Fiat Brava, Marea User Manual

Chapter 1

Routine maintenance & servicing

Contents

Air fitter renewal 19 Automatic transmission fluid level check 5 Auxiliary drivebelt check and renewal 21 Auxiliary drivebelt tension check 7 Battery electrolyte level check 6 Brake fluid renewal 26 Braking system pipes and hoses check 11 Clutch cable adjustment 22 Coolant renewal 31 Engine management system fault code check 25 Engine oil and filter renewal 3 Evaporative emission control system check 29 Exhaust emissions check 24 Exhaust system check 12 Front brake pad check 4 Fuel filter renewal 20

Handbrake adjustment 23 Hinge and lock lubrication 16 Hose and fluid leak check 9 Introduction 1 Lights and horn operation check 15 Manual transmission oil level check 27 Pollen filter renewal 8 Rear brake shoe check 28 Regular maintenance 2 Road test 17 Spark plug renewal 18 Steering and suspension check 13 Timing belt renewal 30 Transmission and driveshaft gaiter check 10 Underbody protection check 14

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Degrees of difficulty

Easy, suitable for novice with little experience

Fairly easy, suitable for beginner with some experience

Fairly difficult, suitable for competent DIY mechanic

Difficult, suitable for experienced DIY mechanic

Very difficult, suitable for expert DIY or professional

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Servicing specifications

Lubricants and fluids Refer to end of Weekly checks on page 0-17

Capacities

Engine oil (including filter):

1.2 litre engine ......................................................................................... 2.8 litres

1.4 litre engine ......................................................................................... 4.1 litres

1.8 litre engine ....................................................................................... 3.8 litres

1.8 litre engine ....................................................................................... 4,3 litres

Cooling system (approximate);

1.2 and 1.4 litre engines ......................................................................... 6.0 litres

1.6 and 1.8 litre engines .......................................................................... 7.0 litres

Transmission (approximate):

Manual transmission:

1.2 and 1.4 litre engine models ........................................................ 1.65 litres

1.6 and 1.8 litre engine models ......................................................... 2.0 litres

Automatic transmission (fluid change) ................................................. 4.3 litres

Fuel tank (approximate):

Except 1.8 litre models ......................................................................... 50 litres

1.8 litre models ....................................................................................... 60 litres

Washer reservoir:

Models with headlight washers ............................................................ 6.4 litres

Models without headlight washers ....................................................... 5.0 litres

Engine

Oil filter:

1.2, 1.4 and 1.6 litre engines ............................................................... Champion F107

1.8 litre engine:

Up to March 1996 ............................................................................ Champion F107*

April 1998 onwards .......................................................................... Champion F133*

*Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283,

Cooling system

Antifreeze mixture:

40% antifreeze ...................................................................................... Protection down to -25°C

50% antifreeze ...................................................................................... Protection down to -35°C

Note: Refer to antifreeze manufacturer for latest recommendations.

Fuel system

Air filter element:

Except 1.2 litre engine ........................................................................... Champion U564*

1.2 litre engine .......................................................................................... Champion type not available*

Fuel filter .................................................................................................... Champion L225*

*Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283.

Ignition system

ignition timing ........................................................................................... Refer to Chapter 5B

Spark plugs:

Except 1.2 litre engine ......................................................................... Champion RC8BYC or RC7YC*

1.2 litre engine ..................................................................................... Champion RA4HCX or RA4HC*

Electrode gap**:

Champion RC8BYC .............................................................................. Not adjustable

Champion RA4HCX .............................................................................. 0.8 mm (0.032 in)

Champion RC7YC or RA4HC ............................................................. 0.7 mm (0.028 in)

*Note: This is the latest information available; if in any doubt, contact Champion on 01274 848283,

**The spark plug electrode gap is as quoted by Champion for their recommended plugs. If spark plugs of any other type are to be used, refer to

their manufacturers specifications.

Clutch

Clutch pedal stroke (see Section 22):

1.2 and 1.4 litre models (where applicable) .............................................. 155 ± 10 mm

1.6 and 1.8 litre models .............................................................................. 170 ± 10 mm

Brakes

Brake pad/shoe friction material minimum thickness.................................. 1.5 mm

Torque wrench settings Nm lbf/ft

Manual transmission drain plug .................................................................... 46 34

Manual transmission filler/level plug ............................................................. 46 34

Roadwheel bolts ............................................................................................ 86 63

Servicing specifications

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Spark plugs:

All except 1.6 litre engine ..................................................................... 25

1.6 litre engine .......................................................................................... 27

Sump drain plug:

1.2 litre engine .......................................................................................... 10

1.4 litre engine ..................................................................................... 25

1.6 litre engine ....................................................................................... 50

1.8 litre engine ....................................................................................... 20

Maintenance schedule

The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum intervals recommended for vehicles driven daily. If you wish to keep your

Every 250 miles (400 km) or weekly

Refer to Weekly checks

Every 12 000 miles (20 000 km) or 12 months

in addition to the items listed in the previous services, carry out the \

following:

Renew the engine oil and filter (Section 3)

Check the front brake pad-thickness (Section 4)

Check the automatic transmission fluid level (Section 5} Check battery electrolyte level - where applicable (Section 6) Check the tension of the auxiliary drivebelt(s) (Section 7) Renew the pollen filter element (Section 8) Check alt underbcmnet/undertsody components

and hoses for fluid leaks (Section 9)

Check the transmission and driveshaft gaiters for

leaks and damage (Section 10)

Check the brake pipes and hoses for teaks and

damage (Section 11)

Check the condition of the exhaust system and its

mountings (Section 12)

Check the steering and suspension components

for condition and security (Section 13) Check Underbody protection for damage (Section 14) Check operation of all lights and horn (Section 15)

Lubricate all hinges, locks and door check straps

(Section 16) Carry out a road test (Section 17)

Every 24 000 miles (40 000 km) or

In addition to the items/fisted in the previous services, carry out the

following:

Renew the spark plugs (Section 18)

Renew the air filter element (Section 19)

Renew the fuel filter, where applicable (Section 20)

vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, since it enhances the efficiency, performance and resale value of your vehicle.

Nm Torque wrench settings (continued)

When the vehicle is new, it should be serviced by a dealer service department, in order to preserve the factory warranty.

Ibf/ft 18

7 18 37 15

Every 24 000 miles (40 000 km) or

Check the condition of the auxiliary drivebelt(s), and renew if necessary (Section 21) Check clutch cable adjustment, where applicable

Check handbrake adjustment (Section 23) Check exhaust gas emissions (Section 24) Check engine management system for fault codes

Every 36 000 miles (60 000 km) or

In addition to the items listed in the previous services, carry out the-

following:

Renew the brake fluid (Section 26) Check the manual transmission oil level (Section 27) Check the rear brake shoe lining thickness

Every 48 000 miles (80 000 km) or

In addition to the items listed in the previous services, carry out the

Check the evaporative emissions control system

Every 72 000 miles (120 000 km)

in addition to all the items listed above, carry out the following:

Renew the timing belt (Section 30)

Note: It is strongly recommended that the interval is halved to

36 000 miles (60 000 km), particularly on vehicles which are subjected to intensive use, ie. mainly short journeys or a lot of stopstart driving, The actual belt renewal interval is therefore very much up to the individual owner, but bear in mind that severe engine damage will result if the belt breaks.

Every 2 years (regardless of mileage)

Renew the coolant (Section 31)

Maintenance - component locations

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Underbonnet view of 1.2 litre model

Brake and clutch fluid

reservoir Fuse and relay box

Engine top cover (remove

for access to coils and spark plugs) Engine management

system ECU Auxiliary fusebox

Air inlet duct

Air cleaner

Battery

8 9

Cooling system expansion

tank

Engine oil dipstick

Oil filler cap

Power steering reservoir

Washer reservoir

Underbonnet view of 1.4 litre model

Air cleaner

Brake and clutch fluid

reservoir Fuse and relay box

3 4

Throttle body airbox

Power steering reservoir Engine management

system ECU

Auxiliary fusebox

Washer reservoir

Battery

Cooling system expansion tank Radiator top hose

11 12

Oil filler cap Oil filter

Engine oil dipstick

14 15

Crankcase breather hose Warm-air inlet duct

16 17

Timing belt cover

Washer reservoir

Inlet manifold (upper section)

Brake and clutch fluid

reservoir Fuse and relay box

Inlet air resonator box

Power steering reservoir

Air inlet duct

Auxiliary fusebox

Air cleaner

Battery

10 11

Engine management system ECU Accelerator cable

Cooling system expansion

tank

Ignition coil

Inlet manifold (lower section)

Oil filler cap

Engine oil dipstick

No 1 spark plug HT lead

Timing belt cover

Maintenance - component locations

Underbonnet view of 1.6 litre model

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1 Washer reservoir

2 Cooling system expansion

tank

3 Fuel hoses, fuel rail and

injectors

4 Brake and clutch fluid

reservoir 5 Inlet manifold 6 Power steering reservoir 7 Idle speed control valve

8 Anti-lock braking system

(ABS) modulator

9 Airflow meter

10 Auxiliary fusebox 11 Air inlet duct 12 Air cleaner 13 Battery 14 Engine top cover (remove

for access to coils and

spark plugs) 15 Oil filler cap 16 Engine oil dipstick 17 Timing belt cover

Underbonnet view of 1.8 litre model

Maintenance - component locations

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Front underside view of 1.6 litre model

1 Horn unit 2 Oil filter 3 Radiator cooling fan 4 Starter motor 5 Radiator bottom hose

6 Front brake caliper

7 Driveshaft CV joint gaiter 8 Track rod end 9 Manual transmission drain

plug 10 Engine oil drain plug 11 Right-hand driveshaft 12 Exhaust downpipe 13 Oxygen sensor 14 Subframe 15 Suspension arm

Rear underside view of 1.6 litre mode!

1 Brake pipe/hose

connection

2 Fuel tank 3 Handbrake cables 4 Fuel tank retaining straps

5 Rear suspension arm 6 Rear shock absorber

mounting 7 Rear coil spring 8 Exhaust rear silencer

9 Exhaust heat shield

10 Brake pressure

proportioning valve

Maintenance procedures

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1 Introduction

General information

This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance.

The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule; Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components.

Servicing your vehicle in accordance with the mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive plan, so maintaining some items but not others at the specified service intervals, will not produce the same results.

As you service your vehicle, you will discover that many of the procedures can and should - be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwise unrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components.

The first step in this maintenance programme

is to prepare yourself before the actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather all the parts and tools required. If a problem is encountered, seek advice from a parts specialist, or a dealer service department.

2 Regular maintenance

1 If, from the time the vehicle is new, the routine maintenance schedule is followed closely, and frequent checks are made of fluid levels and high-wear items, as suggested throughout this manual, the engine will be kept in relatively good running condition, and the need for additional work will be minimised. 2 It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is

purchased. In such cases, additional work may need to be carried out, outside of the

regular maintenance intervals. 3 If engine wear is suspected, a compression test (refer to the relevant part of Chapter 2) will

provide valuable information regarding the overall performance of the main internal

components. Such a test can be used as a

basis to decide on the extent of the work to

be carried out. If, for example, a compression test indicates serious internal engine wear,

conventional maintenance as described in this

Chapter will not greatly improve the perform-

ance of the engine, and may prove a waste of time and money, unless extensive overhaul work is carried out first. 4 The following series of operations are those most often required to improve the performance of a generally poor-running engine:

Primary operations

a) Clean, inspect and test the battery (See

Weekly checks and Section 6, where applicable).

b) Check all the engine-related fluids (See

Weekly checks):

c) Check the condition and tension of the

auxiliary drivebelt (Sections 7 and 21). d) Renew the spark plugs (Section 18). e) Check the condition of the air filter, and

renew if necessary (Section 19). f) Check the fuel filter, Where applicable

(Section 20).

g) Check the condition of all hoses, and

check for fluid leaks (Section 9).

h) Check the exhaust gas emissions (Sec-

tion 24).

5 If the above operations do not prove fully effective, carry out the following secondary operations:

Secondary operations

All items listed under Primary operations, plus the following:

Check the charging system (see Chapter 5A,

Section 4).

b) Check the ignition system (see Chapter 5B). c) Check the fuel system (see relevant Part

of Chapter 4).

d) Renew the ignition HT leads, if applicable.

Every 12 000 miles (20 000 km)

3. Engine oil and filter renewal

1 Frequent oil and filter changes are the most

important maintenance procedures which can

be undertaken by the DIY owner. As engine oil ages, it becomes diluted and contaminated, which leads to premature engine wear 2 The oil change interval given in this Manual

is the same as quoted by the manufacturer,

but owners of older vehicles (or those covering a small annual mileage) may feel justified in changing the oil and filter more frequently, perhaps every 6000 miles, or every

6 months. The quality of engine oil used is a

significant factor in this - the 12 000-mile

interval only applies if a high-quality

synthetic-based oil-is used.

3 Before starting this procedure, gather all

the necessary tools and materials. Also make

sure that you have plenty of clean rags and

newspapers handy, to mop up any spills,

Ideally, the engine oil should be warm, as it

will drain better, and more-built-up sludge will

be removed with it. Take care, however, not to

touch the exhaust or any other hot parts of the engine when working under the vehicle. To avoid any possibility of scalding, and to protect yourself from possible skin irritants and other harmful contaminants in used engine oils, it is advisable to wear gloves when carrying out this work. 4 Remove the oil filler cap (see illustration), and take out the dipstick. 5 Access to the underside of the vehicle will

be greatly improved if it can be raised on a. lift,

driven onto ramps, or jacked up and

3.4 Removing the oil filler cap on a

1.8 litre model

supported on axle stands (see Jacking and

vehicle support). Whichever method is

chosen, make sure that the vehicle remains level, or if it is at an angle, that the drain plug is at the lowest point. 6 Where applicable, unscrew the fasteners and remove the engine undertray, for access to the drain plug. On 1.8 litre engines, the drain plug can be reached from the back of the engine, and a panel is provided in the undertray, which can be hinged down to get to the filter (see illustration).

3.6 Removing the oil filter access panel on a 1.8 litre model

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