickness of the friction material through the slit in the brake caliper; the minimum permis- sible thickness if 1.5 mm.
Page 37 The tension of the various drive belts is checked using tool 1895762000. Engines equipped w i t h auto- matic tensioners are exempt from this check. Bravo-Brava 1581 16v Check that alternator drive belt and power assisted steering drive belt tension, measured using the spe- cial equipment, are within the recommended values given in the table at the bottom of this paragraph.
Page 38 Introduction Bravo-Brava Planned maintenance Bravo 1998 20v Check that the tension values for the alterna- tor/air conditioning compressor drive belt and the power assisted steering drive belt, measured using the special equipment, cor- respond to the recommended figures, given in the table overleaf. If the tension values are...
Page 39 11 mm then it is type AV 11 and so on. poly-v belt in question it is necessary to count the number of teeth (or points) from 3 - 7 on the actual belt, as illustrated in the diagram below. P4A05CA03 Copyright by Fiat Auto...
Page 40 Introduction Bravo-Brava Planned maintenance V I S U A L L Y I N S P E C T CONDITION OF V A R I O U S T R A P E Z O I D AND/OR P O L Y - V D R I V E B E L T S - Disconnect the negative battery lead, remove the right front wheel, then remove the wheel arch lining to gain access to the auxiliary shaft drive belts.
Page 41 NOTE There should be no obstructions P4A07CA02 the area under the pedals preventing the total travel of the pedals: take care, in particular, that any mats are lying flat and not interfering with the pedals. Copyright by Fiat Auto...
Page 42 C H E C K / A D J U S T T A P P E T CLEAR¬ ANCE The following components must be removed in order to check and, if necessary, adjust the tappet clearance. Bravo-Brava 1910 TD 1. Remove the upper engine protection. P4A08CA03 Print no. 506.670/09...
Page 43 Then proceed with checking the tappet clearance. Bravo-Brava 1929 D 3. Undo the bolts fixing the tappet cover, disconnect the brackets connected to it and remove it. Then proceed w i t h check- ing the tappet clearance.
Page 44 Introduction Bravo-Brava Planned maintenance If the tappet clearance does not correspond 2. Lift up the shim to be replaced, working as to the recommended figures, proceed as f o l - appropriate, then remove '\X using pliers 1887001000. lows: 1. Using pressure lever 1860443000, lower...
Page 45 If the values are not within the limits set out in the government circular, the Customer must be notified of the need to check: - that the Lambda sensor is working properly using the Fiat/Lancia tester; - for the presence of air penetration in the area surrounding the Lambda sensor housing;...
Page 46 Introduction Bravo-Brava Planned maintenance [Q C H E C K EXHAUST G A S E M I S S I O N S (diesel engines using opacity meter) Start up the engine and let it reach operating temperature (radiator cooling fan comes on twice).
Page 47 The arrow on the out- er casing indicates the direction in which the fuel should flow. After replacing the filter, start up the engine and check that there are no leaks of fuel from the seals. Copyright by Fiat Auto...
Page 48 Introduction Bravo-Brava Planned maintenance [ 0 R E P L A C E F U E L F I L T E R (diesel en- gines) To replace the fuel filter, after having discon- nected the negative battery lead, proceed as...
Page 49 If the vehicle is used on dusty roads replace the air filter more often. If they ask, the Customer should be provided with suitable information on the optimum maintenance fre- quencies depending on the specific usage of the vehicle. P4A15CA02 Copyright by Fiat Auto...
Page 50 MIN level on the tank. If the level is too low, slowly pour a mixture of 50% distilled water and Fiat Lubrificanti Paraflu 11 through the filler. 137012v -1581 16v NOTE The addition of "Paraflu Formula Eu-...
Page 51 Top up until the level corresponds to the MAX reference, then retighten the cap. Avoid power steering fluid coming in- to contact with the hot parts of the en- gine as it is inflammable. P4A17CA03 Copyright by Fiat Auto...
Page 52 Introduction Bravo-Brava Planned maintenance Windscreen/rearscreen headlamp washer fluid level In order to add fluid, lift up the cap, lift up the filter and pour a mixture of water and Arex- ons DP1 fluid in the following percentages: - 30% Arexons DP1 and 70% water in summer;...
Page 53 Bravo-Brava Introduction Planned maintenance P4A19CA01 P4A19CA02 Bravo 1998 20v Bravo-Brava 1910 TD P4A19CA03 Bravo-Brava 1929 D Battery fluid level The battery is the "reduced maintenance" type: in normal usage conditions it does not need topping up with distilled water. The level of the battery fluid (electrolyte), withthe vehicle on a flat surface, should be between the references on the battery.
Page 54 Planned maintenance P4A12AX02 Q j ] R E P L A C E T I M I N G B E L T Bravo-Brava 1370 12v Position the vehicle on a lift, then: - disconnect the negative battery lead; - remove the right front wheel;...
Page 55 1860899000 for timing the camshaft in the housing, then tighten all the caps to a pre-torque of 1 daNm. Work with due care when raising the lubrication duct to avoid the duct be- ing distorted or broken. Copyright by Fiat Auto...
Page 56 Introduction Bravo-Brava Planned maintenance 1. Complete the refitting of the belt observ- ing the following order: - crankshaft drive pinion ( 1 ) ; - camshaft drive pulley ( 2 ) ; - water pump pulley ( 3 ) ;...
Page 57 (1) on the crankshaft pinion and also checking the engine timing ensuring that the reference (2) on the pulley corresponds w i t h the reference (3) on the timing belt shield. P4A15AX02 Copyright by Fiat Auto...
Page 58 Introduction Bravo-Brava Planned maintenance Bravo- Brava 1581 16v Position the vehicle on a lift, then: - disconnect the negative battery lead; - remove the right front wheel; - remove the right wheel arch liner. To gain access to the timing belt it is nec- essary to remove the alternator drive belt from the damper flywheel.
Page 59 Tools 1860874000 timing shafts differ only in terms of the refer- ence housing (3) in the angle at the bottom which should correspond to the plug (4) in the camshaft housing. Copyright by Fiat Auto...
Page 60 Introduction Bravo-Brava Planned maintenance 1. Only fit the timing drive belt on the crankshaft pinion. With flywheel lock 1860771000 fitted, fit the damper fly- wheel and tighten the fixing nut to a torque of 22 daNm, then remove the fly- wheel lock.
Page 61 If the readings on the dial gauge after the check carried out for point 4 are not the same, repeat the procedure described on the previous pages. Copyright by Fiat Auto...
Page 62 Introduction Bravo-Brava Planned maintenance Tensionamento cinghia distribuzione 1. Complete the fitting of the belt in the f o l - lowing order: 1. Crankshaft gear (already fitted) - 2. Oil pump gear - 3. Fixed pulley - 4. Timing pulley, inlet side - 5. Timing pulley, exhaust side - 6.
Page 63 Introduction Bravo-Brava Planned maintenance Bravo-Brava 1747 16v Position the vehicle on a lift, then: - disconnect the negative battery lead; - remove the right front wheel; - remove the right wheel arch liner. Loosen the tension for the auxiliary shaft...
Page 64 Introduction Bravo-Brava Planned maintenance 1. Remove the spark plugs using a special spanner. Position the dial gauge by cylin- der no. 1 using support 1895879000, ro- tate the crankshaft until T.D.C. is detected. Remove the 2nd cap fixing the inlet side...
Page 65 Fit the belt so that the arrow is point- ing in the direction of rotation of the engine. There are three reference markes on the belt for fitting during production. Copyright by Fiat Auto...
Page 66 Introduction Bravo-Brava Planned maintenance Tensioning the timing belt 1. Introduce tool 1860845000 in the open- ing in the automatic tensioner support; ro- tate the tool to exert force on the automat- ic tensioner until it is in the maximum ten- sion position, then tighten the nut fixing the tensioner to the support.
Page 67 Introduction Bravo Planned maintenance Bravo 1998 20v The removing-refitting of the timing drive belt cannot be carried out on the vehicle as there is insufficient space between the timing belt cover and the bodyshell to do so. It must be replaced with the engine at the bench; for...
Page 68 Introduction Bravo Planned maintenance Using a screwdriver, apply force to the au- tomatic tensioner tab so that the tensioner is in the maximum tension position, then tighten the nut fixing the tensioner to the support. Using spanner 1860831000, torque tight- en the inlet and exhaust side pullies to the recommended figures.
Page 69 Introduction Bravo-Brava Planned maintenance Bravo-Brava 1910 TD 75 e 100 Position the vehicle on a lift, then: - disconnect the negative battery lead; - remove the right front wheel; - remove the right wheel arch liner. 1. Rotate the device tensioning the auxiliary...
Page 70 Introduction Bravo-Brava Planned maintenance 1. Loosen the nut illustrated for the tension- ing device, release the belt tension, then remove it. Refitting and tensioning the timing belt 2. Remove the bolt (1) illustrated fixing the pump; place tool 1860905000 in place of the bolt. Then fit the timing belt on the crankshaft gear o n - 3.
Page 71 (1) in the maximum tension position, then lock the belt ten- sioner fixing nut. 4. For the 1910 TD 75 version, release the injection pump drive pulley by undoing the three bolts positioned previously. Copyright by Fiat Auto...
Page 72 Proceed w i t h refitting the components previously removed reversing the order of the operations described previously. Bravo-Brava 1929 D Position the vehicle on a lift, then: - disconnect the negative battery lead; - remove the right front wheel;...
Page 73 2. Remove the lower timing belt cover. 3. Remove the lower flywheel shield from the bell housing. 4. Place flywheel lock 1860766000 in posi- tion prevent rotation crankshaft. 5. Remove the damper flywheel, then re- move the flywheel lock 1860766000. Copyright by Fiat Auto...
Page 74 Introduction Bravo-Brava Planned maintenance 1. Rotate the crankshaft in its normal direc- tion of rotation until the references on the crankshaft pulley and the injection pump drive pulley are in line with the fixed refer- ences on the engine. Cylinder no. 1 w i l l be at T.D.C, under these circumstances...
Page 75 (for the bolt removed previously). Then loosen the bolt fixing the camshaft drive pulley using tools 1860831000 and 1860848000. Copyright by Fiat Auto...
Page 76 Introduction Bravo-Brava Planned maintenance Fitting and tensioning the timing drive belt 1. Complete the fitting of the timing belt ob- serving the following order: - Crankshaft gear; - fixed pulley; - injection pump pulley; - timing pulley; - belt tensioner.
Page 77 Carry out the following operations 1998 20v Champion RC7BMC with the engine cold. Bravo-Brava 1370 12v 1. Remove the cylinder head shield shown in the diagram. 2. Disconnect the H.T. leads from the spark plugs taking great care w h e n extracting the boots and remove and replace the spark plugs using an appropriate spanner.
Page 78 Bravo-Brava 1747 16v - 1998 20v 2. Remove the cover for the ignition coils, then disconnect the supply connectors. 3. Remove the ignition coils acting on the fixing bolts;...
Page 79 When a fault is detected and confirmed the warning light in the dashboard usually comes on: w h e n the fault is repaired the light goes out. Working with the Fiat/Lancia Tester or the SDC or the Examiner it is possible to carry out a complete system fault diagnosis which consists of three stages: 1.
Page 80 Introduction Bravo-Brava Planned maintenance C H E C K G E A R B O X / D I F F E R E N T I A L OIL L E V E L Position the vehicle on a lift. Undo the filler plug and check that the level of the oil is be- low the lower edge of the opening.
Page 81 - clean the drain plug and tighten it, w i t h the appropriate seal, to recommended torque; - lubricate the seal for the new filter w i t h oil and tighten fully by hand. Copyright by Fiat Auto...
Page 82 Introduction Bravo-Brava Planned maintenance - lower the vehicle, introduce the correct quantity of recommended oil; - check that the oil level is correct using the dip stick; - reposition the oil filler plug, let the engine idle for around 2 minutes, switch off the engine and wait for several minutes, then check the level of the oil and make sure there are no leaks.
Page 83 - check the efficiency of the braking system. NOTE For versions with hydraulic clutches (Bravo 1998 20v) the fluid in the circuit must be drained by connecting a flexible pipe to the clutch operating cylinder bleed screw, loosening it and act- ing on the pedal to drain the fluid into a suitable container.
Page 84 Introduction Bravo-Brava Planned maintenance S J R E P L A C E POLLEN F I L T E R 1. To gain access to the pollen filter it is nec- essary to raise the seal shown in the dia- gram and then undo the bolts shown and remove the access flap for the pollen filter.
Page 85 Untitled Document file:///D|/Volume%203/engine.htm08/07/2006 16:39:49...
Page 86 A I S I N A U T O M A T I C G E A R B O X F R O N T S U S P E N S I O N N.D. Data not available at the time o f printing Copyright by Fiat Auto...
Page 87 (*) Versions for specific markets (Germany) ( A ) Voluntary - Germany P4A003A04 Vehicle type identification code and chassis manufacture number V.I.N. Plate ( E E C regulations) Engine type and number. Vll-97 - Cancels and replaces Copyright by Fiat Auto...
Page 88 1100 1300 1300 system ( A ) 510 for Bravo 1910 TD - 540 for Brava • Loads which must never be exceeded ( • ) With automatic transmission NOTE F O R V E R S I O N S W I T H A C C E S S O R I E S : If special equipment is fitted (non standard air conditioner, sun roof, trailer towing device), the empty weight increases and therefore the carrying capacity may decrease, in relation to the maximum permissible loads.
Page 89 C02 exhaust emissions (g/km) (*) See specification on previous page (%) Versions for specific markets (Germany) ( • ) With automatic transmission NOTE The figures with the shaded background refer to the Fiat Brava Vll-97 Cancels and replaces Copyright by Fiat Auto...
Page 90 Introduction Bravo-Brava Capacities OO.o Quar tity Capacities Unit (kg) • Petrol S s O.R. 95 1581 Unleaded 1910 TD Diesel 1581 (6,4 1 ) 6,55 1910 TD 75 (6,8 • ; Total capacity 1910 TD 100 of cooling system (6,55 • )
Page 91 Compression 20,7 ± 0,5 ratio 24,6 Total volume of combustion chamber (CV) (100) (75) Max power EEC 4200 4 2 0 0 14,7 daNm (20,4) (15, ) (kgm) Max torque EEC 2250 2 7 5 0 Copyright by Fiat Auto...
Page 92 Technical data Bravo-Brava Engine: cylinder head assembly and valve gear components OO.o || TD || TD 100 D E S C R I P T I O N Values in mm Cam lift clearance for 0,50 timing check 0,50 17-20 0,35 ±...
Page 93 Technical data Bravo- Brava Engine: fuel system and turbocharging OO.io Ifl^S) TO 100 BHP iC^S) TD 75 BHP S P E C I F I C A T I O N S S P E C I F I C A T I O N S...
Page 94 Technical data Bravo- Brava @> TD75 Engine: fuel system OO.io TEST DATA FOR BOSCH INJECTION P U M P , t y p e VE R 679 GENERAL TEST CONDITIONS SPECIFIC TEST CONDITIONS -Test oil: ISO 4113 - Bosch 1.688.901.022 Injectors -Test fluid temperature: 45°...
Page 95 Bravo-Brava 9 * Technical data TD100 Engine: fuel system OO.io < / J • 4-" •I- > S--H — • * - » '*-> -Q Q. 4-< .'t: 4 _ > .E § . £ S > ' O J ' D J &...
Page 96 Technical data Bravo-Brava 9 ™ Engine: fuel system OO.io •u •I- ^— Print no. 506.670/07...
Page 97 W > r straight f i g Q££ 1 toothed G e a r s helical f i g toothed W j § 3,909 3,909 2,238 2,238 1,444 1,444 1,029 1,029 Gear ratios 0,815 0,767 3,909 3,909 Copyright by Fiat Auto...
Page 98 Technical data Bravo-Brava Gearbox and differential 00.21-27 TD 75 D I F F E R E N T I A L H r * Ratio 1 7 / 5 7 2 0 / 6 3 • i f ^ j p - T - crown wheel &...
Page 99 3,633 (54/53 x 8 2 / 2 3 ) o o o o o 10,197 o o o o o 5,373 o o o o o 3,633 2,670 O O O O O Ratio at the wheels o o o o o 10,059 Copyright by Fiat Auto...
Page 100 Technical data Bravo-Brava Front suspension 00.44 F r o n t s u s p e n s i o n independent, Mac Pherson type with steel track control arms anchored to an auxil- iary cross member. Offset coil springs and double acting telescopic shock absorbers. Anti-roll torsion bar.
Page 101 S T E E R I N G F R O N T S U S P E N S I O N REAR S U S P E N S I O N W H E E L S Copyright by Fiat Auto...
Page 102 HGT20v OO.o A "SPORT PACK" option is available for the Bravo 1998 20v HGT which makes its behaviour on the road even more sporty. With this option the vehicle is equipped with special suspension and larger tyres w h i c h improve road holding, agility and driving precision.
Page 103 Technical data Bravo ^ H G T Steering 00.41 Type 4 M = H » rack and pinion power assisted f © © - I - no. of turns lock tc > lock Ratio 128 ±1,5 mm rack travel ^ — —...
Page 104 (*) For vehicles with air conditioning Shock absorbers Type: telescopic, double acting BOGE (low pressure gas) Open (start of damping action) 458,5 ± 2 Closed (metal against metal) 291,5 ± 2,5 Travel Stabilizer bar Diameter of stabilizer bar Copyright by Fiat Auto...
Page 105 Technical data Bravo \m HGT20V Rear suspension 00.44 Rear suspension independent w i t h cast iron track control arms. Coil springs and shock absorbers w i t h vulcanized bushes. Torsion anti-roll bar. Rigid H auxiliary frame made up of transverse tubular element and t w o pressed side members connected to it.
Page 106 ( • ) With tyres inflated to the correct pressure and vehicle in running order w i t h 5 litres of fuel ( • ) Angular values, w h i c h cannot be adjusted, used for the correct alignement of the vehicle Copyright by Fiat Auto...
Page 107 Technical data Bravo HGT20v Wheels 00.44 K j f f j || Tyre inflation B i H Pressure in bar ENGINE ENGINE ENGINE Radial, tubeless Radial, tubeless Radial, tubeless Pressed steel wheel Pressed steel wheel Pressed steel wheel Rear Front...
Page 108 Starting Recharing This section contains data relating to cars fitted with a 1581 16v STEP A engine. For further information, refer to data in section 00 of the first and third volume. Copyright Fiat Auto IV-99 - Snpersntes previous vwsion...
Page 109 Exhaust C02 emissions ( g / k m ) 183 (186) N O T E : Values shown in brackets refer to the Fiat Brava. (*) 93/116/EC fuel consumption figures were determined during homologation tests: - an urban cycle, i.e. a cold start followed by a simulated varied urban route - out-of-town cycle, i.e.
Page 110 Technical data Bravo-Brava @) 16v Engine 1998 range OO.io S P E C I F I C A T I O N S Compression 10.5 ± 0.15 ratio 75.8 (BHP) (103.1) Maximum power 5750 daNm 14.2 (kgm) (14.5) Maximum torque...
Page 111 Bravo-Brava Technical data Ijpi Engine: crankcase assembly 1998 range OO.io D E S C R I P T I O N Values in mm 10.2 86.352 - 86.362 86.359 - 86.371 86.368 - 86.378 Piston 1.520 - 1.540 Piston 1.510 - 1.530 ring grooves 3.010 - 3.030...
Page 112 Technical data Bravo-Brava ® 16v Engine: Crankshaft and timing gear 1998 range OO.10 36 15 ! l S 3 | D E S C R I P T I O N Values in mm 24.016-24.041 22.004-22.009 Small end bush Piston pin 0.009-0.019...
Page 113 Bravo- Brava 0> Technical data Engine: cylinder head and valve gear components 1998 range 00.10 DESCRIPTION Values in mm 23.4 - 25.6 daN 33.5 46 - 50 daN Outer valve spring 24.5 17b Fyr 17b Fyr Cam lift Cam lift...
Page 114 Technical data Bravo-Brava fy™ Engine: fuel system 1998 range OO.io INTEGRATED ELECTRONIC INJECTION/IGNITION SYSTEM COMPONENTS Versions with manual I.A.W. 49 F.B4 gearbox tiecTronic coniroi unii I.A.W. 49 F.L2 Versions with automatic transmission Intake air pressure and temperature sensor M. Marelli TPRT 03...
Page 115 Bravo-Brava @ i 16v Technical data Gearbox and differential 1998 range 00.21-27 Copyright Fiat Auto...
Page 116 Technical data Bravo-Brava @ 16v Gearbox and differential 1998 range 00.21-27 D I F F E R E N T I A L Ratio spur 3.353 gear and pinion (17/57) 13.107 7.504 4.842 3.450 Ratio at the wheels 2.736 13.107...
Page 117 SAE 10 W Internal splines and shaft bushes Engagement sleeve and TUTELA MR3 intermediate plate (*) Data measured at environmental temperature of 20°C. N O T E During service, the insulation between commutator bars need not be lowered Copyright Fiat Auto...
Page 118 Bravo-Brava © 16v Technical data Electrical equipment: starting 1998 range 00.55 S T A R T E R MOTOR - WIRING DIAGRAM AND T Y P I C A L C U R V E S Wiring diagram of M. Marelli M70R-1.3/12...
Page 119 Bravo- Brava Technical data Electrical equipment: recharging 1998 range 00.55 lCl& 16V lCl& 16V l^p) l^p) 16V** with air conditioner ALTERNATOR Bosch M. Marelli M. Marelli Bosch KCB2-14V-50/90A Make Bosch* A127IR-14V-40/85A KCB1-14V-45/80A A115I-14V-40/75A KCB2-14V-55/105A Rated system voltage Maximum current 90A (105)*...
Page 121 - Capacities S P E C I A L T O O L S - Fiat Lubricant product characteristics T I G H T E N I N G T O R Q U E S T E C H N I C A L DATA...
Page 122 • 182 BR 1 AA NOTE This section deals w i t h the new engine versions in the 1998 range. For the remaining engine versions, refer to the Bravo-Brava manual, publication no. 506.670, and subsequent updates. Copyright Fiat Auto...
Page 123 Introduction Bravo-Brava Identification data 1998 range OO.o P4A003A02 Vehicle type identification code and chassis manufacture number Engine type and number. Name of manufacturer Homologation number Marking summary plate Vehicle type identification code ( E E C regulation.) Chassis manufacture number >...
Page 124 N O T E F O R V E R S I O N S W I T H A C C E S S O R I E S : With special equipment fitted (non-standard air conditioner, sun¬ -roof, trailer tow hook), the unladen weight increases and maximum carrying capacity may decrease. Copyright Fiat Auto...
Page 125 Introduction Bravo-Brava Performance - Fuel consumption 1998 range OO.o l^^^j E N G I N E STEP A Speed k m / h Speed k m / h Speed k m / h (average load) (average load) (average load) 110*...
Page 126 10°C headlamp washer) ~ - 20°C 100% AREXONS ( A ) Distilled water ( • ) Only engine sump ( • ) For versions with air conditioner (*) For versions 1998 20v (**) For versions 1242 16v Copyright Fiat Auto...
Page 127 Introduction Bravo-Brava Fiat Lubricant product characteristics 1998 range OO.o Description Name Usage product International designation Temperature Semisynthetic multigrade engine oil. Meets specifications S E L E N I A SAE 15 W/40 - 25°C - 40°C API SH, CCMC-G5 and UNI 20153...
Page 128 (bore) 75.65 Stroke 78.86 1242 1998 = I^^^B} Capacity Compression 10.7 ± 0 . 1 5 10.2 ratio (155) (82) (PS) Maximum power 5500 6500 11.3 18.6 daNm (11.5) (19) Maximum (kgm) torque torque • 3750 4250 Copyright Fiat Auto...
Page 129 Technical data Bravo-Brava Engine: typical curves 1998 range OO.10 1000 2000 3000 4000 5000 6000 7000 P4A08HA01 P4A08HA02 Bench test cycles for overhauled engines Speed Time Load when laden W h e n bench-testing serviced engines, it is (rpm) minutes...
Page 130 Main bearing supports 51.713-51.717 70.800-70.810 82.000-82.010 70.810-70.820 82.010-&2.020 Cylinder bore 70.820-70.830 82.020-82.030 12.5 70.760-70.770 81.952-81.962 81.959-81.971 70.770-70.780 70.780-70.790 81.968-81.978 Piston weight difference ± 5 g between pistons 0.038-0.058 0< 0.039-0.061 0.030 - 0.050 3 - i Cylinder liner 0.042-0.062 Copyright Fiat Auto...
Page 131 Technical data Bravo-Brava Engine: crankcase assembly 1998 range OO.io 20v STEP A D E S C R I P T I O N Values in mm Piston 17.982 - 17.986 20.002 - 20.007 pin seat 17.970 - 17.974 19.996 - 20.000...
Page 132 0.014 - 0.035 23.007 - 23.027 ft 0 , ± o f 20.006 - 20.01 2 l o l Small end bush Gudgeon pin 0.006 - 0.020 -4-h- Small end bush Small end bush 0.035 - 0.088 Bush housing Copyright Fiat Auto...
Page 133 Technical data Bravo-Brava Engine: crankcase assembly 1998 range OO.10 20v STEP A D E S C R I P T I O N Values in mm 47.982-47.988 59.994-60.000 Main 47.988-47.994 59.988-59.99 journals 47.994-48.000 59.982-59.98 48.238-48.24 41.990-42.008 Crank 48.232-48.23 pins 48.226-48.23 23.975-24.025...
Page 134 Value (in m m ) of offset between connecting rod ax- is and piston axis D= 0.85 - 1.15 (for 1242 16v) D= 0.10-0.60 (for 1998 20V S T E P A) Copyright Fiat Auto...
Page 135 Technical data Bravo-Brava Engine: cylinder head and valve gear 1998 range OO.io I d a ) 20v STEP A Values in mm D E S C R I P T I O N Camshaft supports on cylinder head 26.045-26.070 | ^ p |...
Page 136 0 i ^ n Valve guide 10.010 - 10.030 13.010 - 13.030 0 2 ' > 0.05-0.10-0.25 Valve guide 13-12 0.049 - 0.051 0.033 - 0.080 Bore in cylinder head Tappet housing 33.000 - 33.025 on cylinder head Copyright Fiat Auto...
Page 137 Technical data Bravo-Brava Engine: cyilnder head and valve gear 1998 range OO.io ItEEElj 20v STEP A DESCRIPTION Values in mm 5.974 - 5.992 6.975 - 6.930 22.250 - 22.550 29.900 - 30.200 45° 30' ± 5' Valve 5.974 - 5.992 6.960 - 6.975...
Page 138 13-l.c Bore m cylinder head Tappet - Bore in cylin 0.046 - 0.051 1 9 - 1 8 j extension e r n e a c 1 7 - 2 0 0.45 ® timing Hydraulic tappets check Copyright Fiat Auto...
Page 139 Technical data Bravo-Brava Engine: cylinder head and valve gear 1998 range OO.io T I M I N G D I A G R A M S 20v STEP A Timing angles start before 0° 9° (•) after TDC Inlet Inlet end after 32°...
Page 140 Bearing seats in crankcase c> P L3-, Ball bearings +0.011 - - 0.025 £ - ' " -4-k- Cylinder block seats tw ot 0[ p Shaft journals +0.020 - - 0.003 4 - k - Ball bearings Copyright Fiat Auto...
Page 141 Technical data Bravo-Brava Engine: lubrication 1998 range OO.io 20v STEP A L U B R I C A T I O N Values in mm forced circulation, via forced circulation, via Engine lubrication system lobe gear pump gear pump with in-line...
Page 142 Bravo- Brava Technical data Engine: cooling system - fuel system 1998 range OO.io \l6v & 2 j l ) 20v STEP A COOLING coolant circulation via centrifugal pump, radiator, Cooling circuit expansion tank and fan operated by thermal switch coolant pump drive...
Page 143 Technical data Bravo- Brava Engine: fuel system 1998 range OO.io I G ^ P ) INTEGRATED ELECTRONIC INJECTION/IGNITION 20vSTEPA SYSTEM COMPONENTS Injection system electronic control unit Bosch 0.261.204.578 Bosch 0.261.204.271 Throttle body Bosch 0.280.750.013 Motorized throttle body Bosch 0.250.003.052 Absolute pressure sensor Bosch 0.261.230.013...
Page 144 Fuel system type Number of cylinders Cylinder liner (bore) Stroke 90.4 1910 Capacity Compression 18.45 ± 0.5 ratio 27.35 Total combustion chamber volume cnrr (BHP) (105) Max power eec 4000 daNm 20.0 (kgm) (20.4) Max EC torque 1500 Copyright Fiat Auto...
Page 145 Technical data Bravo-Brava Engine: typical curves 1998 range OO.io 1000 1500 2000 2500 3000 3500 4000 4500 5000 Bench test cycles for overhauled engines Test Time Load speed When bench-testing serviced engines, it is (rpm) minutes brake not advisable to run the engine at top speed...
Page 146 82.010 - 82.020 Cylinder bore 82.020 - 82.030 81.920 - 81.930 81.930 - 81.940 81.940 - 81.950 > Piston i«r 0.845 - 1.105 Piston projection Weight difference ± 5 g between pistons 1£ Piston 0.070 - 0.090 Cylinder bore Copyright Fiat Auto...
Page 147 Technical data Bravo-Brava Engine: crankcase assembly 1998 range OO-io DESCRIPTION Values in mm Piston pin 25.999 - 26.004 seat 2.685 - 2.715 (*) Piston ring 2.020 - 2.040 grooves 3.020 - 3.040 25.982 - 25.988 > Piston pin Piston pin - Housing 0.004 - 0.014...
Page 148 Small end bush 0.046 - 0.099 Bush housing 59.994 - 60.000 Main 59.988 - 59.994 journals 59.982 - 59.988 i-4-J*- 50.799 - 50.805 Crank 50.793 - 50.799 pins 50.787 - 50.793 26.80 - 27.20 25.90 - 26.10 Copyright Fiat Auto...
Page 149 Technical data Bravo-Brava Engine: crankcase assembly 1998 range OO.io D E S C R I P T I O N Values in mm 1.836 - 1.840 Crankshaft bearings 1.839 - 1.843 1.842 - 1.846 < 0.254 - 0.508 Crankshaft bearings- 0.011 - 0.071...
Page 150 T_n_r --T_rn_r"^^ 26.045 - 26.070 "0 19.100 - 19.150 Camshaft supports . — n — - ^ j - L n n _ (_!—>_/ |_J—>-T_I^- Tappet hous- 37.000 - 37.025 (*) Cap size Copyright Fiat Auto...
Page 151 Technical data Bravo-Brava Engine: cylinder head and valve gear 1998 range OO.io D E S C R I P T I O N Values in mm 8.022 - 8.040 > Valve guide 14.010 - 14.030 0.05 - 0.10 - 0.25...
Page 152 3.25 - 4.90 l ^ ^ ^ S h i m S l g 0.05 0.50 ' HQ timing timing / ^ A / ^ A 0.50 1^5 T 1^5 T 0.30 ± 0.05 0.35 ± 0.05 Copyright Fiat Auto...
Page 153 Technical data Bravo-Brava Engine: cylinder head and valve gear 1998 range OO.10 T I M I N G D I A G R A M S Timing angles start before 0° Inlet Inlet end after 32° ® ® start before 32°...
Page 154 Insufficient oil pressure sender unit electrical ^ b a r ^ ^ ^ ^ ^ ^ ^ 3.43 - 4.9 bar Operating pressure at temperature of 100°C 6.27 - 7.06 daN Oil pressure relief valve spring Copyright Fiat Auto...
Page 155 Technical data Bravo-Brava Engine: cooling system 1 9 9 8 r a n g e OO.io | ^ ^ J COOLING S Y S T E M coolant circulation via centrifugal pump, radiator and two speed electrical fan controlled by engine...
Page 156 Diesel temperature sensor Bosch 0.281.002.209 Rpm sensor Bosch 0.281.002.214 Timing sensor Bosch 0.281.002.213 Turbocharger pressure sensor Bosch 0.281.002.215 Fuel pressure sensor Bosch 0.281.002.210 Injector Bosch 0.445.110.002 Preheating control unit Bosch 0.281.003.215 Glow plug Bosch 0.250.202.028 EGR solenoid 46419651 Copyright Fiat Auto...
Page 157 Technical data Bravo-Brava Clutch 1998 range 00.18 STEP A Values in mm Type dry, single plate w i t h bearing O & Operating mechanism diaphragm spring Spring loading Lining Lining Distance between 155 ± 1 0 140 ± 5...
Page 158 « f | teeth 3.909 3.545 3.909 2.158 2.238 2.238 1.345 1.520 1.444 1.480* 0.974 1.156 1.029 Gear ratios 1.121* 0.829 0.970 0.767 0 . 8 9 1 * 3.818 3.909 3.909 (*) 5D version (Brava) Copyright Fiat Auto...
Page 159 Technical data Bravo-Brava Gearbox and differential 1998 range 00.21-27 l S | STEP A D I F F E R E N T I A L = I - 1 dh± Spur gear 3.887 3.353 3.053 _ T _ ••JDj^Cp...
Page 160 ^ t f l l f c Load proportioning valve wheels w h e e l s 0.36 0.36 Ratio (reduction) (*) Version w i t h o u t A B S Copyright by Fiat Auto...
Page 161 Bravo- Brava Technical Data Brakes 98 range 00.33 1 ^ 1 i » STEP A Values in m m REAR B R A K E S REAR B R A K E S 10.80 - 11.10 10.10 " 9.20 *C A l l o w e d p S ? <...
Page 162 Turning 10.4 m circle — offside 31° 30' ± 3 0 ' i V ^ P wheel 3 8 ' 1 5' ± 3 0 ' wheel Steering angle vT" Steering col- f—\ with 2 universal joints Copyright Fiat Auto...
Page 163 Technical data Bravo-Brava Wheels 1998 range 00.44 i l II TVre R i l l pressure 2 « in bars ENGINE ENGINE ENGINE T u b e l e s s tyre T u b e l e s s tyre...
Page 164 00.44 unladen car ( • ) W H E E L G E O M E T R Y - 7 ' ± 30' camber (**) -33'± 30' (only for Bravo 1998) 2°50' ± 30' caster (**) Front suspension -1 - 1 mm...
Page 165 Technical data Bravo-Brava Front suspension 1998 range 00.44 F r o n t s u s p e n s i o n independent wheel, MacPherson type w i t h forged steel wishbones anchored t o a subframe. Offset coil springs and double-acting telescopic dampers. Anti-roll torsion bar.
Page 166 (low pressure gas type) Open (damping starts) 322.5 ± 2 312 ± 2 322.5 ± 2 Closed (steel against steel) 223 ± 2 223 ± 2 223 ± 2 Stroke 99.5 99.5 Stabilizer bar Diameter of stabilizer bar Copyright Fiat Auto...
Page 167 Technical data Bravo-Brava Electrical equipment 1998 range 00.55 STEP A M. Marelli S T A R T E R M70R-12V-1,4kW M. Marelli E80E-12V-0,9KW MOTOR (with reduction unit) M. Marelli M. Marelli A 1 1 5 I - 1 4 V - 3 8 / 6 5 A...
Page 168 E L E C T R O N I C CONTROL UNIT ENGINE F U E L S Y S T E M N.D. C O N T R O L G L O W P L U G S BOSCH 0.250.202.028 Copyright Fiat Auto...
Page 169 Technical data Bravo-Brava Electrical equipment: starting 1998 range 00.55 < B P STEP S T A R T E R M O T O R M. Marelli BOSCH DIAM 78.5 M. Marelli M. Marelli Type - 12V - 2.0 kW M70R-12V-1.8 kW...
Page 170 ( • ) For vehicles with air conditioner Built in electronic VOLTAGE REGULATOR Type RTM 151 A RTM 151 B Alternator speed for 6000 test Thermal stabilization current Test current Regulation voltage (*) 14.05 - 14.35 (*) Data measured at environmental temperature of 23°C. Copyright Fiat Auto...
Page 171 Technical data Bravo-Brava Electrical equipment: electronic injection-ignition 1998 range 00.55 INTEGRATED E L E C T R O N I C INJECTION-IGNITION CONTROL MODULE Type Bosch 0.261.204.578 Firing order 1 - 3 - 4 - 2 COIL W I T H 4 H I G H T E N S I O N O U T L E T S...
Page 172 K N O C K S E N S O R Bosch Type 0.261.231.131 Code SPARK P L U G S C H A M P I O N RC8BY Make and type Thread M 14x1.25 Electrode gap Copyright Fiat Auto...
Page 173 Technical data Bravo-Brava Electrical equipment: electronic injection 1998 range 00.55 BOSCH C O M M O N RAIL E L E C T R O N I C F U E L S Y S T E M Type Bosch EDC15C...
Page 174: Special Tools
Installer for fitting oil seal to valve guide 1860313000 • 1860313002 Drift for press-fitting oil seal to valve guide • • 1860395000 Drift for valve guide removal • 1860395001 Drift for removing valve guide • 1860443000 Pressure lever Copyright Fiat Auto...
Page 175 Technical data Bravo-Brava Special tools 1998 range 00.A ENGINE Tool TOOL DESCRIPTION number I^Pl | g § ) 2 0 v STEP A • • • 1860470000 Tool for retaining cylinder head during overhaul • Fixture to retain valve tightness test device 1895868000 (to...
Page 176 Tool for dismantling and reassembling half-cones, cups, 1860877000 springs and valves • 1860879000 Universal handle • Tool for fitting rear crankshaft cover 1860881000 • • • 1860893000 Fuel pump cover wrench • 1860898000 Flywheel retainer (on vehicle) • 1860905000 Tool for measuring T.D.C. Copyright Fiat Auto...
Page 177 Technical data Bravo-Brava Special tools 1998 range 00.A ENGINE Tool TOOL DENOMINATION number STEP A • • 1860942000 Angle wrench • Equipment for testing fuel supply circuit 1860955000 • 1860961000 Template for camshaft timing adjustment • 1860985000 Tools for timing and securing camshafts •...
Page 178 Tool for dismantling gearbox gears and hubs 1842134000 • 1845028000 Reaction block for removing differential bearings Tool for removing layshaft 5th speed gear bush 1845057000 • Tool to remove front axle shaft constant velocity joint (to be 1845062000 used with 1847017001) Copyright Fiat Auto...
Page 179 Technical data Bravo-Brava Special tools 1998 range 00.A ENGINE Tool TOOL DESCRIPTION number l ^ p | l ^ P ) 2 0 v STEP A • • • 1847017001 Striker (use with 1860889000) • Plate for removing flanged shaft from differential gear (use...
Page 180 Set of tools to hold cylinder pistons when installing brake 1872273000 shoes • • 1895901000 Tool for adjusting load proportioning valve position S T E E R I N G • • 1847035000 Puller for steering rod ball pins Copyright Fiat Auto...
Page 181 Technical data Bravo-Brava Special tools 1998 range O 0 . A ENGINE Tool TOOL DESCRIPTION number STEP A S U S P E N S I O N S Y S T E M Tool for removing front hub bearing inner race from flange (to •...
Page 182 16.7 mm) mm 10; • • • Centesimal gauge for special tools (10 mm capacity; stem 1895882000 length 88 mm) • • • Centesimal gauge for special tools (10 mm capacity; stem 1895884000 length 16.7 mm) Copyright Fiat Auto...
Page 183 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART PART PART Thread Thread Thread !np) !np) daNm STEP A STEP A ENGINE • M 1 0 x 1 . 2 5 4 + 90° • •...
Page 184 Bolt retaining pulley to power steering pump M10x1.25 • • Spark plugs M12x1.25 • M14x1.5 • • Oil pressure switch Oil pressure switch M14x1.5 • M16x1.5 tapered Coolant temperature sender unit Coolant temperature sender unit • • M16x1.5 tapered Copyright Fiat Auto...
Page 185 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART PART PART Thread Thread Thread I ® I I ® I 1 6 , 1 6 , daNm STEP A STEP A • • Coolant temperature sender unit for i.e. system M1 2x1.5...
Page 186 Nut retaining intake manifold to cylinder head • • M8x1.25 Nut retaining exhaust manifold to cylinder head Nut retaining exhaust manifold to cylinder head • • M8x1.25 • Bolt retaining coils to rear cover • Coil retaining bolt Copyright Fiat Auto...
Page 187 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART PART Thread Thread daNm daNm STEP A Coil cover retaining bolt • Nut retaining upper part of intake manifold to lower part Adjustment screw for securing intake manifold •...
Page 188 • crankcase crankcase • Injector retaining bracket tightening nut Injector retaining bracket tightening nut M32x1.5 11.8 • Fastening, exhaust manifold reaction bracket to crankcase • Bolt retaining injection pump mount, crankcase end Copyright Fiat Auto...
Page 189 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART. PART. Thread Thread daNm daNm STEP A • Bolt retaining injection pump to intake manifold end mount • Injection pump gear retaining nut M 1 4 Fuel temperature sensor M 1 2 •...
Page 190 Bolt with safety washer retaining front section to catalytic converter • Bolt for retaining bracket with block to differential end mount • Nut retaining front exhaust pipe flange to mani- fold • Self-locking nut with metal insert retaining front exhaust half-bracket Copyright Fiat Auto...
Page 191 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART PART PART Thread Thread Thread daNm STEP A STEP A • Self-locking nut w i t h tapered safety washer re- taining bracket to crankcase • Nut joining rear pipe to catalytic converter M10x1.25...
Page 192 • Nut retaining ball heads to levers • • • Nut for bolt retaining selection idler to gearbox • • • Bolt retaining reverse pipe to gearbox • • • Nut retaining ball heads to selection lever Copyright Fiat Auto...
Page 193 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART PART PART Thread Thread Thread daNm STEP A STEP A • • • Bolt retaining reaction bracket to gearbox • • • 0.74 Nut retaining gearbox linkage to mount G E A R B O X AND D I F F E R E N T I A L •...
Page 194 Fitting connecting hose to rear brake caliper M10x1 • • Bolt retaining cylinder to rear brake carrier plate • Bleed screw on rear drum brake cylinder 0 1 8 0 0.65 • • • Brake pump restriction fitting (ABS version) Copyright Fiat Auto...
Page 195 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART Thread r|p| r|p| 2 0 . 2 0 . daNm STEP A STEP A • • Male fitting for flared hoses fastening rigid pipe t o M10x1 rear drum brake cylinder •...
Page 196 Nut retaining front wheel hub to coupling Nut retaining front wheel hub to coupling M 2 4 * 1 . 5 7 + 6 2 ° • • M 1 2 x 1 . 2 5 8 . 6 Wheel stud Copyright Fiat Auto...
Page 197 Technical data Bravo-Brava Tightening torques 1998 range ENGINE Tightening Tightening torques torques PART Thread daNm STEP A STEP A REAR S U S P E N S I O N • • • Screw with broad flange retaining front flexible M 1 2 x 1 .
Page 198 AIR BAG S Y S T E M • • • Bolt retaining air bag control unit • • • Bolt retaining driver module to steering wheel • • • Bolt retaining passenger module to facia beam Copyright Fiat Auto...
Page 200 ' • 7 - Fuel circuit diagram - Electric-electronic system - Input output signals between ECU/sensors and actuators - Wiring diagram - B l o w - b y gas recirculation diagram - Exhaust recirculation system ,. (E.G.R.) Copyright Fiat A uto...
Page 201 Bravo-Brava 0 T D Engine Fuel system F U E L S Y S T E M WITH LUCAS FT09 PUMP INTRODUCTION The devices making up the injection system are collectively responsible for introducing fuel into each cylinder and ensuring the required quantity is provided to provide even, effective combustion.
Page 202 Engine Bravo-Brava 0 ™ Fuelsystem LOCATION O F F U E L S Y S T E M C O M P O N E N T S P4A02EJ01 8. E.G.R. valve. (Mitsubishi) 1. Air temperature sensor 9. Pre-heating control unit 2.
Page 203 The air assumes optimal temperature and density properties and then flows to the intake manifold (7) for distribution to the cylinders. P4A03EJ01 1. Inlet fitting 5. Air cleaner 2. Turbocharger 6. Air temperature sensor 3. Heat exchanger (intercooler) 7. Inlet manifold 4. Air flow meter (debimeter) Copyright Fiat Auto...
Page 204 Engine Bravo-Brava 1 0 Fuel system FUEL F E E D C I R C U I T The main components of the fuel system are as follows: tank, filter, injection pump and injectors. Fuel flows from tank (6) to injection pump (2) through filter (7). A pump (9) is fitted upstream from fil- ter (7) to prime the fuel if necessary (e.g., after replacing the fuel filter).
Page 205 - Pump is lubricated by the fuel used to drive the pump. - Extra fuel under conditions of fuel engine load or when full power is required. - Coded, electronic fuel flow stop device built into the immobiliser system (Fiat CODE). 6. Fast idle actuator control device 1.
Page 206 Engine Bravo-Brava 1 0 Fuel system Principle of operation Fuel taken up from tank (11) and filtered by filter ( 1 2 ) , flows to feed pump (7) which increases fuel pressure. Under the effect of the feed pump pressure regulator valve ( 2 ) , the pressure increases in more or less lin- ear fashion as engine rpm rises.
Page 207 8. Advance actuator control solenoid 2. Feed pressure regulator valve 9. Pressurisation valve 3. Engine stop solenoid 10. Injectors 4. Pumping element 1 1 . Tank 5. Outlet valve 12. Filter 6. Metering device 13. Speed regulator Copyright Fiat Auto...
Page 208 Engine Bravo-Brava 1 0 Fuel system E L E C T R I C - E L E C T R O N I C S Y S T E M The fuel system electric - electronic circuit comprises a wiring circuit, an electronic unit (control unit)
Page 209 Bravo-Brava 1 0 ™ Engine Fuel system F A S T I D L E MANAGEMENT Coolant temperature Air temperature Solenoid The control unit activates the fast idle w h e n fast at least one of the following conditions oc-...
Page 210 Engine Bravo-Brava 1 0 Fuel system A I R CONDITIONING S Y S T E M C O N T R O L Coolant temperature When the air conditioner is turned on, the compressor absorbs power from the engine, w h i c h tends to stall when only idling. The...
Page 211 Bravo-Brava 1 0 Engine Fuel system INPUT AND OUTPUT S I G N A L S B E T W E E N E C U / S E N S O R S AND A C T U A T O R S 9.
Page 212 Engine Bravo-Brava f0r Fuel system WIRING D I A G R A M P4A10EJ02 Publication no. 506.670/06...
Page 213 13. Preheating control unit 3. Air conditioner relay 14. System relay 4. Air conditioner activation button 15. Borg Warner solenoid (E.G.R) 5. Fiat/Lancia Tester fault diagnosis point 16. Battery 6. Injector with controls 7. Rpm and TDC sensor 17. Ignition switch 8.
Page 214 Engine Bravo-Brava 0 ™ Fuel system Air flow meter (Debimeter) The air f l o w meter (Debimeter) is hot film type. In this system, a heated membrane is placed in a mea- surement channel through w h i c h air is taken into the engine.
Page 215 The control unit records a voltage change proportional to the current intensity f l o w i n g through the sensor. When fitting the sensor, take care not to tighten to more than 15 Nm Copyright Fiat Auto...
Page 216 Engine Bravo-Brava I 0 T D Fuel system Preheating control unit The g l o w plugs are controlled by the pre- heating control unit under the direct control of the electronic control unit. The unit contains a smart relay w h i c h sends...
Page 217 Bravo-Brava 1 0 ™ Engine Fuel system B L O W - B Y GAS R E C I R C U L A T I O N DIAGRAM) Crankcase emissions are made up of a mixture of air, diesel and burnt gases which leak through the pis- ton rings, in addition to lubrication oil vapour.
Page 218 Engine Btavo-Brava 1 0 ™ Fuel system EXHAUST G A S R E C I R C U L A T I O N S Y S T E M (E.G.R.)) This system directs a proportion of the exhaust gases to the intake under certain engine operating condi- tions.
Page 219 - Procedure for filling engine cooling cir- cuit (version with heating and air con- ditioning versions) DIAGRAM SHOWING ENGINE L U B R I - C A T I O N S Y S T E M Copyright by Fiat Auto...
Page 220 3. Unscrew the retaining bolts shown and remove the air shroud shown in the figure. 4. Raise the lift and remove the lower engine bay guard. Copyright Fiat Auto...
Page 221 Engine Bravo-Brava 1 0 TD 100 Removing - refitting 1. Use tool 1878077000 to undo the stud, unscrew the bolts and release the dust guard from its seat. 2. Remove the wheel arch guard shown. 3. Disconnect sleeve (1) connecting turbine - intercooler and air outlet sleeve (2) from intercooler to intake manifold.
Page 222 Bravo-Brava 1 0 Engine TD100 Removing - refitting 1. Remove the pipe indicated by disconnect- ing from the clip located on the intake manifold. 2. Remove the coolant intake and outlet pipes from the points shown. 3. Unscrew the relay case cover bolt shown in the figure.
Page 223 Engine Bravo-Brava Removing - refitting 1. Loosen clips (1), unscrew bolts ( 2 ) , dis- connect connection (3) and then discon- nect the first section of the air intake pipe complete with debimeter. 2. Loosen clip (1), unscrew screw (2) dis-...
Page 224 Bravo-Brava 1 0 Engine TD 100 Removing - refitting P4A06FX02 1. Unscrew both bolts retaining the radiator to the body, then remove the radiator - fan assembly. 2. Disconnect the clutch release cable from the anchorages on the gearbox. 3. Disconnect the gear selection and e n -...
Page 225 Engine Bravo-Brava 1 0 TD 100 Removing - refitting 1. Unscrew the nuts, disconnect both elec- trical connections shown and then re- move the diesel filter. 2. Remove the rear sound-proofed guard by unscrewing the bolts shown. 3. Disconnect the accelerator cable from the points shown.
Page 226 Bravo-Brava 1 0 Engine TD100 Removing - refitting Drain the power steering pump fluid and use an appropriate container to collect the fluid. Disconnect the pipe carrying fluid to the power steering pump from the reservoir. Disconnect the earth lead from the gear-...
Page 227 Engine Bravo-Brava 1 0 TDIOO Removing - refitting 1. Disconnect the supply lead from the starter motor. 2. Disconnect the return fitting from the power steering pump. 3. Remove the wiper arms by prising up the plastic protection and unscrewing the u n - derlying nut.
Page 228 Unscrew bolt (1) and loosen bolt (2) re- taining the suspension pillar. Then turn the pillar outward to release the drive shaft from its attachment on the differential. Copyright Fiat Auto...
Page 229 Engine Bravo-Brava 1 0 TDIOO Removing - refitting Remove the bolts indicated from the bell housing in order to position the tool used to remove the power unit. 2. Position tool 1860860000 used to mount the power unit on the hydraulic jack and fasten to the power unit using the tools shown.
Page 230 Engine Bravo-Brava f 0 TD100 Removing - refitting 1. Remove the central power unit mount by unscrewing the bolts retaining it to the body. 2. Remove the timing end engine mount by unscrewing the central bolt. 3. Disconnect gearbox engine mount by unscrewing the retaining bolts shown.
Page 231 Engine Bravo-Brava TD100 Replacing auxiliary belt - Take great care not to damage individual components when the power unit is fitted - When fitting the coo/ant lines, align groove on rubber hose with ridge on associated rigid sleeve. When filling the cooling system, refer to section on "Removing-refitting radiator".
Page 232 3. Remove the lower power unit guard. 4. Remove the gearbox guard by unscrewing the retaining bolts shown and position flywheel retainer 1860898000 to secure the flywheel in position. Copyright Fiat Auto...
Page 233 Engine Bravo-Brava 1 0 TD 100 Replacing timing belt 1. Remove the auxiliary drive pulley and the flywheel retainer described previously. 2. Remove the lower timing belt guard. 3. Unscrew the retaining bolts shown and remove the reaction rod complete w i t h mounting bracket.
Page 234 Bravo-Brava 1 0 Engine Replacing timing belt P4A1SFX02 R E F I T T I N G AND T E N S I O N I N G T I M I N G B E L T 1. Remove bolt (1) retaining the oil pump and replace the bolt with the pin of tool 1860905000.
Page 235 Engine Bravo-Brava f 0 TD 100 Replacing timing belt 1. Loosen the three injection pump pulley re- taining bolts. 2. Turn the injection pump pulley until pin 1860965000 fits into the point shown. 3. Finish fitting the timing belt by assem- bling components in the following order: 1.
Page 236 Bravo-Brava 0 * > < > Engine Replacing timing belt 1. Apply a force at the point indicated on the automatic tensioner and move the ten- sioner mobile pointer to the position of greatest tension. Then lock the belt ten- sioner retaining nut.
Page 237 Engine Bravo-Brava 1 0 TDIOO Removing - refitting cylinder head R E M O V I N G C Y L I N D E R HEAD Place the vehicle on a lift, remove the front wheels, disconnect the battery negative ter- minal and then proceed as follows.
Page 238 4. Disconnect the accelerator cable from the points indicated. 5. Disconnect the air pipe to the brake servo from the vacuum pump. Copyright Fiat Auto...
Page 239 Engine Bravo-Brava 1 0 TDIOO Removing - refitting cylinder head Disconnect fuel vapour cut-off solenoid from the EGR by unscrewing the nuts indicated and remove the bracket shown. Unscrew the bolts indicated, separate the EGR valve from the pipe and then remove.
Page 240 Engine Bravo-Brava 1 0 TD100 Removing - refitting cylinder head 1. Open the wiring guard shown and dis- connect the electrical connection of the pulse injector. 2. Raise the lift and remove the lower engine bay guard. 3. Unscrew the retaining bolts s h o w n and release the exhaust pipe from the vibra- tion-res stant bracket shown.
Page 241 Engine Bravo-Brava 1 0 Removing - refitting cylinder head 1. Position a suitable container to collect the coolant, then disconnect the pipe shown and drain the coolant. 2. Use tool 1860967000 to unscrew the fit- ting on the head, unscrew bolt ( 1 ) , dis- connect clips (2) and remove coolant pipe (3) from the cylinder head.
Page 242 3. Unscrew the nuts shown and disconnect the g l o w plug supply leads. 4. Unscrew the bolts retaining the intake manifold to the injection pump mount bracket. Copyright Fiat Auto...
Page 243 Engine Bravo-Brava 1 0 TD 100 Removing - refitting cylinder head 1. Remove the cam cover. 2. Use wrench 1852152000 to unscrew the bolts retaining the cylinder head to the en- gine block, then remove together with the intake manifold.
Page 244 6.5 daNm using wrench 1852154000. 3. Tighten bolts through an angle of 270° in three different stages ( 9 0 + 9 0 ° + 9 0 ° ) us- ing wrench 1852154000 applied to tool 1860942000. P4A25FX03 Copyright Fiat Auto...
Page 245 Engine Bravo-Brava i j p TD100 Removing - refitting coolant pump R E P L A C I N G COOLANT PUMP Before removing the coolant pump, take off the auxiliary belt and the tim- ing belt as described previously.
Page 246 Engine Bravo-Brava 1 0 TD100 Removing - refitting radiator REMOVING - R E F I T T I N G RADIATOR Place the vehicle on a lift, remove the front wheels, disconnect the battery negative ter- minal and then proceed as follows.
Page 247 Engine Bravo-Brava 1 0 Removing - refitting radiator 1. Unscrew the bolts retaining the radiator to the body, release from the lower pins and then remove from the upper part of the en- P4A05FX01 COOLING S Y S T E M FILLING P R O C E D U R E (Heated and air conditioned version with 75 bhp and 100 bhp engines) - Ensure all cooling system components (engine, heater, radiator etc.) are completely empty.
Page 248 Engine Bravo-Brava j 0 TD100 Removing - refitting radiator Location of engine cooling circuit bleed fittings for 75 bhp and 100 bhp engines (heated and air con- ditioned version) Version with a / c Heated version Copyright Fiat Auto...
Page 249 -C -C o to a > O -C — c In 0"0 - £ > -i: ° c ^ .h C O £ "O C D to » C D 5 •5. " to • £ " =. -a o CO o to o <o...
Page 250 Diagram showing crankcase blowby gas recirculation Injection management Fiat-CODE anti-theft function man- C H E C K S , A D J U S T M E N T S AND agement R E P A I R S TO T H E B O S C H Ml.5.5...
Page 251 ENGINE SPEED AND TDC SENSOR Removing-refitting Checking gap COPYRIGHT Fiat Auto S.p.A. A n y reproduction of the text or illustrations is prohibited. The information contained in this publication is supplied as a guide and may no longer be up...
Page 252 NOTE In the drawings and diagrams, the numbers indicate the corresponding engine control unit pins (number/A for connector A, number/B for connector B). Copyright by Fiat Auto...
Page 253 Bravo-Brava l $ i 16v Engine Fuel system 98 range BOSCH 1.5.5 I N J E C T I O N / I G N I T I O N S Y S T E M F U N C T I O N A L D I A G R A M 5 9 13 14 15 16 •...
Page 254 Bravo-Brava @ » 16v E n g i n e Fuel system 98 range DIAGRAM SHOWING INFORMATION E N T E R I N G / L E A V I N G T H E CONTROL UNIT AND BOSCH 1.5.5 I N J E C T I O N / I G N I T I O N S Y S T E M C O M P O N E N T S P4A03JJ01 18.
Page 255 Bravo-Brava E n g i n e Fuel system 98 range LOCATION O F B O S C H 1.5.5 I N J E C T I O N / I G N I T I O N S Y S T E M C O M P O N E N T S IN T H E E N G I N E C O M P A R T M E N T 1.
Page 256 Bravo-Brava & i E n g i n e Fuel system 98 range S Y S T E M M A N A G E M E N T S T R A T E G I E S Operating principle Any engine operating point is identified by t w o parameters;...
Page 257 E n g i n e Fuel system 98 range In particular, the signal is composed as follows. There are sixty teeth on the flywheel, t w o of w h i c h have been removed to create discontinuity: the angle between the t w o consecutive teeth is therefore 6°: The synchronism point is recognized at the end of the first tooth following the t w o missing teeth: the fly- wheel is fitted so that as the engine passes this tooth cylinders 1 and 4 are 17 teeth before TDC.
Page 258 Bravo-Brava i § i E n g i n e Fuel system 98 range Controlling the mixture strength N O T E The mixture strength is defined and the ratio is indicatd by the greek fetter a (a/fa). quantity of air drawn in by the engine quantity of fuel injected The stoichiometric ratio is defined and the ratio is indicated by ctst.
Page 259 Bravo-Brava £pi 16v Engine Fuel system 98 range Starting and operation when cold During cold starting the management of the injection is simultaneous (full-group), i.e. not phased: this situation persists until the coolant reaches a certain temperature (about 0°C), after w h i c h the manage- ment becomes phased.
Page 260 The timing of the injectors varies according to the engine speed. M A N A G E M E N T O F T H E FIAT C O D E A N T I - T H E F T F U N C T I O N The system is equipped w i t h an anti-theft function.
Page 261 Engine Bravo-Brava igi ie Fuel system 98 range M A N A G E M E N T O F T H E IGNITION The management of the ignition basically consists of determining the desired ignition advance accord- ing to the engine operating conditions and its implementation through the operation of the power tran- sistor located inside the control unit.
Page 262 Bravo-Brava \^ iev E n g i n e Fuel system 98 range Starting During starting the normal management of the advance is not possible on account of the considerable fluctuations in the rotation speed w h i c h do not allow the dwell and the advance to be calculated cor- rectly.
Page 263 Bravo-Brava i g i 16v Engine Fuel system 98 range M A N A G E M E N T O F T H E E N G I N E IDLE S P E E D The general objective of this strategy is to keep the engine speed around the value memorized (engine warm: 800 [ r p m ] ) the position assumed by the butterfly depends on the engine speed and the vehicle speed.
Page 264 - in conditions where the engine power requirements are high (strong acceleration); - during vehicle take-off; - as long as the following critical conditions persist: - temperature of the engine coolant above a certain level (engine overheating); - engine speed below 700 rpm. Copyright by Fiat Auto...
Page 265 Bravo-Brava & | 16v Engine Fuel system 98 range M A N A G E M E N T OF T H E RADIATOR FAN N O T E Since the coolant temperature is detected by the appropriate sensor there is no longer a thermal contact on the radiator.
Page 266 - activation of certain actuators (active diagnosis). Recovery strategy If a fault is detected with the sensors/actuators, the control unit, where possible, replaces the missing i n - formation, reconstructing it using software (recovery) to allow the opertion of the engine. Copyright by Fiat Auto...
Page 267 Bravo-Brava i g | 16v Engine 98 range Fuel system E L E C T R I C A L / E L E C T R O N I C C I R C U I T Wiring The system has t w o distinct sets of wiring for...
Page 268 34 Operation of charcoal filter solenoid valve 35 Four stage thermostat signal (if fitted) 35 Operation of idle speed actuator 36 N.c. 36 N.c. 37 N.c. 37 N.c. 38 N.c. 38 Operation of coil for cylinders 1/4 Copyright by Fiat Auto...
Page 269 Bravo-Brava i E n g i n e Egg i 6 v Fuel system 98 range BOSCH 1.5.5 S Y S T E M WIRING D I A G R A M Connector A (vehicle side) 1 2 3 < 5 8 9 It 1112 13 14 15 16 17 IB 19 21 •0...
Page 270 Bravo-Brava i g | E n g i n e Fuel system 98 range Bosch 1.5.5 system wiring diagram key Connector A (vehicle side) 1. Control unit 2. Radiator fan 3. Electric fan high speed relay 4. Electric fan low speed relay 5.
Page 271 Bravo-Brava ^ 16v E n g i n e Fuel system 98 range BOSCH 1.5.5 S Y S T E M W I R I N G D I A G R A M Connector B (engine side) 1 J 3 4 5 6 7 8 9 10 1! 12 13 14 15 16 17 II 19 a o 9 .
Page 272 Bravo-Brava @ t E n g i n e Fuel system 98 range Bosch 1.5.5 system wiring diagram key Connector B (engine side) 1. Control unit 2. Active charcoal filter solenoid valve 3. Detonation sensor 4. Coolant temperature sensor 5. Engine idle adjustment actuator/butterfly position sensor 6.
Page 273 Engine Bravo-Brava igi ie Fuel system 98 range LOCATION O F F U S E S AND R E L A Y S N O T E For more information, see Group 55-Electrical equipment Main fuses (maxi-fuse) System fuse Fuse controlled by the ignition P4A22JJ01 Print no.
Page 274 E n g i n e Bravo-Brava £ p aii6v Fuel system 98 range E N G I N E RPM AND T D C S E N S O R The engine rpm and TDC sensor (1) is fixed to the cylinder block/crankcase and is facing the flywheel on the crankshaft pulley.
Page 275 Bravo-Brava E n g i n e iggi Fuel system 98 range LAMBDA S E N S O R The Lambda sensor measures the oxygen content in the exhaust gases: it is fitted on the exhaust pipe upstream of the catalytic s i - lencer.
Page 276 Bravo- Brava 0 Engine 1998 range Fuel system ENGINE COOLANT T E M P E R A T U R E S E N S O R This sensor is fitted on the thermostat. It is made up of brass casing which affords...
Page 277 Engine Bravo- Brava © Fuel system 1998 range INTAKE P R E S S U R E T E M - P E R A T U R E S E N S O R The intake air pressure a n d temperature sensor...
Page 278 Bravo-Brava i § | E n g i n e Fuel system 98 range V E H I C L E S P E E D SENSOR This sensor is positioned at the differential output, by the left driveshaft coupling and...
Page 279 Bravo-Brava Engine njp* Fuel system 98 range IGNITION C O I L S The ignition circuit is the inductive discharge, static advance type where the high tension is provided from two t w i n outlet coils fitted at the side of the cylinder head.
Page 280 Bravo-Brava \§B& lev E n g i n e 98 range Fuel system I N T A K E C I R C U I T This consists of the various components w h i c h ensure that the air f l o w rate required by the engine is correctly directed in different operating conditions.
Page 281 Bravo-Brava i g i lev E n g i n e Fuel system 98 range B U T T E R F L Y C A S I N G The butterfly casing has the task of metering the quantity of air drawn in by the engine...
Page 282 F U E L C I R C U I T DIAGRAM P4A31JJ01 1. Air bleed connector 2. Injectors connector 3. Supply pipe 4. Tank filler pipe 5. Drip tray complete w i t h pump, filter, pressure regulator and gauge 6. Fuel tank Copyright by Fiat Auto...
Page 283 Bravo-Brava E n g i n e Fuel system 98 range F U E L DRIP T R A Y A S S E M B L Y Electric fuel pump The pump is housed insde the fuel tank on a special drip tray w h i c h also supports the fuel gauge and it has a filter on the pump inlet.
Page 284 Wiring connector The injector resistance can be measured by disconnecting the connector and connecting an ohmmeter as shown in the diagram. Resistance value: 14.5±5% ohm. Copyright by Fiat Auto...
Page 285 Bravo-Brava n$i 16v Engine Fuel system 98 range INERTIA S A F E T Y SWITCH The inertia switch has the task of interrupting the electrical supply for the electric fuel p u m p if the vehicle is subject to violent deceleration...
Page 286 Bravo-Brava | p iev E n g i n e Fuel system 98 range E M I S S I O N C O N T R O L D E V I C E S The devices used for this purpose have t w o aims: - to keep d o w n the levels of pollutant substances in the exhaust, through the catalytic silencer;...
Page 287 1. Lambda sensor 2. Exhaust manifold 3. Catalytic silencer 4. Silencer 5. CO intake Print no. 506.670/16...
Page 288 1. vapour supply pipe to the butterfly casing 2. Charcoal filter solenoid valve 6. Multi-purpose valve 3. Charcoal filter 7. Tank 4. Vapour supply pipe from the tank to the 8. Injection/ignition control unit charcoal filter Copyright by Fiat Auto...
Page 289 Bravo-Brava i § | iev Engine Fuel system 98 range A N T I - E V A P O R A T I O N S Y S T E M C O M P O N E N T S...
Page 290 Bravo-Brava i g i E n g i n e Fuel system 98 range Safety and ventilation valve This valve is located in the fuel filler cap and, depending on the pressure in the tank, carries out the f o l l o w i n g functions: - When the pressure inside the fuel tank ex- ceeds 0.13 - 0.18 bar, it allows the excess...
Page 291 Bravo-Brava I 0 i 16v Engine Fuel system 98 range Charcoal filter solenoid valve The function of this valve is to control the quantity of fuel vapours drawn in by the ac- tive charcoal filter and directed to the inlet manifold by means of the injection/ignition electronic control unit.
Page 292 Bravo-Brava igi iev Engine 98 range Fuel system C H E C K S , A D J U S T M E N T S AND REPAIR O P E R A T I O N S ON THE B O S C H 1.5.5 S Y S T E M The following precautions should be observed when working on a vehicle equipped with the Bosch 1.5.5 system:...
Page 293 Bravo-Brava l £ i 16v E n g i n e Fuel system 98 range P4A42JJ01 Table summarizing pollutant emission tolerance values CO (%) HC (p.p.m.) C02 (%) Upstream of the catalyzer 0,4 - 1 < 500 > 12 Downstream of the catalyzer <...
Page 294 - disconnect the adaptor from the attachment and refit the protective cover. Copyright by Fiat Auto...
Page 295 Bravo-Brava @ i 16v E n g i n e Fuel system 98 range Checking fuel supply circuit pressure Prepare the test equipment 1860955000 using the adaptors produced previously and fitted as illustrated in the diagram b e l o w placing the ball valves (a)', (b) and (d) in the maximum open position and valve (c) in a closed position.
Page 296 Bravo-Brava @ i ie E n g i n e 98 range Fuel system If there is a decrease in pressure to below the values mentioned above, check the section of the system upstream of the manifold and if there are no leaks or damage to the fuel supply pipe, replace the electric fuel pump drip tray assembly because the pressure regulator is housed in the actual unit and C A N N O T be replaced.
Page 297 Bravo-Brava Engine ifpi i e v Fuel system 98 range Removing the test equipment Remove the test equipment 1860955000 with the key in the OFF position, following these instructions: - introduce the end of the pipe connected to the valve (c) into a suitable container;...
Page 298 Bravo-Brava i p i E n g i n e Fuel system 98 range discharge the fuel pressure inside the supply pipe and disconnect the pipe from the rapid connector, following the instructions in the previous paragraphs; attach the end of the supply pipe to the female rapid connector for the FLOWTRONIC equipment and the male connector to the rapid connector;...
Page 299 Bravo-Brava ^ 16v Engine Fuel system 98 range F U E L DRIP T R A Y A S S E M B L Y NOTE /n order to extract the assembly from the tank, the fuel should not be high- er than the halfway mark.
Page 300 (B) and move the accelerator cable away; disconnect the engine idle speed actuator connector ( 1 ) ; undo the bolts (arrow) fixing the upper half of the manifold and remove the vapour recirculation pipe (2). Copyright by Fiat Auto...
Page 301 Bravo-Brava kjp 16v E n g i n e Fuel system 98 range - disconnect the air temperature and pres- sure sensor connector (2) and the injectors cable connector (1) and remove the char- coal filter intake pipe (3); - partly raise the half-manifold and remove the brake servo vacuum inlet pipe (arrow);...
Page 302 Bravo- Brava © Engine Fuel system '98 range T H R O T T L E BODY Removing-refitting Proceed as f o l l o w s to remove throttle body: - remove the collars indicated ( a r r o w e d ) , then unscrew both bolts (detail) and remove the intake sleeve w i t h resonator;...
Page 303 Engine Bravo- Brava 9 Fuel system '98 range Zeroing - Ensure the ignition key is turned off. - Check that the climate control system is off, the accelerator pedal is not depressed and the accelerator cable is correctly adjusted (see next paragraph).
Page 304 Bravo- Brava © ^ Engine Fuel system '98 range Removing-refitting Disconnect the accelerator cable as f o l l o w s : - w o r k i n g from inside the vehicle ( A ) , d i s c o n - nect the control cable from its anchorage o n accelerator pedal ( B ) ;...
Page 305 Engine Bravo- Brava 9 Fuel system '98 range ENGINE C O N T R O L UNIT Removing - refitting Remove the control unit as follows: - disconnect both connectors in t w o stages: A) turn the metal hook up to release the connection;...
Page 306 E n g i n e Bravo ' g i Index 98 range p a y c page F U S E S A N D R E L A Y S BOSCH M O T R O N I C M E 3.1.4 M.P.I.
Page 307 In the case of detonation, it is possible t o selectively delay the ignition in the individual cylinder, recog- nized by the combination of values trasmissted by the detonation and timing sensors. Copyright by Fiat Auto...
Page 308 35. Fuel vapour separator 15. Air f l o w meter 36. Multi-purpose valve 16. Butterfly casing electronic actuator 37. Fiat CODE control unit 17. Clutch pedal s w i t c h 38. Coolant temperature gauge 18. Fuel manifold 19.
Page 309 - connection w i t h the engine immobilizer de- vice (Fiat CODE); - restriction of the maximum engine speed; - management of the climate control system; - control of combustion through the Lambda sensor; - management of the radiator fans. - fuel vapour recovery; Copyright by Fiat Auto...
Page 310 Bravo ft 20v Engine Fuel system 98 range S Y S T E M M A N A G E M E N T S T R A T E G I E S Adjustment of the injection time Digital technology has made it possible to achieve optimum fuel economy and performance using pro- grammed maps, stored inside the electronic control unit memory, dependent of the engine speed and load.
Page 311 Copyright by Fiat Auto...
Page 312 Bravo @ 2 Engine Fuel system 98 range Fuel vapour recovery The fuel vapours (pollutant according to regulations) are sent to an active charcoal filter and from these to the engine where they are burnt; this takes place by means of a solenoid valve which is only operated by the control unit w h e n the engine load condition is such as to allow correct combustion w i t h o u t the operation of the engine being "disturbed": in effect, the control unit compensates for this quantity of i n -...
Page 313 A special t w o - w a y serial line allows the exchange of data between the injection/ignition control unit and the Fiat CODE control unit. If there is a fault w i t h the Fiat CODE system, the enginecan be started up using the emergency proce- dure.
Page 314 Bravo ft 20v Engine Fuel system 98 range Management of the climate control system The injection/ignition control unit is operationally connected to the climate control system, in that: 1. it receives a request to switch on the compressor from the climate control control unit via pin F6 and carries out the relevant operations (additional air);...
Page 315 30. Radiator fan 12. Detonation sensors 3 1 . Radiator fan 2nd speed relay 13. Timing sensor 32. Fiat CODE control unit 14. Air conditioning compressor relay 33. Water temperature gauge 15. Climate control system 16. Electric fuel pump relay 17.
Page 316 Bravo 0 » 20v Engine 98 range Fuel system DIAGRAM SHOWING F U E L S U P P L Y C I R C U I T P 4 A 1 0 U 0 1 1. Fuel supply manifold...
Page 317 Bravo ft 20v E n g i n e Fuel system 98 range D I A G R A M SHOWING F U E L A N T I - E V A P O R A T I O N C I R C U I T 5.
Page 318 Engine Bravo ^ 2 0 v Fuel system 98 range S Y S T E M F O R R E C I R C U L A T I N G G A S E S C O M I N G F R O M T H E E N G I N E C R A N K C A S E ( B L O W - B Y )
Page 319 Bravo ft 20v E n g i n e Fuel system 98 range E N G I N E E X H A U S T A S S E M B L Y DIAGRAM 1. Exhaust manifold 3. Catalytic silencer 4.
Page 320 Bravo E n g i n e Fuel system 98 range I N J E C T I O N / I G N I T I O N S Y S T E M W I R I N G D I A G R A M P4A14U01 Print no.
Page 321 2. Rev counter signal 3. Engagement of climate control 4. Diagnostic socket 5. Fiat CODE control unit 6. Vehicle speed sensor 7. Rpm and TDC sensor 8. Detonation sensor 1 9. Detonation sensor 2 10. Coolant temperature sensor 1 1 .
Page 322 Engine Bravo ft 2 0 v Fuel system 98 range LOCATION O F I N J E C T I O N / I G N I T I O N S Y S T E M C O M P O N E N T S P4A16LJ01 1.
Page 323 E n g i n e Bravo \^ 2ov Fuel system 98 range F U S E S AND R E L A Y S NOTE For more information, Group 55-Electrical equipment Main fuses (maxi-fuse) system fuse fuse controlled by the ignition...
Page 324 Bravo 0 i 20v E n g i n e Fuel system 98 range D I A G N O S T I C S O C K E T The exchange of data between the injec- tion/ignition control unit and the diagnostic...
Page 325 Connector F 1. Engine coolant overheating warning light 1. Butterfly casing motor (-) 2. Not connected 2. Not connected 3. Fiat CODE control unit 3. Injector for cylinder 4 4. Not connected 4. Variable geometry manifold actuator 5. Not connected 5.
Page 326 Bravo ft 2o Engine Fuel system 98 range Connector M Connector F 24. Butterfly casing potentiometer 1 signal 24. Accelerator pedal potentiometer 1 earth 25. Accelerator pedal potentiometer 2 earth 25. Coolant temperature and air flow meter 26. Butterfly casing, temperature sensor po- 26.
Page 327 Bravo ft 20v E n g i n e Fuel system 98 range IGNITION C O I L S (0.221.504.014) The ignition is the static advance eletronic type w i t h a single coil for each spark plug; this solution eliminates the high tension cir-...
Page 328 Bravo Engine i£9> Fuel system 98 range T I M I N G S E N S O R (0.232.101.026) In the Bosch Motronic ME 3.1 system the injec- tion is the sequential, phased type, in other words the fuel is injected in sequence for each cylinder during the inlet stroke.
Page 329 Bravo ft 20v E n g i n e Fuel system 98 range R P M AND T D C S E N S O R (0.261.210.160) This sensor w h i c h detects the engine speed and TDC is the inductive type, i.e. it operates...
Page 330 Bravo ft 20v Engine Fuel system 98 range Checking the gap The rpm and TDC sensor is fixed directly to the cylinder block/crankcase and therefore the gap and the angular position do not need adjusting. If a fault is suspected, the gap can be checked as follows: - remove the rpm and TDC sensor;...
Page 331 The fuel manifold is made from die-cast aluminium and incorporates the housings for the injec- tors. The fuel inlet has a fixing w i t h a bolt w i t h a tapered seal. Copyright by Fiat Auto...
Page 332 Qbov Bravo Engine Fuel system 98 range I N J E C T O R S (0.280.155.770) The t w i n jet type injectors are fitted on the inlet manifolds, immedeiately before the inlet valve. These injectors have been specially designed for engines w i t h 4 valves per cylinder and allow the jets to be directed towards the t w o inlet valves.
Page 333 There is a switch ( 2 ) , on the clutch pedal, connected to pin F59 of the injection control unit. The "clutch pedal activated" signal is used by the injection control unit t o distinguish the gear engaged and gear shift conditions. Copyright by Fiat Auto...
Page 334 Bravo ft 20v Engine Fuel system 98 range AIR F L O W M E T E R (0.281.002.199) The f l o w meter is on the air inlet hose and is the "hot film" type. The intake air temperature sensor is inside the flow"...
Page 335 Bravo ft 20v E n g i n e Fuel system 98 range Wiring connector The numbers indicate the corresponding con- trol unit pins. B U T T E R F L Y C A S I N G A C T U A T O R...
Page 336 Bravo I 0 i 20v Engine Fuel system 98 range L A M B D A S E N S O R (B.258.040.092) The Lambda sensor is the "planar" type and is fitted on the front section of exhaust pipe and...
Page 337 The control unit uses this information for i m - proving the management of the engine idle adjustment actuator and for the CUT-OFF strategy. P4A31LJ02 Wiring connector The numbers indicate the corresponding control unit pins Copyright by Fiat Auto...
Page 338 Bravo ft 20v E n g i n e Fuel system 98 range PHASE T R A N S F O R M E R In order t o achieve a g o o d compromise between good performance in terms of power at high speeds and good torque at l o w speeds, a phase transformer ( w i t h electronic operation and hydraulic implemen- tation) has been fitted on this engine for the inlet camshaft.
Page 339 Bravo ft 20v E n g i n e Fuel system 98 range Diagram showing operation of the phase transformer 1. Solenoid valve- 7. Piston spring 2. Valve body 8. Battery 3. Valve body spring 9. Injection/ignition system relay 4. Piston 10.
Page 340 Bravo ft 20v Engine Fuel system 98 range C O O L A N T T E M P E R A T U R E S E N S O R (Jaeger 402.183.01) (Elth 2690350) The sensor is fitted on the themostat casing;...
Page 341 Inertia switch components Complete inertia sensor Outer casing Button Upper side Engagement side Permanent magnet Permanent magnet housing Steel ball Common terminal N.C. Normally closed contact N.A. Normally open contact XI-98 - Cancels and replaces Copyright by Fiat Auto...
Page 342 Bravo I P 20v E n g i n e Fuel system 98 range A N T I - E V A P O R A T I O N S Y S T E M C O M P O N E N T S Charcoal filter and fuel vapour cut out solenoid valve These components form part of the fuel vapour recovery and anti-evaporation system.
Page 343 Bravo- Brava 9 Engine 99 range Fuel system Checking the resistance The resistance of the solenoid valve can be measured by disconnecting the connector and connecting an ohmmeter as illustrated in the diagram. Resistance: 17.5-23.5 ohm at 20 °C Wiring connector...
Page 344 Bravo- Brava 9 Engine 98 range Fuel system Learning procedure NOTE During the /earning procedure, from the moment the ignition is turned to the ON position until the end of the procedure, do not press the accelerator pedal, the brake pedal or the clutch pedal.
Page 345 Bravo ^ 2ov E n g i n e Fuel system 98 range Checking exhaust concentration of CO and HC The exhaust concentration of carbon monoxide (CO) and unburnt hydrocarbons ( H C ) is measured by inserting a suitably calibrated CO tester probe at least 30 cm into the end of the exhaust pipe as s h o w n in the diagram.
Page 346 Bravo ft 20v Engine Fuel system 98 range D I A G N O S T I C S The complete fault diagnosis of the system can be carried out through an active dialogue using the d i a g - nostic equipment.
Page 347 Bravo ft 2 E n g i n e 98 range Fuel system Cancelling errors When the frequency counter reaches 0, the fault and the parameters associated w i t h it are cancelled. The immediate cancelling of the entire errors memory takes place through the "cancel errors memory"...
Page 348 Bravo 0 i E n g i n e Fuel system 98 range Parameters displayed Engine rpm Injection time Advance Intake air temperature Coolant temperature Butterfly valve opening angle Battery voltage Lambda sensor Self-adjustment Flow meter Engine knock (detonation) Vehicle speed...
Page 349 E M I S S I O N C O N T R O L D E V I C E - Catalytic converter - Exhaust recirculation circuit (EGR) - EGR modulating valve - Recirculation circuit for vapours c o m - ing from the crankcase ( b l o w - b y ) Copyright by Fiat Auto...
Page 350 I N T R O D U C T I O N The Fiat Bravo and Brava 1.9 JTD are equipped with a 4 cylinder in line 1920 cc turbodiesel engine w i t h t w o valves per cylinder, a counter-balance shaft, an overhead camshaft, supercharged by a turbocharger w i t h an intercooler and w i t h electronic fuel injection.
Page 351 2. Heater plugs control unit 18. Climate control system connector 3. Vehicle speed 19. Diagnostic socket 4. Rev counter 20. Fiat CODE system connector 5. Heater plugs warning light 2 1 . Flow meter 6. Infocenter (system failure indication) 22. Timing sensor 7.
Page 352 The cut-off strategy is implemented w h e n the injection control unit receives the information from the potentiometer that the accelerator pedal is released. Under these circumstances, the control unit removes the supply to the injectors and reactivates before the idle speed is reached. Copyright by Fiat Auto...
Page 353 Bravo-Brava Engine Fuel system 98 range Control of the idle speed On the basis of the signals coming from the rpm sensor and the engine coolant temperature sensor, the injection control unit controls the pressure regulator and varies the operating times for the injectors t o keep the idle speed stable.
Page 354 The system is equipped with an engine immobilizer function. This function is achieved through the presence of a special control unit (Fiat CODE), capable of dialogue w i t h the injection control unit and an electronic key, w i t h a special transmitter for sending a recognition code.
Page 355 Print no. 506.670/16...
Page 356 13. Coolant temperature sensor 14. RPM sensor 15. Fuel temperature sensor 16. Tester connection 17. Fiat CODE control unit 18. Four stage pressure switch 19. Injection electronic control unit 20. Timing sensor 21. Fuse (7.5A) protecting injection control unit ( + 15 power supply from ignition switch) 22.
Page 357 Bravo- Brava © ™ Engine Fuel system 1998 range INJECTION E L E C T R O N I C C O N T R O L UNIT The injection control unit processes signals from the various sensors by applying software algorithms and controls the actuators accordingly (particularly the injectors and pressure regulator) to achieve the best possible engine service conditions.
Page 358 4 - 1 3 Fuel pressure sensor supply 3 - 1 2 Not connected 4 - 1 4 Flow meter signal 3-13 Fiat CODE control unit 4 - 1 5 Four stage pressure switch 3 - 1 4 Not connected...
Page 359 5. Engine radiator fans Battery 6. Heater plugs control unit Four stage pressure switch 7. Accelerator pedal potentiometer Fiat CODE control unit 8. Brake and clutch pedal switches Diagnostic socket 9. Fuel pressure sensor 2 1 . Fuel pressure regulator 10.
Page 360 Winding resistance: 860 Ohm ± 1 0 % at 20 C 1. M a x i m u m mangetic f l o w 2. M i n i m u m magnetic f l o w 3. Alternating voltage Copyright by Fiat Auto...
Page 361 Engine Bravo-Brava ft™ Fuel system 98 range T I M I N G S E N S O R This Hall effect type sensor is fitted on the cylinder and is facing the camshaft pulley (exhaust). There is an opening in the pulley which allows the timing sensor to detect the engine timing position and signal it to the injection control unit.
Page 362 14. Fuel inlet connector (high pressure) shutter (6) to the closed position w h i c h restores 15. Spring a balance w h i c h returns the pin (2) to the closed position and consequently the injection ends. Copyright by Fiat Auto...
Page 363 Bravo-Brava Engine Fuel system 98 range E N G I N E C O O L A N T T E M P E R A T U R E S E N - S O R This sensor is fitted on the thermostat and de-...
Page 364 ( 3 ) : one main one and one safe- ty one. There is a coil spring on the shaft w h i c h ensures the correct resistance to the pressure, whilst a second spring ensures the return on release. P4A16KJ02 Copyright by Fiat Auto...
Page 365 Bravo-Brava Engine Fuel system 98 range B R A K E PEDAL S W I T C H There is a switch (1) on the brake pedal w h i c h operates the brake lights; the same switch sends a signal to pin 2-8 of the in- jection control unit.
Page 366 Bravo-Brava ft ™ E n g i n e Fuel system 98 range F U E L S U P P L Y C I R C U I T The fuel supply circuit is operationally divided into a low pressure circuit and a high pressure circuit.
Page 367 Bravo-Btava Engine Fuel system 98 range I M M E R S E D ( A U X I L I A R Y ) E L E C T R I C P U M P AND F U E L GAUGE This assembly is basically composed of: - a roller type electric pump;...
Page 368 The pressure regulator basically consists of the following components: 1. Shutter w i t h ball 2. Pin 3. Valve 4. Pre-loading spring 5. Coil 6. Casing 7. Keeper Copyright by Fiat Auto...
Page 369 Bravo-Brava ft™ Engine Fuel system 98 range M U L T I - P U R P O S E V A L V E The multi-purpose valve is located on the fuel tank and carries out the following tasks:...
Page 370 Common terminal N.C. Normally closed contact N.C. N.A. C N.A. Normally open contact Copyright by Fiat Auto X I - 9 8 - C a n c e l s a n d r e p l a c e s...
Page 371 Engine Bravo-Brava ft™ Fuel system 98 range AIR S U P P L Y C I R C U I T The air supply circuit is supercharged by means of a variable geometrye GARRET turbocharger and an intercooler. The turbocharger is the reduced inertia type, based on a new supercharging concept where the use of the turbocharger is designed to increase the torque in the most frequently used range (e.g.
Page 372 200 °C and 350 °C. A b o v e ' 3 5 0 °C, the sulphur contained in the P4A23KJ02 diesel fuel starts t o oxidize, producing sulphur dioxide and sulphur trioxide. Copyright by Fiat Auto...
Page 373 Engine Bravo-Brava ft™ Fuel system 98 range EXHAUST GAS R E C I R C U L A T I O N C I R C U I T ( E G R - Exaust Gas Recirculation) This system makes it possible to send part of the exhaust gases to the inlet in certain engine operating conditions.
Page 374 (E) raises the moving element (4) (case I), closing the passage (C) and placing the valve (5) in the ideal condition (E in contact w i t h F) and the cy- cle is repeated. P4A25KJ01 P4A25KJ02 Copyright by Fiat Auto...
Page 375 Bravo-Brava E n g i n e Fuel system 98 range R E C I R C U L A T I O N C I R C U I T FOR V A P O U R S...
Page 376 Bravo- Brava ft m> Engine Fuel system 1998 range 1. Remove the return manifold by loosening both retaining nuts 2. Undo the manifold end pipe fittings from the rail leading to the injectors and remove them 3. Undo the retaining nuts and remove firstly the bracket and then the injectors.
Page 377 Engine Bravo- Brava ft Fuel system 1998 range R E M O V I N G - R E F I T T I N G RAIL Disable the alarm (if present) by means of the s w i t c h under the junction unit cover.
Page 378 Bravo- Brava ft ^ Engine Fuel system 1998 range Remove the return manifold by loosening b o t h retaining nuts. Remove the fuel delivery pipe f r o m the pressure pump to the rail pipe. Disconnect the electrical c o n n e c t i o n from...
Page 379 Bravo- Brava ft ™ Engine Fuel system 1998 range P4A30KJ03 P4A30KJ04 R E M O V I N G - R E F I T T I N G G L O W P L U G S - Disable the alarm (if present) by means of the switch beneath the j u n c t i o n unit cover.
Page 380 Bravo-Brava ft™ Engine Fuel system 1998 range Refitting Reverse procedure described for removal to the point where the pressure pump is refitted. Then refit and tension the timing belt and auxiliary drivebelt. Check that the timing belt and auxiliary drive- belt do not show signs of cracking or wear that could impair operation.
Page 381 Btavo- Brava Engine ft ™ Fuel system 1998 range Lower the lift 1. Turn the toothed drive pulley to align the timing notches. Raise the lift and finish fitting the timing belt. Check the timing. 2. Use a screwdriver to apply a force to the automatic tensioner to adjust the tensioner to maximum tension.
Page 382 Untitled Document file:///D|/Volume%203/Fuel%20System.htm08/07/2006 16:45:03...
Page 383 - Air temperature sensor - Diagram showing recirculation of gases coming from engine crankcase ( b l o w - b y ) - Exhaust recirculation system (E.G.R.) Removing-refitting injection pump 1X-96 - Cancels and replaces Copyright by Fiat Auto...
Page 384 6. Fast idle device 7. Connector for diesel supply pipe from the filter 8. Connector for diesel supply pipe to the injectors 9. Advance actuator 10. Fast idle control cable P4A05EJ01 IX-96 - Cancels and replaces Copyright by Fiat Auto...
Page 385 Engine Bravo-Brava TD100 Fuel system Operating principle The fuel, taken from the tank (11) and filtered by the filter ( 1 2 ) , reaches the transfer pump (7) which has the task of further increasing the pressure of the fuel.
Page 386 9. Pressure valve trostop) 10. Injectors 1 1 . Tank 4. Pumping element (a) front section view 12. Filter (b) side section view 13. Speed regulator 5. Supply valve 6. Meter IX-96 - Cancels and replaces Copyright by Fiat Auto...
Page 387 Engine Bravo-Brava ft TD 100 Fuel system Flow rate supplement In order to facilitate both starting up the en- gine and the supply of full power, a system is fitted which, by altering the stroke of the pumping element pistons, allows an increase in the maximum fuel flow rate.
Page 388 1. Transfer pump rotor 2. Brushes 3. Eliptical seal IX-96 - Cancels and replaces Copyright by Fiat Auto...
Page 389 Engine Bravo-Brava TD100 Fuel system Transfer pump regulating valve The transfer pump regulating valve is housed in the hydraulic head and carries out three distinct func- tions: - creating the transfer pressure; - controlling this pressure by maintaining a precise relationship between the transfer pressure and the rotation speed;...
Page 390 1. Cam seal condition ready for a new pressurizing cycle. 2. Cam seal bolt Copyright by Fiat Auto " C i , n C t j l J l l l i...
Page 391 (1) and the f l o w of the metering valve (4). The cut out solenoid, also known as the Electrostop, is directly con- nected to the Fiat CODE system and for this reason it is suitably protected by an anti-tamper cover. 1. Passage for transfer pressure 2.
Page 392 Valve body Piston Spacer < z ) Diaphragms Spring Adjustment screw Connector for the super- charging pressure ® Discharge of the transfer © pressure Recovery connector P4A13EJ01 IX-96 - Ctinculi. cincl iitplau.-<i Copyright by Fiat Auto...
Page 393 Bravo-Brava Engine TD100 Fuel system Speed regulator The speed regulator connects the accelerator lever (1) to the metering valve ( 7 ) . Its function is to con- trol the idle speed (and the fast idle) and the maximum engine speed.
Page 394 - injection advance management - fast idle management - exhaust gas recirculation management - air conditioning system management - heater plugs pre/post heating management Location of electronic unit P4A15EJ01 IX 96 O l d i <iii<i lepl.irts Copyright by Fiat Auto...
Page 395 Bravo-Brava Engine Fuel system I N J E C T I O N ADVANCE MANAGEMENT By means of information relating to the engine speed/TDC, accelerator lever position, atmospheric pres- sure, temperature of the intake air and temperature of the engine coolant, the electronic control unit cal-...
Page 396 3. Air conditioning control switch 4. Rpm sensor 5. Compressor relay feed 6. Air conditioning compressor I X - ' l f i - C a n c e l s a n i l r- p U c . Copyright by Fiat Auto...
Page 397 Bravo-Brava Engine TD100 Fuel system HEATER P L U G S P R E / P O S T HEATING M A N A G E M E N T The electronic control unit directly controls the heater plugs control unit managing the pre and post heating times mainly according to the values for the engine coolant temperature and the intake air t e m - perature.
Page 398 13. Air f l o w meter 5. Heater plugs warning light 14. Fast idle valve 6. Injection system failure warning light 15. Coolant temperature sensor 7. Borg Warner solenoid valve 16. Air temperature sensor 8. Diagnostic socket Copyright by Fiat Auto " " Update...
Page 399 Bravo-Brava Engine ft™*>o Fuel system WIRING D I A G R A M P4A20EJ01 IX-96 - Update Print no. 506.670/08...
Page 400 13. Pre-heating control unit 3. Climate control relay 14. System relay feed 4. Climate control on button 15. Fuel vapour solenoid valve 5. Fiat/Lancia Tester diagnostic socket 6. Instrument injector 16. Battery 7. Rpm and TDC sensor 17. Ignition switch 8.
Page 401 Bravo-Brava Engine ftroioo Fuel system Air flow meter The air f l o w meter is the "heated film" type; the operating principle is based on a heated diaphragm which is placed in a measuring channel through w h i c h the intake air which enters the engine flows.
Page 402 The control unit detects the variation in volt- age proportional to the current intensity cir- culating in the sensor. The sensor should be fitted taking care not to exceed the tightening torque of 15 Nm IX 9b - UpdJte Copyright by Fiat Auto...
Page 403 Engine Bravo-Brava TD100 Fuel system Pre-heating control unit The operation of the heater plugs takes place via the pre-heating control unit, under the d i - rect control of the electronic control unit. There is an "intelligent" relay inside w h i c h...
Page 404 The remaining gases, on the other hand, are directed, via the pipe ( 5 ) , to the inlet circuit. There is a spark-out (6) fitted inside the gas outlet pipe (1) on the cylinder head to prevent combustion due to flame returns. IX-9H - Updjtn Copyright by Fiat Auto...
Page 405 Bravo-Brava Engine {tymioo Fuel system EXHAUST G A S R E C I R C U L A T I O N S Y S T E M (E.G.R. - Exhaust Gas Recirculation) This system makes it possible to send part of the exhaust gases to the inlet in certain engine operating conditions.
Page 406 3. Act on the automatic tensioner to loosen the tension at the auxiliary shaft drive belt, then remove the belt. 4. Remove the lower protection for the t i m - ing drive belt. IX 9fa Upditf Copyright by Fiat Auto...
Page 407 Bravo-Brava Engine Fuel system 1. Disconnect the engine colant pipe after having loosened the fixing band. 2. Undo the bolts s h o w n , then remove the reaction connecting rod and the mounting bracket (engine side). 3. Undo the fixing bolts and remove the t i m - ing belt upper shield.
Page 408 3. Undo the fixing bolts and remove the sound insulation shield. 4. Disconnect the electrical connections, disconnect the diesel supply pipe be- tween the tank and the filter, undo the fix- ing nuts and remove the diesel filter. IX-96 - Update Copyright by Fiat Auto...
Page 409 Engine Bravo-Brava TD100 Fuel system 1. Let the band (1) slide in the direction shown by the arrow, then remove the ac- celerator cable from the injection pump releasing it from the attachment pin and removing it from the mounting and adjust- ment bracket (2).
Page 410 Before refitting the timing belt it is necessary to check the timing and then the tension of the belt as speci- fied in the paragraph "Replacing tim- ing belt" in the chapter "Removing-r- efitting power unit". IX-96 - Update Copyright by Fiat Auto...
Page 412 Ignition coils - Management of engine starting block Lambda probe function (Fiat CODE) - Management of radiator fan - Management of engine idle control C H E C K S - A D J U S T M E N T S...
Page 413 (outputs), the devices which enable the engine to operate, namely: 1. fuel injectors; 2. ignition coils; 3. various types of solenoids; 4. electric fuel pump; 5. engine idle speed actuator; 6. control relays. Copyright Fiat Auto...
Page 414 28. Fuel vapour cut-off solenoid 7. Ignition switch 29. Activated charcoal filter 8. Fuel injection relay 30. Air conditioner compressor 9. Fiat CODE control unit 3 1 . Lambda probe 10. Inertial switch 32. Catalytic converter 1 1 . Vehicle speed sensor 33.
Page 415 The system management strategies are basically as follows: -management of fuel injection; -management of ignition; -management of engine starting block function (Fiat CODE); -management of radiator fan; -management of engine idle control; -management of fuel vapour recirculation;...
Page 416 Engine Bravo-Brava Fuel system '98 range The stoichiometric ratio is obtained using a heated Lambda probe. This probe, by means of constant analysis of oxygen present in the exhaust gases, informs the control unit which, on the basis of data memorized in it, can correct in real time the mixture strength (air-petrol) if it is not stoichiometric.
Page 417 After starting, the coefficient is gradually reduced until it disappears within^ a particular time period which is all the longer the lower the engine temperature. k: enrichment coefficient t : time a : decrease in relation to engine temperature ON: engine driven (crank) OFF: engine started (run) Copyright Fiat Auto...
Page 418 Engine Bravo-Brava ft 1 * Fuel system '98 range Operation when cold Under these conditions, the mixture is naturally weakened by poor turbulence of the fuel particles at l o w temperature, low evaporation and high condensation on the inner walls of the inlet manifold, all height- ened by the greater viscosity of the lubricating oil which, as is known, at low temperature increases the resistance to rolling of the engine's mechanical components.
Page 419 2. 1270 rpm Version w i t h automatic transmission 1. 1750 rpm 2. 1650 rpm A. entry into cut-off B. exit from c u t - o f f 8 0 °C TEMP. H 2 0 Copyright Fiat Auto...
Page 420 Bravo-Brava <0i 16v Engine Fuel system '98 range Operation in acceleration In this stage, the control unit increases as appropriate the quantity of fuel required by the engine (to obtain the maximum torque) in accordance with signals coming from the following components: - throttle potentiometer;...
Page 421 After acquiring the correct signal picture w i t h reference to the TDC signal through the power module (internal) (5), the electronic control unit (see figure on next page) establishes the point of commence- ment of conduction (supply) of the primary circuits of the coils (6). Copyright Fiat Auto...
Page 422 Bravo-Brava > 0 i 16v Engine Fuel system '98 range The leading edge of the signal (graph B-figure on preceding page) thus represents the moment w h e n alternative conduction of the primary windings " c o u l d " occur. This point is established solely by the control unit's power module.
Page 423 7. Fuel injection relay 2. Crankshaft pulley with phonic wheel 8. Fuel injection-ignition electronic control unit 3. Battery 9. Fuel injection-ignition system fuse 4. Ignition switch 10. Fuse protecting fuel injection-ignition 5. Spark plugs control unit 6. Ignition coils Copyright Fiat Auto...
Page 424 MANAGEMENT OF T H E ENGINE S T A R T I N G B L O C K F U N C T I O N (FIAT C O D E ) The system has an engine starting block function.
Page 425 If a fault is detected on sensors or actuators, signal reconstruction (recovery) strategies are immediately activated to ensure engine operation at an acceptable level without impairing its functionality. It is thus possible to drive the vehicle to a repair garage for the appropriate operations. Copyright Fiat Auto...
Page 426 Bravo-Brava < 0 k 16v Engine Fuel system '98 range M A N A G E M E N T OF C L I M A T E C O N T R O L S Y S T E M The fuel injection-ignition control unit is connected functionally to the climate control system, as: 1.
Page 427 14. Air conditioner 1. Electronic control unit 15. Engine coolant temperature sensor 2. Speedometer sensor 3. Fiat CODE control unit 16. Intake air temperature and pressure sensor 4. Rev counter 5. Engine idle speed actuator 17. Throttle valve position sensor 6.
Page 428 Bravo-Brava ft 16v Engine Fuel system '98 range DIAGRAM OF AIR INTAKE S Y S T E M The air intake system comprises various components which convey the necessary air f l o w to the engine under the various operating conditions.
Page 429 The fuel pump is enclosed in the cage w h i c h also incorporates the fuel pressure regulator, fuel gauge sender and fuel filter. The system also has an inertial switch w h i c h cuts off the supply from the fuel pump in the event of a crash. Copyright Fiat Auto...
Page 430 Bravo-Brava ft 16v Engine Fuel system '98 range DIAGRAM OF F U E L EVAPORATION C O N T R O L S Y S T E M 1. Petrol vapour cut-off valve 5. Tank 2. Activated charcoal filter 6. Fuel vapour inlet connection in inlet man- ifold 3.
Page 431 Bravo-Brava ft i * E n g i n e '98 range Fuel system D I A G R A M OF C R A N K C A S E GAS R E C I R C U L A T I O N S Y S T E M ( B L O W - B Y ) 4.
Page 432 Engine Bravo-Brava ft ^ Fuel system '98 range W I R I N G D I A G R A M OF F U E L I N J E C T I O N - I G N I T I O N (*) Connection only present on cars fitted with four-stage pressure switch.
Page 433 19. Fuel vapour cut-off solenoid 20. Fuel injectors 2 1 . Fuel injection-ignition fault warning light 22. Fiat CODE control unit 23. Vehicle speed sensor 24. Pressure switch (the pressure switch may be three or four stage) 25. Engine idle actuator (stepper motor) 26.
Page 434 Bravo-Brava ft i * Engine Fuel system '98 range DIAGRAM OF E X H A U S T A S S E M B L Y P4A22IJ01 On the I.A.W. system, the closed-loop control of the mixture strength is activated by the Lamba sensor which measures the oxygen content present in the exhaust gases upstream of the catalytic converter.
Page 435 Bravo-Brava ft 1 * E n g i n e Fuel system 98 range Components key 13 Injection/ignition control unit 1 Intake air pressure and temperature sen- 14 Coolant temperature sensor 15 Ignition coils 2 Lambda sensor coupling 3 Injection system relay...
Page 436 Bravo-Brava ft 16v Engine Fuel system 98 range I N J E C T I O N / I G N I T I O N S Y S T E M R E L A Y AND F U S E S General system protective fuse (fig.
Page 437 Data acquisition and coding section It consists of a set of electronic components ( A / D converters) assigned to receiving the data in the form of analogue electrical signals. The signals are then converted into digital signals, processed and stored. Copyright Fiat Auto...
Page 438 Bravo-Brava ft 16v Engine Fuel system '98 range b. Microprocessor This electronic component calculates and manages the acquired data; in this respect it should be considered an actual computer mainly responsible for the following: interrogating the memories, comparing the data being processed with the sample data and managing the actuator control circuits.
Page 439 During diagnosis, before replacing the control unit, make sure that the component under exami- nation is really not working, as when a new control unit is supplied, the secret code of the Fiat CODE system is memorized, rendering the control unit totally unusable on other cars.
Page 440 9. Lambda probe (negative) 53. Rpm sensor (positive) 10-12. Not connected 54. Earth of coolant temperature, air pres- 13. Fiat CODE control unit sure/temperature and throttle valve p o - sition sensors. 14. Radiator fan high speed control (ver- sions with air conditioner) 55.
Page 441 1 -4 at 114° be- fore TDC. 1. Sensor 2. Winding 3. Permanent magnet 4. Sensor connector 5. Output signal 6. Signal corresponding to the t w o missing teeth 7. Crankshaft pulley w i t h phonic wheel Copyright Fiat Auto...
Page 442 Bravo-Brava <0i 16v Engine Fuel system '98 range Wiring connector The sensor is connected to the control unit by means of twisted cables covered by a shield- ed anti-interference sheath. Pin 1 - Signal Pin 2 - Earth Pin 3 - Shielding NOTE The numbers in boxes indicate the corresponding control unit pins.
Page 443 Bravo- Brava 9 Engine 1998 range Fuel system K N O C K S E N S O R (KNE-03) This sensor is the piezoelectric type and is f i t - ted on the cylinder block/crankcase in a p o s i - tion w h i c h is symmetrical in relation t o the pairs of cylinders 1 -2 and 3-4.
Page 444 Engine Bravo- Brava @ Fuel system 1998 range THROTTLE B O D Y The throttle body meters the quantity of air drawn in by the engine (and consequently the power devel- oped) according to the driver's request via the accelerator.
Page 445 Engine Bravo- Brava W Fuel system 1998 range T H R O T T L E V A L V E POSITION S E N S O R A. Sensor used on premodification cars B. Sensor used on postmodification cars...
Page 446 Engine Bravo-Brava Fuel system 1998 range Wiring connectors The numbers in squares indicate the corre- sponding control unit pins. Pin A - Earth Pin B - Positive Pin C - Signal Checking the resistance Sensor resistance may be measured as fol-...
Page 447 Engine Bravo- Brava 9 Fuel system 1998 range ENGINE COOLANT T E M P E R A T U R E S E N S O R The sensor is fitted o n the thermostat case;lt is made up of brass casing w h i c h affords pro-...
Page 448 Engine Bravo- Brava 9 Fuel system 1998 range ENGINE IDLE SPEED ACTUATOR (step motor) Bearing Screw W o r m screw Anti-turn grooves Coils Plunger M a g n e t Actuator used on premodification cars B. Actuator used on postmodification cars...
Page 449 Engine Bravo- Brava 0> Fuel system 1998 range The step motor is very precise and offers high resolution (about 220 steps per second). Pulses sent by the electronic control unit to the engine are converted from rotary motion into linear movement (about 0.04 mm/step) via a worm screw mechanism.
Page 450 Engine Bravo- Brava ©> Fuel system 1998 range INTAKE P R E S S U R E T E M - P E R A T U R E S E N S O R ( T - P R T 03)
Page 451 Bravo-Brava ft *» E n g i n e '98 range Fuel system E L E C T R I C F U E L PUMP ( E S S 291) The electric pump assembly basically c o m - prises: - an electric fuel pump ( 1 ) ;...
Page 452 Bravo-Brava <0i 16v Engine Fuel system '98 range F U E L MANIFOLD ( C B 1 6 8 ) The fuel manifold is secured to the inside of the inlet manifold, and its function is to send fuel to the fuel injectors.
Page 453 Self-adaptivity of mixture strength is inhibited. Checking the resistance The solenoid's resistance can be measured by disconnecting the connector and connecting an ohmmeter as s h o w n in the figure. Resistance: 17.5 - 23.5 ohm to 20 C Copyright Fiat Auto...
Page 454 Engine Bravo-Brava Fuel system '98 range M U L T I - F U N C T I O N V A L V E (SIRIO 0175.00) This valve is used for carrying out various functions, such as: - prevent the passage of liquid fuel, w h e n the tank is too full or if the vehicle overturns in an accident;...
Page 455 0.13 - 0.18 bar, it discharges the sur- plus vapours to the outside (safety f u n c - tion). If instead there is a vacuum in the tank of 0.020 - 0.030 bar, it allows air to enter (ventilation function). Copyright Fiat Auto...
Page 456 Bravo-Brava ft 16v Engine '98 range Fuel system F U E L I N J E C T O R S ( I W P 064) The fuel injectors are of the double jet "top-feed" type (with spray angled in relation to the injector axis).
Page 457 Complete inertial switch Sheath Button Engagement side. Permanent magnet Permanent magnet seating Steel ball C= Shared terminal N.C. Normally closed N.C. N.A. C N.A. Normally open Copyright Fiat Auto...
Page 458 Bravo-Brava ft lev E n g i n e Fuel system '98 range IGNITION C O I L S (Bae 920A) (Beru 0.040.100.029) The coils are bracketed onto the camshaft covers; they are of the closed magnetic circuit type, formed by a segment pack whose cen- tral core, broken by a thin gap, carries both windings.
Page 459 In the case of open circuit or short circuit to earth, a fixed charge time is assumed. Removing refitting 1. Disconnect the high-tension cables and wiring connector from the ignition coils assembly. 2. Undo the bolts (arrowed) and remove the ignition coils. Copyright Fiat Auto...
Page 460 Bravo-Brava ^ Engine Fuel system '98 range LAMBDA P R O B E (NTK 0ZA334-A1) This is the sensor w h i c h measures the oxygen content in the exhaust gases. The sensor's output signal is sent to the electronic control unit to adjust the air-petrol mixture, in order to maintain the mixture's stoichiometric ratio as close as possible to the theoretical value.
Page 461 Heater resistance = 4.3 - 4.7 ohm Recovery The Lambda data are ignored (open loop). Wiring connector The numbers in boxes indicate the corre- sponding control unit pins. Copyright Fiat Auto...
Page 462 Bravo-Brava < Q k l 6 v Engine Fuel system '98 range Removing - refitting lambda probe - Place the car on ramps. - Disconnect the battery's negative cable. - Disconnect the wiring connector installed against the rear wall of the engine compart- ment.
Page 463 Bravo-Brava ft i » E n g i n e '98 range Fuel system C H E C K S - A D J U S T M E N T S AND R E P A I R S ON T H E F U E L I N J E C T I O N / I G N I T I O N...
Page 464 Bravo-Brava I 0 i 16v Engine Fuel system '98 range 1. Undo the bolts jointing the t w o sections of the inlet manifold and remove the first sec- tion (1). 2. Undo the bolts securing the fuel supply manifold and the bolts securing the second section of the inlet manifold to the engine block, and remove it.
Page 465 Bravo-Brava ft i » E n g i n e '98 range Fuel system R E M O V I N G - R E F I T T I N G F U E L TANK Before removing-refitting the tank, drain the fuel, place the car on ramps and disconnect the battery's negative pole.
Page 466 Bravo-Brava < 0 k 16v E n g i n e Fuel system '98 range Remove the bolt (arrowed) and plug se- curing the fuel filler to the bodywork. 2-3. Open the clips s h o w n by the arrows and release the handbrake cables from the attachments on the fuel tank.
Page 467 2. Gradually lower the hydraulic jack, check- ing that the tank is correctly balanced, then disconnect the fuel vapour recovery pipe. 3. If necessary, also disconnect the vent pipe (2) on the tank. 4. Fuel tank. Copyright Fiat Auto...
Page 468 Bravo-Brava <0i 16v Engine Fuel system '98 range R E M O V I N G - R E F I T T I N G T H R O T T L E C A - Disconnect the battery lead then proceed as described below: 1.
Page 469 Faults should therefore be sought by means of full diagnosis using the Fiat/Lancia Tester. C H E C K I N G C O N C E N T R A T I O N O F P O L L U T I N G E M I S S I O N S...
Page 470 Bravo-Brava ft i » Engine Fuel system '98 range Checking C O and HC concentration in the exhaust The concentration of carbon monoxide (CO) and unburnt hydrocarbons (HC) in the exhaust is mea- sured by inserting the probe of a suitably calibrated CO tester in the end of the exhaust pipe for at least 30 cm, as s h o w n in the figure.
Page 471 Bravo- Brava © Engine Fuel system 1998 range C H E C K S T O F U E L S U P P L Y C I R C U I T C h e c k i n g f u e l s u p p l y p r e s s u r e...
Page 472 Engine Bravo- Brava 9 Fuel system 1998 range C h e c k i n g fuel supply pressure using t e s t e r . Fuel supply pressure can also be checked using an EXAMINER or SDC. In this case, remove the...
Page 473 Bravo-Brava ft 1 * E n g i n e Fuel system range - disconnect the fuel delivery pipe from the quick-fit connector located against the rear wall of the en- gine compartment and, using the connectors of the test equipment 1860955000, make the connec- tions to the Flowtronic device (1806149001) as follows: 1.
Page 474 Bravo-Brava ft 16v Engine Fuel system '98 range F A U L T D I A G N O S I S Full diagnosis of the fuel injection-ignition is possible by active dialogue w i t h the Examiner or SDC sta- tion.
Page 475 This indicates that the engine conditions are too far beyond the standards, so the causes should be sought in mechanical faults. Speed sensor Implausible signal Speed exceeds maximum speed Knock sensor A.C.-D.C. Code not recognized or not received Fiat CODE Copyright Fiat Auto...
Page 476 Engine Bravo-Brava Fuel system '98 range Active diagnosis During active diagnosis, some components can be activated and some particular functions can be car- ried out, for example the error deletion command, as shown in the table below. In active diagnosis, the ignition must be on and, only for some functions, the engine must be running.
Page 477 - Main shaft rpm sensor - Vehicle speed sensor R E M O V I N G - R E F I T T I N G - Removing-refitting gearbox - Precautions VI-96 - Update Copyright Fiat Auto »...
Page 478 I n t r o d u c t i o n The Fiat Brava 1581 16v Torque uses an AISIN 60-40 LE automatic gearbox and differenetial unit, 4-speed version AW 596/Y024, specially designed for front-wheel drive vehicles with transverse-mount- ed engine, fitted with an electronic control system connected to the engine management control unit.
Page 479 Bravo-Brava Auto transmission and differential Components and operation 21-27. C r o s s s e c t i o n of a u t o m a t i c t r a n s m i s s i o n a n d differential 1.
Page 480 S connected to the gearbox outer casing. The c o n - verter is filled completely w i t h oil w h i c h , because of the kinetic energy impressed upon it by the pump, permits the transmission of the driving torque. Copyright Fiat Auto...
Page 481 Bravo-Brava Auto transmission and differential ft*» Components and operation 21-27. P. Pump S. Stator T. Turbine P4A04AB01 NOTE The torque converter does not sustain any kind of wear as there is no mechanical connection between the driven part and the driving part.
Page 482 K2. Crownwheel of P2 5 1 . Sun gear of P1 52. Sun gear of P2 ST1. Planet gears of P1 ST2. Inner planet gears of P2 ST3. Outer planet gears of P2 T 1 . Gear train carrier Copyright Fiat Auto...
Page 483 Bravo-Brava Auto t r a n s m i s s i o n and differential ftiev Components and operation 21-27. CONTROL C O M P O N E N T S The control components of the automatic transmission consist of clutches, multiple disc brakes, band...
Page 484 The band brake B1 blocks the rotation of the sun gears S1 and S2 (connected to each other), w h i c h form part of the gear sets P1 and P2. The multiple disc brake B2 blocks the rotation of the crownwheel K2 of the gear set P2. Copyright Fiat Auto...
Page 485 Bravo-Brava Auto transmission and differential Components and operation 21-27. Free wheels The free wheels consist of t w o c o n - centric races and a cage enclosing a set of asymmetrical pawls, w h i c h permit the relative rotation of the t w o...
Page 486 ( 1 s t ) * ( 2 n d ) * NOTE 0=Solenoidactivated (*) Speed < 7 k m / h (**) Speed > 7 k m / h ( • ) Intermediate selection in manual scale. Copyright Fiat Auto...
Page 487 Bravo-Brava Auto transmission and differential Components and operation 21-27. Neutral (selector lever on position N) The gearbox input shaft E rotates in a clockwise direction. The clutch C 3 couples the crownwheel K1 to the clutch carrier drum D, to permit the transmission of motion w i t h o u t delays or stresses, caused by the simultaneous engagement of several clutches and brakes, w h e n the selector lever is positioned on R or D (1st gear).
Page 488 - rection to the gear train carrier T I and the gear 11 coupled to it. The gear 11 transmits motion to the wheels via the gear 12 and the dif- ferential relay shaft. P4A11AB02 Copyright Fiat Auto...
Page 489 Auto transmission and differential Bravo-Brava i f l ^ Components and operation 21-27. T h i r d g e a r (selector lever on position D-3) The gearbox input shaft E rotates in a clockwise direction. The crownwheels K1 and K 2 are coupled to the input shaft E by the engagement of the clutch C I , clutch carrier drum D and the clutches C 3 and CO.
Page 490 - the selector lever to be moved from position P with the engine running only w i t h the brake pedal pressed; - the ignition key to be withdrawn only with the selector lever in position P. Copyright Fiat Auto...
Page 491 Auto transmission and differential Bravo-Brava ftiev Components and operation 21-27 Wiring diagram of safety control unit connections 26. Ignition switch solenoid 2. Selector lever position sensor 8. Rear earth 27. Shift-lock solenoid 11. Left dashboard earth 28. STOP lights 29. Front left button controlling courtesy 12.
Page 492 12. Gear engagement solenoid S1 5. Stop lights switch 13. Gear engagement solenoide S2 14. Lock-up clutch solenoid SL 6. Instrument panel 15. Pressure control solenoid STH 7. Main shaft rpm sensor (black) 8. Vehicle speed sensor (grey) Copyright Fiat Auto...
Page 493 Auto transmission and differential Bravo-Brava ftiev Components and operation 21-27. CONTROL M O D U L E The control module contains the electronic control logic of the automatic transmission, where the vari- ous functions are memorized, and is located under the rear seat.
Page 494 14. Gearbox oil cooling fan relay 5. Stop lights switch 15. Fuel injection-ignition control unit 6. Main shaft rpm sensor 16. Diagnostic socket 7. Vehicle speed sensor 8. Gearbox oil temperature sensor 9. Selector lever position sensor Copyright Fiat Auto...
Page 495 Auto transmission and differentia! Bravo-Brava Components and operation 21-27. Identification of control module connections uiinjn LTjr L13 L12 L11 R8 R7 R6 R3 R2 • • • • • • • • L26 L25 L24 L15 L14 IsllsllsllS B H B a a SBOIsl...
Page 496 - N O R M A L to obtain the maximum driving comfort, while minimizing fuel consumption; - SPORT to obtain the maximum performance of the vehicle; - ICE to increase driving safety under slippery conditions. Copyright Fiat Auto...
Page 497 Bravo-Brava Auto transmission and differential Components and operation 21-27. At every start-up, the system is set to the N O R M A L mode. When NORMAL/SPORT pushbutton pressed, the N O R M A L mode is changed to SPORT mode and vice versa.
Page 498 3. operation under recovery conditions. : : : : : ! : : i Km/h 10 20 3 0 4 0 50 60 70 80 90 1 00 110 1 20 1 30 1 40 1 50 Lock-up program Copyright Fiat Auto...
Page 499 Auto transmission and differential Bravo-Brava ftiev Components and operation 21-27. Operation in I C E mode The ICE mode can be selected by pressing the ICE pushbutton located on the right of the selector lever, when the latter is at position D. This strategy improves driving safety on slippery roads by ensuring that the vehicle sets off gently by selecting 2nd gear on departure.
Page 500 1st gear or reverse gear. Copyright Fiat Auto...
Page 501 The electronic control system constantly monitors the sensors, control solenoids and all the other elec- tronic components, in order to detect faults and malfunctions immediately; these errors are memorized in the control module and can be read using the FIAT/LANCIA Tester. Error detection conditions The control module can detect errors in the various components only under particular conditions.
Page 502 - error in selector lever position sensor; torque reduction signal; - error in throttle position sensor; - error in battery voltage; - error in main shaft rpm sensor; - error in gearbox mechanism; - error in vehicle speed sensor; Copyright Fiat Auto...
Page 503 Auto transmission and differential Bravo-Brava ft** Description and operation 21-27. The recovery stragegy involves the deactivation of all the solenoids, so no automatic gear changes are ef- fected, the torque converter is not locked and the hydraulic pressure is not varied.
Page 504 The solenoid also regulates the pressure driv- ing the hydraulic valves in accordance w i t h the throttle valve aperture and the vehicle speed. P4A27AB05 Copyright Fiat Auto...
Page 505 Auto transmission and differential Brava Description and operation 21-27 The resistance of the line pressure control solenoid STH can be measured by dis- connecting the connector and connect- ing an ohmmeter as shown in the figure. P4A28AB03 Gearbox sensors/actua- tors connector (view of Resistance: 3.5 ±...
Page 506 The sensor sends the control modue a pulse signal (12 pulses per shaft revolution) proportional to the output speed of rota- tion of the gearbox, i.e. to the vehicle speed. This signal is used to effect the gear changes. Gearbox sensors/actuators connector (view of contact side) Copyright Fiat Auto...
Page 507 Auto transmission and differential Bravo-Brava i g | i Description and operation 21-27. The resistance of the main shaft rpm and ve- hicle speed sensors can be measured by dis- connecting the connectors and connecting an ohmmeter as shown in the figure.
Page 508 O < D ID w as o 8 » " !? = — « S.5> Q . M - >- "O fill" • — ' w _ r o -js £2 a> a. « « 2 £ •o ? o < " S ft ^ ' co o H „...
Page 509 Auto transmission and differential Bravo-Brava © i ^ Description and operation 21-27. DIAGNOSIS Operating problems in the AISIN electronic automatic transmission may be caused by the engine, c o n - trol system or automatic transmission itself. The fault-finding procedure begins with very simple operations, carried out in order of difficulty, initially aimed at establishing whether the fault depends on the engine, control system or gearbox.
Page 510 T e s t s with F I A T / L A N C I A Tester Guided fault finding on the electrical part can be conducted by connecting the FIAT/LANCIA Tester w i t h M 3 9 - A memory to the control module's diagnostic socket.
Page 511 Bravo-Brava @u Auto transmission and differential Description and operation 21-27. Stall speed test This test serves to check the performance of the transmission and engine, and is conducted by measur- ing the maximum rpm that can be reached by the engine w i t h the selector lever at position D and R.
Page 512 Bravo-Brava i p i ^ Auto transmission and differential Description and operation 21-27. Gear engagement time test This test is for checking the condition of clutches C2 and C3 and the brake B2, and is conducted by measuring the time taken to engage first gear or reverse gear.
Page 513 Auto transmission and differential Bravo-Brava i g j u e . Description and operation 21-27. Hydraulic test To measure the line pressure, proceed as fol- lows: - place the car on ramps, then working from under the vehicle remove the gearbox oil screw plug and screw in its place the con- nector 1860870000;...
Page 514 Less than specified value in both D and R Regulating valves faulty Oil pump faulty Less than specified value only in D Leaks in hydraulic circuit in forward gears Less than specified value only in R Leaks in hydraulic circuit in reverse and neutra Copyright Fiat Auto...
Page 515 Auto transmission and differential Bravo-Brava ftiev Description and operation 21-27. Road t e s t s These tests are for checking that the automatic transmission is working correctly under actual conditions of use. Carry out the following tests with the gearbox oil at normal operating temperature.
Page 516 COLD. possi- ble, recheck the oil level at the correct temperature (70 - 80 °C). P4A32AB01 Copyright Fiat Auto...
Page 517 Auto transmission and differential Bravo-Brava i f p u e v Servicing and adjustments 21-27. Also check the condition of the oil, and in particular that there is no white contamination caused by contact with the coolant from the oil cooling circuit, and that there are no metal particles to wear of internal components or a burnt smell.
Page 518 Before removing the cage, disconnect the cable clip underneath. Remove the split pin and washer shown in the figure; lift the gear change cable head so as to disconnect it from the gear change lever position sensor. P4A41AB05 Copyright Fiat Auto...
Page 519 Auto transmission and differential Bravo-Brava Servicing and adjustments 21-27. P4A42AB02 Lift the gearbox control cable retaining bracket to release it from the mounting bracket. Working from inside the car, position the selector lever on P, remove the retaining bolt on the front...
Page 520 Bravo-Brava i f i ^ Auto transmission and differential Servicing and adjustments 21-27. 1. Disconnect the Lambda probe wiring connector, then disconnect the first sec- tion of the exhaust pipe from the exhaust manifold. 2. Remove the first section of the exhaust pipe by undoing the attachments to the catalytic converter.
Page 521 Auto transmission and differential Bravo-Brava i§Su Servicing and adjustments 21-27. P4A44AB02 Remove the split pin (1) and bracket (2) securing the gear change cable to the se- lector lever. Undo the nuts securing the selector lever mounting and remove the mounting.
Page 522 - the engine must only start w i t h the selector lever in position P or N; - each position of the selector lever must be accompanied by the relevant indications on the indicator panel and instrument panel display. Copyright Fiat Auto...
Page 523 Auto transmission and differential Bravo-Brava ifiBuev Servicing and adjustments 21-27. GEAR CHANGE L E V E R P O S I T I O N S E N - Removing Remove the air intake duct, battery, relay and fuse box (move it to one side) the i.e. control...
Page 524 6 and 10 of the sup- ply connector. Rotate the sensor the centre of the area in which ohmmeter detects continuity (con- tacts N and P closed), then tighten the sensor screws. P 4 A 4 7 A B 0 4 Copyright Fiat Auto...
Page 525 Auto transmission and differential Bravo-Brava ft** Servicing and adjustments 21-27. Finish refitting the selector lever position sensor by reversing the procedure for re- moval. Finally carry out the following checks: - the engine must only start with the selector lever in position P or N;...
Page 526 Bravo-Brava lfi| Auto transmission and differential Servicing and adjustments 21-27 R E M O V I N G - R E F I T T I N G S A F E T Y CON- T R O L UNIT The safety control unit is located under the front passenger's seat.
Page 527 Auto transmission and differential Bravo-Brava ftiev Servicing and adjustments 21-27. P4A60AB02 To remove the gearbox oil cooling radiator, first remove the fan, then disconnect the coolant inlet and outlet pipes from the radia- tor. Undo the nuts shown in the figure, secur- ing the radiator.
Page 528 4. Remove the relay and fuse box cover by undoing the bolt indicated. P4A40AB03 Copyright Fiat Auto...
Page 529 Auto transmission & differential Bravo-Brava ft ^ Removing-refitting 21-27. P4A41AB01 P4A52AB01 1. Remove the nuts securing the fuse and re- lay box to the battery cage, then move the box over to one side. 2. Disconnect the i.e. control unit supply connector.
Page 530 (gear change, lock-up clutch control and pressure control) after releasing them from the retaining clips. 4. Disconnect the connector s h o w n in the figure. 5. Disconnect the speedometer drive cable. P4A63AB06 Copyright Fiat Auto...
Page 531 Bravo-Brava Auto transmission & differential Removing-refitting 21-27. Remove the bolt (1) securing the retain- ing bracket for the pipes shown in the f i g - ure. Remove the windscreen wiper arms (right and left) by undoing the central fixing nut, after removing the protective cap.
Page 532 Secure the cross member hook to the eye positioned previously, near the thermostat. 2. Remove the starter motor by undoing its bolts; then move the starter motor to one side, securing it, taking care not to dam- age the supply cables. Copyright Fiat Auto...
Page 533 Auto transmission & differential Bravo-Brava Removing-refitting 21-27. 1. Relieve the staking then remove the wheel hub nut (gearbox side and timing gear side). 2. Remove the plastic wheelarch trim on the gearbox side by undoing the screws and retaining button shown in the figure. To...
Page 534 Withdraw them perfectly horizontally. 5. Remove the connectors shown in the f i g - P4A57AB03 ure in order to disconnect the oil pipes from the gearbox. Then place the pipes over to one side. P4A57AB04 Copyright Fiat Auto...
Page 535 Auto transmission & differential Bravo-Brava Removing-refitting 21-27. Remove the guard shown in the figure from the bottom of the gearbox. Remove the bolts securing the converter to the flywheel. First undo the t w o visible bolts, then turn the crankshaft to gain ac- cess to the remaining bolts (total of 6 ) .
Page 536 For greater safety, fit a bracket, to be manufactured on site, screwing it into the seat of the bolt secur- ing the gearbox bottom guard, to prevent the converter falling out of its seating. P4A69AB04 Copyright Fiat Auto...
Page 537 Auto transmission & differential Bravo-Brava Removing-refitting 21-27. 1. Manoeuvre the hydraulic jack as appropri- ate to release the gearbox from the sur- rounding parts. Gradually lower the jack and withdraw the gearbox. Take particular care to prevent converter falling out of its seating.
Page 538 29.4 mm. When fitting the gearbox, check that the cen- tring pins are positioned correctly, and also check that there is no gap between the con- tact line between the engine and gearbox cas- ing. Copyright Fiat Auto...
Page 539 Auto transmission & differential Bravo-Brava itti Removing-refitting 21-27. When coupling the converter to the flywheel, use bolts of the correct length (M8x1.25 bolts with tapered shakeproof washer draw- ing 46450230, of the dimensions indicated in the figure) and make sure that they are not mixed up w i t h other bolts.
Page 540 1847038000 (repeat the procedure on the other track rod end). 4. Remove the bolts securing the vertical link (gearbox side and timing gear side) to the shock absorber. Copyright Fiat Auto...
Page 541 Auto transmission & differential Bravo-Brava Drive shafts 21-27. 1. Rotate the vertical link in order to w i t h - draw the drive shaft from the wheel hub (repeate the procedure for the other side). 2. Disconnect the drive shaft on the gearbox side from the differential, levering on the anchorage point.
Page 542 Whenever a gaiter is removed, it is advisable to replace it, and it is im- portant to fill both the constant locity joint or sliding joint and the gaiter with TUTELA MRM2 grease. P4A65AB04 Copyright Fiat Auto...
Page 543 Auto transmission & differential Bravo-Brava @* Drive s h a f t s 21-27 Drive shaft-joint coupling, wheel side Shaft classification Joint classification Category Colour Category Colour When refitting, the constant velocity joints Green Green must be coupled to the shaft as indicated in the table.
Page 544: Valve Assembly
Bravo-Brava ft ^ Auto transmission & differential Valve assembly 21-27. Replacing differential oil seal Disconnect the drive shaft from the differen- tial as described above, then remove the oil seal from the differential, using a screwdriver as a lever. When refitting, use the drift 1 8 7 0 6 2 9 0 0 0 with an appropriate handle.
Page 545 Auto transmission & differential Bravo-Brava Valve assembly 21-27. 1. Undo the bolts shown in the figure securing the valve assembly, then remove the complete assembly. Refitting 2-3. Insert the lever (1) of the selector valve in the hole of the lever ( 2 ) .
Page 546 Disconnect the supply connector ( 1 ) , then replace the switch. It is virtually essential replace the kick-down switch if it is re- moved, as the retaining lugs could break during removal. P4A69AB02 Copyright Fiat Auto...
Page 547 - Removing - Refitting - Drive shafts E X T E R N A L C O N T R O L S - Diagram showing external gearbox controls - Removing-refitting - Dismantling at the bench Copyright by Fiat Auto...
Page 548 4. Remove the battery drip tray undo the bolts fixing it to the bodyshell. P4A01BB04 Copyright by Fiat Auto...
Page 549 Gearbox and differential Bravo-Brava Removing-refitting 98 range 21.27 P4A02BB02 1. Disconnect the connector for the revers- ing lights switch and the earth cable. 2. Acting on the nut (1) and the lock nut ( 2 ) , disconnect the clutch cable from the con- trol lever.
Page 550 Fix the hook for the cross member to the heater water supply pipe so that the e n - gine is resting in the centre. P 4 A 0 3 B B 0 5 Copyright by Fiat Auto...
Page 551 Gearbox and differential Bravo-Brava Removing-refitting 98 range 2 1 . 2 7 P4A04BB02 1. Remove the button fixing the dust shield to the bodyshell, then undo the bolts and release the shield from the housing. Re- peat the operation for the dust shield on the other side.
Page 552 4. Remove the engine flywheel shield acting on the fixing bolts. 5. Undo the bolt fixing the gearbox to the engine. Copyright by Fiat Auto...
Page 553 Gearbox and differential Bravo-Brava ft** Removing-refitting 98 range 21.27 P4A06BB02 1. Remove the centre power unit support from the bodyshell and the gearbox. 2.3 Position the tool illustrated for support- ing the gearbox during the removal oper- ation. 4. Remove the power unit mounting, gear- box side from the bodyshell and the gear- box.
Page 554 D R I V E S H A F T S For the removing-refitting and the disman- tling of the drive shafts, refer to the "Drive shafts" paragraph for the 1370 12v version. P4A07BB03 Copyright by Fiat Auto...
Page 555 Bravo-Brava ' g l ^ Gearbox and differential External controls 98 range 21.27 DIAGRAM SHOWING E X T E R N A L G E A R - BOX C O N T R O L S P4A08BB01 6. Gear selector cable 1.
Page 556 Undo the bolt securing the relay casing cover and remove it, then undo the nuts fixing the casing to the battery drip tray and place the casing at the side. P4A01 BB03 Copyright by Fiat Auto...
Page 557 Bravo-Brava ft 1 * Gearbox and differential External controls 98 range 21.27 P4A01BB04 P4A02BB03 1. Remove the battery drip tray undo the bolts fixing it to the bodyshell. 2. Disconnect the end of the gear engage- ment cable and undo the bolts fixing it to the mounting bracket.
Page 558 3. Undo the bolt fixing the exhaust pipe front mounting bracket. 4. Undo the bolt fixing the exhaust pipe rear mounting bracket, then extract it from the vehicle. 5. Remove the heat shield acting on the fix- ings illustrated. P4A11BB03 P4A11BB04 Copyright by Fiat Auto...
Page 559 Gearbox and differential Bravo-Brava ft** External controls 98 range 2 1 . 2 7 1. Undo the front and rear bolts fixing the support for the external gearbox controls and handbrake. - Carefully lower the external controls sup- port assembly from its housing, then re-...
Page 560 2. Using tool 1870668000, remove the knob from the gear lever, the internal spring and the reverse gear inhibitor outer sleeve. 3. Remove the circlip ( 1 ) and dismantle the gear lever mechanism. P4A13BB03 Copyright by Fiat Auto...
Page 562 - EBD function failure signal - Wiring diagram of ABS system inte- grated w i t h EBD function - Fault diagnosis V A R I A N T S FOR 98 RANGE - Wheel rpm (active) sensors Copyright by Fiat Auto...
Page 563 Braking system Bravo-Brava EBD device 3 3 . E L E C T R O N I C A L L Y O P E R A T E D BRAKE F O R C E D I S T R I B U T I O N D E V I C E (EBD)
Page 564 Braking system Bravo-Brava EBD device 3 3 . Diagrams showing braking system with A B S s y s t e m integrated with E B D function P4A02BD02 Print no. 506.670/13...
Page 565 D. EBD control B. Ideal distribution As it can be noted, the EBD function for the ABS system is capaable of adapting to the ideal pressure curve, always taking advantage of the adhesion available in all braking conditions. Copyright by Fiat Auto...
Page 566 Braking system Bravo-Brava EBD device 3 3 . The integration of the EBD function into the normal implementation logic of the A B S system allows the simultaneous operation of the two strategies; as a result, the system normally intervenes to keep the "creeping"...
Page 567 EBD device being adversely affected. If there is a failure in the EBD function, the distribution of the brake force between the front and rear axles starts to fail with the consequent risk of the rear wheels locking during braking. Copyright by Fiat Auto...
Page 568 Braking system Bravo-Brava E B D d e v i c e 3 3 . Wiring d i a g r a m f o r A B S s y s t e m integrated w i t h E B D f u n c t i o n...
Page 569 - a reduction in the weight and size on the vehicle. J i — P 4 A 0 7 B D 0 1 1. Active sensor body 2. Multi-polar ring 3. Gap 4. Example of an output signal from the wheel rpm sensor Copyright by Fiat Auto...
Page 570 Braking system Bravo-Brava Active sensors 98 range 3 3 . The recommended distance (gap), to obtain the correct signals, between the end of the sensor and the multi-polar ring should be between: 0.16 -1.71 m m f o r t h e f r o n t w h e e l s 0.37 - 1.13 m m f o r t h e rear w h e e l s...
Page 571 - Operation of the electronic control unit for the compressor - Maintenance and service operations - Draining the system - Compressor ADDITIONAL HEATER - Introduction - Location of components on vehicle For anything not dealt with, refer to previous edition (print 506.670/01) Copyright by Fiat Auto...
Page 572 - engaging the compressor (air refrigeration circuit) - engaging the air recirculation - " M A X DEF" function Lastly, the adjustment of the distribution of the air flows to the various air vents is totally manual (by means of bowden cables). Copyright by Fiat Auto...
Page 573 Auxiliary units Bravo-Brava Climate control 98 range OPERATING L O G I C A special electronic control unit manages the automatic operation of the system controlling the thermo- dynamic parameters to ensure a comfortable climate (temperature and humidity) for the vehicle occu- pants.
Page 574 "dynamic"air f l o w from the outside. Engagement is entirely manua): the recirculation function is only excluded in the " M A X DEF" setting even if the button is pressed. Copyright by Fiat Auto...
Page 575 Auxiliary units Bravo-Brava Climate control 98 range "MAX-DEF" Function With the distribution knob turned completely in a clockwise direction the " M A X DEF" rapid demisting function is activated by a special microswitch. This function involves: - maximum air f l o w rate...
Page 576 1 . EGR control unit 2. Climate control controls 3. Climate control control unit 4. Four stage pressure switch 5. Compressor relay 6. Compressor 7. Thermostatic switch on water p u m p 8. Remote control switch for disengaging compressor Copyright by Fiat Auto...
Page 577 Auxiliary units Bravo-Brava Climate control 98 range S Y S T E M C O M P O N E N T S Electronic control unit The electronic control unit manages the automatic operation of the system controlling the thermody- namic parameters to produce a comfortable climate (temperature and humidity) for the occupants of the vehicle.
Page 578 It receives a 5V supply from the control unit and has a controlled earth and gives a signal w h i c h corresponds to the position of the knob: R1 - R16= 681 Ohm ± 1% P4A07CH03 Copyright by Fiat Auto...
Page 579 Auxiliary units Bravo-Brava Climate control 98 range Requested air flow rate potentiometer This potentiometer is connected to the air ventilation knob and detects the various a n - gular positions, sending a signal to the elec- tronic control unit: there are.four possible air flow rates which are set manually ( 1 , 2, 3 e 4 ) , plus an "AUTO"...
Page 580 A motor w i t h a 1 2 V supply controls the ro- tary movement of a drive pin w h i c h acts d i - rectly on the flap. Reversing the polarity re- sults in a movement in the opposite direction. Copyright by Fiat Auto...
Page 581 Auxiliary units Bravo-Brava Climate control 98 range Frost s e n s o r The frost sensor is located inside the duc- t-distributor assembly, fitted directly on the evaporator detects temperature warning the control unit, if necessary, to switch off the compressor to avoid freezing.
Page 582 ON position - Within 10 seconds, turn the centre knob, placing it in the following positions: "0" - " A U T O " - "0" - " A U T O " - "0" Copyright by Fiat Auto...
Page 583 Auxiliary units Bravo-Brava Climate control 98 range At this point the control unit w i l l send a series of messages to the on board panel display: an error code, in accordance w i t h the table below, w i l l be displayed in place of " C l i " .
Page 584 P4A13CH01 The evaporator (6) is located between the duct (1) and the distributor ( 2 ) . Copyright by Fiat Auto...
Page 585 Auxiliary units Bravo-Brava Climate control 98 range Dynamic / recirculation air The special actuator rotates the air intake flap (P) between the t w o extreme positions: the one if figure A closes the internal air intake and consequently the electric fan only draws in outside air; the latter is i n - hibited and recirculation air is drawn in if the flap is positioned as illustrated in figure B.
Page 586 View of positioning of the various distribution flaps when the knob i s rotated completely in a c l o c k w i s e direction Copyright by Fiat Auto...
Page 587 Auxiliary units Bravo-Brava Climate control 98 range LOCATION OF C L I M A T E CONTROL S Y S T E M C O M P O N E N T S The climate control system consists of the following components: - a variable f l o w rate compressor (SKROLL,for 1242 1 6 v a n d 1910 J T D versions - NIPPONDENSO TV 12SC for other versions) w h i c h is fixed to the engine by brackets;...
Page 588 - the wear of the spirals produces an improved seal of the side panels of the actual spirals; - the absence of valves, knocking and impulses reduces noise levels. P4A17CH01 1. Fixed scroll (casing) 5. Shield 2. Orbital scroll 6. Compressor supply electrical connection 3. Camshaft 7. Balancing mass 4. Camshaft seal Copyright by Fiat Auto...
Page 589 Auxiliary units Bravo-Brava Manually operated climate control 98 range Compression mechanism The contact between the compressor fixed scroll and the orbital scroll produces a chamber ( 1 ) in w h i c h the gas is imprisoned with the volume tending to gradually decrease as the orbital scroll rotates. As...
Page 590 5 , 0 ± 0 , 5 ° C In particular, the control unit activates the coupling when the temperature of the air exceeds 5.0 ± 0 . 5 °C and deactivates it when the temperature goes below 3.5 ±0.5 °C. Copyright by Fiat Auto...
Page 591 Auxiliary units Bravo-Brava Manually operated climate control 98 range MAINTENANCE AND S E R V I C E O P E R A T I O N S Lubricant oil The compressor is lubricated by about 80±20 cc of ND8 oil. Only this type of oil...
Page 592 0 (off), then engage the connector for the light blue flexible pipe w i t h the nee- dle valve on the section of pipe w h i c h con- nects the evaporator to the compressor. P4A21CH04 Copyright by Fiat Auto...
Page 593 Auxiliary units Bravo-Brava Manually operated climate control 98 range Attach the connector for the red flexible pipe to the needle valve on the four stage pressure switch connector. N O T E Move the ring nut shown by the ar-...
Page 594 N O T E The radiator/condenser cooling fan is switched on at a high pressure circuit pressure of 15 - 16 bar. Quantity of R 134 A refrigerant fluid contained in the system: 650 ± 25 c c . Copyright by Fiat Auto...
Page 595 Bravo-Brava 2nd volume Manual (print no. 506.670/01). N O T E To improve safety, the rapid...
Page 596 Also check that there are no cracks cuts on the belt or else it will have to be replaced. P4A25CH02 P4A25CH03 P4A25CH04 Copyright by Fiat Auto...
Page 597 Auxiliary units Bravo-Brava Manually operated climate control 98 range Undo the bolt shown in the diagram and release the pipe from the compressor inlet duct; seal both the end of the pipe and the com- pressor duct using suitable plugs;...
Page 598 70 °C to 65 °C if the temperature of the air is assumed to be greater. Copyright by Fiat Auto XI-98 - Update...
Page 599 Auxiliary units Bravo-Brava ^fy™ Additional heater 98 range The second piece of information is the electrical power available and is obtained from the battery voltage value; of the voltage is above 12.8 V, the operation of the heater plugs is enabled, below this figure one, t w o or all three heater plugs are gradually deactivated.
Page 600: Additional Heater
355. Passenger compartment coolant heater 3 5 1 . Safety relay for heating passenger com- plugs partment coolant 357. Passenger compartment coolant heater 352. Relay for heating passenger compart- plugs control unit ment coolant XI-98 - Update Copyright by Fiat Auto...
Page 601 FfVl-RDS band (Autostore) - Cassette player - Fast forward winding of cassette tape - Fast rewind of cassette jape - Autoreverse function - Equalization ' - Clock function - Display information - Care and maintenance Copyright Fiat Auto...
Page 602 - non-removable A D 185 M radio and cassette player w h i c h is located at the centre of the instrument panel; its front, customized for FIAT, is fully integrated in the line of the dashboard; - t w o loudspeakers located on the inside panels of the front doors;...
Page 603 Electrical system Bravo-Brava Radio D E S C R I P T I O N OF OPERATION O F M O D E L AD 185 M RADIO S W I T C H I N G RADIO ON A D J U S T I N G V O L U M E...
Page 604 To immediately select the maximum search sensitivity, keep one of the t w o above-mentioned buttons pressed until the letters DX are displayed. R v l Do not keep the button pressed for long, otherwise manual tuning search would be selected ESSri the LW, MW or FM bands. Copyright Fiat Auto...
Page 605 Electrical system Bravo-Brava Radio T U N I N G - M A N U A L S E A R C H P4A03CL02 P4A03CL03 Briefly press the button several Keep buttons Press (**) one of the t w o but- times until the desired fre- pressed until the letters "...
Page 606 N O T E Instructions are given below for carrying out each of the operations described in points a), b) and c) above. Copyright Fiat Auto...
Page 607 Electrical system Bravo-Brava Radio Point a) - Select an RDS I, RDS II or RDS III band as described above; - briefly press the "TP" button so that the letters "TP" are displayed. If the outgoing transmitter is not enabled to supply traffic information, the radio will automatically tune to the nearest transmitter enabled to do so.
Page 608 THE C A S S E T T E T A P E Fully press the button indicated Fully press the button indicated To stop the forward winding or rewinding of the cassette tape, gently press the button next to the one previously pressed. Copyright Fiat Auto...
Page 609 Electrical system Bravo-Brava Radio A U T O R E V E R S E F U N C T I O N At the end of the tape, the side of the tape is changed automatically (Autoreverse). The side of the tape being listened to is shown on the display.
Page 610 Briefly press the button (6) to switch between the display of the clock and the messages relating to the radio function, for a duration of 10 seconds; after w h i c h the indication w h i c h has priority depending on the selected display mode w i t h reappear automatically. Copyright Fiat Auto...
Page 611 Electrical system Bravo-Brava Radio Power cut If the power supply to the radio is cut off 00-DO ) ^ (even for a few minutes), when it is recon- nected, the display shows " 0 0 : 0 0 " w i t h the digits flashing and the colon fixed, indicat- ing that the clock has to be reset.
Page 612 D B 3 C 1. Earth on right dashboard 5. Battery supply ( + 30) 2. Radio 6. Lighting supply 3. Loudspeaker on left door 7. Key supply ( + 15) 8. Fishpole aerial 4. Loudspeaker on right door Copyright Fiat Auto...
Page 613 Electrical system Bravo-Brava Contents page - Wiring diagrams - Connector blocks - K e y Copyright Fiat Auto...
Page 615 IIIIIIII: i® Hazard Windscreen wiper pressure Auto transmission fluid Indicators Electric sunroof temperature Handbrake on and l o w Catalytic converter brake fluid Km/h temperature Speed limits Resistor Fuel gauge Recharging Coolant temperature Engine oil pressure Diode Copyright Fiat Auto...
Page 616 Electrical system Bravo-Brava Wiring diagrams Electrical symbols Trip computer control Differential lock Warning light Auto transmission fluid Electronic fuel injec- Bulb temperature tion Temperature Fuse Engine oil level Brake fluid level B R A K E Anti-theft device Switch open...
Page 617 Analogue fuel gauge '<M2 Analogue coolant tem- perature gauge » Econometer Digital coolant tempera- ture gauge i n i i i i i i i i i Engine oil temperature Engine oil pressure gauge Voltmeter Copyright Fiat Auto...
Page 618 Electrical system Bravo-Brava Wiring diagrams Explanation to reading wiring diagram 1 7 7 1 7 9 ( 0 J 51° 50 5 0 50 8 0 L®J STOP N. U . LHD 181 * 95 - RU -AR- 1 2 3 ( 5 6 7 8 3 1 0 1 1 1 2 1 3 1 4 •...
Page 626 •6 i 5 >- 3 C © O (tj o i_ o ^ o ^ «? to ©...
Page 634 (0 3 4 - * O a) LU O O O D) " to 1> 2 •£ ' £ t ~ S « ! E S S U 0} g 5 5 S § s s i S E -p c to ( a ic i ! 3 •...
Page 638 O Ui -a g m 2 "S c (5 o g C D C D C D t 0 >...
Page 645 Wiring colour code Connector blocks * With regard to the 1910 Turbo D engine, the connector blocks have been added from the previous publication; for aspects not cov- ered, refer to the Bravo-Brava publication no. 506.670/02. 4A57ZL Copyright Fiat Auto...
Page 646 Electrical system Bravo-Brava Connector blocks INTRODUCTION I n t e r p r e t a t i o n of the c o d e s on the c o n - n e c t o r b l o c k s...
Page 647 9 heated diesel filter 2 4 2 t i ° control relay control relay Rn.d N222 2 ^ 2 Engine advance adjustment solenoid 2 4 4 Fast idle adjustment solenoid Copyright Fiat Auto...
Page 648 Electrical system Bravo-Brava Connector blocks 2 4 1 electronic control unit SB 244 E.G.R. solenoid Heated fuel filter 2 4 5 2 4 6 HV249 * HV241 Variant connections for 1 0 0 BHP version Heated fuel filter thermal contact...
Page 649 . MG 55 R n.d. HV245 BR 139 N222 Cn.d. V 248 . Earth for K.S.B. device Thermal switch for K.S.B. 2 5 2 C 251 2 5 3 f ° switching off compressor HN 127 HG55 P4A612L01 Copyright Fiat Auto...
Page 650 J1 Low fuel level warning light 26 Rear window wiper motor Fuel gauge 27 Rear connections contact assembly with Fiat CODE fault warning light built-in boot light switch M Fuel injection fault warning light 28 Dash./longitudinal cables connection Heater plugs warning light...
Page 651 S>-00 D C C D g < D •o g 2-o>=S 0 5 - •n <">- — — — — — >-CD 03 C C C 3 0. ' ' • , , a > , , < B — .
Page 652 E l e c t r i c a l s y s t e m Bravo-Brava Contents page - Electrical symbols - How to read the wiring diagrams - Wiring diagrams - Key to wiring diagrams Copyright Fiat Auto...
Page 654 Hazard warning Windscreen wiper pressure Auto transmission fluid Indicators Electric sunroof temperature Handbrake on and low Catalytic converter brake fluid level Km/h Speed limits temperature Heating element Recharging Fuel gauge Engine coolant temperature gauge Engine oil pressure Diode Copyright Fiat Auto...
Page 655 Electrical system Bravo-Brava Wiring diagrams Electrical symbols Trip computer control Differential lock Warning light Auto transmission fluid Bulb Electronic injection temperature Fuse Engine oil level Temperature Brake fluid level BRAKE Switch open (Japan version) Anti-theft device Selector switch Doors open...
Page 656 I I I I I I I I I I I I I Analogue fuel gauge Analogue coolant tem- perature gauge Econometer Digital coolant tempera- ture gauge f£3 Engine oil temperature Engine oil pressure gauge SJElJ Voltmeter Copyright Fiat Auto...
Page 657 Electrical system Bravo-Brava Wiring diagrams How to read the wiring diagrams ••MIIIlK' 1 7 9 50 5 0 Oil y STOP N. D . •RN-^-RN- * 95 R - ml -AR- 1 2 3 4 5 6 7 9 9 1 0 1 1 1 2 1 3 1 4 •...
Page 659 >» C C < o LU u O— iS < o " D d) B 3 0)15 = CO Q. ° « -c . c £ 2 -° J ) £ CO ro ". -5 C5 CD O " — ** CO o>...
Page 661 C o C S • c - o - „ + J b > > • F ™ "" '> J2 ^ i o 'r= (0 v> c/i .E .E J2 S5 c f l " C D -, E a a. a. g o t o S E E E ' °...
Page 677 ; O »- *- 5 in O O J C C O if> D 03 C C D « C O 0 to to < D > co ra J OJ C D C D 5 0 0 £ = •0X1 >...
Page 679 m c c < o o o o o o o)£o_io:<» < a 0 0 < J I » 0 • & +-> •o-D-D-q3gi;K'°"tST! = O J O : Z O as Oi « <D tO 1 / 3 & ;...
Page 684 •S3 « > U> < c - O Q F >...
Page 687 =552SSfI § 8 s o o < _ i x m o £ « l tc m I D M n « <N o> n : t e z o u S o c M r t m c c c C E C a <o;...
Page 690 . i l z z O ) x o o x: " • | I ° 3>Z-E. E o o > ' c XJ — S O U ) , _co <o o j co co > > c : . >...
Page 691 a j t u a j < r > 5 <j ' i> < D > > . > . a ) ' - L ^ i 3 £ £ S £ 3 = = = = g S « ^ ^ ^ ^ . £ £ 2 2 S = S = 5 l >...
Page 692 Electrical equipment Bravo- Brava Index 98 range page page RADIO SYSTEM PROTECTION AND SAFETY DEVICES Cassette-radio AD 182 H2 Protection and safety devices General description LOCATION OF COMPONENTS ON VEHI- Operation Switching on radio Location of relays and fuses on ve-...
Page 693 Electrical equipment Bravo-Brava Index 98 range page Delayed BOOSTER activation / de- activation ( B D L Y ) Technical information FIAT CODE Storing e n g i n e ignition keys (1920 JTD version) SERVICE CONTROL UNIT Integrated service electronic control...
Page 694 1910 TD S O F T Air conditioned Heated 1910 J T D Air conditioned P4A01HL01 petrol versions C: 40A fuse for air conditioning for 1910 JTD ** Diesel versions only D: 60A fuse for ABS XI-98 - Cancels and repLices: Copyright by Fiat Auto...
Page 695 Electrical equipment Bravo-Brava Protection and safety devices 98 range Diagram showing device with hot cables *J 145 iHIIIII 30 50 40 30 80 80 201* v w v 3. Power fuse box 10. Earth for battery on bodyshell 1 1 . Battery 96.
Page 696 150. Injection system relay feed 290. Electric fuel pump relay feed 307. I.E. system protective fuse (1242 1 6v) 308. 1 5A fuse protecting canister solenoid valve 335. 15A fuse protecting Lambda sensor XI-98 - Cancels and replaces Copyright by Fiat Auto...
Page 697 Electrical equipment Bravo-Brava Location of components on vehicle 98 range LOCATION OF R E L A Y S AND F U S E S ON V E H I C L E (Engine compartment 1998 20v) P4A04HL01 3. Power fuse box 93.
Page 698 122. Engine cooling fan low speed relay (1910 JTD) 123. Engine cooling fan high speed timer 282. Fiat CODE- I.E. control unit 3 0 A pro- 123A. Engine cooling fan high speed relay tective fuse 124. Air conditioning compressor relay 350.
Page 699 Electrical equipment Bravo-Brava Location of components on vehicle 98 range LOCATION O F R E L A Y S AND F U S E S ON V E H I C L E (Passenger compartment S X version) 4. Junction unit F 10A fuse protecting EURO-BAG 32.
Page 700 LOCATION O F R E L A Y S AND F U S E S ON V E H I C L E (Passenger compartment G T - E L X - H S X - H G T Junction unit B 20A fuse protecting windscreen wiper Fog lights relay C 7.5A fuse protecting Fiat-CODE, cooling sys- tem/I.E. Power relay controlled by the ignition D 10A fuse protecting anti-lock braking system 150.
Page 701 Electrical equipment Bravo-Brava Location of components on vehicle 98 range LOCATION OF CONTROL UNITS AND D I A G N O S T I C S O C K E T S (Engine compartment- petrol ver- sions) P4A08HL01 * Engine 100.
Page 702 139. Diagnostic socket for injection system 2 0 1 . Heater plugs control unit ( 1 9 1 0 J T D ) (1910 J T D ) 176. Diagnostic socket for anti-lock braking system (A.B.S.) XI-98 - Cancels and replaces Copyright by Fiat Auto...
Page 703 114. EURO-Bag electronic control unit 295. Injection/ignition electronic control 130. Diagnostic socket for EURO-Bag unit 1910 JTD 131. Fiat CODE electronic control unit 297. Climate control control unit 160. Injection/ignition electronic control 299. Diagnostic socket for climate control unit 1747 16v system 272.
Page 704: Control Units
Rear view of the junction unit and Location of relays E1. Ignition discharge relay dur- ing starting E2. Heated rear windscreen relay E3. Horn relay P4A11HL02 XI-98 Cancels and replaces Copyright by Fiat Auto...
Page 705 Electrical equipment Bravo-Brava Control units 98 range List of fuses and main circuits protected Fuse Fuse Ideo- Ideo- Amp. Amp. Circuit protected Circuit protected gram gram SERVIZI Right main beam headlamp. Reversing lights -Brake SERVICES lights - Additional brake light (if fitted) - Direction...
Page 706 - t - t i l l l l l l l l l l l l i l i P4A13HL02 E3. Heated rear windscreen relay E1. Ignition discharge relay during starting E2. Horn relay XI-98 - Update Copyright by Fiat Auto...
Page 707 Electrical equipment Bravo-Brava Control units 98 range D E S C R I P T I O N O F C A B L E S AND C O N N E C T O R S CONNECTOR A CONNECTOR B Term.
Page 708 Instrument panel supply Radio with clock Supply for instrument panel Switch control unit Hazard warning lights switch unit Cigar lighter light - Instrument panel G R / G N Supply for instrument panel light dimmer XI-98 - Update Copyright by Fiat Auto...
Page 709 Electrical equipment Bravo-Brava Control units 98 range R E M O V I N G - R E F I T T I N G J U N C T I O N UNIT AND S H I E L D...
Page 710 4. A.B.S. failure warning light present for 1910 SOFT TD) 5. Brake pad wear warning light 18. FIAT CODE system failure warning light 6. Left direction indicator warning light 19. Glow plug warning light (only for TD ver- 7. Side lights warning light sions) 8.
Page 711 I A n t i - l o c k brakes failure w a r n i n g light J1 Fuel reserve warning light K Fuel gauge L Fiat-CODE failure w a r n i n g light M Petrol/Diesel injection system failure w a r n i n g light...
Page 712 H EURO BAG system failure warning light I Anti-lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat-CODE failure warning light M Petrol/Diesel injection system failure warning light O Glow plug warning light Q Front brake pad wear warning light...
Page 713 4. A.B.S. failure warning light 19. Injection system failure warning light 5. Brake pad wear warning light 20. Fiat CODE system failure warning light 6. Left direction indicator warning light 21. Glow plug warning light (only for JTD ver- 7. Side lights warning light 8.
Page 714 H EURO BAG system failure warning light I Anti-lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat-CODE failure warning light M Petrol/Diesel injection system failure warning light O Glow plug warning light (only for JTD)
Page 715 Electrical equipment Bravo- Brava Control panel 1998 range Operations to be carried out w h e n replacing control panel New instrument panels come w i t h caps in place of the A B S and A I R - B A G device w a r n i n g lights. The caps must therefore be replaced w i t h the releavnt w a r n i n g lights if one or both devices are present.
Page 716 Bravo- Brava Electrical equipment Control panel 1998 range Rear side (connector seats are s h o w n ) Connector A on left front lead Connector B on facia lead Wiring No. Wiring Wiring Circuit involved Circuit involved Circuit involved...
Page 717 1 9 1 0 SOFT T D ) 6. Left direction indicator w a r n i n g light 18. Fiat CODE system failure w a r n i n g light 7. Side lights warning light 19.
Page 718 Z2 Trip counter display light I Anti-lock brakes failure warning light J1 Fuel reserve warning light K Fuel gauge L Fiat-CODE failure warning light M Injection system failure warning light O Glow plug warning light (only for Turbo Die- sel)
Page 719 19. Injection system failure w a r n i n g light 8. Right direction indicator w a r n i n g light 20. Fiat CODE system failure w a r n i n g light 9. M a i n beam headlamps warning light 10.
Page 720 19. Injection system failure w a r n i n g light 8. Right direction indicator warning light 20. Fiat CODE system failure w a r n i n g light 9. Main beam headlamps warning light 2 1 . G l o w plug warning light 10.
Page 721 K Fuel gauge Y1 Speed control module L Fiat-CODE failure warning light Z M i l o m e t e r / t r i p meter display M Petrol/Diesel injection system failure w a r n i n g...
Page 722 Electrical equipment Bravo- Brava Control panel 1998 range n i 7 7i . Y S Y T M = w n J3L- £=L ==FLJ—J • Rear side (connector sockets are shown) Connector A on left front lead Connector B on facia lead...
Page 723 19. Main beam headlamps warning light 8. Engine coolant temperature gauge 20. Side light failure warning light 9. A.B.S. failure warning light 21. EURO BAG system failure warning light 10. Fiat CODE system failure warning light 22. Automatic transmission system failure warning light 11.
Page 724 J1 Fuel reserve w a r n i n g light K Fuel gauge L Fiat-CODE failure warning light M Petrol injection system failure w a r n i n g light P A u t o m a t i c transmission failure w a r n i n g light...
Page 725 Electrical equipment Bravo- Brava Control module 1998 range Present only for ELX version Rear side (connector sockets are s h o w n ) Connector A on left front lead Wiring Circuit involved Colour Generator Brake fluid level Injection failure...
Page 726 Electrical equipment Bravo- Brava Control panel 1998 range V++Y++++w+++ Connector B on facia lead Wiring Wiring Circuit involved Circuit involved Colour Colour Left turn signal Main beam headlamps Instrument panel light Right turn signal Side lights Not connected Automatic transmission signal...
Page 727 Bravo- Brava Electrical equipment Control panel 1998 range The following tables contain values for checking the various gauge positions: fuel level and coolant level F U E L G A U G E Values for checking settings Pointer position Value in Ohms ' 4/4 (F) 16 ±...
Page 728 Brake pad wear warning light versions) Side lights w a r n i n g light 2. Fiat-CODE failure warning light Main beam headlamps w a r n i n g light 3. Injection system failure warning light 1 0 .
Page 729 <©) I " 5>0c C O D E 1. Fiat-CODE failure warning light 6. Side lights warning light 2. Injection system failure warning light 7. Main beam headlamps w a r n i n g light 3. Battery recharging warning light 8.
Page 730 1 second during the 20 seconds w h e n the mileage is displayed causes the zeroing of the trip meter, but does not interrupt the "warning cycle". The milometer display is also used to carry out a fault diagnosis of the thermostatically adjusted air conditioning electronic system (see group 50) XI-98 - Update Copyright by Fiat Auto...
Page 731 Electrical equipment Bravo-Brava Instrument panel 98 range 7'=^ 7'=^ 7'=^ 7'=^ R E M O V I N G - R E F I T T I N G Remove the steering column upper and lower covers and then proceed as described below: 1.
Page 732 Using a screwdriver in the side slit, remove the courtesy light from its housing; disconnect the connector and remove the courtesy light; release the bulb from the flexible tabs and remove it. Copyright by Fiat Auto XI 98 - Update...
Page 733 Electrical equipment Bravo-Brava Various devices 98 range L O C A T I O N OF A D D I T I O N A L F U S E S - R E - L A Y S (dashboard - passenger side) 1.
Page 734 With the voltage below 8.5 V, the control unit displays the engine oil level memorized at the last reading via the warning light. With the engine oil level below the minimum level, the warning light remains on constantly for 30 sec- onds. XI 98 - Update Copyright by Fiat Auto...
Page 735 Electrical equipment Bravo-Brava Radio equipment 98 range AD 182 H2 RADIO C A S S E T T E PLAYER P4A36H L01 4. VOL control: switching on/off of radio, adjustment of high/low tones and Balance/Fader functions 2. Cassette eject button 3.
Page 736 - Expert control level section - Anti-theft protection (*) The DOLBY noise reduction circuit is manufacturered, under licence, by Dolby Laboratories Licens- ing Corporation. DOLBY and the double D symbol are the registered trade marks. XI-98 - Update Copyright by Fiat Auto...
Page 737 Electrical equipment Bravo-Brava Radio equipment 98 range OPERATION Switching on the radio Press the VOL control (1) once: the radio should come on. If the radio is on when the engine is switched off, it switches off auto- matically after about 20 minutes.
Page 738 The values w h i c h can be selected range from (Dct(De$tfire the basic setting, press the A U D I O button (2) for about 3 seconds until the mes- sage " 0 0 " or "- -" appears on the display. XI-98 - Update Copyright by Fiat Auto...
Page 739 Electrical equipment Bravo-Brava Radio equipment 9ft range Adjustment of balance between front and rear speakers (FADER) By selecting the FADER function it is possi- ble to modify the "distribution of the volume" between the front and rear speakers. The FADER function is selected by pressing the AUDIO button (1) once or more until the message "FAD 0"...
Page 740 "IS O N " . By pressing one of the " A " " T " buttons briefly it is possible to gradually recall the transmitters memorized. XI-98 - Update Copyright by Fiat Auto...
Page 741 Electrical equipment Bravo-Brava Radio equipment 98 range Automatic tuning into RDS transmitters Select the FM or A M frequency desired using the BAND control (1). The IS function should not be activated for this type of selection. If the IS function is switched on, press one of the "...
Page 742 RDS stations only broadcasting traffic news; b) receive traffic news even if the cassette player or Compact Disc player are working; c) receive traffic news at a pre-set quiet volume even with radio volume at zero. XI-98 - Update Copyright by Fiat Auto...
Page 743 Electrical equipment Bravo-Brava Radio equipment 98 range N O T E Below are the instructions for carry- ing out each of the operations illus- trated in points a), b) and c) men- tioned previously. Point a) To select a transmitter w i t h a traffic news ser- vice, press the TP button (1) briefly.
Page 744 " A " ( 2 ) , " Y " ( 3 ) buttons for about 2 seconds. The search is interrupted when a transmitter broadcasting the type of programme desired is found. XI-98 - Update Copyright by Fiat Auto...
Page 745 Electrical equipment Bravo-Brava Radio equipment 98 range Tuning into the type of programme using the list Activate the PTY function by pressing the TP (1) button for about 6 seconds until the dis- play shows the message "PTY O N " .
Page 746 The messages "TAPE A" and "TAPE B" refer to the upper and lower sides of the cassette, respectively. P4A47HL03 Copyright by Fiat Auto X I - 9 8 - U p d a t e...
Page 747 Electrical equipment Bravo-Brava Radio equipment 98 range Fast forward/rewind Whilst listening, briefly press the " A " (1) or " T " (2) button to fast forward or rewind the tape. During this operation the display w i l l show the message "WIND»"...
Page 748 Impurities on the head caused by tapes can, in time, cause a deterioration in the high tones dur- ing reproduction, therefore it is advisable to clean the head periodically using a special, non abrasive, cleaner. XI-98 - Update Copyright by Fiat Auto...
Page 749 (CD) player, w h i c h consists of a multi-polar cable ending in the luggage compartment on the left side. A kit is available from Linea Accessori FIAT which includes a Compact Disc player, an additional multi¬ -polar connecting cable and a mounting bracket.
Page 750 (e.g. "03:14" = 3 minutes and 14 I I C D C H E C K ] seconds) and the number of the CD (for ex- ample " 4 " ) . XI 98 • Update! Copyright by Fiat Auto...
Page 751 Electrical equipment Bravo-Brava Radio equipment 98 range Possible error messages If the loader has not been introduced or has not been inserted correctly in the Compact Disc player, the w o r d "MAGAZINE" will appear on the display. If the loader does not contain any Compact Discs, the words "NO C D " will appear on the display.
Page 752 To end the serach for the random track se- quence, press the station selection button 3 RttD RtiD ( 2 ) . The message "RND OFF" w i l l appear on the display. XI-98 - Update Copyright by Fiat Auto...
Page 753 Electrical equipment Bravo-Brava Radio equipment 98 range Once all the tracks have been played, another Compact Disc is selected and so on. Once all the discs have been played, the random re- production starts again in the same way. N O T E If the "CD Repeat"...
Page 754 By pressing frequency selection button 5 the display will show the message "SYNC O N " , whilst press- ing frequency selection button 4 afterwards, will produce the message "SYNC OFF" on the display. XI-98 - Update Copyright by Fiat Auto...
Page 755 Electrical equipment Bravo-Brava Radio equipment 98 range Minimum listening volume for traffic news The desired level can be set using the fre- quency selection buttons 4 (1) and 5 (2) to increase or decrease the volume, respectively. During the adjustment, the message "TAVOL YY"...
Page 756 The 4 digit secret code is on the "Security Code Card" w h i c h is given at the same time as the "Fiat Code Card". The secret code should be kept in a safe place (for example, together with the vehicle documents), not in the vehicle.
Page 757 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Deactivating the code The code has to be deactivated before re- moving the radio. To deactivate the code, proceed as described below: Press the EXP button (1) and press the " A "...
Page 758 (supply voltage) etc. Contact A 2 should be earthed from the tele- phone/receiver-transmitter mute outlet A1 S C V ( + ) connection "for adjusting vol- ume according to the speed. XI-98 - Update Copyright by Fiat Auto...
Page 759 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Speakers Blade contacts B Maximum power at speakers 4 : 4 x 20 W. Front speaker: B3 right + B4 right - B5 left + B6 left - Rear speaker:...
Page 760 1 1 . TP button: for selecting the TP function, for selecting AF alternative frequencies, for acting the PTY function. 12. N4 station programming button, for altering EXPERT adjustments. 13. N5 station programming button, for altering EXPERT adjustments. 14. EXP button: for activating EXPERT control level. 15. Audio cassette housing. XI-98 - Update Copyright by Fiat Auto...
Page 761 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 ! G E N E R A L D E S C R I P T I O N The vehicle is available, on request, w i t h a radio system, consisting of the following main components:...
Page 762 "Audio cassette" mode it is resumed from where it left off. If the "Audio cassette" func- tion is selected whilst listening to the radio, on returning to the "Radio" mode, the last station selected is tuned into. XI-98 - Update Copyright by Fiat Auto...
Page 763 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . V O L U M E adjustment The volume can be adjusted via the VOL c o n - trol ( 1 ) . The volume level, between "VOL 0 0 " and "VOL 3 1 "...
Page 764 " F M 1 " , " F M 2 " , " F M 3 " for FM frequency ranges " M W " , medium wave, " L W " , long wave, for A M ranges XI-98 - Update Copyright by Fiat Auto...
Page 765 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Automatic intelligent search tuning function) Using the BN button (1), select the " F M 1 " , " F M 2 " or " F M 3 " band.
Page 766 N O T E Below are the instructions for carrying out each of the operations illustrated in points a), b) and c) previously. Copyright by Fiat Auto XI-98 - Update...
Page 767 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Point a) To select a transmitter w i t h a traffic news ser- vice, press the TP (1) button briefly. The message "TP" will appear on the display. If the transmitter is not enabled to provide...
Page 768 The automatic search can be started by pressing one of the buttons " A " " T " again for about 2 seconds. The search is interrupted when the first transmitter broadcasting the type of pro- gramme desired is found. XI-98 - Update Copyright by Fiat Auto...
Page 769 Electrical equipment Bravo-Brava Radio equipment 98 range Tuning into the type of programme using the list Activate the PTY function by pressing the TP button (1) for about 6 seconds until the mes- sage "PTY O N " appears on the display.
Page 770 When the tape has been fast forwarded or re- wound, the player will resume the automatic re- production of the same side or the other side. P 4 A 7 1 H L 0 2 Xi-98 - Update Copyright by Fiat Auto...
Page 771 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Ejecting the cassette. To eject the cassette from the audiocassette housing, briefly press buttons 1 and 2 simulta- neously. After the audio cassette has been ejected, the message "TAPE" will appear on the display and the radio will operated, tuned into the last transmitter listened to.
Page 772 4 (1) and 5 ( 2 ) , respectively. The messages "LRN O N " and "LRN OFF" re- spectively, will appear on the display when the function is switched on or off. Copyright by Fiat Auto XI-98 - Update...
Page 773 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . Automatic programme change ( R E G I O N - When the RDS programme consists of vari- regional broadcasts, the radio switch between transmitters, selecting the one w i t h the most powerful signal.
Page 774 4 (2). The VOL control (3) is used to regulate the intensity of the sound, emphasizing the sound coming from the front speakers or from the rear speakers. FRDER P 4 A 7 5 H L 0 3 XI 98 - Update Copyright by Fiat Auto...
Page 775 Electrical equipment Bravo-Brava Radio equipment 98 range Delay in switching B O O S T E R on/off ( B D - To switch the Booster delay on or off, press frequency selection buttons 5 (1) and 4 ( 2 ) , respectively.
Page 776 Connection for 2 x 15 W B3 right + B2 right - B5 left + B8 left - When operating with 2 x 15 W the FADER should be switched off in the EXPERT Menu XI-98 - Update Copyright by Fiat Auto...
Page 777 Electrical equipment Bravo-Brava Radio equipment 98 range 5 5 . The connections for the speakers should not be electrically connected to each other or earthed! Additional connections Blade contacts C Line output Possibility of connection for power amplifier (Booster) or speaker activated.
Page 778 PROGRAMMING IGNITION K E Y S (only on 1910 J T D version) For anything not dealt with in the pages which follow, refer to the Fiat C O D E system described in the Fiat Bravo-Brava Service Manual 11° volume (print no. 506.670/01) On the version in question, as a result of a differenti CODE system software configuration, the specific procedure described below must be followed.
Page 779 Electrical equipment Bravo-Brava 98 range Fiat C O D E 5 5 . When the CODE warning light goes out, turn the MASTER key to the OFF position and ex- tract it. Within 10 seconds: - insert a new key (1) in the ignition and turn it to the ON position ( + 1 5 ) , the CODE warning light should come on for 0.7 sees.
Page 780 Repeat the t w o previous operations until, when the MASTER key is turned to the ON position, the CODE warning light rather than coming on for 0.7 seconds remains on c o n - stantly. XI-98 - Update Copyright by Fiat Auto...
Page 781 Electrical equipment Bravo-Brava 98 range Fiat C O D E Place the MASTER key in the OFF position, extract it and return it, the key programming procedure is over. P4A79HL01 If the procedure has been carried out correctly, i.e. as far as the timing and operations are concerned, if the ignition key is placed in the ON position, the CODE warning light w i l l go out after coming on initi- cally for 0.7 seconds, otherwise it will start to flash in rapidly (1.6 Hz);...
Page 782 Electrical equipment Bravo- Brava Services control unit 98 range 5 5 . INTEGRATED SERVICES ELECTRONIC CONTROL UNIT A single electronic control unit k n o w n as the A B I (Alzacristalli Bloccaporte Integrati - Integrated electric w i n d o w and door lock) located beneath the right facia trim controls a set of functions a n d controls that are normally controlled by several different components.
Page 783 Electrical equipment Bravo- Brava Service control unit 98 range 5 5 . FRONT E L E C T R I C W I N D O W OPERATION Operation is automatic for w i n d o w raise lower on the driver side, but only for l o w e r i n g on the passenger side.
Page 784 (protected programming). The Dealer must remove the plate at the time of sale and place it on the back of the Code Card (refer to the Fiat CODE chapter). If the plates are lost, the remote control can still be used but NEW REMOTE CONTROL UNITS cannot be stored (see next page), if this is necessary, replace the receiver on the courtesy light and the keys (to obtain the plates).
Page 785 Electrical equipment Bravo- Brava Service control unit 98 range 5 5 . 1. Green led 2. Store button Receiver connector 1. Not connected 2. Provision for alarm system SEES 3. Positive from battery ( + 3 0 ) 4. Earth 5.
Page 786 Electrical equipment Bravo- Brava Services control unit 98 range 5 5 . Press button ( 5 ) as many times as is indicated by the first figure of the Password (e.g, if t h e Pass- w o r d is 5.2.0.3, press 5 times). Whenever the button is operated, LED (4) lights up briefly t o give visual confirmation.
Page 787 Electrical equipment Bravo- Brava Service control unit 98 range 5 5 . 6 second w h e n the door is reclosed t o allow the driver to enter the car and turn the ignition key o n ; 6 seconds w h e n the door is reclosed to allow the driver to enter the car and insert the i g n i - tion key.
Page 788 Chapter 1 Click here to choose chapter • B r a k i n g s y s t e m j file:///D|/Volume%203/rhdrive.htm08/07/2006 16:53:11...
Page 789 This supplement contains the main rules to be followed for the repair and maintenance of the right hand drive version of F i a t Bravo a n d F i a t B r a v a c a r s .
Page 790 Rearscreen w a s h / w i p e Dimension to measure Lv^TJ w i t h pump Measurement - Check rear washer fluid • H i Thickness - Clearance nflB) — Rolling torque Engine Copyright Fiat Auto...
Page 791 Engine Bravo-Brava Contents page F U E L S Y S T E M - Removing-refitting accelerator cable - Removing-refitting accelerator pedal I 0 | T D 7 5 - Removing-refitting accelerator cable - Removing-refitting accelerator pedal Copyright Fiat Auto...
Page 792 3. Remove the pipe connecting the air clean- er to the butterfly valve case. 4. Remove the relay unit protective cover. 5. Unscrew the relay bracket retaining bolts and position unit to one side. P4A01DA03 Copyright Fiat Auto...
Page 793 Engine Bravo-Brava Fuel system 1 0 . P4A02DA01 P4A02DA02 1. Remove the stud shown in the figure and move the lining of the bulkhead between engine bay and passenger compartment to one side. 2. Unscrew the bolt retaining the accelerator...
Page 794 3. Disconnect the control cable from the an- chorage on the accelerator pedal. Disconnect the clutch pedal reaction P4AOIDAO2 spring (attached to the accelerator pedal P4A03DA02 Copyright Fiat Auto...
Page 795 Bravo-Brava iQk Engine Fuel system 1 0 . P4A04DA02 -2. Unscrew both nuts retaining the accel- erator pedal bracket, then remove from the car. Publication no. 508.876...
Page 796 . Disconnect the pipe from below to allow access to the cable anchorage on the accelerator pedal. 4. Disconnect the control cable from its an- chorage on the accelerator pedal. Copyright Fiat Auto...
Page 797 Engine Bravo-Brava TD 75 Fuel system 1 0 . 1 . Remove the trim shown in the figure by undoing the retaining bolts and releasing the diesel lines from the retaining clip. 2. Remove the bolt retaining the bracket joining the fuel lines.
Page 798 1. Proceed as described for the 1370 12v en - gine, but remove the air pipe bracket shown in the figure in order to release the pipe and gain access to the accelerator ca- ble anchorage on the pedal. P4A07DA01 Copyright Fiat Auto...
Page 800 - Removing-refitting clutch pump - Removing-refitting pipe connecting clutch pump-slave cylinder - Removing-refitting master cylinder - Bleeding TD 75 - Removing-refitting clutch pump - Removing-refitting pipe connecting clutch pump-slave cylinder - Removing-refitting slave cylinder 4 A 9 1 Copyright Fiat Auto...
Page 801 The clutch is single, dry plate type, w i t h a hydraulic release device and thrust bearing constantly in touch with the thrust spring. The driven plate is controlled by pressure exercised by a diaphragm spring. 4A09DA Copyright Fiat Auto...
Page 802 Clutch Bravo-Brava Clutch operation R E M O V I N G - R E F I T T I N G C L U T C H P E D A L Before removing the clutch pedal, re- move the accelerator pedal as de- scribed in "Section 10 - Fuel system".
Page 803 R E M O V I N G - R E F I T T I N G C L U T C H P U M P 1. Remove pipe connecting air cleaner to butterfly valve case by undoing the fas- tenings shown in the figure. P4A01 DA03 4A11DA Copyright Fiat Auto...
Page 804 Bravo-Brava @ i Clutch Clutch operation P4A01DA05 Remove the relay protective cover. Unscrew both nuts retaining the relay bracket, disconnect the connection indi- cated and position the bracket to one side. Remove the stud retaining the lining of bulkhead between lining to one side.
Page 805 To refit the pump connec- tion line to the reservoir, first position the rubber fitting over the hole in the body, and then thread the pipe from inside the car into the engine bay. P4A13DA03 Copyright Fiat Auto...
Page 806 Clutch Bravo-Brava Clutch operation R E M O V I N G - R E F I T T I N G PIPE C O N N E C T - ING C L U T C H PUMP - S L A V E C Y L I N D E R...
Page 807 Clutch Bravo-Brava @ i Clutch operation 1. Release the pipe connecting clutch pump - slave cylinder from the retaining clip shown in the figure. 2. Disconnect the pipe fitting on the slave cylinder and then remove the pipe. R E M O V I N G - R E F I T T I N G S L A V E...
Page 808 Clutch Bravo-Brava Clutch operation NOTE Proceed as described for the left hand drive version to remove the reverse in- hibitor, Note, however, that the bolt re- taining the inhibitor also secures the clutch slave cylinder; remove the latter without disconnecting the fittings. It will now be possible to disconnect the re- verse inhibitor as shown in the figure.
Page 809 4. Disconnect the fitting of the line connected to the slave cylinder from the clutch pump. 5. From inside the car, remove the left foot rest and disconnect the air pipe from the points indicated, then position to one side. P4A17DA02 P4A05DA03 Copyright Fiat Auto...
Page 810 Clutch Bravo-Brava i ^ i TD 75 Clutch operation 1. Working from inside the car, remove the roll pin retaining the clutch pump rod to the pedal. 2. Unscrew the bolts retaining the clutch pump to the body, remove slightly to re-...
Page 811 Disconnect the fitting of the pipe c o n - nected to the clutch pump, then unscrew the slave cylinder retaining bolts and re- move from the car. Bleeding clutch system Copyright Fiat Auto...
Page 813 Removing-refitting servo brake Removing-refitting pedal unit Removing-refitting brake servo vacu- um inlet pipe Removing-refitting one-way valve TD 75 Brake-clutch fluid reservoir Removing-refitting brake pump Removing-refitting servo brake Removing-refitting brake servo vacu- um inlet pipe and one-way valve Copyright Fiat Auto...
Page 814 5. Servo brake pump 6. Complete pedal mount 3. Brake pump According to the version, the brake fluid reservoir may be connected to the pump by pipes or may be fit- ted directly to the brake pump. 421 DAA Copyright Fiat Auto...
Page 815 Braking system Bravo-Brava Hydraulic operation 3 3 . R E M O V I N G - R E F I T T I N G BRAKE P E D A L Before removing the brake pedal, remove the clutch pedal as described in "Section 18"...
Page 816 Bravo-Brava @ i Braking system Hydraulic operation 3 3 . B R A K E - C L U T C H FLUID R E S E R V O I R Checking low brake fluid warning light NOTE At intervals, check warning light opera- tion by pressing down on the top edge of the reservoir cover (arrowed).
Page 817 Braking system Bravo-Brava l § | Hydraulic operation 3 3 . P4A01 DA03 R E M O V I N G - R E F I T T I N G BRAKE PUMP Proceed as follows to remove the brake pump: 1.
Page 818 Bravo-Brava @ i Braking system Hydraulic operation 3 3 . 1. Disconnect the brake fluid inlet pipes from the reservoir from the brake pump. 2. Use wrench 1856132000 to disconnect the brake pipe fittings from the brake pump. Bleeding brake system 3.
Page 819 Braking system Bravo-Brava $ Hydraulic operation 3 3 . P4A01 DA04 R E M O V I N G - R E F I T T I N G S E R V O B R A K E . mA...
Page 820 Bravo-Brava !0| Braking system Hydraulic operation 3 3 . 1 . Remove the brake pump without d i s c o n - necting the connected brake lines, in order to release the brake servo rod from the pump. 2. Release the injection wiring bundle from the retaining clip, then disconnect t h e va- cuum intake line from the brake servo.
Page 821 Braking system Bravo-Brava Hydraulic operation 3 3 . P4A28DA02 1. Disconnect electrical connection from the ig- nition, then unscrew the bolts fastening the steering column and remove from the car. 2. Disconnect the braking light switch con- nector. 3. Unscrew both nuts retaining the accelera- tor pedal retaining bracket and release the clutch pedal return spring from the bracket.
Page 822 5. At the bench, unscrew the four bolts re- taining the brake servo to the pedal unit. P4A29DA04 Copyright Fiat Auto...
Page 823 Braking system Bravo-Brava Hydraulic operation 3 3 . 1. Separate the brake servo from the pedal unit by releasing the brake servo rod from the transmission on the control pedal. Refitting 2. Reverse removal instructions to refit. Take care to position the control rod and wash-...
Page 824 3. Pull the bolt out further until the brake pedal comes off too. 4. Unscrew bolt retaining the brake pedal transmission anchoring the brake servo rod, then remove the pedal. 5. View of pedals: 1. Clutch pedal - 2. Brake pedal. Copyright Fiat Auto...
Page 825 Bravo-Brava @ i Braking system Hydraulic operation 3 3 . R E M O V I N G - R E F I T T I N G B R A K E S E R V O V A C U U M INPUT P I P E...
Page 826 Ensure fluid remaining in the reser- voir does not leak out. NOTE Carry out brake and clutch fluid reservoir removal operations in reverse order to re- fit. Ensure the reservoir extremely clean before filling. Bleeding hydraulic brake and clutch system Copyright Fiat Auto...
Page 827 Braking system Bravo-Brava TD 75 Hydraulic operation 3 3 . R E M O V I N G - R E F I T T I N G B R A K E PUMP Carry out operations described for re-...
Page 828 5. Unscrew the bolts fastening the diesel f i l - ter bracket, disconnect the connections shown and position the bracket to one side. Copyright Fiat Auto...
Page 829 Braking system Bravo-Brava 1 0 Hydraulic operation 3 3 . 1. Release the EG R control unit wiring bundle from the clips shown. 2. Move the lining of the bulkhead between engine bay and cabin further to one side, then disconnect the vacuum inlet pipe from the brake servo.
Page 830 Bravo-Brava 1 0 Braking system Hydraulic operation 3 3 . R E M O V I N G - R E F I T T I N G B R A K E S E R V O V A C U U M...
Page 832 - Steering column - Removing-refitting - Rack and pinon power steering box - Removing-refitting - Components of power steering system I 0 | T D 7 5 - Components of power steering system 4 A 9 3 D A Copyright Fiat Auto...
Page 833 S T A L K U N I T - R E L E A S E Removing-refitting Remove the stalk unit-release as follows: 3. Use a socket wrench to loosen the bolt of the stalk unit-release retaining collar and withdraw. 4. Disconnect electrical connectors from the stalk unit-release and remove. Copyright Fiat Auto...
Page 834 Steering Bravo-Brava Operation P4A40DA01 S T E E R I N G COLUMNRemoving-refitting Proceed as follows to remove the steering column: 1 . Remove the left foot rest located beside the clutch pedal. 2. Unscrew bolt retaining the lower steering column shaft to the power steering box pinion.
Page 835 4. Remove the left foot rest located along- side the clutch pedal. 5. Unscrew bolt retaining the lower steering shaft to the power steering box pinion. P4A03DA01 Copyright Fiat Auto...
Page 836 Steering Bravo-Brava Operation © © © © © 1. Remove the front wheels, then unscrew the bolts retaining the steering link heads (right and left) to the pillars and remove from pilars using extractor 1847038000. 2. Release the reverse inhibition lead from...
Page 837 4. Disconnect the fitting for the inlet line for fluid under pressure from the pump and the fitting of the fluid return line to the reservoir. 5. Unscrew the bolts fastening the power steering box to the front beam. P4A43DA05 Copyright Fiat Auto...
Page 838 Steering Bravo-Brava Operation P4A44DA02 Power steering box 1 . Remove the power steering box from the vehicle, by moving the entire assembly t o - 1. Fitting for pipe carrying fluid under ward the gearbox end and taking out from pressure from the pump the middle as s h o w n in the figure.
Page 839 C O M P O N E N T S O F POWER S T E E R I N G S Y S T E M TO 75 1. Pump 2. Fluid delivery line to pump 3. Power steering fluid reservoir 4. Fluid return line to reservoir 5. Power steering box 6. Pipe carrying fluid under pressure from pump 4A45DA Copyright Fiat Auto...
Page 841 Auxiliary units Bravo-Brava Contents page H E A T E R WITH MANUAL C O N T R O L S - Distributor heater assembly moving-refitting - Removing-refitting cabin fan 4A94DA Copyright Fiat Auto...
Page 842 2. Release the air bag lead from the retaining brackets. 3. Disconnect electrical connection located alongside the clutch pedal. 4. Disconnect electrical connections located alongside the cabin fan. P4A47DA04 Copyright Fiat Auto...
Page 843 Auxiliary units Bravo-Brava Heater with manual controls 4A48DA Publication no. 508.876...
Page 844 R E M O V I N G - R E F I T T I N G C A B I N FAN 1. Disconnect the battery negative terminal, then work from the lower left part of the facia to disconnect the supply connector and remove the fan cover retaining bolt. P4A49DA03 4A490A Copyright Fiat Auto...
Page 845 Auxiliary units Bravo-Brava Heater with manual controls 4A50DA Publication no. 508.876...
Page 846 - Perspective view of facia wiring I N S T R U M E N T PANEL - Instrument panel - Removing-refitting AIR BAG - Removing-refitting driver's air bag - Removing-refitting clock spring 4 A 9 5 D A Copyright Fiat Auto...
Page 847 a> 5 >. to — x : o a r c — o in ca ! _ o w -p — 2 o r- ™ C O T ! o = > | - ° - c j > 8 | s i —...
Page 848 Bravo-Brava Instrument panel 1. Fuel reserve warning light 5. Speedometer and dual mileometer (total and trip counter) 2. Fuel level gauge 6. Coolant temperature gauge 3. Rev counter 7. Warning lights 4. Turn signal warning lights 4A53DA Copyright Fiat Auto...
Page 849 Electrical equipment Bravo-Brava Instrument panel 5 5 . R E M O V I N G - R E F I T T I N G 1. Disconnect the battery negative terminal, then remove the lower steering column trim by undoing the bolts indicated in the figure.
Page 850 T E N S I O N E R S " IN T H E M A N U A L FOR T H E L E F T HAND D R I V E V E R - SION Unscrew both hexagonal-headed socket screws indicated. Turn the steering wheel to gain access to each screw. P4A55DA03 Copyright Fiat Auto...
Page 851: Air Bag
NOTE After the operation, check the system using a Fiat/Lancia Tester. R E M O V I N G - R E F I T T I N G C L O C K S P R I N G...
Page 852 Reverse order of removal operations to refit. When refitting the steering wheel, tighten the nut securing it to the steering column to a torque of 5 daNm. Copyright Fiat Auto...
Page 853 Bodywork Bravo-Brava Contents page INTERIOR T R I M - Dashboard - General exploded view - General view of retainers - Removing-refitting dashboard Removing-refitting bonnet opening cable Removing-refitting bonnet opening cable 4A96DA Copyright Fiat Auto...
Page 854: Interior Trim
2 1 . Instrument panel 9. Car radio 22. Junction unit protection 10. Central panel 23. Door sill trims) 1 1 . Hazard warning switch 24. Left ventilation outlet 12. Switch unit 25. Upper grille 13. Panels Copyright Fiat Auto...
Page 855 Bodywork Bravo-Brava Interior trim GENERAL V I E W OF R E T A I N E R S P4A60DA01 4A60DA Publication no. 508.876...
Page 856 3. Remove the rear ashtray by lifting out and unscrew the underlying central tunnel re- taining bolts. 4. Undo the retaining tabs t o lift the door mirror control panel. 5. Disconnect supply connector for the elec- tric door mirrors and remove the panel. P4A61DA03 Copyright Fiat Auto...
Page 857 Bodywork Bravo-Brava Interior trim P4A62DA02 P4A62DA01 1. Remove the clips, unscrew the bolts shown and remove the tunnel trim from the car. Lift the parking brake lever fully t o allow removal of the trim. 2. Remove the junction unit protection by undoing the fastenings shown in the f i g - ure.
Page 858 1860897000 and following the pro- cedure described previously. Protect the area of the instrument facia below the radio using a cloth, pull out the radio fully and disconnect the supply leads and aerial lead. P4A63DA03 Copyright Fiat Auto...
Page 859 Bodywork Bravo-Brava Interior trim P4A64DA02 P4A64DA01 1. Unscrew the lower screws securing the ashtray to the instrument facia. 2. Unscrew bolts indicated in figure, discon- nect connector for the cigar lighter/light- ing and remove the ashtray. 3. Use a screwdriver to prise up panel ( 1 ) .
Page 860 4. Work from inside the glove compartment to undo clips (1) and remove the c o m - partment lining. 5. Unscrew the bolts indicated, w h i c h retain the glove compartment, and pull out slightly. Copyright Fiat Auto...
Page 861 Bodywork Bravo-Brava Interior trim 1. Disconnect connector of the glove c o m - partment light, then remove the light from the car. 2. Unscrew the bolts fastening the left venti- lation outlet, then remove. 3. Unscrew the screw indicated, which se- cures the left hand side of the instrument facia.
Page 862 5. R e m o v e t h e central b o l t s e c u r i n g t h e i n - s t r u m e n t facia t o the b o d y . P4A67DA03 P4A67DA04 P4A67DA05 Copyright Fiat Auto...
Page 863 Bodywork Bravo-Brava Interior trim 1. Unscrew the bolts fastening instrument facia to the front beam. 2. Unscrew screw retaining the facia, located near the steering wheel adjustment lever. Remove the instrument facia retaining screw on the rihgt hand side near the junction unit.
Page 864 Bravo-Brava 1 0 Bodywork Interior trim R E M O V I N G - R E F I T T I N G B O N N E T O P E N - ING C A B L E 1.
Page 865 Bodywork Bravo-Brava @t Interior trim 1. Disconnect bonnet opening cable from the seats of fastenings (2) and (3) and from the retaining clip ( 4 ) . 2. Release the bonnet opening cable from the retaining clip located beneath the in- jection control unit.
Page 866 5. Unscrew the bolts fastening the diesel filter bracket, disconnect connections shown and place the bracket to one side. P4A06DA02 P4A06DA03 Copyright Fiat Auto...
Page 867 Bodywork Bravo-Brava Interior trim P4A72DA02 Move the lining of the bulkhead between engine bay and cabin further, then remove the nut retaining the bonnect opening ca- ble to the above bulkhead. Remove the air duct by undoing the fas- teners indicated in figure.
Page 868 Fasten the opening cable to a probe in order to facilitate refitting through the bulkhead between engine bay and passenger compartment. Withdraw and disconnect the bonnet opening cable by releasing from the retaining clip. NOTE Reverse order of removal operations to refit. 4A73DA Copyright Fiat Auto...

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Summary of Contents for Fiat Bravo

Page 174: Special Tools

Page 544: Valve Assembly

Page 600: Additional Heater

Page 704: Control Units

Page 851: Air Bag

Page 854: Interior Trim

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