Brava
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
1-1
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
1-2
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
1-3
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
20
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
1-4
Underbonnet view of 1.2 litre model
Brake and clutch fluid
1
reservoir
Fuse and relay box
2
Engine top cover (remove
3
for access to coils and
spark plugs)
Engine management
4
system ECU
Auxiliary fusebox
5
Air inlet duct
6
Air cleaner
7
Battery
8
9
Cooling system expansion
tank
Engine oil dipstick
10
Oil filler cap
11
Power steering reservoir
12
Washer reservoir
13
Underbonnet view of 1.4 litre model
Air cleaner
1
Brake and clutch fluid
2
reservoir
Fuse and relay box
3
4
Throttle body airbox
5
Power steering reservoir
Engine management
6
system ECU
Auxiliary fusebox
7
Washer reservoir
8
Battery
9
10
Cooling system expansion
tank
Radiator top hose
11
12
Oil filler cap
Oil filter
13
Engine oil dipstick
14
15
Crankcase breather hose
Warm-air inlet duct
16
17
Timing belt cover
Washer reservoir
1
Inlet manifold (upper section)
2
Brake and clutch fluid
3
reservoir
Fuse and relay box
4
Inlet air resonator box
5
Power steering reservoir
6
Air inlet duct
7
Auxiliary fusebox
8
Air cleaner
9
Battery
10
11
Engine management
system ECU
Accelerator cable
12
Cooling system expansion
13
tank
14
Ignition coil
15
Inlet manifold (lower
section)
18
Oil filler cap
17
Engine oil dipstick
18
No 1 spark plug HT lead
19
Timing belt cover
Maintenance - component locations
Underbonnet view of 1.6 litre model
1-5
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
1-6
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
1-7
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:
a)
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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