stop start FIAT TEMPRA 1988 Service And User Guide

• Step 3: ...and
remove the caliper
support bracket.
Ll Step 4: Unscrew
the disc fixing bolts and
withdraw the disc.
clean and undamaged.
• Before refitting the disc,
ensure that the mating
surfaces
-
hub to disc, are
Job 10. Master cylinder
replacement.
H INSIDE INFORMATION: • On right-hand drive cars, the
master cylinder is on the driver's side and is VERY
different to get at, behind the engine.
• To remove the master cylinder on these cars you may
need to remove the complete assembly
-
master cylinder,
servo and pedal assembly
-
from inside the car. Q
• Step 1: IMPORTANT NOTE: Protect all paint surfaces
from possible brake fluid spillage before starting work.
You know what a good paint stripper it is!
• Step 2: Syphon off as much brake fluid as possible or
bleed it out
through one of the
front brakes until
the master cylinder
makes 'sucking'
noises.
• Step 3:
Remove the
reservoir from the
master cylinder.
138
• Step 4: Use a spanner
-
preferably a purpose-made split
ring spanner
-
to undo all the pipe unions from the master
cylinder.
• Step 5:
Undo the nuts
securing the
master cylinder
to the servo and
remove it.
• Step 6: Refit
in the reverse
order and refer
to Job
77
for
bleeding the
brakes.
Job 11. Servo check
and refit.
remove
Q INSIDE INFORMATION: • Before condemning the
servo for lack of efficiency, check the condition of the
one-way valve and vacuum pipe connecting it to the
inlet manifold.
• Ease the valve out of the front of the servo and
disconnect the pipe from the inlet manifold.
• Check that you can only blow one way through the
valve
-
from the servo end towards the inlet manifold (or
the brake vacuum pump
-
Diesel models).
• The vacuum pipe can suffer failure in many ways. Age
can harden it until it cracks, causing an air leak which
sometimes results in a whistling noise and rough slow-
running.
• Loose connections could also produce the same result.
• The other type of vacuum hose failure is an implosion
(where the hose is sucked flat by the vacuum) often
because oil has softened the hose.
• This is not so easily detected, as it rarely upsets the
engine performance and resumes its normal shape
shortly after the engine is stopped.
• The inner lining can also deteriorate, causing a
blockage. Q
• Step 1: Follow Job
10
to remove the master cylinder.
• Step 2: From inside the car, unhook the accelerator cable
from the pedal fork.
• Step 3:
Undo the
fixing nuts,
remove the
retaining
plate and
pedal
assembly.
•
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Job 15. Flexible hoses -
replacement.
• Step 8: Bleed the brakes, see Job
17

H INSIDE INFORMATION: When disconnecting brake
pipes or hoses, it is helpful to minimise brake fluid loss.
This can be done by unscrewing the master cylinder
reservoir cap, laying a sheet of plastic across the
opening, and refitting the cap. This will prevent atmos-
pheric pressure from pushing the fluid out of opened
lines. D
/ • If a rigid pipe starts to
twist with the union, grip
the pipe as lightly as
possible, and see if you can stop it from turning.
• If not, cut through the pipe with a junior hacksaw
and replace the length of rigid pipe.
Job 16. Metal pipes -
replacement.
B INSIDE INFORMATION: When disconnecting brake
pipes or hoses, it is helpful to minimise brake fluid loss.
This can be done by unscrewing the master cylinder
reservoir cap, laying a sheet of plastic across the
opening, and refitting the cap. This will prevent atmos-
pheric pressure from pushing the fluid out of opened
lines. A pipe spanner makes the job much easier! B
Step 1: Undo the unions at each end of a pipe length.
Patience is often required because of the union seizing both in
its threads and on the pipe. See MAKING IT EASY! after Job

15,
Step 8 Use penetrating oil to help free seized unions, and
use a split-ring spanner rather than an open-ended one, to
reduce the risk of rounding off the union nuts.
• Step 2: Detach the pipe length from its securing clips and
remove it.
i^vj ens s * ^ step 3: where possible, use the old pipe as
a pattern to shape the new
one prior to fitting.
• Step 4: Follow the original route and secure the pipe in
the body clips.
Q Step 5: Connect the unions and bleed the system. See
Job
17

Job 17. Brake bleeding.
B INSIDE INFORMATION: Unless the master cylinder or
pressure regulating valve has been disturbed, it will only
be necessary to bleed the end of the braking system
which has been opened. If bleeding the whole system,
start bleeding at the left-hand rear brake. B
G Step 6: These are the correct positions of clips and
protective washers on the hose. Figures with a * are for 1929
turbo Diesel only.
• Step 7: B INSIDE INFORMATION! Changing the rear
hoses is the same, but there are no electrical cables or
protective washers. B
s • When bleeding the rear
brakes, keep the normal
weight on the rear wheels
to prevent the pressure limiting valve from inhibiting
the brake fluid flow.
expert22 f
\9\ http://rutracker.org 141
Ul Step 1: Undo the front hose rigid pipe union (see illus-
tration Job
15-2,
part a) where hose and pipe join at the
support bracket. Use the spanner underneath the bracket to
stop the hose twisting. Take care not to damage the bracket
or tear it off the body.
• Step 2: Pull out the
dip (b).
G Step 3: Unplug the
electrical connection for
the brake pad wear
sensor and unclip it from
the hose.
G Step 4: Unscrew and
remove the hose
from its other end -
it screws into a
female thread.
• Step 5: Refit in
reverse order and
position the
washers and the
position of the
hose at the
anchorage point
(A) as shown, so as
to prevent chafing
on the body when suspension and steering movement take
place. When tightening each union, make sure you haven't
put a twist in the hose!

97 Solenoid for automatic cold-start advance device 160 Potentiometer 270 Front cable connection (K.S.B.) 161 Junction between engine lead and facia leads for 271 Maximum turbo boost pressure warning light 98 Engine cut out solenoid on injection pump SPI system switch 99 Cooling fan second speed activation relay 161A Engine lead connection for IAW injection system 272 Front cable connection 100 Fuel pump facia lead connection 163 Bosch SPI electronic injection control unit 273 Front cable connection 101 Electromagnetic sensor for rpm sensor 163A Bosch SPI ignition/injection ECU 274 Front cable connection 102 Turbocharger air pressure switch 164 Diagnostic socket (S.P.I.) 281 Left-hand brake lining connection cable joint 104 10A fuse for ABS device 165 Electric fuel pump 281A Right-hand brake lining connection cable joint 105 Connection for anti-lock brake circuit (Antiskid) 166 Hot Lambda probe 282 CO regulation potentiometer 106 Left hand brake lining wear sensor lead 167 Step motor 286 Electromagnetic sensor on flywheel connection 171 Air temperature sender unit 287 Seat belt undone indicator switch 107 Cut-off control module 173 Throttle position sensor 288 Headlight washer intermittent function 108 Cable connection for air conditioner 174 Absolute pressure sender unit 292 Earth for anti-lock brake system (A.B.S.) 109 Front cable connection 180 Rem. contr. switch for legally specified system 293 Earth for air conditioner fan 111 Electric window ECU supply lead connection 181 Daylight side light remote control switch 294 Facia lead connection 112 Sensor on left front wheel 182 Daylight side light remote control switch 295 Connection between facia cable and rear cable 113 Sensor on right front wheel 184 Power earth 297 EGR device ECU 114 Sensor on left rear wheel 185 Electronic earth 298 Diagnostic socket for EGR device 115 Sensor on right rear wheel 186 Electric sun-roof ECU 299 EGR device control solenoid 116 Hydraulic control unit (A.B.S.) 187 Electric sun-roof circuit connection 300 EGR coolant temperature recording sensor 117 ABS control relay 188 Electric sun-roof end-stop sensor microswitch 301 Potentiometer on injection pump 118 Anti-lock brakes electronic control unit (A.B.S.) 189 Sun-roof operating motor 302 Sensor connection cable junction 119 Device for heated filter 190 Safety pressure switch 303 Low engine oil level indication sensor 120 Heated filter device relay 199 IAW multiple relay 304 Low coolant level indication sensor 121 20A fuse for heated filter device 200 Earth on hydraulic control unit bracket 305 Low washer fluid level indication sensor 122 Device for detecting presence of water in fuel filter 200A IAW injection/ignition ECU bracket earth 306 Oil temperature indication sensor 123 Left fog light 207 Starter enablement relay 307 Oil pressure indication sensor 124 Right fog light 208 Switch on gearbox indicating reverse or neutral 308 Junction with coolant temperature sender unit 125 Connection between front cable and fog light 209 Switch on gear selector leads cables 210 Automatic transmission speed selection ECU (CTX) 311 Front cable connection 126 Fog light switch 211 Parking not engaged warning light 312 Front cable connection 127 Sun-roof activation switch 214 Automatic transmission lead connection 313 Junction between facia lead and legally-specified 129 Electric door mirror control switch 215 T.D.C. AND RPM SENSOR (I.A.W.) leads 130 Electrically-adjustable and heated right-hand door 216 Injection/ignition ECU I.A.W. 314 Relay for legally-specified system mirror 219 1st injector 316 60A fuse for air conditioning system 130-A Electrically-adjustable and heated left-hand door 220 2nd injector 317 40A fuse for air conditioner system mirror 221 3rd injector 318 Diagnostic socket for IAW injection system 131 Left headlight wiper motor 222 4th injector 319 Automatic transmission device display 132 Right headlight wiper motor 224 15A fuse for injectors (Volkswagen) 133 Headlight washer pump 225 Idle speed control solenoid A Economy warning light 135 Left front seat heat pads 226 Provision for air conditioner B Sporty drive warning light 135A Right front seat heat pads 228 Ignition distributor with timing sensor 320 Right rear earth for automatic transmission 136 Air conditioner cable connection 231 Coupling with injection lead (Volkswagen) 137 Air conditioner cable connection 241 Automatic transmission electronic control unit 327 Junction with injector cable 138 Air conditioning system compressor (Volkswagen) 328 Advance cut out heat switch 139 Three stage pressure switch 242 Automatic trans, lead connection (Volkswagen) 329 Remote control switch for shifting advance curve 141 Air Recirculation/outside air intake control motor 243 Automatic trans, lead connection (Volkswagen) 330 Negative battery lead connection 142 Air conditioning system switch 244 ECU for decoding speed selector lever position 331 Prewired engine lead connection 143 Outside air/recirculation switch 245 Solenoid unit on transmission 332 Right hand rod lead connection 146 Air conditioning system ECU 246 Diagnostic connection for automatic transmission 333 Right front seat heating control switch A 40A fuse for engine cooling fan (Volkswagen) 334 Right front seat heating activated warning light B 30A fuse for interior ventilation fan and air 247A Automatic transmission lead connection 335 20A fuse for headlight washer system recirculation motor (Volkswagen) with I.A.W. injection system 336 Air conditioning system switch cable connection C 15A fuse for compressor 248 Automatic transmission lever lock solenoid 337 Ignition coil (1-4) D Interior ventilation fan and air recirculation 249 Kick-down switch 338 Ignition coil (2-3) motor relay 250 Rpm electromagnetic sensor E Compressor dual contact relay 251 Car speed electromagnetic sensor N.D. Connector block welded with ultrasound (band in F Cooling radiator fan first speed relay 252 Multifunction switch unit wiring harness) H Relay for compressor activation 253 Sporty drive switch I Timer for engine cooling fan 261 Junction between facia cable and right rear door Wiring colours: 147 Fast idle valve cables 148 Additional resistor for DIM-DIP circuit 262 Facia lead connection A Light blue 149 DIM-DIP circuit relay 263 Check-panel display B White 150 7.5A fuse for DIM-DIP circuit A Front side light failure warning light C Orange 151 Fuel pump control relay B Driver side front door open warning light G Yellow 152 SPI ECU and injector supply relay C Driver side rear door open warning light H Grey 152A Injector control contactor D Tail-gate open warning light L Blue 153 NA fuel vapour cut-off solenoid E Passenger side rear door open warning light M Brown 154 NC fuel vapour cut-off solenoid F Passenger side front door open warning light N Black 155 10A fuse for fuel pump G Rear side light failure warning light R Red 155A 25A fuse for fuel pump and injectors H Rear fog light failure warning light S Pink 156 Injector and air temperature sensor 1 Right brake light failure warning light V Green 157 Resistor L Number plate light failure warning light z Violet 158 10A fuse for Lambda probe M Left brake light failure warning light 158 5A fuse for I.A.W. ECU 264 Recharging indicator cable connection Most wires have two colours, shown as, for example, 159 Coolant temperature sender unit 269 Air conditioning cable connection CN, which means Orange and Black.