Fiat Brava Service Manual

Page 3: Summary

Bravo- brava summary t e c h n i c a l s e r v i c e m a n u a l c o m p o s i t i o n at present, october 1999, the bravo-brava 3rd volume manual is composed of the booklets indicated below: print n° sections page nos. Notes 506.670/06 (ml/95) 00 1 - 6 technical data bravo 1988 hgt 20v sport pack 5...

Page 5: Summary

Bravo- brava summary print n° sections page nos. Notes 35 - 36 fuel system update l ^ ^ ) 20v 98 range 10 fuel system update l ^ ^ ) 20v 98 range 10 21 - 22 fuel system update keuji) jtd 98 range 506.670/17 21 -27 1 - 13 gearbox and differential m&z£) 161/98 range (1/1999) 33 7 - 8 abs with active s...

Page 8: Summary

Summary bravo- brava print n° sections page nos. Comments 506.670/11 (vi/1997) 10 4 removing - refitting 1910 td 100 engine 506.670/11 (vi/1997) 10 5 removing - refitting 1910 td 75 engine 506.670/11 (vi/1997) 21-27 4 automatic transmission and differential 506.670/12 (vii/1997) 00 4 algemeen 506.67...

Page 11: Summary

Bravo- brava summary s e r v i c e m a n u a l c o m p o s i t i o n at present, march 1999, the bravo-brava 3 volume manual is composed of the booklets indicated below print n° sections page nos. Comments 506.670/06 (ml/95) 00 1 - 6 technical data bravo 1988 hgt 20v sport pack 506.670/06 (ml/95) 10...

Page 13: Summary

Bravo- brava summary print n° sections page nos. Comments 506.670/17 (1/1999) 10 35 - 36 fuel system update 20v 98 range 506.670/17 (1/1999) 10 21 - 22 fuel system update jtd 98 range 506.670/17 (1/1999) 21-27 1 - 13 gearbox and differential 16v 98 range 506.670/17 (1/1999) 33 7 - 8 abs with active ...

Page 16: Summary

Summary bravo-brava 4a06sv print n° sections page nos. Comments 506.670/14 (111/1998) 00 1 - 10 ^ l6v 98 range 506.670/14 (111/1998) 10 1 - 64 fuel system i6v 98 range 506.670/14 (111/1998) 55 1 - 37 wiring diagrams ^p) i6v 98 range 506.670/16 ( i x / 1 9 9 8 ) 00 1 - 77 technical data 98 range 506....

Page 18: Summary

Summary bravo-brava print n° sections page nos. Comments 5 0 6 . 6 7 0 / 1 4 ( 1 1 1 / 1 9 9 8 ) 00 1 - 10 0 1 lev 98 range 5 0 6 . 6 7 0 / 1 4 ( 1 1 1 / 1 9 9 8 ) 10 1 - 64 fuel system @ l lev 98 range 5 0 6 . 6 7 0 / 1 4 ( 1 1 1 / 1 9 9 8 ) 55 1 - 37 wiring diagrams l @ t x6v 98 range 5 0 6 . 6 7 ...

Page 20: Summary

Summary bravo-brava 4a06sv publication no. Sections page numbers notes 506.670/14 (111/1998) 00 1 ± 10 0 lev 1998 range 506.670/14 (111/1998) 10 1 ± 64 fuel system 0 t i6v 1998 range 506.670/14 (111/1998) 55 1 ± 37 wiring diagrams'®! Lev 1998 range publication no. 506.670/14.

Page 23: Summary

Bravo-brava summary service manual composition at present, september 1996, the bravo-brava 3rd volume manual is composed of the following booklets: print no. Sections page nos. Comments 506.670/06 (111/1995) 00 1 + 6 tech. Data bravo 1988 hgt 20v pack-sport 506.670/06 (111/1995) 10 1 + 18 1910 td 10...

Page 27: Summary

Bravo-brava summary service manual composition at present, april 1996, the bravo-brava 3rd volume manual is composed of the following booklets: print no. Sections page nos. Comments 506.670/06 (vi/1995) 00 1 -5- 6 tech. Data bravo 1988 hgt 20v pack-sport 506.670/06 (vi/1995) 10 1 + 18 1910 td engine...

Page 30: Foreword

Foreword bravo-brava the fiat bravo is a 2 box, 3 door vehicle w i t h a load carrying structure, transversely mounted engine and front wheel drive it is produced with 6 different engine types. The engines have 4 or 5 cylinders in line w i t h clockwise rotation and are mounted transversely at the f...

Page 33: Introduction

Bravo-brava introduction planned maintenance oo. Planned m a i n t e n a n c e p r o g r a m m e n° o p e r a t i o n t h o u s a n d s o f km page n° o p e r a t i o n 20 40 60 80 100 120 140 160 180 page d check tyre condition and wear 1 b check operation of front disc brake pad wear sensor 2 b ch...

Page 36: Introduction

Introduction planned maintenance bravo-brava 00. N c h e c k operation o f front d i s c b r a k e pad w e a r s e n s o r disconnect the connector for the front disc brake pad wear sensor, place the terminal for the wiring side coupling to earth and check that the relevant warning light in the inst...

Page 38: Introduction Bravo-Brava

Introduction bravo-brava planned maintenance oo. 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 over...

Page 40: Introduction

Introduction planned maintenance bravo-brava 00. Q v i s u a l l y i n s p e c t condition o f 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 auxiliar...

Page 42: Introduction

Introduction planned maintenance bravo-brava 00. N c h e c k / a d j u s t handbrake l e v e r t r a v e l operate the handbrake lever several times and check that the travel of the toothed sec- tor is 5 notches. If this is not the case, proceed w i t h the ad- justment as follows: - remove the prot...

Page 44: Introduction

Introduction planned maintenance bravo-brava 00. If the tappet clearance does not correspond to the recommended figures, proceed as f o l - lows: 1. Using pressure lever 1860443000, lower the cup for the tappet concerned and i n - sert tool 1860724000 for retaining tap- pets positioning the notches ...

Page 46: Introduction

Introduction planned maintenance bravo-brava 00. [q check exhaust gas 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). Place the opacity metering measuring unit in a stable position near the vehic...

Page 48: Introduction

Introduction planned maintenance bravo-brava 00. [ 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 follows: - disconnect the connector (1) for the fuel supply pipe from the tank from the filter; - di...

Page 50: Introduction

Introduction planned maintenance oo. 137012v -1581 16v p4a16ca02 1747 16v - 1998 20v -1910 td -1929 d bravo-brava e3 t o p up f l u i d l e v e l s engine coolant do not remove the radiator cap when the engine is very hot as there is a danger of being scalded. The fluid level should checked w i t h ...

Page 52: Introduction

Introduction planned maintenance bravo-brava 00. P4a18ca04 windscreen/rearscreen and 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; - 5...

Page 54: Introduction

Introduction planned maintenance bravo-brava 00. P4a12ax02 qj] replace timing 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; - remove the right wheel arch liner to gain access to the auxiliary shaft drive bel...

Page 56: Introduction

Introduction planned maintenance bravo-brava 00. 1. Complete the refitting of the belt observ- ing the following order: - crankshaft drive pinion ( 1 ) ; - camshaft drive pulley ( 2 ) ; - water pump pulley ( 3 ) ; - automatic tensioner ( 4 ) . Note the belt should be fitted avoiding bending it at ac...

Page 58: Introduction

Introduction planned maintenance bravo-brava 00. 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...

Page 60: Introduction

Introduction planned maintenance bravo-brava 00. 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. 2. Remove the auxiliary shaft belt tensioni...

Page 62: Introduction

Introduction planned maintenance bravo-brava 00. 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. Automat...

Page 64: Introduction

Introduction planned maintenance bravo-brava 00. 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 camshaft and the 3rd cap fixing the ex-...

Page 66: Introduction

Introduction planned maintenance bravo-brava 00. 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 t...

Page 68: Introduction

Introduction planned maintenance bravo 00. 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 pulli...

Page 70: Introduction

Introduction planned maintenance bravo-brava 00. 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 oil pump; place the pin for tool 1860905000 in place of the bol...

Page 72: Introduction

Introduction planned maintenance bravo-brava 00. For the 1910 td 100 version, fix the injec- tion pump pulley tightening the fixing bolts to the recommended torque and re- moving pin 1860965000 from the hous- ing. 2. Rotate the crankshaft through t w o revolu- tions in its normal direction of rotati...

Page 74: Introduction

Introduction planned maintenance bravo-brava 00. 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 w i t h the fixed refer- ences on the engine. Cylinder no. 1 w i l l be at t . D . C , under t...

Page 76: Introduction

Introduction planned maintenance bravo-brava 00. P4a42ca01 fitting and tensioning the timing drive belt 1. Complete the fitting of the timing belt o b - serving the following order: - crankshaft gear; - fixed pulley; - injection pump pulley; - timing pulley; - belt tensioner. A check that the refere...

Page 78: Introduction Bravo-Brava

Introduction bravo-brava planned maintenance oo. Bravo-brava 1581 16v 1. Disconnect the h.T. Leads from the spark plugs taking great care when extracting the boots and remove and replace the spark plugs using an appropriate spanner. Bravo-brava 1747 16v - 1998 20v 2. Remove the cover for the ignitio...

Page 80: Introduction

Introduction planned maintenance bravo-brava 00. M 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. If necessary, top up until the correct level is restor...

Page 82: Introduction

Introduction planned maintenance bravo-brava 00. - 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 m...

Page 84: Introduction

Introduction planned maintenance bravo-brava 00. 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. P4a50ca01 p4a60ca02 2. Release the s...

Page 87: Introduction

Bravo-brava introduction identification data oo.O g e a r b o x c h a s s i s e n g i n e v e r s i o n bravo brava 9 9 9 6 6 6 182 ab 1aa 01 • 182 ab 1 a a 0 1 8 ( a ) • • 182 a4.000 182 bb 1aa 11 • 182 a4.000 182 bb 1aa 11 b ( a ) • 182 ab 11a 02 • 182 bb 11a 12 • • zfa 182 000 182 a6.000 (*) 182 ...

Page 92: Technical Data Bravo-Brava

td 75 cv values in mm 17 cam lift hq 8,5 8,5 8,5 8,5 clearance for timing check 17-20 btt 1 h q operational clearan • e 0,50 0,50 0,35 ± 0,05 0,35 i 0,05 t i m i n g d i a g...

Page 94: Technical Data

Technical data engine: fuel system bravo- brava @> td75 oo.Io test d a t a for bosch injection p u m p , t y p e ve r 679 general test conditions -test oil: iso 4113 -test fluid temperature: 45° ± 1°c (reflux -outlet • ) -pump intake pressure: 0.35 bars -clockwise rotation specific test conditions -...

Page 96: Technical Data

Technical data engine: fuel system oo.Io ops . O r check s t o b e carrie d ou t superchargin g pressur e 1 ba r superchargin g pressur e 0 ba r superchargin g pressur e 0 ba r pul l th e specifi c lever s releas e th e specifi c lever s leve r draw n pul l th e sto p leve r superchargin g pressur e...

Page 99: Technical Data

Technical data engine: typical curves bravo-brava oo.Io a i s i n a u t o m a t i c g e a r b o x engine t y p e 16v gears . 1 . O o o o o hoqllk o o o o o o o o o o gear ratios o o o o o o o o o o 2,807 1,479 1,0 0,735 2,769 idler ratio 1,019 (54/53) fa torque ^ converter 0 mm 216 1 x -• ratio (mul...

Page 101: !§pi

Bravo !§pi mhgt20v introduction and technical data • • ' i n d e x 00. S p o r t pack i n t r o d u c t i o n s t e e r i n g f r o n t s u s p e n s i o n r e a r s u s p e n s i o n w h e e l s page, 1 2 3 4 5 copyright by fiat auto.

Page 103: Technical Data Bravo

Technical data bravo ^ h g t 2 o . Steering 00.41 type 4 m = h » rack and pinion power assisted f © © - i - / no. Of turns lock tc 2.3 > lock ratio f w f rack travel 128 ±1,5 mm / ^ — — \ / \ turning / \ circle i, 0 12 m 26° ± 3 0 ' 1 i n n e r a 2 steering angle v 34° ± 30' j ^ \ steering col. W i ...

Page 105: Technical Data

Technical data 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. Coil...

Page 107: Technical Data

tyre inflation b i h mn pressure bfl in bar engine 1 pressed s t e e l w h e e l rim type radial, t u b e l e s s tyre front rear engine 1 pressed s t e e l w h e e l rim type...

Page 109: Bravo-Brava ©

Bravo-brava © 16v introduction 1998 range identification data - performance - fuel consumption oo.O g e a r b o x c h a s s i s e n g i n e v e r s i o n bravo brava 182 a b 1 a a 01 c • 16v zfa 182.000 182 a4.000 182 a b 1 a a 1 1 b 01 d ( a ) • 16v zfa 182.000 182 a4.000 182 bb 1 a a 11 c • • 182 ...

Page 111: Technical Data

Bravo-brava ijpi 1998 range 16v technical data engine: crankcase assembly oo.Io d e s c r i p t i o n values in mm 0 piston 0 10.2 86.352 - 86.362 86.359 - 86.371 86.368 - 86.378 0.4 piston ring grooves 1 2 3 1.520 - 1.540 1.510 - 1.530 3.010 - 3.030 0 1 2 3 piston rings 0 > 1.470 - 1.490 1.470 - 1....

Page 115: @ I 16V

Bravo-brava @ i 16v 1998 range technical data gearbox and differential 00.21-27 copyright fiat auto 1.

Page 117: Technical Data

Bravo-brava 0 1998 range 16v technical data electrical equipment: starting s t a r t e r motor 00.55 type m. Marelli m70r-12v-1,3 kw (with reduction unit) voltage v 12 rated power kw 1.3 rotation, pinion side clockwise no. Of poles 4 field coil series-parallel w i n d i n g engagement free wheel con...

Page 119: 00.55

Bravo- brava technical data 1998 range electrical equipment: recharging 00.55 lcl& 16v l^p) 16v l^p) 16v** lcl& 16v with air conditioner a l t e r n a t o r make m. Marelli a115i-14v-40/75a m. Marelli a127ir-14v-40/85a bosch kcb1-14v-45/80a bosch kcb2-14v-50/90a bosch* kcb2-14v-55/105a rated system ...

Page 121

Bravo-brava 1998 range introduction and technical data contents page introduction - identification data 1 - weights 3 - performance - fuel consumption 4 - capacities 5 - fiat lubricant product characteristics 6 t e c h n i c a l data e n g i n e ^ 1 6 v 9*20vstepa - characteristics 7 - typical curve...

Page 124: Bravo-Brava Introduction

Bravo-brava introduction 1998 range weights oo.O w e i g h t s (values expressed in kg) e n g i n e step a l^^^l jtd 3 doors 1010 1190 1170 5 doors 1040 - 1195 _ 3 doors c s s 5 doors 1510 1690 1680 _ 3 doors c s s 5 doors 1570 - 1735 3 doors 850 970 920 maximum permitted loads c 5 doors »-» v l mum...

Page 126: Technical Data

Bravo-brava 1998 range technical data capacities oo.O c a p a c i t i e s unit amount dm 3 (l) (kg) 0 petrol > n.O. 95 unleaded diesel s 1242 16v 50 1998 step a 60 1910 jtd 60 50% + 9 ( a ) 1242 16v 5.3 (6.4b) 1998 step a 7.4 (7.2b) total cooling system capacity 1910 jtd 6.3 (6.5h) petrol engines: s...

Page 129: Technical Data Bravo-Brava

Technical data bravo-brava engine: typical curves 1998 range oo.10 1000 2000 3000 4000 5000 6000 7000 p4a08ha01 p4a08ha02 speed time load when laden in at (rpm) minutes brake 8 0 0 - 1 0 0 0 10' no load 1500 10' no load 2 0 0 0 10' no load bench test cycles for overhauled engines w h e n bench-testi...

Page 131: Technical Data

Technical data engine: crankcase assembly bravo-brava 1998 range oo.Io d e s c r i p t i o n tea 16v 20v step a values in mm piston pin seat 0 17.982 - 17.986 20.002 - 20.007 o 0 17.970 - 17.974 19.996 - 20.000 piston pin 0 0.2 4-3 piston pin - housing 0.008 - 0.016 0.002 - 0.011 m piston ring groov...

Page 134: Bravo-Brava Technical Data

Bravo-brava technical data 1998 range engine: crankcase assembly o o .I o d e s c r i p t i o n 1 ^1 16v ]^ppf 20l , s t e p a d e s c r i p t i o n values in mm . . A 10-8 c t p connecting rod b * * bearings - pins c 0.024 - 0.060 0.030 - 0.056 thrust q 11 r ^ r ^ f l h a l , " i n s s 2.310 - 2.36...

Page 138: Technical Data

Bravo-brava 1998 range technical data engine: cylinder head and valve gear oo.10 description values in mm 18 01 35.045-35.070 02 48.045-48.070 camshaft bearings in camshaft hous- ^ 3 ing 49.045-49.070 18 n — i - u - i t - l 5ip tappet housings0 28.400 - 28.421 _ — n _r-u-u — l _ j l — ' — i _ j — " ...

Page 140: Technical Data

Bravo-brava 1998 range technical data engine: counter-rotating shaft oo.10 d e s c r i p t i o n values in mm 25 counter-rotating shaft drive via oil pump driven gear 0 27 4 t t p i 2 0 0 0 1 19.900 - 20.000 • 0 2 46.989 - 47.000 ball bearings for counter-rotating shaft 10 25 counter-rotating shaft ...

Page 142: Technical Data

Bravo- brava 1998 range technical data engine: cooling system - fuel system oo.Io c o o l i n g \l6v & 2 j l ) 20v step a cooling circuit coolant circulation via centrifugal pump, radiator, expansion tank and fan operated by thermal switch coolant pump drive via belt d thermal switch forfan activati...

Page 145: Technical Data

Technical data engine: typical curves bravo-brava 1998 range oo.Io kw cee 80 75 70 65 60 55 50 45 40 35 30 25 20 15 nm cee 1000 1500 2000 2500 3000 3500 4000 4500 5000 rpm test time load speed in at (rpm) minutes brake 8 0 0 - 1 0 0 0 10' no load 1500 10' no load 2000 10' no load bench test cycles f...

Page 147: Technical Data

Technical data engine: crankcase assembly bravo-brava 1998 range oo-io description values in mm ft is piston pin seat 0 25.999 - 26.004 piston ring grooves 2.685 - 2.715 (*) 2.020 - 2.040 3.020 - 3.040 0 piston pin 0 > 25.982 - 25.988 4 - 3 piston pin - housing 0.004 - 0.014 0 1 k piston rings 0 > 2...

Page 149: Technical Data

Technical data engine: crankcase assembly bravo-brava 1998 range oo.Io d e s c r i p t i o n jtd values in mm crankshaft bearings 0 1.836 - 1.840 1.839 - 1.843 1.842 - 1.846 0.254 - 0.508 9-8 crankshaft bearings- main journals 0.011 - 0.071 10 q ) connecting rod 1 bearings ^ 0 1.527 - 1.531 1.530 - ...

Page 151: Technical Data

Technical data engine: cylinder head and valve gear bravo-brava 1998 range oo.Io d e s c r i p t i o n jtd values in m m 13 0 ^ valve guide 0 - 0 2 0 > 8.022 - 8.040 14.010 - 14.030 0.05 - 0.10 - 0.25 13-12 *h valve guide bore in cylinder head 0.033 - 0.080 01 0 14 • e 0 a valve 0 0 a 7.974 - 7.992 ...

Page 153: Technical Data Bravo-Brava

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 a inlet start before tdc 0° b inlet end after bdc 32° c exhaust ® start before bdc 32° d exhaust ® end after tdc 0° 32 publication no. 506.670/16.

Page 156: Technical Data

Bravo-brava 1998 range technical data engine: fuel system c o m p o n e n t s o f b o s c h c o m m o n r a i l e l e c t r o n i c f u e l s y s t e m 00.55 jtd control unit bosch 0.281.001.928 debimeter bosch 0.281.002.199 coolant temperature sensor jaeger 402.183.01 diesel temperature sensor bosc...

Page 161: Technical Data

Technical data brakes bravo- brava 98 range 00.33 rear b r a k e s 1 ^ 1 i » step a rear b r a k e s values in m m - 240 - - 10.80 - 11.10 - * " d ' s c s ^ - 10.10 - i 1 *c a l l o w e d - 9.20 - j i p s ? S - 1.5 - n _ [ s j l ^ 0 caliper 0 - 34 - load p r o p o r t i o n i n g v a l v e vehicle e...

Page 163: Technical Data

Technical data wheels 00.44 bravo-brava 1998 range engine 1 wheel rim type t u b e l e s s tyre radial tread, type i l ii tvre r i l l mh pressure k m 2 « in bars engine 1 wheel rim type t u b e l e s s tyre radial tread, type front rear engine 1 wheel rim type t u b e l e s s tyre radial tread, typ...

Page 165: Technical Data Bravo-Brava

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. A n t i - r o l l torsion bar. Coil springs e n g i n e i 0 ...

Page 167: Technical Data

Technical data electrical equipment bravo-brava 1998 range 00.55 16v 20v step a s t a r t e r motor m. Marelli e80e-12v-0,9kw m. Marelli m 7 0 r - 1 2 v - 1 , 4 k w (with reduction unit) a l t e r n a t o r m. Marelli a 1 1 5 i - 1 4 v - 3 8 / 6 5 a m. Marelli a 1 1 5 i m - 1 4 v - 5 0 / 9 0 a ( • )...

Page 169: Technical Data Bravo-Brava

Technical data bravo-brava electrical equipment: starting 1998 range 00.55 jtd s t a r t e r m o t o r step a type m. Marelli e80-12v-0.9 kw m. Marelli m70r-12v-1.4 kw (with reduction bosch diam 78.5 - 12v - 2.0 kw (with reduction unit) m. Marelli m70r-12v-1.8 kw (with gearing) voltage v un,t, ^ pow...

Page 171: Technical Data

Technical data electrical equipment: electronic injection-ignition bravo-brava 1998 range 00.55 integrated e l e c t r o n i c i n j e c t i o n - i g n i t i o n control m o d u l e 16v type bosch 0.261.204.578 firing order 1 - 3 - 4 - 2 c o i l w i t h 4 h i g h t e n s i o n o u t l e t s type bo...

Page 173: Technical Data Bravo-Brava

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 spontaneous firing order 1 - 3 - 4 - 2 p r e h e a t i n g c o n t r o l u n i t type bosch code 0.281.003.21 5 top d e a d c e n t ...

Page 176: Bravo-Brava Technical Data

Bravo-brava technical data 1998 range special tools 00.A engine tool number tool description step a jtd 1860822000 oil pump timing adjustment tool • 1860824000 tool for fitting camshaft seal • 1860831000 wrench for timing pulley • 1860833000 hexagonal, splined wrench for removing-refitting oil sump ...

Page 178: Bravo-Brava Technical Data

Bravo-brava technical data 1998 range special tools 00.A engine tool number tool description step a j ^ j l jtd 1870718000 blade for removing oil sump • 1890385000 valve guide bore reamer • 1895615000 tool to check piston pin unseating load (to be used with 1895884000) • 1895762000 torque wrench for...

Page 181: Technical Data Bravo-Brava

Technical data bravo-brava special tools 1998 range o 0 . A engine tool number tool description step a s u s p e n s i o n s y s t e m 1845028000 tool for removing front hub bearing inner race from flange (to be used with 1840005003, 1840005302 and 1840005400) • • • 1847014000 puller, wheel hub cap ...

Page 183: Technical Data Bravo-Brava

Technical data bravo-brava tightening torques 1998 range oo. Part thread tightening torques engine part thread tightening torques !Np) 20v step a part thread danm !Np) 20v step a engine bolt retaining main bearing caps to crankcase m 1 0 x 1 . 2 5 4 + 90° • bolt retaining main bearing caps to crankc...

Page 185: Technical Data Bravo-Brava

Technical data bravo-brava tightening torques 1998 range oo. Part thread tightening torques engine part thread tightening torques i ® i 1 6 , step a part thread danm i ® i 1 6 , step a coolant temperature sender unit for i.E. System m1 2x1.5 2 • • bolt retaining sensors to crankcase and cylinder hea...

Page 189: Technical Data

Technical data tightening torques 00 bravo-brava 1998 range part. Thread tightening torques danm engine part. Thread tightening torques danm step a jtd bolt retaining injection pump to intake manifold end mount m8 2.6 • injection pump gear retaining nut m 1 4 5 • fuel temperature sensor m 1 2 1.6 nu...

Page 192: Bravo-Brava Technical Data

Bravo-brava technical data 1998 range tightening torques oo. Tightening torques engine part thread tightening torques »§pll6v step a danm »§pll6v step a bolt retaining brace to differential end mount m12x1.25 8 • bolt retaining differential end flexible block to beam m8 3.6 • • • bolt retaining brac...

Page 194: Technical Data

Bravo-brava 1998 range technical data tightening torques oo part thread tightening torques engine part thread tightening torques 20v step a j^^j jtd part thread danm 20v step a j^^j jtd tapered, thread m22x1.5 4.6 • • • tapered threaded plug for filling gear case with oil m22x1.5 4.6 • • • screw ret...

Page 197: Technical Data Bravo-Brava

Technical data bravo-brava tightening torques 1998 range oo. Tightening torques engine part thread tightening torques step a danm step a rear s u s p e n s i o n screw with broad flange retaining front flexible block to rear subframe m 1 2 x 1 . 2 5 1 0 . 8 • • • screw with broad flange retaining re...

Page 201: Bravo-Brava  0

Bravo-brava 0 t d engine fuel system 10. F u e l s y s t e m with l u c a s ft09 pump i n t r o d u c t i o n 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 comb...

Page 203: Bravo-Brava Engine

Bravo-brava engine fuel system 10. Air i n t a k e c i r c u i t the air intake circuit is turbocharged by means of a garrett gt15 turbocharger with waste-gate. Air is taken in through intake (1) and flows through filter (5) before compression in exhaust gas-driven turbocharger (2). Air then flows t...

Page 205: Bravo-Brava 0

Bravo-brava 0 td engine fuel system 10. Injection pump the lucas ft09 injection pump is designed specifically for indirect injection diesel pumps. New innova- tive features optimise engine service characteristics under all operating conditions. More specifically, the pump reduces fuel consumption, h...

Page 207: Engine

Bravo-brava engine fuel system 10. F u e l c i r c u i t diagram =0* © / / / / / / /v © 1. Turbocharging control valve 2. Feed pressure regulator valve 3. Engine stop solenoid 4. Pumping element 5. Outlet valve 6. Metering device 7. Feed pump 8. Advance actuator control solenoid 9. Pressurisation va...

Page 209: Ecu

Bravo-brava 1 0 ™ engine fuel system 10. I i i f a s t i d l e m a n a g e m e n t c o o l a n t temperature air temperature r p m air conditioner ecu solenoid fast idle coolant temperature accelerator lever position r p m intake air quantity ecu atmospher- ic pressure borg warner solenoid the contr...

Page 211: Bravo-Brava  1 0

Bravo-brava 1 0 td engine fuel system 10. Input and o u t p u t 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 1. Electronic control unit 2. Injection pump 3. Glow plug control unit 4. Heating/ventilation system 5. Glow plug warning light 6. Injection system failure warning ...

Page 213: Engine

Bravo-brava key to wiring diagram 1. Heater plugs warning light 2. Rev counter signal 3. Air conditioner relay 4. Air conditioner activation button 5. Fiat/lancia tester fault diagnosis point 6. Injector with controls 7. Rpm and tdc sensor 8. Coolant temperature sensor 9. Accelerator lever position ...

Page 215: Bravo-Brava 0

Bravo-brava 0 td engine fuel system 10. Coolant temperature sensor coolant temperature is measured by a sensor containing an ntc resistance, w h i c h alters resistance in inverse proportion to tempera- ture as shown in the diagram. The control unit records a voltage change proportional to the curre...

Page 217

Bravo-brava 1 0 ™ engine fuel system 10. B l o w - b y gas r e c i r c u l a t i o n d i a g r a m ) 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. This mixture is defined " b l o w - b y " or ...

Page 219: Bravo-Brava 0

Bravo-brava 0 td 100 engine index 10. Page r e m o v i n g - r e f i t t i n g - removing - refitting power unit 1 r e p l a c i n g a u x i l i a r y s h a f t b e l t - removing - refitting^ alternator and power assisted steering drive belt 12 r e p l a c i n g t i m i n g b e l t - removing timin...

Page 221: Engine

Engine removing - refitting bravo-brava 1 0 td 100 10. 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 s h o w n . 3. Disconnect sleeve (1) connecting turbine - intercooler and air outlet sleeve (2) from intercooler ...

Page 223: Engine

Engine removing - refitting bravo-brava 0 td 100 10. 1. Loosen clips (1), unscrew bolts ( 2 ) , dis- connect connection (3) and then discon- nect the first section of the air intake pipe complete w i t h debimeter. 2. Loosen clip ( 1 ) , unscrew screw (2) dis- connect electrical connections (3) and ...

Page 225: Engine

Engine removing - refitting bravo-brava 1 0 td 100 10. 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. 4. Disconne...

Page 227: Engine

Engine removing - refitting bravo-brava 1 0 tdioo 10. 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. 4. Remove the pollen filter ...

Page 229: Engine

Engine removing - refitting bravo-brava 1 0 tdioo 10. 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 s h o w n . ...

Page 231: Engine

Engine replacing auxiliary belt bravo-brava 0 td100 10. - 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 "remov...

Page 233: Engine

Engine replacing timing belt bravo-brava 1 0 td 100 10. 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. 4. Remove the lower ...

Page 235: Engine

Engine replacing timing belt bravo-brava f 0 td 100 10. 1. Loosen the three injection pump pulley re- taining bolts. 2. Turn the injection pump pulley until pin 1860965000 fits into the point s h o w n . 3. Finish fitting the timing belt by assem- bling components in the following order: 1. Cranksha...

Page 237: Engine

Engine removing - refitting cylinder head bravo-brava 1 0 tdioo 10. 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. 1. Remove the upper cylinder head protec- tion by unscrewing the reta...

Page 239: Engine

Engine removing - refitting cylinder head bravo-brava 1 0 tdioo 10. 4. Disconnect the 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. Disconnect the fuel recove...

Page 241: Engine

Engine removing - refitting cylinder head bravo-brava 1 0 td 100 10. 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 cool...

Page 243: Engine

Engine removing - refitting cylinder head bravo-brava 1 0 td 100 10. 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 w i t h the intake manifold. F i t t i n g c y l i n d e r head g a s k e t check the am...

Page 245: Engine

Engine removing - refitting coolant pump bravo-brava i j p td100 10. 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. 1. Position a suitable container to collect the coolant and disconnect the coolant sleeves ...

Page 247: Engine

Engine removing - refitting radiator bravo-brava 1 0 to 100 10. 1. Unscrew the bolts retaining the radiator to the body, release from the lower pins and then remove from the upper part of the e n - p4a05fx01 g i n e b a y c o o l i n g s y s t e m f i l l i n g p r o c e d u r e (heated and air cond...

Page 249

Cd -c -c a.-a o o tc ' a u ib p q. Cd w _ \w t? J) rn n i/i m ® o) - 0> ° £ ~ s — co a3 c o co cd c o £ •5. C co o -a t £2 o to = a; cd q. O "3 - q s> .E » is to c o j - - a ^ a c c 3 o e o to s.E id co — c 0) (o 0) cd " to • to o — c o » c o oj £ "o . C (j 10 ' •• o cd ~ o vi £ > c 3 £ •- 3 e i f ™...

Page 251: Engine

Engine contents bravo-brava '98 range 10. Page lambda probe 54 - r e m o v i n g - r e f i t t i n g 5 4 engine speed and tdc sensor 54 r e m o v i n g - r e f i t t i n g 5 4 c h e c k i n g gap 5 4 copyright fiat a u t o s.P.A. A n y reproduction of the text or illustrations is prohibited. The inf...

Page 254: Bravo-Brava  @ »

Bravo-brava @ » 16v 98 range e n g i n e fuel system 10 d i a g r a m s h o w i n g i n f o r m a t i o n e n t e r i n g / l e a v i n g t h e c o n t r o l u n i t a n d 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 p4a03jj01 1. Engine control unit 18. Speedom...

Page 256: & I

Bravo-brava & i 16v e n g i n e 98 range fuel system 10. 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 a n y engine operating point is identified by t w o parameters; - rotation speed; - engine load. If these parameters are k n o w n by means of appropriate processing it is...

Page 258

Bravo-brava i § i e n g i n e 98 range fuel system 10. 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 i...

Page 260

Bravo-brava $ ** e n g i n e 98 range fuel system 10- rotation speed restricter this strategy restricts the maximum speed w h i c h can be reached by the engine enabling the cut-off. There are t w o different cut-off thresholds: - static restriction (the engine speed approaches the level s l o w l y...

Page 262

Bravo-brava \^ iev e n g i n e 98 range fuel system 10. 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. The control unit impl...

Page 266: E N G I N E

Bravo-brava @ 98 range 16v e n g i n e fuel system 10. Diagaiostica the system is equipped w i t h an autodiagnostic function w h i c h is designed to verify an irregular state for the f o l l o w i n g components: actuators injectors coils charcoal filter solenoid valve engine idle adjustment actua...

Page 269: E N G I N E

E n g i n e fuel system bravo-brava i egg i 6 v 98 range 10. B o s c h 1.5.5 s y s t e m w i r i n g d i a g r a m connector a (vehicle side) 8 d o c i 9 •0 t. /k 0 0 - 0 — 4 o i 1 2 3 i 1 8 9 it 1112 13 14 15 16 17 ib 19 21 0 10 11 o •o £ ) o o £ ) o o o e o o e e o o q o o e o o g o o o o o o o o ...

Page 272: E N G I N E

Bravo-brava @ t 16v e n g i n e 98 range fuel system 10. 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. Absolut...

Page 274: Bravo-Brava  £ P

Bravo-brava £ p 98 range aii6v e n g i n e fuel system 10. E n g i n e rpm a n d 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. Operating principle the sensor consists of a tubular casing (1) containin...

Page 276: Bravo- Brava 0

Bravo- brava 0 1998 range 16v e n g i n e fuel system injection ntc ntc c o °c a -20 15970 40 1150 -10 9620 50 807 0 5975 60 576 10 3816 70 418 20 2500 80 309 25 2044 90 231 30 1679 100 176 ins1 •rument c q 80 300.8-313.2 90 226.3-234.1 100 172-177 110 132.9-136.1 120 103.6-106.6 engine c o o l a n ...

Page 279: E N G I N E

E n g i n e fuel system 10. Bravo-brava njp* 16v 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 t w o t w i n outlet coils fitted at the side of the cylinder head. The coils used are the closed magnetic circuit...

Page 281: E N G I N E

E n g i n e fuel system 10. P4a30jj01 1 . Accelerator control lever 2. Idle speed adjustment actuator and but- terfly position sensor 3. Accelerator cable adjustment bracket 4. Anti-tamper screw bravo-brava i g i lev 98 range b u t t e r f l y c a s i n g the butterfly casing has the task of meterin...

Page 283: E N G I N E

E n g i n e fuel system 10. 1. Electric fuel pump 2. Fuel filter 3. Fuel gauge w i t h float 4. Pressure regulator 5. Gauze pre-filter bravo-brava 16v 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 support...

Page 285: E N G I N E

E n g i n e fuel system 10. Bravo-brava n$i 16v 98 range inertia s a f e t y s w i t c h 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 (an impact) to prevent the fuel from c o m i n g out and caus...

Page 288: Lop*

Bravo-brava lop* 98 range 16v e n g i n e fuel system 10. D i a g r a m showing a n t i - e v a p o r a t i o n c i r c u i t the anti-evaporation system is designed to prevent the fuel vapours, consisting of the lightest particles of hydrocarbons which form in the tank from being discharged into th...

Page 291: E N G I N E

E n g i n e fuel system 10. Bravo-brava i 0 i 16v 98 range charcoal filter solenoid valve the function of this valve is to control t h e 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. If...

Page 293: E N G I N E

E n g i n e fuel system 10 bravo-brava l £ i 16v 98 range p4a42jj01 table summarizing pollutant emission tolerance values co (%) hc (p.P.M.) c02 (%) upstream of the catalyzer 0,4 - 1 > 12 downstream of the catalyzer ^ 13 checking concentration of co and hc at the exhaust the exhaust concentration of...

Page 295: Bravo-Brava  @ I

Bravo-brava @ i 16v 98 range e n g i n e fuel system 10. 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 va...

Page 297: Engine

Engine bravo-brava ifpi i e v fuel system 98 range 10. Removing the t e s t equipment remove the test equipment 1860955000 w i t h the key in the off position, f o l l o w i n g these instructions: - introduce the end of the pipe connected to the valve (c) into a suitable container; - open the valve...

Page 299: E N G I N E

E n g i n e fuel system 10. Bravo-brava ^ 16v 98 range f u e l drip t r a y a s s e m b l y n o t e /n order to extract the assembly from the tank, the fuel should not be high- er than the halfway mark. Removing-refitting proceed w i t h removing the fuel drip tray as- sembly as follows: - remove th...

Page 301: E N G I N E

E n g i n e fuel system 10. Bravo-brava k j p 16v 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 303: Engine

Engine fuel system bravo- brava 9 '98 range 10. 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). - connect switch mpx 97 (tool 1806365000) to t...

Page 305: Engine

Engine fuel system bravo- brava 9 '98 range engine c o n t r o l unit removing - refitting remove t h e control unit as f o l l o w s : - disconnect both connectors in t w o stages: a) turn the metal hook up to release the c o n n e c t i o n ; b) pull a w a y the c o n n e c t i o n ; - unscrew t h...

Page 307: E N G I N E

Bravo @ 20v e n g i n e 98 range fuel system 10. B o s c h m o t r o n i c m e 3.1 m.P.I. I n t e g r a t e d i n j e c t i o n / i g n i t i o n s y s t e m introduction the bosch motronic system fitted on the 1998 5 cylinder 20 valve engine belongs to the category of static advance, inductive disc...

Page 309: 2Ov  E N G I N E

Bravo ^ 2ov e n g i n e 98 range fuel system 10. These values have been obtained experimentally, by means of a long series of practical tests carried out on prototypes at the engine test bench, to identify the advances w h i c h give the best compromise be- t w e e n the conflicting requirements of ...

Page 311: E N G I N E

Bravo ft 20v e n g i n e 98 range fuel system 10. Having reached this condition, the normal functions for idling and cut-off during deceleration are only reactivated w h e n the fuel cut-off threshold is exceeded to prevent the engine from not running s m o o t h - ly. The levels for restoring the s...

Page 313: Bravo Ft 2O

Bravo ft 2o v e n g i n e 98 range fuel system 10. Self-adjustment of the system the control unit is equipped w i t h a self-adjustment function w h i c h is designed to recognize the changes w h i c h take place in the engine due to the bedding in processes over a period of time and the ageing of b...

Page 315: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. D i a g r a m s h o w i n g i n f o r m a t i o n e n t e r i n g / l e a v i n g t h e 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 n t r o l u n i t and s e n s o r s / a c t u a t o r s 1. Electronic control unit 2. Four stage pressure sw...

Page 317: Bravo Ft 20V

Bravo ft 20v 98 range e n g i n e fuel system 10. 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 1. Fuel vapour cut out solenoid valve 2. Charcoal filter 3. Multi-purpose valve 4. Fuel vapour separator 5. Safety and ventilation valve 6. Float valve 7. Tank 8. Injection/i...

Page 319: Bravo Ft 20V

Bravo ft 20v 98 range e n g i n e fuel system 10. 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 2. Lambda sensor 3. Catalytic silencer 4. Silencers 5. Presa co the control of the mixture strength, w h i c h is the closed-loop type, is activated by the lambda sensor w h i c h...

Page 321: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. Connection between control unit/ignition coils and injectors key: 1. Injection/ignition system failure warning light 2. Rev counter signal 3. Engagement of climate control 4. Diagnostic socket 5. Fiat code control unit 6. Vehicle speed sensor 7. Rpm ...

Page 323: Bravo \^ 2Ov

Bravo \^ 2ov 98 range p4a22jj01 e n g i n e fuel system 10. F u s e s and r e l a y s note for more information, see group 55-electrical equipment main fuses (maxi-fuse) a. System fuse b. Fuse controlled by the ignition copyright by fiat auto 17.

Page 325: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. Identification of the control unit connections (pin-out) m o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o...

Page 327: E N G I N E

Bravo ft 20v 98 range e n g i n e fuel system 10. I g n i t i o n 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 p l u g ; this solution eliminates the high tension cir- cuit, increasing reliability and safety and de- creasing the ris...

Page 329: E N G I N E

Bravo ft 20v 98 range e n g i n e fuel system 10. 1. Rpm sensor 2. T o o t h e d pulley 3. Engine flywheel 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 through the variation of the magnetic field produced b...

Page 331: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. L e c t r i c f u e l p u m p (0.580.313.011) the electric fuel pump is located inside the fuel tank, in a special housing w h i c h also i n - cludes: - the fuel pressure regulator; - the fuel gauge; - the fuel filter. 1 . Electric fuel pump; 2. Fue...

Page 333: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. A c c e l e r a t o r pedal p o t e n t i o m e t e r (0.281.002.203) the position of the accelerator pedal is trans- formed into an electrical voltage signal and sent to the injection control unit by the p o - tentiometer connected to the appropriat...

Page 335: Bravo Ft 20V

Bravo ft 20v 98 range e n g i n e fuel system iot 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 the actuator is fixed to the inlet chamber and regulates the quantity of air d r a w n in by the e n - gine. According to the s...

Page 337: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system 10. A the sensor can be rapidly put out of action by even small amounts of lead in the fuel. Checking the resistance the resistance of the heater and the sensor can be measured by disconnecting the c o n - nector and connecting an ohmmeter as s h o w n i...

Page 339: Bravo Ft 20V

Bravo ft 20v 98 range diagram s h o w i n g operation of the phase transformer e n g i n e fuel system 10 1. Solenoid valve- 7. Piston spring 2. Valve body 8. Battery 3. Valve body spring 9. Injection/ignition system relay 4. Piston 10. Injection/ignition control unit 5. Pinion 1 1 . Ignition switch...

Page 341: E N G I N E

Bravo ft 98 range 20v e n g i n e fuel system ibt i n e r t i a s w i t c h in order to increase the safety of the o c c u - pants, in the case of an impact, the vehicle is equipped w i t h an inertia switch located i n - side the passenger compartment, fixed to the left side panel. This sensor redu...

Page 343: Bravo- Brava 9

Bravo- brava 9 99 range e n g i n e fuel system 10. Checking the resistance the resistance of the solenoid valve can be measured by disconnecting the c o n n e c t o r and connecting an ohmmeter as illustrated in the diagram. Resistance: 17.5-23.5 ohm at 20 °c wiring connector the numbers indicate t...

Page 345

Bravo ^ 2ov e n g i n e 98 range fuel system 10. 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 ...

Page 347: Bravo Ft  2

Bravo ft 2 0 v e n g i n e 98 range fuel system 10. 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" command sent by the diagno...

Page 349: E N G I N E

Bravo-brava ft-m> e n g i n e 98 range index 10. Page f u e l s y s t e m 1 - introduction 1 - system management strategies 1 - functional diagram s h o w i n g fuel system 2 i n j e c t i o n s y s t e m w i r i n g d i a g r a m 6 - injection electronic control unit 8 - diagram showing information...

Page 351

E n g i n e bravo-brava ft™ fuel system 98 range 10. F u n c t i o n a l d i a g r a m s h o w i n g f u e l s y s t e m p4a02kj01 1. Auxiliary electric fuel p u m p 2. Heater plugs control unit 3. Vehicle speed 4. Rev counter 5. Heater plugs warning light 6. Infocenter (system failure indication) 7...

Page 353: E N G I N E

E n g i n e bravo-brava ft™ fuel system 98 range 10. 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 id...

Page 355

6 print no. 506.670/16.

Page 357: Engine

Engine bravo- brava © ™ fuel system 1998 range 10. 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 achi...

Page 359: Engine Bravo-Brava Ft™

Engine bravo-brava ft™ fuel system 98 range 10. Diagram s h o w i n g i n f o r m a t i o n e n t e r i n g / l e a v i n g t h e i n j e c t i o n c o n t r o l u n i t and s e n s o r s / a c t u a t o r s p4a10kj01 1. Auxiliary electric fuel pump 13. 2. Climate control compressor 14. 3. Egr modul...

Page 361: Engine Bravo-Brava Ft™

Engine bravo-brava ft™ fuel system 98 range 10. T i m i n g s e n s o r this hall effect t y p e sensor is fitted on the cylinder and is facing the camshaft pulley (exhaust). There is an opening in the pulley w h i c h allows the timing sensor to detect the engine timing position and signal it to th...

Page 363: E N G I N E

E n g i n e fuel system 10. P4a14kj03 bravo-brava ft™ 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- tects the temperature of the engine coolant by means of an ntc thermistor w i t h a negative re- sistance coefficient. The sens...

Page 365: Engine

Engine fuel system jtd bravo-brava ft 98 range 10. 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. The "brake pedal pressed" signal is used by the control unit: - for ...

Page 367: E N G I N E

E n g i n e fuel system 10. 1. Impeller 2. Volumes 3. Inlet port 4. Supply port 5. Rollers 6. Outer ring 7. Excess pressure valve p4a18kj02 bravo-btava ft™ 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 g a u g e this assembly is basically composed of: - a roller ...

Page 369: Engine

Engine bravo-brava ft™ fuel system 98 range 10. 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 f o l l o w i n g tasks: - pressurizing the tank - ventilation - seal in case of overturn pressurizing the tank the tank pressure is kept at bet...

Page 371: Engine Bravo-Brava Ft™

Engine bravo-brava ft™ fuel system 98 range 10. 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 turboc...

Page 373: Engine Bravo-Brava Ft™

Engine bravo-brava ft™ fuel system 98 range 10. E x h a u s t g a s 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. This dilutes the fuel mixture w i t h t...

Page 375: E N G I N E

E n g i n e fuel system 10. P4a26kj01 bravo-brava ft™ 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 c o m i n g f r o m t h e c r a n k c a s e ( b l o w - b y ) the crankcase emissions are composed of m i x - tures of air/diesel and exhaust gases w h i c h es- cape from the pis...

Page 377: Engine

Engine fuel system jtd bravo- brava ft 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 j u n c t i o n unit cover. Disconnect the terminals and remove the battery 1. Disconnect the f l o w meter electrical c o n - nection. 2. L...

Page 379: Engine

Engine fuel system bravo- brava ft ™ 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 s w i t c h beneath the j u n c t i o n unit cover. - disconnect the terminals and remove the battery. 1. Disconnect the electric...

Page 381: Engine

Engine btavo- brava 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 tensio...

Page 384: E N G I N E

Bravo-brava ft td100 e n g i n e fuel system 10. I n j e c t i o n pump the lucas ft09 injection pump has been specifically designed for indirect injection diesel engines w i t h special innovative features w h i c h ensure optimum engine running in all operating conditions; in partic- ular, it allo...

Page 386: E N G I N E

Bravo-brava ft td100 e n g i n e fuel system 10. F u e l c i r c u i t diagram 1. Supercharing control valve 2. Transfer pressure regulator valve 3. Engine cut out solenoid valve (elec- trostop) 4. Pumping element (a) front section view (b) side section view 5. Supply valve 6. Meter 7. Transfer pump...

Page 388: E N G I N E

Bravo-brava ft td100 e n g i n e fuel system 10. 1. Fuel inlet 2. Small piston 3. Cylinder 4. Pin 5. Spring 6. Cam seal 7. Solenoid valve 8. Fuel outlet adjusting injection advance the injection advance adjustment system makes it possile to vary the start of the injec- tion so that it takes place at...

Page 390: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. Hydraulic head the functions of metering, pumping and distributing take place in the main section of the injection p u m p , known as the hydraulic head. The hydraulic head is composed of t w o groups: - the hydraulic head stator; - the distributor r...

Page 392: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. Supercharging control valve the function of the supercharging control valve is to adjust the value of the maximum fuel f l o w rate ac- cording to the variations in the pressure of the intake air created by the turbocharger. The supercharging control...

Page 394: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. 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 the electrical/electronic circuit for the fuel system basically comprises wiring, an electronic control unit and the f o l l o w i n g sensors and actuators: - rpm sensor - coolant temperature s...

Page 396: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. E x h a u s t g a s r e c i r c u l a t i o n m a n a g e m e n t the electronic control unit calculates the weight ratio between the "clean" intake air and the quantity of burnt gases w h i c h can be returned to the intake. Depending on the engine ...

Page 398: E N G I N E

Bravo-brava ft td100 e n g i n e fuel system 10. S i g n a l s a r r i v i n g a t and l e a v i n g t h e c o n t r o l u n i t / s e n s o r s and a c t u a t o r s 1. Electronic control unit 2. Injection pump 3. Heater plugs control unit 4. Climate control system 5. Heater plugs warning light 6. ...

Page 400: E N G I N E

Bravo-brava ft td100 wiring diagram key 1. Heater plugs warning light 2. Rev counter signal 3. Climate control relay 4. Climate control on button 5. Fiat/lancia tester diagnostic socket 6. Instrument injector 7. Rpm and tdc sensor 8. Coolant temperature sensor 9. Fuel introduction lever position sen...

Page 402: E N G I N E

Bravo-brava ft mm td 100 e n g i n e fuel system 10. Coolant temperature sensor the temperature of the engine coolant is measured by a sensor w h i c h comprises an ntc resistor where the resistance varies in a manner which is inversely proportional to the temperature, as illustrated in the diagram....

Page 404: E N G I N E

Bravo-brava ft td100 e n g i n e fuel system 10. Diagram showing recirculation of g a s e s coming f r o m t h e engine crankcase ( b l o w - b y ) the engine crankcase emissions are composed of a mixture of air, diesel fuel and burnt gases w h i c h es- cape from the piston seals in addition to lub...

Page 406: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. R e m o v i n g - r e f i t t i n g p u m p i n j e c t i o n position the vehicle on a lift, disconnect the positive battery terminal, remove the right front wheel and proceed as f o l l o w s : 1. Remove the bolts shown and remove the right front w...

Page 408: E N G I N E

Bravo-brava ft to 100 e n g i n e fuel system 10. 1. Stop the rotation of the injection p u m p drive pulley by tightening the t w o service bolts (1) in the special openings in the pump support, then undo the bolts (2) fixing the pulley, undo the bolts ( 1 ) and remove the pulley. 2. Acting at the ...

Page 410: E N G I N E

Bravo-brava ft td 100 e n g i n e fuel system 10. 1. Disconnect the vaccum pipe from the inlet manifold and from the fast idle actuator acting at the points shown. 2. Using spanner 1852138000 undo the connectors for the fuel supply pipes at the injectors. 3. Undo the connectors s h o w n at the pump...

Page 413: E N G I N E

Bravo-brava ft 16v e n g i n e '98 range fuel system 10. M . M a r e l l i - w e b e r i.A.W.-49f i n t e g r a t e d f u e l i n j e c t i o n - i g n i t i o n introduction the i.A.W.-49f system fitted to the 1581 i.E. 16v engine belongs to the group of digital electronic igni- tion systems w i t ...

Page 415: E N G I N E

Bravo-brava ft 16v e n g i n e '98 range fuel system 10. The management strategies ensure the best ignition advance and fuel delivery, thus providing the cor- rect mixture strength at all times as the engine load and environmental conditions vary. The system management strategies are basically as fo...

Page 417

Bravo-brava ft e n g i n e '98 range fuel system 10. Self-adaptivity the control unit has a strength self-adaptivity function, w h i c h memorizes any deviations between basic mapping and corrections imposed by the lambda probe which may arise peristently during operation. These deviations (due to a...

Page 419: E N G I N E

Bravo-brava ft '98 range e n g i n e fuel system 10 operation in deceleration during this stage of use of the engine, t w o strategies are superimposed: 1. A negative transient strategy for maintaining a stoichiometric quantity of fuel supplied to the engine (less pollution). This stage is recognize...

Page 421: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. M a n a g e m e n t o f ignition the ignition circuit is of the static type w i t h inductive discharge, i.E. W i t h o u t high tension distributor w i t h power modules located inside the fuel injection-ignition electronic control unit. The ...

Page 423: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. When examining the voltages required for the spark between the plug electrodes, it may be noted that in the cylinder at the compression stroke, this voltage is high (over 10kv) while in the cylinder in the ex- haust stroke the voltage is l o w...

Page 425: E N G I N E

Bravo-brava ft 16v e n g i n e '98 range fuel system 10. M a n a g e m e n t o f engine i d l e c o n t r o l the general aim of the strategy is to keep the engine idle speed around the value stored in memory (hot engine: 850 rpm): the position assumed by the actuator depends on the engine condition...

Page 427: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. D i a g r a m o f i n p u t / o u t p u t i n f o r m a t i o n b e t w e e n c o n t r o l unit and s e n s o r s / a c - t u a t o r s o f t h e f u e l i n j e c t i o n - i g n i t i o n 1. Electronic control unit 2. Speedometer sensor 3. ...

Page 429: E N G I N E

Bravo-brava ft '98 range lev e n g i n e fuel system 10. D i a g r a m o f f u e l s u p p l y s y s t e m because of the particular shape of the tank, during filling, an air pocket would be created which would pre- vent complete filling; the pipe (4) allows air to flow out from the bot- tom part, t...

Page 431

Bravo-brava ft i * e n g i n e '98 range fuel system 10. D i a g r a m of c r a n k c a s e g a s 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. Throttle body 5. Pipe for exhaust gas recirculation during idling 6. Calibrated hole the system controls the emissions, from the crankcase, of ...

Page 433: E N G I N E

Bravo-brava ft lsv e n g i n e '98 range fuel system 10. Key to components on fuel injection-ignition wiring diagram 1. Fuel injection-ignition electronic control unit 2. Battery 3. 4 0 a main fuse protecting ignition-dependent devices 4. 3 0 a main fuse protecting fuel injection-ignition 5. Ignitio...

Page 435: Ft  1 * Engine

Bravo-brava ft 1 * engine 98 range fuel system 10. Components key 1 intake air pressure and temperature sen- sor 2 lambda sensor coupling 3 injection system relay 4 protective fuses 5 engine idle speed actuator 6 butterfly valve position sensor 7 vehicle speed sensor 8 30a general system protective ...

Page 437: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. C o m p o n e n t s o f t h e f u e l i n j e c t i o n - i g n i t i o n the fuel injection-ignition mainly comprises wiring, an electronic control unit and the f o l l o w i n g sensors and actuators: sensors - rpm and tdc sensor - knock sen...

Page 439: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. Removing-refitting pull the locking device (1) upwards and disconnect the top connector ( 2 ) . 2. Pull the locking device (1) d o w n w a r d s and disconnect the bottom connector (2) then undo the nuts ( 3 ) . 3. Remove the bracket (1) and m...

Page 441: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. Rpm and t d c s e n s o r (jaeger cvm02) the sensor (1) for rpm and reference of the crankshaft angle (identification of tdc) is secured to the engine block and is opposite the phonic wheel (7) located on the crankshaft pulley. Principle of op...

Page 443: Bravo- Brava 9

Bravo- brava 9 1998 range engine fuel system a a a v 1 2 3 70 63 56 10. K n o c k s e n s o r (kne-03) this sensor is the piezoelectric t y p e a n d is f i t - ted on the cylinder block/crankcase in a p o s i - t i o n w h i c h is symmetrical in relation t o the pairs of cylinders 1 -2 and 3-4. Th...

Page 445: Engine

Bravo- brava w 16v 1998 range engine fuel system the f o l l o w i n g graph shows sensor voltage o u t p u t for different throttle opening angles. 10. T h r o t t l e v a l v e position s e n s o r a. Sensor used o n premodification cars b. Sensor used o n p o s t m o d i f i c a t i o n cars the ...

Page 447: Bravo- Brava 9

Bravo- brava 9 1998 range b1 b2 0" i_ injection ntc ntc instrument c q c fi- -20 15970 40 l l 50 -10 9620 50 807 0 5975 60 576 10 3816 70 418 20 2500 80 309 25 2044 90 231 30 1679 100 176 c q 60 90 120 512-602 184-208 76-88 engine s e n s o r coolant engine fuel system t e m p e r a t u r e the sens...

Page 449: Bravo- Brava 0>

Bravo- brava 0> 1998 range engine fuel system 10. 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. Th...

Page 451

Bravo-brava ft *» e n g i n e '98 range fuel system 10. 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 ) ; - a fuel filter ( 2 ) ; - a float type level indicator ( 3 ) ; - a diaphgragm pressure regulator ( 4 ) ; - a mesh pre...

Page 453: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. Fuel vapour cut-off solenoid ( e c 1 ) the function of this valve is to control, via the fuel injection-ignition electronic control unit, the quantity of fuel vapours drawn in by the activated charcoal filter and directed to the inlet manifold...

Page 455: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. V e h i c l e s p e e d s e n s o r ( s o g e c o ) the sensor is positioned at the differential output, near the left drive shaft c o u p l i n g , and it transmits to the control unit the vehicle speed information: the signal is also used fo...

Page 457: E N G I N E

Bravo-brava ft '98 range lev e n g i n e fuel system 10. N.C. N.A. C i n e r t i a l s a f e t y s w i t c h in order to increase the safety for the vehicle's occupants in a crash, the car has an inertial switch located in the interior compartment under the driver's seat. This sensor reduces the pos...

Page 459: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. Checking winding resistance primary circuit (a cylinders 1 -4, b cylinders 2-3) place the leads of an ohmmeter in contact w i t h the positive terminal (central pin) and negative terminal (pin 1 for circuit a and pin 2 for circuit b). The resi...

Page 461: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. O f 1. 2. 3. 4. Electrode ( + ) in c o n - tact w i t h the external air electrode (-) in c o n - tact w i t h the exhaust gases ceramic casing protective pipe metal casing heating element when the probe provides a l o w voltage level (below 2...

Page 463

Bravo-brava ft i » e n g i n e '98 range fuel system 10. 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 the following instructions should be followed when working on a car fitted with i.A.W. Fuel injection-ignition: - do not start the engin...

Page 465

Bravo-brava ft i » e n g i n e '98 range fuel system 10. R e m o v i n g - r e f i t t i n g f u e l t a n k before removing-refitting the tank, drain the fuel, place the car on ramps and disconnect the battery's negative pole. Then proceed as follows: - lift the boot trim after removing the re- tai...

Page 467: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. 1. Remove the bolts and rear plugs securing the tank to the bodywork. 2. Gradually lower the hydraulic jack, check- ing that the tank is correctly balanced, then disconnect the fuel vapour recovery pipe. 3. If necessary, also disconnect the ve...

Page 469

Bravo-brava ft ** e n g i n e '98 range fuel system 10. C h e c k i n g e n g i n e i d l e s p e e d if the engine idle speed is not 850 ± 50 rpm, and as the fuel injection-ignition is self adjusting, no a d - justments can be made, so it is not necessary to check the correct adjustment of the thro...

Page 471: Engine

Bravo- brava © 1998 range 16v engine fuel system 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 10. 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 check fuel supply pressure as follows: -unscrew the nuts indicated by the arrows and remove bracket (1); -disconnect the injector supply connecto...

Page 473

Bravo-brava ft 1 * e n g i n e '98 range fuel system 10. - 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)...

Page 475: E N G I N E

Bravo-brava ft '98 range 16v e n g i n e fuel system 10. Communications between control unit and diagnostic equipment in the engine compartment, there is a socket for connecting the diagnostic equipment. The data exchange between control unit and diagnostic equipment takes place by means of a bidire...

Page 477: ; " _ •

Bravo-brava ft i » auto t r a n s m i s s i o n & differential - contents ; " _ • 1 . ' , > ; ; , - . . , ,. - 2 1 - 2 7 . Page page d e s c r i p t i o n and operation d r i v e s h a f t s •» description • 1 - selector lever 3 - torque converter, 3 - lock-up clutch 4 - ,oil pump 5, - epicyclic gea...

Page 480: 21-27.

Bravo-brava fti auto t r a n s m i s s i o n and differential components and operation 21-27. S e l e c t o r l e v e r to select a gear, use the selector lever located on the central console, w h i c h comprises a safety button (2) to protect against accidental gear engagements. It is connected to ...

Page 482: 21-27.

Bravo-brava ft 16v auto t r a n s m i s s i o n a n d differential components and operation 21-27. 1. Flywheel attachments 2. Casing connected to pump 3. Lock-up clutch 4. Turbine 5. Pump 6. Stator 7. M o t i o n input shaft oil p u m p the oil pump used for the aisin automatic transmission is of th...

Page 484: 21-27.

Bravo-brava §m auto t r a n s m i s s i o n a n d differential components and operation 21-27. Brakes there are t w o brakes in the aisin automatic transmission, one of the multiple disc type ( b 2 ) , and one band brake (b1). They are activated by the valve assembly located in the gearbox hydraulic...

Page 486: 21-27.

Bravo-brava auto t r a n s m i s s i o n and differential components and operation 21-27. T r a n s m i s s i o n o f motion the diagram below illustrates in a simplified manner the composition of the gear sets and control c o m - ponents (clutches, brakes and free wheels) of the gearbox. The same w...

Page 488: 21-27.

Bravo-brava igguev auto transmission and differential components and operation 21-27. F i r s t gear (selector lever on position d-3-2) w i t h the selector lever on one of the three positions, the gearbox functions in the same w a y and w i t h the same transmission ratio as w i t h the selector le...

Page 490: 21-27.

Bravo-brava ftiev auto transmission and differential components and operation 21-27. R e v e r s e (selector lever on position r ) the gearbox input shaft e rotates in a clockwise direction. The sun gears s1 and s 2 are coupled by the input shaft e, by the engagement of the multiple disc clutch c 2 ...

Page 493: 21-27.

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. The control module receive...

Page 495: 21-27.

Auto transmission and differentia! Components and operation bravo-brava ft 16v 21-27. Identification of control module connections ltjr l13 l12 l11 l 2 li l26 l25 l24 l15 l14 isllsllslls b h b a a sboisl = l j = uiinjn r8 r7 r6 r5 r4 r3 r2 r1 • • • • • • • • r16 r15 r14 r13 r12 r11 r10 r9 3= view of...

Page 497: Igliev

Auto t r a n s m i s s i o n a n d differential bravo-brava igliev components and operation 21-27. A t every start-up, the system is set to the n o r m a l mode. When the n o r m a l / s p o r t pushbutton (1) is pressed, the n o r m a l mode is changed to sport mode and vice versa. When the ice pus...

Page 500: 21-27.

Bravo-brava @ u 6 v auto transmission and differential components and operation 21-27. Hydraulic pressure variations the pressures in the hydraulic system are regulated by the control module, in order to achieve the f o l - l o w i n g functions: - increase in line pressure w h e n cold; - reduction...

Page 502: 21-27.

Bravo-brava i f t u s v auto transmission and differential components and operation 21-27. W i t h the vehicle moving, the f o l l o w i n g are detected: - error in main shaft rpm sensor; - error in vehicle speed sensor; - error in transmission ratio, when the ratio between the main shaft rpm and v...

Page 504: 21-27.