Fiat Tipo ('88 to '91) Hb Haynes Service & Repair Manual 9781850106258, 1850106258

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"We fit C h ampi o n - so should you"

Acknowledgements Thanks are due to the Champion Sparking Plug Company Limited who supplied' the illustrations showing spark plug conditions. to Holt Lloyd Limited who supplied the illustrations showing bodywork repair. and to Duckhams Oils who provided lubrication data. Certain other illustrations are the copyright of the FIAT Motor Company (UKI Limited and are used with their permission. Thanks are also due to S.y kes-Pickavant iUmiled who supplied some of the workshop tools. and all those people at Sparkford who assisted in the production of this Manual.

© Haynes Publishing Group 1991 A book in the Haynes Owners Workshop Manual Series Printed by J. H. Haynes 8. Co. Ltd .• Sparkford. Nr Veovil. Somerset BA22 7JJ. England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means. electr.onic or mechanical, including photocopying. recording or by any information storage or retrieval system, without permission In writing from the copyright holder.

ISBN 1 85010625 8 British Library Cataloguing In Publication Data Hendle. Steve 1966Fiat Tipo owners workshop manual. 1, Cars. Maintenance I. Title II, Series 629'.28722 ISBN 1-85010-625-8

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be .accepted by the authors or publishers for loss. damage or injury caused by any errors in, or omissions from. the information given.

, Many of the cars we strip for our manuals are from our own fieet of vellicles or loaned by garages, Often they are Celrs with many thousands of miles on the ciock. As a malter of course we alwa)'s fit new plugs when reassembling the engine, and these days. it has to be Champion Double Copper. The extra performance, ease of starting, anti-fouling and longer trouble-free life, due to the copper earth and centre core electrodes, means you cannot fit a better plug. We also fit Champion oil, air and fuel filters and, when necessary, Champion wiper blades because, as they say, "You can't beat a Champion", '

Jim Scott, Managing Director - Haynes

CHAMPION Go by the book. Fit Champion.

Contents Page Acknowledgements

2.

About this manual

5

Introduction to the Fiat Tipo

5

General dimenSions, weights and capacities

6

Jacking, towing and wheel changing

7

Buying spare parts and vehicle i,d entification numbers

9

General repair proced ures

10

Tools and work.i ng facilities

11

Safety firstl

13

Routi ne maintenance

14

Recommended lubricants and fluids

19

Conversion factors

20

Fault diagnosis

21

Chapter 1 Engine

24

Chapter 2 Cooling system

57

Chapter 3 Fuel and exhaust systems

65

Chapter 4 Ignition system

85

Chapter 6 Clutch

96

Chapter 6 Man.ualgearbox

102

Chapter 1 Driveshafts

122

Chapter 8 Braking system

127

Chapter 9 Suspension and steering

142

Chapter 10 Bodywork and fittings

160

Chapter 11 :Elect,ica" system

186

Index

238

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FIAT Tipo DGT

FIAT Tipo DGT/SX

About this manual Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, ancl' give a logical' course, of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lof of money can be saved by avoiding the costs a 9arage must charge to cover its labour 'and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. r hen the tasks are described and photo.graphed in a step-by-step sequence so that even a novice can do tme work.

Its arrangement The manual is divided into eleven Chapters, each covering a logical sub-division of tile vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections.into pQ'ragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in

sequence with decimal numbers, according to their position in the Chapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the 'left' or 'right' of the vehicle are In the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liabilitv can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Project vehicles The main project vehicle used in the preparation of ,this manual, and appearing in the majority of the photographic sequences, was a 1989 Fiat r ipo 1.6 DGT SX. Additional work was carried out and photographed on a 1989 Fiat Tipo 1.4 Formula, and a 1989 Fiat Tipo 1.6 DGT.

Introduction to the FIAT Tipo The FIAT Tipo was first introduced to the UK market in July 1988 With the option of three engine Sizes and three trim levels. This manual covers the petrol engines, but other models in Ihe range are fitted with Diesel engines. The Tipo was introduced by FIAT as the successor to the Strada. However, the Tipo was conceived as a totally fresh design, and shares very little with its predecessor. The.controversial styling incorporates all' unusually long wheelbase for a car of this class, togetleler with a high roof line, which allows maximum use of interior space. All models share the same 5-door Hatchback body style and a five-

speed manual gearbox. 1.4 and 1.6 litre engines are available. All-round independent suspension is fitted, and the suspension and drivetrain components are mounted on subframes to reduce the transmission of road noise to the passenger corpp(lrtment, and to preserve the alignment of the components in the event of minor impact. The standard equipment fitment is comprehensive across tile range, and as a result, few options are available. For the home mechanic, the Tipo is a straightforward vehicle to maintain, and most of the items requiring frequent attention are easily accessible.

General dimensions, weights and capacities Dimensions Overalilengtl1 .............................. ,........................................................................... Overall width (excluding door mirrors) ............................................................. Overall height ................................................ ......................................................... . Wheelbase .............................................................. ........ .......................... .............. . Front Uack ............................................................ .................................................... Rear track ................................................................................................................ . Turning circle ........................................... ................................................................

3958 mm (156.0 in) 1700 mm (67.0 in) 1445 mm (57.0 in) 2540 mm (100.0 in) 1429 mm (56.3 in) 1415 mm (55.8 in) 10.3 m (33.8 ft)

Weights Kerb weight:* 1.4 litre models ................................................................................................. 1:.6 litre models ................................................................................................. Maximum gross vehicle weight ...................... .................................... .............. . Maximum towing weight: Braked trailer. 1.4litre models ........................................................................................... 1.6 litre models ........................................................................................... Unbraked trailer: .~ 1.4 litre mOdels ........................................................................................... 1.6 litre models ........................................................................................... Maximum towing hitch downward load: 1 A litre models ................................................................................................ . 1i6litre. models .............................................................................................. .. . *Exact kerb weights depend upon model and specification

945 to 965 kg (2084 to 21 281bs) 970 kg (21 391bs) Refer to VIN plate

1 100 kg (2426 Ibs) 1200 kg (2646 Ibs) 525 kg (1158 Ibs) 550 kg (1213 Ibs) 77 kg (170 Ibs) 84 kg (t 851bs)

Capacities Engine oil (including filter): Drain and refill ....................................................................................... ............ From dry (after major overhaul) ................................................................. .. Cooling system ...... :............................................................................................... . Fuel tank .................................................................................................................. . Manual gearbox ......................................................................................................

3.30 litres (5.80- pints) 3.75 litres (6.60 pints) 6.5litres 1.4 pints) 55.0 litres (12.1 gals) 1Alitres (2.5 pints)

't

Jacking, towing and wheel changing Jacking and wheel changing Note: A "space-saver" spare wheel is provided on all Tipo models. The tyre fitted to this wheel;s smaller thaN the standard lyres, and the wheel should only be used to travel the distance necessaty to reach a suitable tyre repair specialist where the damaged tyre can be repaired. Do not exceed a speed of 50 mph 180 kmh) when using the spare wheel. The spare tyre has a maximum life of 1800 miles (3000 km) The jack supplied with the vehicle tool kit should only be used for changing roadwheels. When carrying out any other kind of work, raise the vehicle using a hydraulic jac'k, and always supplement the jack with axle stands positioned under the vehicle jacking points. To change a roadwheel, first remove the spare wheel and jack from their stowage position with the spare wheel under the luggage compartment floor. Firmly apply the handbrake and engage first gear. Place chocks at tthe front and rear of the wheel diagonally opposite the one to be changed. . Remove the wheel trim and loosen the roadwheel bolts using the. wheel brace pr0vided in the tool kit. Position the jack head under the Jacking point nearest the wheel to be changed. Raise the jack. Until the

wheel is clear of the ground. Note that as the car is raised, it will 'tend to move inorizontally due to the geometry of the front suspension; the curved base of the jack is designed to. compensate ~or this. Remove tne wheel bolts and the wheel. Fit the spare wheel and secure it with the wheel bolts, noting ,t haI the locating peg on the brake disc or drum must locate in one of the tour holes in the wheel rim. Lower the jack until the wheel is just touching the ground, and ti9hten the wheel, bolts moderately tight. Now lower the jack fully and tighten the wheel bolts securely in a diagona'i Sequence. Refil the wheel trim, then withdraw the jack and stow the wheel, Jack and wheel brace in t/;leir respective locations. When jacking up the vehicle with a I:lydraulic jack, position the jack head under one of the relevant jacking points.I'f the rear of the v.e hide is to be jacked up" al;)locl< of wood should be positioned under t/;le rear crossmember between the jack and the vehicle, as shown in the accompanying illustration. If the front of the vehicle is to be jacked up, a block of wood shou'ld be placed between the gearbox casing and tl:le jack. Do not jack the vehicle under the sump or any of the steering or suspension components. Supplement the jack with axle stands. The jacking points and axle stand positions are shown in the accompanying illustrations. Never work I,Inder, around, or near a raised vehide, unless it is adequately supported in at least two places.

Jacking point for use with vehicle jack

Rear jacking point for use with hydraulio jack Dimensions of wooden b/ock - 400x 70 x 70mm (16x 3 x 3 in) with groove 10 mm (0.4 in) wide and 25 mm (1.0 in) deep

Front jacking point for use with hydraulic jack Position jack head under gearbox casing with interposed block of wood

8

Jacking, towing and whee' changing

Front towing eye (A)

Rear towing eye (8)

Towing eyes are fitted to the front and rear of the vehicle for attachment of a tow rope. Always turn the ignition key to the "MAR" position when the vehicle is being towed. so that the steering lock is released and the direction indicator and brake lamps are operational.

Before being towed. release the hand brake and place the gear lever in neutral. Note that greater than usual pedal pressure will be'required to operate the brakes, since the vacuum servo unit is only operational with the engine running. Similarly. on models with power steering. greater than usual steering effort will be required. '

Towing

Buying spare parts and vehicle identification numbers Buying spare parts Spare parts are available from many sources, for example: FIAT garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows. Officially appointed FIA T garages - This is the best source for parts which are peculiar to your car, and are not generally available (eg complete cylinder heads, ,internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if the vehicle is still under warranty. To be sure of obtaining the correct parts, it will' be necessali)' to give the store man your car's vehicle ,identi.fication number, and if possible, take the old part along for positive identification. Many parts are available under a factoli)' exchange scheme - any ~rts returned should always be clean. It obviously makes good sense to go straight to the specialists on your car for this type of part, as they are best equipped to supply you. Other garages and accessory shops - These are often very good places to buy materials and components needed for the maintenance of your car (eg oil filters, spark plugs, bulbs, drivebelts, oils, and greases, touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors - Good factors will stock all the more important

components which wear out comparatively quickly (eg exhaust systems, brake pads, seals and hvd~aulic parts, clutch components, bearing shells, pistons, valves etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

Vehicle identification numbers Modifications are .a continuing and unpublicised process in vehicle manufacture, quite apart from major model changes. Spare parts.manuals and lists are compiled upon a numerical basis, the individual vehicle identification numbers being essential to correct identification of the component concerned. When ordering spare parts, always give as much information as possible. Quote the car model, year of manufacture, body and engine numbers as appropriate. The vehicle identification number (VIN) is located on a plate in the engine compartment on the right-hand side of the body front panel (photo). The body (chassis) number is stamped into the right-hand suspension turret. The engine number is stamped into the flywheel end of the cylinder block casting, just below the cylinder head.

Identification number locations

A

Vehicle type code and chassis number

8

C

Engine number (on end-face of cylinder block) VlNplate VIN plate location

,G eneral repair pr'o cedures Whenever servicing, repair or overhaul work is carried out on the car or its componen'ts, it is necessary to observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanship.

Joint mating faces and gaskets Where a gasket is used between the matiflg faces of two components, ensure that it is renewed on reassembl.y, and fit it dry unless otherwise stated in the repair procedure. Make sure that the mating faces are clean and dry with all traces of old gasket removed . When cleaning a joint face, USe a tool which is not likely to score ordamage the face, and remove allY burrs or nicks with an oilstone or fine file. Make sure that tapped 110les are clealled with a pipe creaner, and keep them free of jointing compound if tllis is being used unless specifically illstructed otherwise. Ensure that all orifices, channels or pipes are clear afld I:>low through them, preferably using compressed air.

Oil seals Whenever an oil seal is removed from its working locatioJ), either individually or as part of an assembly, it should be renewed. The very fine sealing lip of the seal is easily damaged and will not seal if the surface it contacts is not completely clean and free from scratches, nicks or grooves. If the original sealing surface of the .c omponent cannot be restored, the component should be renewed. Protect the lips of the seal from any surface which may damage them in the course of fitting . Use tape or a conical sleeve where possible. Lubricate the seal lips with oil before fitting and, on dual lipped seals, fill the space:between the lips with grease. Unless otherwise stated, oil seals must be fitted with their sealing lips toward the lubricant to I;>e sealed. Use a tubular drift Or block of wood of tfrle appropriate size to install the seal and, if the seal housing is shouldered, drive the seal down to tfrle shoulder. If the seal housing is unsfrlouldered, the seal should be fitted with its face flush with the housing top face.

''11

threads and fastenings / s ensure that a blind tapped hole is completely free from oil.

grease, water or other fluid before installing the bolt or stud. Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in. When tightening a castellated nut to accept a split pin, tighten the Ilut to the specified torque, where applicable, and then tighten further to the next split pin hole. Never slacken the nut to align a split prn hole unless stated in the repair procedure. When checking or retightening a nut or bolt to a specified torque setting, slacken the nut or bolt by a quarter of a turn, and then retighten to the specified setting.

Locknuts, locktabs and washers Any fastening which will rotate against a component or housing in the course of tightening should always have a washer between it and the relevant component or housing. Spring Of split washers. should always be renewed when they are used to lock a critical component suchas a big-elld beari ng retaining nut or bolt. locktabs which are folded over to retain a nut or bolt should always be renewed . Self-locking nLlts can be reused in non-critical areas, providing resistance can be felt when the locking portion passes over the bolt or stud thread. Split pins must always be replaced with new ones of the correct size for the hole.

Special tools Some repair procedures in this manual entail the use of special tools such as a press, two or three-legged pullers, spring compressors etc. Wherever possible, suitable readily available alternatives to the manufacturer's special tools are described, and are shown in use. In some instances, where no alternative is possible, it has been necessary to resort to the use of a manufacturer's tool, and this has been done for reasons of safety as well as the efficient completion of the repair operation. Unless you are highly skilled and have a thorough understanding,of the procedure described, never atlempt to bypass tfrle use of any special tool when the pr.ocedure described specifies its use. Not only is tfrlere a very great risk of personal injury, but expensive damage could be·caused to the components involved.

Tools and working facilities Introduction

Repair and overhaul tool kit

A selection o.f good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, prov'ided tnat the tools purchased meet the relevant national safety standards and are of good quality, they will last for many years and prove an extremely worthwhile investment. To help the average owner (0 decide which tools are needed to carry out the various tasks detailed in this manual, we have compiled three ~sts of tools under the following headings: Maintenance and minor repair, Repair and overhaul, and Special. The newcomer to practical mechanics should slart off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grow, he can undertake more difficult lasks, buying extra tools as, and when, they are needed. In this way, a Maintenance and minor repair tool ki,t can be built-up into a Repair and overhaul tool kit over a considerable period of time Without any major cash outlays. The experienced do-it-yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when he feels the expense is justified by the amount of use to which these tools will be put. It is obviously not possible to cover the,subject of tools fully here. For Ihose who wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the publishers of this manual.

These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle, and are addit.ional to toose given in the Maintenance and minor repair list. Included in this list is a comprehensive set of sockets. Although these are expensive, they will be found invaluable as t,hey are so versatile - particularly if various drives are included in the set. We recommend the t in square-drive type, as this can be used with mOst proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools hom the Special list.

Maintenance and minor repair tool kit The tools given in this list should be considered as a minimum requirement if routine maintenance, servicing' and minor repair operations are to be undertaken. We recommend the purchase of combinalion spanners (ring one end, open-ended the other); although more expensive than open-ended ones, they do give the advantages of both types of spanner. COmbination spanners - 10, 11, 12, 13, 14 & 17 mm

- n ,!. h. i, ti, t &ti inAF Adjustable spanner - 9 inch Engine sump/gearbox drain plug key Spark plug spanner (with rubber insert) Spark plug gap adiustment tool Set of feeler gauges Brake bleed nipple spanner Screwdriver - 4 in long x t in dia (flat blade) Screwdriver - 4 in long x in dia (cross blade) Combination pliers - 6 inch Hacksaw (iunior) Tyrepump Tyre pressure gauge Oi/can Oil filter removal tool Fine'emery cloth Wire brush (small) Funnel (medium size)

*

Sockets (or box spanners) to cover range in previous list Reversible ratchet drive {for use with sockets} Extension piece, 10 inch (for lise with sockets) Universal ioint (for use with sockets) Torque wrench (for use with sockets) Self-locking grips Bal/ pein hammer Soft-faced mal/et (plastic/aluminium, or rubber) Screwdriver - 6 in long x -h in dia (flat blade! Screwdriver - 2 in long x h in dia (flat blade) Screwdriver - , t in long K t in dia (crosS blade) Screwdriver - 3 in long x t in dia (electrician'S) Pliers - electrician's side cutters Pliers - needle-nosed Pliers - circlip (internal and external) Cold chisel - t inch Scriber Scraper Centre punch Pin punch Hacksaw Brake hose clamp Brake bleeding kit Selection of twist drills Steel rule/straight edge AI/en keys Selection of files Wire brush Axle-stands Jack (strong trol/ey or hydraulic type) Light with extension lead

Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers' instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where this is the case, you could consider clubbing together with friends (or joining a motorists' club) to make a joint purchase, or borrowing the tools against a deposit from a local garage or tool hire specialist.

Tools and working facilities

12

The following list contains only those tools and instruments freely available to. the public, and not those special tools produced by the, vehicle manufacturer specifically for its dealer netwOl"k. You will find occasional references to these manufacturers' special tools in the text of this manual. Generally, an alternative method of doing the job without the vehicle manufacturers' special too/' is given. However, sometimes, there is no alternative to using them. Where this is the case and the relevant tool cannot be bought or borrowed, you will have to entrust the work to a franchised garage. Valve spring compressor Coil spring compressors Piston ring cOmpressor Ballioint separator Universal.hub/bearing puller Impact screwdriver Micrometer and/or vernier gauge Dia/gauge Stroboscopic timing light Dwell angle meterltachometer Universal electric mvlti-meter Cylinder compression gauge Lifting tackle Trolley iack

Buying tools For practically all tools, a tool factor is the best source since he will have a very comprehensive range compared with the average garage or accessory shop. Having said that, accessory shops of.ten offer excellent quality tools at discount prices, so it pays to shop around. There are plenty of good tools around at reasonable prices, but always aim to purchase items which meet the relevant national safety standards. I'f in doubt, ask the proprietor or manager of the shop for advice before making a purchase.

Care and maintenance of tools Having purchased a reasonable tool kit, it is necessary to keep the tools in a clean serviceable condition. After use, always wipe off any dirt, grease and metal ,particles using a clean, dry cloth, before putting the tools away. Never leave them lying around after they have been used. A simple tool rack on the garage or workshop wall, for items such as screWdrivers and pliers is a good idea. Store all normal wrenches and sockets in a metal box. Any measuring instruments, gauges, meters, etc, must be carefully stored where they cannot be damaged or become rusty. Take a little care when tools are used. Hammer heads ineVitably become marked and screwdrivers lose the keen edge on their blades from time to time. A little timely attention with emery cloth or a file will soon restore items like this to a good serviceable finish.

Working facilities Not to be forgotten when discussing' tools, is the workshop itself. If anything more than routine maintenance is to be carried out, some form of suitable working area becomes essential. It is appreciated that many an owner mechanic is forced by circumstances to remove an engine, or similar item, without the benefit of a garage or workshop. Having done this, any repairs should always be done under the cover of a roof. Wherever possible, any dismantling should be done on a clean, flat workbench or table at a suitable working height. Any workbench needs a vice: one with a jaw opening of 4 in (100 mm) is suitable for most jobs. As mentioned previousl"y, some clean dry storage space is also required for tools, as well as for lubricants, cleaning fluids, touch-up paints and so on, which become necessary. Another item which may be required, and which has a much more general' usage, is an electric dril with a chuck capacity of at least rt in (8 mm). This, together with a good range of twist drills, is virtually essential for fitting accessories such as mirrors and reversing lights. Last, buI not least, always keep a supply of old newspapers and clean, lint-free rags available, and try to keep any working area as clean as possible.

Spanner jaw gap comparison table Jawgap- in 0.250 0.275 0.312 0.315 0.343 0.354 0.375 0.394 0.433 0.437 0.445

0.472 0.500 0.51"2 0.525 0.551 0.562 0.591 0.600 Q..625 0.630 0.669 0.687 0.709 0.710 0.748 0.750 0.812 0.866 0.875 0.920 0.937 0.945 1,000 1.010 1.024 1.062 1.063 , .125 1.182 1.200 1.250 1.260 1.312 1.375 1.418 1.437 1.480 1.500 1.575 1.615 1.625 1.670 1.688 1.811 1.813 1.860 1.875 1.969 2.000 2.050 2.165 2.362

Spanner size inAF 7mm -h in AF 8mm H in AF; t in Whitworth 9mm i in: Af 10mm 11 mm .,z, inAF f,; in Whitworth; in BSF 12mm t inAF 13mm * in Whitworth; in BSF 14min . -h in AF 15 mrn -h in Whitworth; iin BSF iinAF 16mm 17mm tt in AF 18mm i in Whitworth;.,z, in BSF 19mm f inAF +i in AF 22mm i inAF ; in Whitworth; -h. in BSF HinAF 24mm 1 inAF -h in Whitworth; i in BSF 26mm In in AF; 27 mm 27mm in AF 30mm ti in Whitworth; i in BSF HinAF 32mm h\ inAF 11 in AF 36mm 1-h in AF t in Whitworth; 1 in BSF 1; in AF 40 mm; H in Whitworth 41 mm 11 in AF 1 in Whitworth; 1j in BSF 1H inAF 46mm 1+i in AF 1i in Whitworth; 1* in BSF in AF 50mm 2 inAF 1* in Whitworth; 1i in BSF 55mm 60mm

*

*

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1,

1.

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Safety first! Professional motor mechanics are trained in safe working procedures. However enthusiastic yOu, may be about getting on with the job in hand, do take 1he lime to ensure thaI your safety is no! put at risk. A moment's lack of attention can result in an accident as can failure to observe certain elementary precautions. There will always be new ways of having accidents, and the following points do not pretend to be a comprehensive list of all dangers; they are intended rather to make you aware of the risks and to encourage a safety-conscious approach to all work you carry out on your vehicle.

Essential DOs and DON'Ts DON'T rely on a single jack when workin.g underneath the vehicle. Always use reliable additiona'l means of support, such as axle stands, securely placed under a part of the vehicle that you know will not give way. DON'T attempt to loosen or tighten high-torque nuts (e.g. wheel hub nuts) while the vehicle is on, a jack; it may be pulled off. DON'T start the engine without first ascertaining that the transmission is in neutral (or 'Park' where applicable) aAd the parl.

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11 .18 Wiring diagram - Rear foglamps, reversing lamps, direction indicator/hazard warning flasher lamps, brake lamps (1.4 litre non-DGT models)

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11 .19 Wiring diagram - Rear foglamps, reversing lamps, direction indicatorlhazard warning flasher lamps, brake lamps (1.4 and 1.6 litre DGT models)

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11 .20 Wiring diagram - Fuel gauge, low brake fluid level and hand brake warning lamp, coolant temperature gauge, brake pad wear warning lamp, clock (1 .4 litre non-DGT models)

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11 .21 Wiring di"a gram - Fuel gauge, econometer, low brake fluid level and l1andbrake warning lamp, coolant temperature gauge, clock, speedometer, tachometer, instrument pane'l illumination (1.4 and 1'.6 litre DOT models)

227

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11.22 Wiring diagram - Horn, heated rear window, windscreen wipers, tailgate wiper, windscreen and tailgate washer fluid pumps (1.4 litre non-DGT models)

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11 .24 Wir,i ng diagram - Central door ,l ocking system, door ajar warning system (1.4 and 1.6 litre DGT models)

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11.25 Wiring diagram - Electric windows system 11 .4 and 1.6 litre DGT models)

231

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11 .26 Wiring diagram - Headlamp wash/wipe, heated driver's seat (1.4 and 1.6 DGT models)

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11.27 Wiring diagram - Electric door mirrors (1.4 and 1.6 litre DGT)

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11.28 Wiring diagram - Sunroof (1.4 an d 1.6 litre DGTmodels)

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11.29 Wiring diagram - Check control system (1 .4 and 1.6 litre DGT models)

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11.29 Wiring diagram - Check control system (1 .4 and 1.6 litre OGT models) (continued)

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11.30 Wiring diagram - Wiring junction/fuse/relay box (1.4 litre non-DGT models)

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11.31 Wiring diagram - Wiring junction/fuse/relay box (1.4 and 1.6 litre DGT models)

Index A About this manual - 5 Accelerator pump - 77 Acknowledgements - 2 Aerial- 209 Air cleaner - 67, 68 Alternator - 188, 189 Anti-roll bar front - 149, 150 rear - 153 Auxiliary shaft - 45

B Battery - 188 Bearings big-end - 52, 54 clutch release - 100 driveshaft - 125 mail1- 52, 54 wheel - 146,. 150 Big-end bearings - 52, 54 Bleeding (braking system), - 128 Blower motor (heater) - 185, 196 Body damage repair - 161, 162 Bodywork and fittings - 160 et seq Bonnet -163 Brake pedal - 140 Braking system - 127 et seq, 198 Bulb renewa'i cigarette lighter lamp - 202 courtesy lamp - 202 direction indicator lamp - 206 glove box - 202 hazard warning flasher switch lamp - 203 head lamp - 205 heater control panel lamp - 203 ,instrument panel lamps - 199.. 200, 203 luggage compartment lamp - 202 map readillglamp - 202 number plate lamp - 206 rear lamps - 206 sidelamps - 205 stalk switch lamps - 203 Bumpers - 172

c

Capacities - 6 Carburettor - 72 to 79 Cassette player - 210 Central door locking - 208 Centre console - 180 Check control system - 201 Choke adjustment - 79 Choke cable - 71 Cigarette lighter - 198, 202 Clock - 1,99, 200 Clutch - 96 et seq Clutch cable - 97 Clutch pedal- 98 Clutch release bearing - 100 Coil spring (rear suspension) - 151 Connecting rods - 49, 51, Console - 180 Conversion factors - 20 Coolant mixture - 60 Coolant pump - 62 Coolant temperature gauge - 199 Cooling system - 57 et seq, 199 Courtesy lamp switch - 196, 202 Crankcase ventilation system - 31 Crankshaft - 46,47,52,54 Crankshaft speed/position sensor - 93 Cylinder block and bores - 54 Cylinder head - 42, 43, 44

o Dashboard - 179 Differential (manual gearbox) - 113 Dimensions - 6 Direction indicator lamp - 204, 206 Disc (braking system) - 133, 135 Distributor - 88 to 90 Doors - 166 to 168, 170 to 172, 196, 208 Draining «:ooling system - 59 Drivebelts alternator - 62, 188 coolant pump - 62 power steering pump - 156 Driveshaft damper weight - 126 Driveshaft inboard gaiter bearing - 125 Driveshaft joints - 124 Driveshahs - 122 et seq Drum (braking system) - 133

Cables bonnet release - 163 choke - 71 clutch - 97 handbra ke - 138, 139 speedometer - 210 throttle - 71 Caliper (braking system) - 132 Cam followers - 40,41 Camshaft - 40, 41

E Economy gauge - 199, 210 Electric door mirror - 196 Electric windows - 208 Electrical system - 186 et seq Electronic modules - 93 Engine - 24 et seq, 176 Exhaust system - 82

Index

F Facia panel - 178, 196 Fault diagnosis braking system - 140 clutch - 100 cooling system - 63 driveshafts - 126 electrical system - 211 engine - 55 fuel and exhaust systems - 84 general - 21 ignition system - 95 manual gearbox - 121 steering - 158 suspension - 158 Filling cooling system - 60 Flushing cooling system - 59 Flywheel - 46 Front brakes - 129, 132, 133, 135 Fuel and exhaust systems - 65 et seq Fuel cut-off system - 94 Fuel filler flap - 176 Fuel filter - 69 Fuel gauges - 199 Fuel level sender unit - 70 Fuel pump - 69 Fuel tank - 69 Fuses - 193

G Gaiters driveshaft - 124 steering gear - 154 Gear selector lever assembly - 113 Gear selector linkage - 103 Gearchange lever - 104 Glovebox - 179, 202

H Handbrake - 138 to 140, 198 Handle (door) - 170 Hazard warning flasher switch - 196, 203 Headlamps - 203, 205, 207 Headlining - 181 Heater - 179, 182 to 185, 196, 203 Horn!s) - 201 HTleads - 88 Hubs front - 146 rear - 151 Hydraulic pipes and hoses (braking system) - 138

Idle speed adjustment - 74 Ignition coil - 87, 88 Ignition switch - 195 Ignition system - 85 et seq, 195 Ignition timing - 92, 93 Inlet manifold heater - 80 Input shaft (manual gearbox) - 107, 113 Instrument panel - 196, 199, 203 Introduction to the Fiat Tipo - 5

J Jacking - 7

L Locks bonnet - 163 central locking - 208 door - FO,208 steering : 95 tailgate - 165, 208 LCXJdspeakers - 209 Lower arm (front suspension) - 148 Lubricants and fluids - 19 Luggage compartment lamp - 202

M Main bear-ings - 52, 54 Mainshaft (manual gearbox) - 110 Manjfolds - eo, 81 Manual gearbox - 33, 35, 36, 102 et seq, 176 Map reading lamp ~ 197,202 Master cylinder (braking system) - 135, 136 MirrOls(door) - 172, 196 Mixture adjustment - 74 Mountings (engine) - 36 Multi-function stalk switches - 195, 203

N Number plate lamp - 204, 206

o Oil pressure warning lamp switch - 198 Oilpump - 48 Oil seals camshaft - 40 crankshaft - 46, 47 input shaft (manual gearbox) - 113

p Pads (braking system) - 129 Pedals brake - 140 clutch - 98 throttle - 70 Pistons - 49, 51 Power steering - 155, 156 Printed circuit board - 199

R Radiator - 50, 61 Radiator cooling fan - 63 Radiator grille panel - 173 Radio/cassette player - 209 Rear brakes - 130, 133, 134 Rear lamp unit - 204, 206 Rear wheel cylinder (braking system) - 134 Relays - 193 Repair procedures - 10 Reversing lamp switch - 198 Rotor arm - 88

239

240 Routine maintenance bodyworkandfittings - 14,160,161 braking system - 14, 128 clutch - 97 cooling system - 14,58 driveshafts - 14, 122 electr,ical system - 14, 187 engine - 14,27 fuel and exhaust systems - 14, 66 ignition system - 14, 87 manual gearbox - 14, 103 steering - 14,143 suspension - 14, 143

s Safety first! electrical system - 187 fuel system - 66 general - 13 Seat belts - 182 Seats - 181 Shock absorber (rear) - 151 Shoes (braking system) - 130 Side repeater lamp - 204, 206 Sidelamps - 205 Spare parts - 9 Spark plugs - 87 Speedometer - 199,210 Splash shields - 176 Starter motor - 191,192 Steering column - 153, 179, 195 ~teering gear - 154, 155, l' 56 Steering wheel - 153 Struts front suspension - 147, 148 tailgate - 166 Subframe door - 168 front suspension - 149 Sump - 47 Sunroof - 176, 198, 210 Suspension and steering - 142 et seq Switches brake lamp - 198 clock - 200 courtesy lamp - 197 facia panel - 196 handbrake "on" warning lamp - 198 hazard warning - 196 heater - 196 ignition - 195 instrument panel - 196, 200 map reading lamp - 197 mirror - 196 oil pressure warning lamp - 198 radiator cooling fan - 63 reversing lamp - 198

Index steering column stalk - 195 sunroof - 198 trip meter - 200 Synchro units (manual gearbox) - 112

T Tailgate - 164, 165, 166,207,208 Temperature gauge sender - 63 Thermostat - 61,62 Thermostatic vacuum valve - 79 Throttle cable - 71 Throttle pedal - 70 Timing belt - 37,39 Tools- 11 Towing - 7 Track-rod end - 157 Trailing arm - 152 Transmission see Manual gearbox Trim panels door - 167 facia - 178 interior - 177 Trip meter switch - 200 Tyres - 158

v Vacuum servo (braking system) - 136 Valve clearances - 29 Vehicle identification numbers - 9 Ventilation nozzles - 179

w Washer fluid pumps - 208 Washer fluid reservoir - 208 Washer nozzles - 207 Weights - '6 Wheel alignment - 157 Wheelareh liners - 176 Wheel bearings front - 146 rear - 150 Wheel changing - 7 Wheels - 158 Window regulator - 171 Windows - 171,208 Windscreen - 171, 206, 207 Wiper arms - 206 Wiper blades - 206 Wiper motor - 207 Wiring diagrams - 211,213 Working facilities - 11