Fiat Bravo/Brava Instruction manual

FiatBravo/aWorkshopManualVolume4
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file:///D|/Volume%204/Vol4.htm08/07/2006 16:59:52

Bravo-Brava Summary
TECHNICALSERVICEMANUALCOMPOSITION
AsofJanuary2001,theBravo-Brava4thvolumemanualiscomposedofthefollowingsections
PrintN°
506.670/18
(11/1999)
506.670/19
(XI/1999)
506.670/20
(V/1999)
506.670/21
(X/1999)
Sections
10
55
55
00
10
55
55
10
55
Page
No(s)
1- 35
1- 249
1- 38
1- 9
1- 54
25- 26
249
1- 41
33- 34
1- 2
1- 8
23- 25
83- 86
177- 178
201- 204
229- 230
249
Notes
Engine16V1998range- Removing-refitting
Electricalequipmentwiringdiagramsfor98rangever-
sions(*)
Electricalequipment:AirBagnewfeatures- Side
TechnicaldataIflpl16V1999 update
Fuelsystem16V 1999update
Updatetowiringdiagrams- 1998range
Electricalequipmentwiringdiagramsrip 16V 1999
update
Removal-refittingupdate«£KJ)161/1998range
FuelSystemupdate!0p>16V1999update
UpdatedAirBagwithnewfeatures(98range)
98rangewiringdiagramsupdate
(*)Thesewiringdiagramsreplacethediagramsinthe3rdvolumemanualupdate- printno.
506.670/16whichshouldthereforebedisposedof
Copyright Fiat Auto

SummaryBravo-Brava
PrintN°
506.670/22
(1/2001)
Sections
00
10
55
Page
No(s)
1- 38
1- 8
1- 8
1- 36
1- 28
1- 115
Notes
2000rangetechnicaldata
12428 valvoleEuro3 fuelsystem
159616valvoleEuro3 fuelsystem
1910JTDEuro3 fuelsystem
RadioSystem
2000rangeEuro3 wiringdiagrams
Print n° 506.670/22

Bravo-Brava Summary
TECHNICALSERVICEMANUALCOMPOSITION
Atpresent,October1999,theBravo-Brava4thvolumemanualiscomposedofthefollowingbooklets:
PrintN°
506.670/18
(11/1999)
506.670/19
(XI/1999)
506.670/20
(V/1999)
506.670/21
(X/1999)
Sections
10
55
55
00
10
55
55
10
55
Page
No(s)
1- 35
1- 249
1- 38
1- 9
1- 54
25- 26
249
1- 41
33- 34
1- 2
1- 8
23- 25
83- 86
177- 178
201- 204
229- 230
249
17- 29
Notes
Engine16V98range- Removing-refitting
Electricalequipmentwiringdiagramsfor98rangever-
sions(*)
Electricalequipment:AirBagnewfeatures- SideBag
Technicaldata|Q3)i6v1999update
FuelsystemlOSSl)16V1999 update
Updatetowiringdiagrams- 1998range
Electricalequipmentwiringdiagrams YULl£) isv 1999
update
Removing-refittingupdatel^^)16V98range
Fuelsystemupdatei^p|iev (99update)
UpdateforAirBagnewfeatures98range
98rangewiringdiagramsupdate
Updateforinstrumentpanels98range
Thesewiringdiagramsreplacethosewhicharepartofthe3rdvolumemanualupdate- printno.
506.670/16whichshouldthereforebedisposedof
Copyright Fiat Auto

Bravo- Btava
Summary
TECHNICALSERVICEMANUALCOMPOSITION
AsofMay1999,theBravo-Bravavolume4 manualiscomposedofthefollowingparts
506.670/18
(11/1999)
506.670/19
(111/1998)
506.670/20
(V/1999)
10
55
55
00
10
55
55
1- 35
27-44
1- 249
1- 38
1- 9
1- 54
25- 26
249
1- 41
Enginenjgzi) 16V98 range- Removing-refitting
FuelsystemIftfjji) JTD 98range- Removing-refittingcom-
ponents.
Electricalequipmentwiringdiagramsfor98rangeversions
(*)
Electricalequipment:AirBagnewfeatures- SideBag
Technicaldata16V1999 update
FuelsystemIflZS)16V1999 update
Updatetowiringdiagrams- 1998range
Electricalequipmentwiringdiagramsluczi)161/1999up-
date
(*)Thesewiringdiagramsreplacediagramsinthevolume3 manualupdate- printno.506.670/16which
shouldthereforebedisposedof
Copyright Fiat Auto

Bravo- Brava
Summary
SERVICEMANUALCOMPOSITION
ith
Atpresent,March1999,theBravo-Brava4 volumemanualiscomposedofthefollowingbooklets
506.670/18
(11/1999)
506.670/19
(Ml/1998)
10
55
55
1- 35
27-44
1- 249
1- 38
Engineifgj^)16V98 range- Removing-refitting
Fuelsystemn&ui) JTD 98range- Removing-refittingcom-
ponents.
Electricalequipmentwiringdiagramsfor98rangeversions
C)
Electricalequipment:AirBagnewfeatures- SideBag
(*)Thesewiringdiagramsreplacethosewhicharepartofthe3rdvolumemanualupdate- printno.
506.670/16whichshouldthereforebedisposedof
Copyright Fiat Auto

UntitledDocument
ffle:///D|/Volume%204/intro&tech.htm08/07/2006 17:00:18

Bravo-Brava 0^Introductionandtechnicaldata
99updateContents
;~~~00.
■page
INTRODUCTION
-Identificationdata- Weights1
-Dimensions2
-Capacities4
-Performance- Fuelconsumption5
TECHNICALDATA
ENGINEi|pU6i/
Cylinderheadandvalvegearcom-6
ponents
Fuelsystem7
ELECTRICALEQUIPMENT
Electronicinjection/ignition8
SPECIALTOOLS9
This section contains the specific technical data relating to the 7747 16v version with a returnless
fuel system, for anything not dealt with, refer to the Bravo-Brava 1st volume manual.
Copyright Fiat Auto

Bravo- Brava • ™
99update Introduction
Identificationdata - Weights
l^p) 16V
CHASSIS
ZFA182000
ENGINE
182A2000
VERSION
182AC1AA03
182BC1AA13
182BC1AA13B(•)
3
Door
&
5
Door
*
*
OO.o
GEARBOX
999
5tl
' *
(•) Versions for specificmarkets(Germany)
WEIGHTS(inkg)
lOI
500=
550=
3door
5door
I5WI5WI")JL* 3 door
nnnnn MEi
(■1I5I5WI")JL+ 5 door
nnnnn ill
1100
1130
1600
1680
NOTE FOR VERSIONSWITHACCESSORIES: Inthe presence of specialequipment (non standard air
conditioning, sun roof,trailertowingdevice,etc.), the emptyweightincreases and therefore the carrying
capacity may decrease in relation tothe maximumpermissibleloads.
Copyright Fiat Auto 1

Introduction
Dimensions
oo.
5-DOOR VERSION
Engine
version
l^ptiev
Wheel
rim
51/2Jx14»"3
7
6Jx14"»43
DIMENSIONS (mm)
A
858
B
2540
C
789
D
4187
E
1412
F
1451
1439
G
1453
1441
H
1741
2Print n° 506.670/20
Bravo- Brava W w
1999update

Bravo- Brava ®»«v
99 update Introduction
Dimensions
OO.o
3DOORVERSION
Engine
type
tfpUv
Wheel
rim
6Jx14"43
6Jx15"40
DIMENSIONS (mm)
A
858
B
2540
C
627
D
4025
E
1415
F
1439
1445
G
1441
1447
H
1755
Copyright Fiat Auto
3

Technicaldata
Capacities
Bravo- Brava © w
99update
OO.o
3DOORVERSION
Description Unit Quantity
dm3 (I) (kg)
B Petrol> O.R.95
Unleaded
if
60
*t
(^
50%
+
(A)
^ ^
Totalcapacity
ofcoolingsystem
7.4
7.3
Petrolengines
SELENIA20K
(SAE10W/40)
Totalcapacity I^^^Bh
Partialcapacity
(periodicreplacement)
5.5 4.7
4.8
(4,5•) 4.3 (4,0•)
a= TUTELA
ZF75Synth h 1.98 1.8
a=
b=
TUTELA
Gl/A
K854
1,0
1.0
0 b= TUTELA
MRM2
0.003
TUTELA
||TOP4 o>.._iKJ|^
Totalcapacity
without
ABS 0.40
with
ABS 0.54
*>
4^)
+ E
AREXONS ^
10°C
-- 20°C
3%
50%
100%
<3?
+ EP
2.5-5
(6.4
with
headlam
pwash-
ers)
(▲) Distilledwater
(•)Enginesumponly
4 Print n° 506.670/20

Bravo- Brava © ™
99update Introduction
Performance- Fuelconsumption
OO.o
ENGINETYPE l^p!
16V
3door 5door
50
Speedkm/h
(averageload)
87
128
169
193 190
50
Fuelconsumptionfigures
inaccordancewithstandard
93/116/CE(litres/100km) Urban 11.3
Extra-urban 6.5
B Combined 8.3
11.5
6.6
8.4
CO2exhaustemissions(g/km) 197 193
Theconsumptionandemissionfiguresinthetablearemeasuredinaccordancewiththenewdirective
93/116/CEinforcesinceJanuary1996.
Thisdirectiveinvolvesa realisticdeterminationoffuelconsumptionaimedatthedailyuseofthevehicle.
Thefollowingproceduresarefollowedtomeasurethefuelconsumption:
-urbancycle:beginswitha coldstartthenthenormalurbanusageissimulated;
-extra-urbancycle:thedrivingincludesfrequentaccelerationinallgearscorrepondingtothenormal
usageofthevehicle;thedrivingspeedvariesbetween0 and120km/h;
-averagecombinedconsumption:thisiscalculatedbyincludingabout37%oftheurbancycleand63%
oftheextra-urbancycle.
Thetypeofroute,trafficconditions,drivingstyle,weatherconditions,trimlevel/equipment/accessories,
presenceofspecialequipmentandthestateofthevehicleingeneralcanleadtodifferentfuelconsump-
tionfiguresfromthoseestablishedusingtheabovementionedprocedures.
TheC02exhaustemissions(ing/km)aremeasuredduringtheaveragecombinedcycle.
Copyright Fiat Auto 5

Technicaldata
Engine:cylinderheadandvalvegearcomponents
Bravo- Brava © ™
99update
OO.io
TIMINGDIAGRAMS
W
TIMINGANGLES
A lr»la+jT\
iniet■»i
B^
C
Lxnaust\ *j
D^
opensbefore
TDC
closesafter
BDC
opensbefore
BDC
closesafter
TDC
ICpliev
0°
27°
29°
2°
6 Print n° 506.670/20

Bravo-Brava 9> lev Technicaldata
99updateEngine:fuelsystem
OO.io
INTEGRATEDELECTRONIC
INJECTION/IGNITIONSYSTEMCOMPONENTS
Electroniccontrolunit
Injector
Fuelpressureregulator(incorporatedintheelectricpump)
Coolanttemperaturesensor
Electricfuelpump
Lambdasensor
Idleactuator
Butterflyvalvepositionsensor(potentiometer)
Fuelvapoursolenoidvalve
TopDeadCentreandrpmsensor
Knocksensor
Timingsensor
Butterflycasing
JOS) 16V
HITACHIMFI-155
HITACHIMFI -160(*)
MarelliIWP006
MarelliRPM84
Jaeger40218301
Eth2690350
MarwallESS276
N.TKOZA341-A1
HITACHIGL108771
HITACHIGL212875
MarelliEC1
HITACHIRS-314
NGKKNE03-A
BoschB.232.101.037
HITACHIM646WA
(*)SpecificversionforGermanmarket
Copyright Fiat Auto 1

Technicaldata
Electricalequipment:electronicinjection-ignition
Bravo- Brava ®>™
1999update
OO.io
INTEGRATEDELECTRONICINJECTION-IGNITION
SYSTEM
Make
Firingorder
ICpliu
HITACHI MFI-1
1-3-4-2
IGNITIONCOIL (1PER SPARKPLUG)
Make
Type
Ohmicresistance of primarywinding at 20°C Q
Ohmicresistance of secondarywinding at 20°C Q.
HITACHIGL212875
Ge215492
0.66
-
TOPDEADCENTREANDRPMSENSOR
Make and type
Sensorwindingresistance at 20°C Q
Distance (gap) betweensensor and
mm
crankshaftpulleytooth
HITACHI GE 110492
RS-314
513-627
0.4-1.2
KNOCKSENSOR
Make and type NTKKNE
03-A
TIMINGSENSORSANDCYLINDERIDENTIFICATION
Make and type Bosch
B 232.101.037
ADVANCEONENGINE
Withengineidling (850± 50/min) 9°
± 1°
SPARKPLUGS
Make and type
Thread
Electrode gapmm
NGKBKR6EKC
Champion - RC8BYC
M14x1.25
0.8
8 Print n° 506.670/20

Bravo- Btava © ™
99update Technicaldata
Specialtools
00.A
Tool
number NAMEOFTOOL
ENGINETYPE
igpu,
ENGINE
1860955000
1870684000
1860875000
Fuelconsumptiontestequipment
Petrolpressuredrainageconnector
Toolfortimingcamshafts
•
•
•
Copyright Fiat Auto 9

Bravo-Brava Introductionandtechnicaldata
2000rangeIndex
00.
page
INTRODUCTION
-Identificationdata1
'-.'-■Weights3
-Performance- Fuelconsumption4
-Capacities5
-Productspecifications6
TECHNICALDATA
ENGINEifeiev©)i6v
Specifications
Cylinderblock/crankcase,crankshaft
andassociatedcomponents
Auxiliarydriveshaft
Cylinderheadandvalvegeartiming
components
Timingdiagrams
Lubrication
Coolingsystem- Fuelsystem
IGINEImpure
Specifications
Cylinderheadgasket
Timingdiagrams
Supercharging
Fuelfeedsystem
7
8
12
13
16
17
18
20
21
21
22
22
CLUTCH23
GEARBOXANDDIFFERENTIAL24
BRAKINGSYSTEM26
STEERING27
WHEELS28
FRONTSUSPENSION30
REARSUSPENSION31
ELECTRICALEQUIPMENT32
-Starting34
-Recharging35
-Electronicinjection/ignition36
Copyright by Fiat Auto

Bravo- Btava Introduction
2000rangeIdentificationdata
OO.o
iflpi16v
l(5Bii6v
l^plJTD
CHASSIS
ZFA182000
ENGINE
188A5000
182B6000
182B9000
VERSION
182AT1AA25
182BT1AA26
182AU1AA27
182BU1AA28
182AV1AA29
182BV1AA30
3
Door
•
•
•
5
Door
•
•
•
GEARBOX
SSI
•
•
•
NOTEThis section only deals with the 2000 range CEE F3 versions.
For subjects not dealt with, refer to the Bravo-Brava Manual print n" 506.670 and subsequent
updates.
Copyright by Fiat Auto 1