fuel cap FIAT TEMPRA 1988 Service And Repair Manual

Running The Vehicle
NEVER start the engine unless the gearbox is in neutral (or
'Park' in the case of automatic transmission) and the hand
brake is fully applied.
NEVER run catalytic converter equipped vehicles without the
exhaust system heat shields in place.
TAKE CARE when parking vehicles fitted with catalytic
converters. The 'cat' reaches extremely high temperatures and
any combustible materials under the car, such as long dry
grass, could be ignited.
Personal Safety
NEVER siphon fuel, antifreeze, brake fluid or other such toxic
liquids by mouth, or allow contact with your skin. Use a
suitable hand pump and wear gloves.
BEFORE undertaking dirty jobs, use a barrier cream on your
hands as a protection against infection. Preferably, wear
suitable gloves, available from DIY outlets.
WEAR IMPERVIOUS GLOVES for sure when there is a risk of
used engine oil coming into contact with your skin. It can
cause cancer.
WIPE UP any spilt oil, grease or water off the floor
immediately.
MAKE SURE that spanners and all other tools are the right size
for the job and are not likely to slip. Never try to 'double-up'
spanners to gain more leverage.
SEEK HELP if you need to lift something heavy which may be
beyond your capability. Don't forget that when lifting a heavy
weight, you should keep your back straight and bend your
knees to avoid injuring your back.
NEVER take risky short-cuts or rush to finish a job. Plan ahead
and allow plenty of time.
BE METICULOUS and keep the work area tidy
-
you'll avoid
frustration, work better and lose less.
KEEP children and animals right-away from the work area and
from unattended vehicles.
ALWAYS tell someone what you're doing and have them
regularly check that all is well, especially when working alone
on, or under, the vehicle.
Fire!
Petrol (gasoline) is a dangerous and highly flammable liquid
requiring special precautions. When working on the fuel
system, disconnect the vehicle battery earth (ground) terminal
whenever possible and always work outside, or in a very well
ventilated area. Any form of spark, such as that caused by an
electrical fault, by two metal surfaces striking against each
other, by a central heating boiler in the garage 'firing up', or
even by static electricity built up in your clothing can, in a
confined space, ignite petrol vapour causing an explosion.
Take great care not to spill petrol on to the engine or exhaust
system, never allow any naked flame anywhere near the work
area and, above all, don't smoke.
Invest in a workshop-sized fire extinguisher. Choose the
carbon dioxide type or preferably, dry powder but NEVER a
water type extinguisher for workshop use.
DON'T disconnect any fuel pipes on a fuel injected engine
without following the advice in this manual. The fuel in the
line is under very high pressure
-
sufficient to cause serious
injury. Remember that many injection systems have residual
pressure in the pipes for days after switching off. If necessary
seek specialist advice.
Fumes
Petrol (gasoline) vapour and that given off by many solvents,
thinners, and adhesives are highly toxic and under certain
conditions can lead to unconsciousness or even death, if
inhaled. The risks are increased if such fluids are used in a
confined space so always ensure adequate ventilation. Always
read the maker's instructions and follow them with care.
Never drain petrol (gasoline) or use solvents, thinners
adhesives or other toxic substances in an inspection pit. It is
also dangerous to park a vehicle for any length of time over
an inspection pit. The fumes from even a slight fuel leak can
cause an explosion when the engine is started.
v ,,, Oil;::;s

Mains Electricity
Avoid the use of mains electricity when working on the vehicle,
whenever possible. Use rechargeable tools and a DC inspection
lamp, powered from a remote 12V battery
-
both are much
safer. However, if you do use mains-powered equipment,
ensure that the appliance is wired correctly to its plug, that
where necessary it is properly earthed (grounded), and that the
fuse is of the correct rating for the appliance. Do not use any
mains powered equipment in damp conditions or in the vicinity
of fuel, fuel vapour or the vehicle battery.
Always use an RCD (Residual Current Device) circuit breaker
with mains electricity. Then, if there is a short, the RCD circuit
breaker minimises the risk of electrocution by instantly cutting
the power supply.
Ignition System
Never work on the ignition system with the ignition switched
on, or with the engine being turned over on the starter, or
running and you are recommended never to do so.
Touching certain parts of the ignition system, such as the HT
leads, distributor cap, ignition coil etc., can result in a severe
electric shock or physical injury as a hand is pulled sharply away.
Voltages produced by electronic ignition systems are much
higher than those produced by conventional systems and could
prove fatal, particularly to people with cardiac pacemaker
implants. Consult your handbook or main dealer if in any
doubt.
Cooling Fan
On many vehicles, the electric cooling fan can switch itself on
even with the ignition turned off. This is especially likely after
driving the car and parking it before turning off, after which
heat rises to the top of the engine and turns the fan on,
suddenly and without warning. If you intend working in the
engine bay, it's best to do so when the engine is cold, to
disconnect the battery, or keep away from the fan, if neither of
these are possible.
Battery
Never cause a spark, smoke, or allow a naked light near the
vehicle's battery, even in a well ventilated area. Highly explosive
hydrogen gas is given off as part of the charging process.
Battery terminals on the car should be shielded, since a spark
can be caused by any metal object which touches the battery's
terminals or connecting straps.
IMPORTANT NOTE: Before disconnecting the battery earth
(ground) terminal read the relevant FACT FILE in Chapter 5
regarding saving computer and radio settings.)
When using a battery charger, switch off the power supply
before the battery charger leads are connected or disconnected.
If the battery is not of the 'sealed-for-life' type, loosen the filler
plugs or remove the cover before charging. For best results the
battery should be given a low rate trickle charge overnight. Do
not charge at an excessive rate or the battery may burst.
Always wear gloves and goggles when carrying or when
topping up the battery. Acid electrolyte is extremely corrosive
and must not be allowed to contact the eyes, skin or clothes.
Brakes and Asbestos
Obviously, a car's brakes are among its most important safety
related items. ONLY work on your vehicle's braking system if
you are trained and competent to do so. If you have not been
trained in this work, but wish to carry out the jobs described in
this book, we strongly recommend that you have a garage or
qualified mechanic check your work before using the car.
Whenever you work on the braking system components, or
remove front or rear brake pads or shoes: i) wear an efficient
particle mask; ii) wipe off all brake dust from the brakes after
spraying on a proprietary brand of brake cleaner (never blow
dust off with compressed air); iii) dispose of brake dust and
discarded shoes or pads in a sealed plastic bag; iv) wash your
hands thoroughly after you have finished working on the
brakes and certainly before you eat or smoke; v) replace shoes
and pads only with asbestos-free shoes or pads. Note that
asbestos brake dust can cause cancer if inhaled; vi) always
replace brake pads and/or shoes in complete 'axle' sets of four
-

never replace the pads/shoes on one wheel only.
Brake Fluid
Brake fluid absorbs moisture rapidly from the air and can
become dangerous resulting in brake failure. You should
change the fluid in accordance with your vehicle manufacturer's
recommendations or as advised in this book. Never store (or
use) an opened container of brake fluid. Dispose of the
remainder at your Local Authority Waste Disposal Site, in the
designated disposal unit, not with general waste or with waste
oil.
Engine Oils
Always wear disposable plastic or rubber gloves when draining
the oil from your engine, i) Note that the drain plug and the oil
are often hotter than you expect. Wear gloves if the plug is too
hot to touch and keep your hand to one side so that you are
not scalded by the spurt of oil as the plug comes away; ii) There
are very real health hazards associated with used engine oil. In
the words of one manufacturer's handbook "Prolonged and
repeated contact may cause serious skin disorders, including
dermatitis and cancer." Use a barrier cream on your hands and
try not to get oil on them. Always wear gloves and wash your
hands with hand cleaner soon after carrying out the work. Keep
oil out of the reach of children; iii) NEVER, EVER dispose of old
engine oil into the ground or down a drain. In the UK, and in
most EC countries, every local authority must provide a safe
means of oil disposal. In the UK, try your local Environmental
Health Department for advice on waste disposal facilities.
Plastic Materials
Many of the materials used (polymers, resins, adhesives and
materials acting as catalysts and accelerators) contain dangers in
the form of poisonous fumes, skin irritants, and the risk of fire

EMERGENCY STARTING
To release the spare
wheel, jack and tool kit:
16A. Undo strap A to
release the jack from the support. Unscrew nut B, to
remove the spare wheel.
16B. Release the jack from the tool stand by lifting tab C.
The arrangement of the tools in their holder might have
one of the configurations shown in illustration 16B.
• 17. RAISING
THE VEHICLE
17A. To raise the vehicle,
position the jack under
the side member, about
20 cm from the wheel
arch. Turn the jack
handle until the its
grooved head (see inset)
fits the flange at the base of the sill.
REMOVING A WHEEL
17B. Loosen all the wheel bolts in the
order shown.
• Lift the car until the wheel is about
25 mm
(1
in.) off the ground.
• The hub cap is secured by only three wheel bolts.
• Remove the hub cap, then unscrew the fourth wheel
bolt, and remove the wheel.
• Put the spare wheel on, making sure that the aligning
peg or pegs on the hub fits into the hole/s in the rim.
• Attach the wheel with a single bolt and then put the
wheel cover back on so that the largest hole fits over
the bolt holding on the wheel. Screw in the other three
bolts, which also hold on the wheel cover.
• Lower the car and remove the jack. Tighten the wheel
bolts evenly in a criss-cross fashion, as shown in
illustration 17C.
RAISING THE VEHICLE WITH A TROLLEY JACK
• 17C. FROM THE FRONT
-
Place a hardwood board
between the jack and the car, see inset. The jack must
ONLY be positioned under the gearbox case support on
the side of the differential gears.
• 17D. FROM THE REAR
-
Put a hardwood board
between the jack and the car ONLY at the back of the
spare wheel housing.
• 18. ENGINE STARTING
JUMP STARTING YOUR CAR
Choose a fully charged battery with the same or higher
capacity than the flat battery in your car, then ...
• Make sure that the car with the flat battery's electrical
equipment has its ignition turned OFF, and that the
ignition keys are removed.
18. • Connect
one of the jump
lead clamps to
the positive
battery post of
your flat
battery. Then
clamp the other
end of the same
lead on to the positive post of the second (charged)
battery.
• Connect one end of the second jump lead to the
negative pole of the charged battery, and attach the
other end to the metal terminal (as shown) of the earth
cable from your car's flat battery.
• Run the engine of the car with the charged battery at
a medium to slow speed.
• Start the engine of the car with the flat battery, and
run the engines of both cars for about three minutes.
• To reduce voltage peaks when disconnecting the
jump leads, turn on the air fan and the heated rear
screen of the car that had the flat battery.
• Remove the jump leads, starting with the negative
clamp connected to the car with the flat battery's earth.
IMPORTANT NOTE: When disconnecting the jump
leads DO NOT switch on the headlights in place of
the heated rear screen, as the peak voltage may
blow the headlight bulbs.
BUMP STARTING YOUR CAR
IMPORTANT NOTES: 1) Never bump start a car
fitted with a catalytic converter, as the sudden rush
of unburnt fuel into the catalytic converter could
damage the converter beyond repair.
2) On models fitted with automatic transmission
bump starting is not possible.
3) Ensure that the key is in the ignition and is
turned to MAR while the car is being pushed, or
the steering wheel will lock.
To bump start a car:
• Place the key in the ignition and turn to MAR.
• Engage a medium gear (2nd or 3rd), NOT REVERSE.
• Hold the clutch pedal down while someone pushes.
• When the pushed car has reached a fair speed, with
the car still in gear, release the clutch pedal.
• The engine should now turn over and start running.
Depress the clutch and keep the car running.
16

CHAPTER 3
FACTS ARID FIGURES
This chapter provides you with
all the information you will
need about your car, especially
in connection with servicing and
repairing it. First, you'll need to
identify the engine type. If you
don't know it already, see
Chapter 6, Repairs and
Replacements.
Before buying parts, be sure to
take your vehicle's chassis and
engine numbers with you
-
see
Auto-Biography on page 1
and PART G: IDENTIFICATION
NUMBERS in this chapter.
Chapter Contents
• -< Page No. Page No.
PART
A:
MAJOR MILESTONES 17 PART E: REPAIR DATA 20
PART
B:
VITAL STATISTICS 18 PART
F:
TORQUE WRENCH SETTINGS 23
PART C: CAPACITIES 19 PART G: IDENTIFICATION NUMBERS 27
PART
D:
SERVICE DATA 19
•
IMPORTANT NOTE: Many detail changes have taken place over the years, and there have been many different Special
Editions and Options available. The following information will be true of most cases but can only be taken as a general
guide. Consult your local FIAT dealer for confirmation.
PART A: MAJOR MILESTONES
Overview Although the Tipo and Tempra were presented as
separate models, they are essentially the same cars, with detail
differences. However, all Tipos are 5-door hatchbacks (apart
from some 3-door 1.4 and the relatively rare 2.0 i.e. 16v, both
from 1993); all Tempras are 4-door saloons (with a boot) or
5-door estates. Apart from the rear bodywork and very slight
differences in rear suspension rates, both models are the
same, although years of production and options available
(including some engine options and some model names) are
not necessarily the same, and changes were not always
introduced to both model names at the same time
-
if at all.
All models come with front disc, rear drum brakes, except the

Tipo
2.0 i.e. 16v (but NOT the 2.0 i.e. GT), and the Tempra 2.0
i.e. SXand SLX models, which have discs front and rear.
IMPORTANT NOTE: This manual does NOT cover 1.8 and
2.0 litre Tipo or Tempra models.
June 1988 Tipo range introduced, as 1.4, 1.4 DGT, 1.6 DGT
and 1.6 DGT SX models with 1372ccand 1580cc petrol
engines. Also 7.97".dswith 1929 turbo diesel engine DGT and
Ids with digital instruments. All models with galvanised steel
body.
October 1988 Tipo 1.7D diesel version launched.
April 1990 Formula and S versions of Tipo 1.4 introduced.
April 1990 Also 1.6 DGT Selecta version introduced with CVT
gearbox.
July 1990 Tempra 1.4 and 1.6 (petrol) and 1.9D, (non-turbo
diesel), and 1.9 TD5 and TD5X (turbo diesel) 4-door saloon
models introduced. CVT auto-transmission available on 1.6
petrol models only
-
same as Selecta on Tipo models, but not
named as such. Tempra 1.8 i.e. SX with high performance
1756cc double-overhead camshaft (DOHC) fuel-injected
engine introduced. Tempra 1.4 and 1.6 basic and 5 models
with regular, analogue instruments; Tempra SXand SX i.e.
with digital instruments.
Tipo 1.8 i.e. DGT model, with high performance 1756cc fuel
injected, DOHC petrol engine introduced.
June 1991 Tempra Station Wagon introduced, as 1.6 or 1.8
i.e. models, with 2-part horizontally split tailgate and high-
roof styling.

PART F: TORQUE WRENCH SETTINGS
Key for engine types and sizes: A
-
1372cc; B
-
1581cc;
C
-
1697cc Diesel; D
-
1929cc Diesel; E
-
1929cc Turbo Diesel.
Engine
Screw retaining caps to crankcase (M10 x 1.25)
Screw retaining intermediate and central caps to crankcase (M12 x 1.25)...
Self-locking screw retaining front and rear caps to crankcase (M12 x 1.25)
Bolt, cylinder head to engine block (M10 x 1.25)
IMPORTANT NOTE: All torque settings shown in
Newton-meters (Nm). Bolt, nut or screw sizes in
brackets in left-hand column.
Bolt, cylinder head to engine block (M12 x 1.25)
Bolts, top to bottom cylinder head (M8)
Nut for connecting rod cap retaining bolt (M9 x 1)
Screw, connecting rod cap (M10 x 1)
Screw retaining engine vent to crankcase
(M8)
(M8)
Screw retaining front cover to crankcase
(MlOx 1.25)
(M8)
Bolt retaining rear cover (flywheel side) to crankcase (M6)
Nut retaining inlet and exhaust ducts to cylinder head
(M8)
(M8)
Screw, flywheel to crankshaft
(M10x 1.25)
(M12
x
1.25)
Lower belt cover retaining screw (M8)
Screw, damping flywheel to drive gear (M8)
Nut retaining auxiliary drive pulley to crankshaft (M20 x 1.25)
Screw retaining drive shaft to crankshaft (*) (M14 x 1.5 left)
Screw, timing gears
(M10x 1.25)
(M12x 1.25)
Belt tensioner retaining bolt
(M8)
(M10x 1.25)
Fixed belt tensioner retaining screw (M10 x 1.25)
Screw retaining auxiliary component driven gear (oil pump) (M10 x 1.25)
Nut for camshaft cap retaining stud (M8)
Nut retaining camshaft and air vacuum pump end mounts (M8)
Combustion prechamber retaining ring (M32 x 1.5)
Nut, injection pump stud (M8)
Screw, injection pump (M8)
Nut fastening flexible block to coolant pump case (M12 x 1.25)
Nut, injection pump gear (M12 x 1.75)
Screw retaining reaction bracket to oil filter support and injection pump (M8).
Top retaining screw or nut, oil filter support and injection pump (M12 x 1.25)
Lower retaining screw, oil filter support and injection pump (M10 x 1.25)
Complete injector (M24 x 2)
Glow plugs (M12 x 1.25)
Nuts retaining fuel delivery line to injection pump and injector (M12 x 1.25)...
Bolt, coolant pump to engine block (M8 x 1)
Bolt retaining cover and bracket to coolant pump case (M8)
Oil pressure switch (M14 x 1.5)
Coolant temperature sender unit
(M16 x 1.5 tapered)
(M18x 1.5 tapered)
Coolant temperature thermal switch (M16 x 1.5 tapered)
(*) The bolt need not be greased.
A B C D E Torque (Nm)
• • 80
• • • 113
• • • 113
• • 40
+
90 degrees
+ 90 deqrees
• • • 100
+
90 degrees
+ 90 deqrees
• • 28
• • 51
• • • 25 + 50 deqrees
• •
• • •
25
20
• • 50
25
• 10
• •
• • •
28
25
• •
• • •
83
142
• • 25
• • • 28
• • 155
• • • 190
• •
• • •
83
118
• •
• • •
25
44
• • • 44
• • 83
• • • 19
• • • 19
• • • 118
• • • 25
• • • 25
• • 80
• • • 49
• • • 29
• • • 98
• • • 71
• • • 55
• • • 15
• • • 29
• • • 25
• • • 23
32
• •
• • • 34
30
• • 30
expert22 fl/i* http://rutracker.org 23

O 23. Have your assistant press down firmly on the brake pedal while you check the rear brake flexible hoses for bulges, splits or other deterioration.
o 24. Check the fuel tank for leaks or corrosion. Remember also to check the fuel filler cap
-
a correctly sealing filler cap is a part of the MoT test.
O 25. Examine the handbrake mechanism. Frayed or broken cables or worn mounting points, either to the bodywork or in the linkage will all be failure points.
o 26. Check each of the rear wheel
bearings as for the fronts.
o 27. Spin each rear wheel and check that neither the wheel bearings nor the brakes are binding. Pull on and let off the handbrake and check once again to make sure that the handbrake mechanism is releasing.
SAFETY FIRST!
• Only run the car out of doors.
• Beware of burning yourself on a hot exhaust system.
o 28. While you are out from under the car, but with the rear end still raised off the ground, run the engine. Hold a rag over the end of the exhaust
pipe and listen for blows or leaks in the system. You can now get back under the car and investigate further if necessary.
o 29. Check the exhaust system mountings and check for rust, corrosion or holes in the rear part of the system.
o 30. Check the rear brake back plate or calipers (as appropriate) for any signs of fluid leakage.
o 31. Check the insides and the outsides of the tyres as well as the tyre treads for damage, as for the front tyres.
PART D: EXHAUST EMISSIONS
This is an area that is impossible to
check accurately at home. However,
the following rule-of-thumb tests will
give you a good idea whether your car
is likely to fail or not.
H INSIDE INFORMATION: If you
feel that your car is likely to fail
because of the emission test, have
your MoT testing station carry out
the emission part of the test first so
that if it fails, you don't waste
money on having the rest of the
test carried out. Q
O 1. PETROL ENGINES BEFORE 1 AUGUST 1973 AND DIESEL ENGINES BEFORE 1 AUGUST 1979 only have to pass visible smoke check. Rev the engine to about 2,500 rpm (about half maximum speed) for 20 seconds and then allow it to return to idle. If too much smoke is emitted (in the opinion of the tester) the car will fail.
O 2.DIESEL ENGINES FROM 1 AUGUST 1979 The engine will have to be taken up to maximum revs several times by the tester, so make certain that your timing belt is in good condition, otherwise severe damage could be caused to your engine. If the latter happens, it will be your responsibility!
FACT FILE: VEHICLE EMISSIONS

PETROL
ENGINED VEHICLES WITHOUT
CATALYSER

Vehicles first used before 1 August 1973

• visual smoke check only.

Vehicles first used between 1 August 1973 and 31 July 1986

• 4.5% carbon monoxide and 1,200 parts per million, unburned
hydrocarbons.

Vehicles first used between 1 August 1986 and 31 July 1992

• 3.5% carbon monoxide and 1,200 parts per million, unburned
hydrocarbons.
PETROL ENGINED VEHICLES FITTED WITH
CATALYTIC

CONVERTERS
i

Vehicles first used from 1 August 1992
(K-registration on)

• All have to be tested at an MoT Testing Station specially equipped to
handle cars fitted with catalytic converters whether or not the vehicle
is fitted with a 'cat'. If
the
test, or the garage's data, shows that the
vehicle was not fitted with a 'cat' by the manufacturer, the owner is
permitted to take the vehicle to
a
Testing Station not equipped for
catalysed cars, if he/she prefers to do so (up to 1998-only). Required
maxima are
-
3.5% carbon monoxide and 1,200 parts per million,
unburned hydrocarbons. The simple emissions test (as above) will be
supplemented by a further check to make sure that the catalyst is
maintained in
good
and efficient working order.
• The tester also has to check that the engine oil is up to a specified
temperature before carrying out the test. (This is because 'cats' don't
work properly at lower temperatures
-
ensure your engine is fully
warm!)
DIESEL ENGINES'EMISSIONS
STANDARDS

• The Tester will have to rev your engine hard,
several times. If it is not in good condition, he is
entitled to refuse to test it. This is the full range of
tests, even though all may not apply to your car.

Vehicles first used before 1 August, 1979

• Engine run at normal running temperature; engine speed taken to
around 2,500 rpm (or half
governed
max. speed, if lower) and held for
20 seconds. FAILURE, if engine emits dense blue or black smoke for
next 5 seconds, at tick-over. (NOTE: Testers are allowed to be more
lenient with pre-1960 vehicles.)

Vehicles first used on or after 1 August, 1979

• After checking engine condition, and with the engine at normal
running temperature, the engine will be run up to full revs between
three and six times to see whether your engine passes the prescribed
smoke density test. (For what it's worth
-
2.5k for non-turbo cars; 3.0k
for turbo diesels. An opacity meter probe will be placed in your car's
exhaust pipe and this is not something you can replicate at home.)
Irrespective of the meter readings, the car will fail if
smoke
or vapour
obscures the view of other road users.
• IMPORTANT NOTE: The diesel engine test puts a lot of stress on the
engine. It is IMPERATIVE that your car's engine is properly serviced,
and the cam belt changed on schedule, before you take it in for the
MoT test. The tester is entitled to refuse to test the car if
he
feels that
the engine is not in serviceable condition and there are a number of
pre-Test checks he may carry out.

Thanks
are due to the excellent, knowledgeable and helpful staff at FIAT main dealers, Ryauto of Amblecote, in the West
Midlands for supplying vehicles and for their assistance with this chapter. In particular, thanks are due to the efficient Maurice
Hough, Service Manager, the experienced Foreman, Tony Morris, and young demon mechanic, Matthew Worsfold.
Some of the suggested inspection/replacement intervals may not correspond to those shown in the original handbook. The suggested
schedule, based on FIAT'S recommendations, takes into account the age of the vehicle and the annual MoT test in the UK.
In practice, because of the split between (mainly) 12 month/9,000 mile and 18 month/13,500 mile intervals, you will need to
service your Tipo or Tempra at most, if not every, 6 month interval.
IMPORTANT NOTE: Each service should be carried out at EITHER the recommended mileage OR the recommended time
interval, whichever comes first.
SERVICE INTERVAL CHART
SERVICE INTERVALS: KEY
A
-
Every week, or before every long journey. F
-
Every 3 years or 27,000 miles.
B
-
Every 6 months, or 4,500 miles. G
-
Every 4 years or 36,000 miles.
C - Every 12 months, or 9,000 miles. H
-
Every 6 years or 54,000 miles.
I
-
Every 63,000 miles. D - Every 18 months , or 13,500 miles.
H
-
Every 6 years or 54,000 miles.
I
-
Every 63,000 miles.
E
-
Every 2 years or 18,000 miles J
-
Every 72,000 miles.
PART A: REGULAR CHECKS
SERVICE INTERVALS
Job 1. Engine oil
-
check level A
Job 2. Cooling system
-
check level A
Job 3. Brake/clutch fluid
-
check level A
Job 4. Battery
-
check electrolyte level A
Job 5. Screen washer fluid
-
check level A
Job 6. Tyres
-
check pressures and
condition (road wheels) A
Job 7. Check lights/change bulbs A
PART B: THE ENGINE AND
COOLING SYSTEM
Job 8
-
Petrol. Change engine oil and filter C
Job 8
-
Diesel. Change engine oil and filter B
Job 9. Check crankcase ventilation H
Job 10. Check/adjust valve clearances D
Job 11. Check camshaft timing belt F
Job 12. Change camshaft timing belt I
Job 13. Check cooling system C
Job 14. Change engine coolant E
PART C: TRANSMISSION
Job 15. Check manual gearbox oil level C
Job 16. Change manual gearbox oil J
Job 17. Check auto, transmission fluid level C
Job 18. Change auto, transmission
fluid and filter F
Job 19. Check driveshaft gaiters C
Job 20. Check/adjust clutch C
Job 21. Check auto, transmission selector
cable E
PART D: IGNITION AND ELECTRICS
SERVICE INTERVALS
Job 22. Check/clean/gap spark plugs B
Job 23. Change spark plugs D
Job 24. Check/clean HT leads and
distributor cap C
Job 25. Check ignition timing C
Job 26. Check/adjust drive belt/s D
Job 27. Check electric fan operation C
Job 28. Run diagnostic ignition/injection test D
PART E: FUEL AND EXHAUST
Job 29. Check fuel pipes for leaks C
Job 30. Change petrol air filter D
Job 31. Change diesel air filter C
Job 32. Change petrol fuel filter F
Job 33. Drain diesel fuel filter B
Job 34. Change diesel fuel filter C
Job 35. Check/adjust petrol engine idle
and emissions C
Job 36. Check emission/evaporative/EGR systems F
Job 37. Check Lambda sensor F
Job 38. Check/adjust diesel idle speed C
Job 39. Check/adjust diesel injection timing E
Job 40. Check inlet and exhaust manifold fixings D
Job 41. Check exhaust system C
PART F: STEERING AND
SUSPENSION
Job 42. Check front wheel bearings C
Job 43. Check front suspension C
Job 44. Check steering column, joints and rack C
Job 45. Check power steering fluid C
Job 46. Check rear wheel bearings C
Job 47. Check rear suspension C
Job 48. Check wheel bolts for tightness C

PART G: BRAKING SYSTEM
Job 49. Check front brakes
Job 50. Check rear brakes
Job 51. Check/adjust handbrake
Job 52. Check brake pipes
Job 53. Change brake hydraulic fluid
SERVICE INTERVALS
C
C
C
C
E
Job 56. Check seat and seat belt mountings C
Job 57. Check headlight alignment C
Job 58. Check underbody C
Job 59. Check spare tyre B
Job 60. Change pollen filter C
Job 61. Replace airbag gas generator 10 years
PART I: ROAD TEST
PART H: BODYWORK & INTERIOR
Job 54. Lubricate hinges and locks
Job 55. Check windscreen
Job 62. Road test and specialist check. AFTER EVERY
SERVICE

ENGINE BAY LAYOUTS
These are the engine bay layouts common to almost all Tipo/Tempras. Note that there is no carburettor fitted to fuel-injected
vehicles.
1 - PETROL ENGINES 2 - DIESEL ENGINES
1
-
oil filler cap 7
-
distributor (ignition) 12 - oil filter location
2
-
engine oil dipstick 8
-
coil (ignition) 13
-
fuel pump (mechanical)
3
-
coolant filler cap 9
-
electronic control unit (ECU), 14
-
diesel injection pump
4 - brake fluid reservoir Digiplex 2 15
-
alternator location (behind engine)
5 - battery 10
-
air filter housing
6
-
screenwash reservoir cap 11
-
fuel filter
PART A: REGULAR CHECKS
1B. ...and the diesel's
dipstick is in a similar
spot, located at the
front edge of the
timing cover, behind
the right-hand
headlight.
Q INSIDE INFORMATION: The
difference between MIN and MAX
marks is approximately one litre of
oil. Q
We recommend that these Jobs are carried out on a weekly
basis, as well as before every long journey. They consist of
checks essential for your safety and for your car's reliability.
• Job 1. Engine oil
-
check level.
Check the engine oil level with the car on level ground. If the
engine has been running, leave it turned off for several
minutes to let the oil drain into the sump.
1A. All petrol engines
have the dipstick at
the front of the block,
towards the timing
belt end...
1C. Lift the dipstick out,
wipe it dry and re-insert it. The oil
level is correct when between the
MAX and MIN marks.

(ignition-ON) position and press down the button between the
two terminals on the reservoir cap
-
when fitted. The warning
light on the dash should light up. When no button is fitted,
unscrew and raise the cap (ignition key ON) to check the
warning light. Check the bulb, check the fuse, or have your
FIAT dealer repair the warning system, if faulty.
• Job 4. Battery
-
check electrolyte level.
FACT FILE: DISCONNECTING THE
BATTERY
• Many vehicles depend on a constant
power supply from the battery; with
these you find yourself in trouble if you
simply disconnect the battery. You
might find the car alarm goes off, or that the engine
management system forgets all it ever 'learned', making
the car feel odd to drive until it has re-programmed
itself. You might also find that the radio refuses to
operate until its correct security code is keyed into it.
• On cars with engine management systems and/or
coded radios, you must ensure the car has a constant
electrical supply, even with the battery removed. You
will need a separate 12 volt battery; put a self-tapping
screw into the positive lead near the battery terminal
before disconnecting it, and put a positive connection
to your other battery via this screw.
• Be EXTREMELY CAREFUL to wrap insulation tape
around the connection so that no short is caused. The
negative terminal on the other battery must be
connected to the car's bodywork.
SAFETY FIRST!
• The gas given off by a battery is highly explosive.
Never smoke, use a naked flame or allow a spark in
the battery compartment.
• Never disconnect the battery (it can cause sparking)
with the battery caps removed.
• All vehicle batteries contain sulphuric acid. If the
acid comes into contact with the skin or eyes, wash
immediately with copious amounts of cold water and
seek medjcal advice.
• Do not check the battery levels within half an hour
of the battery being charged with a separate battery
charger because the addition of fresh water could
cause electrolyte to flood out.
4. Check the electrolyte
level in the battery. MAX
and MIN lines (arrowed)
are moulded into the
translucent battery
casing. In the case of
non-FIAT-supplied
batteries, the cell caps or
strip (a) may need to be
removed to see the level.
Original FIAT batteries are of the 'maintenance-free' type and
usually do not need topping-up. However, if necessary, top up
after prising off the cell sealing strip with a screwdriver. Top-
up each cell ONLY with distilled or de-ionised water.
• Job 5. Screen/headlight washer fluid
check level.
5A. Top up with a mixture of
water and screen-wash
additive, mixed according to
the instructions on the
container. FIAT recommend
Arexons DP1. The reservoir
for front screen, rear screen
and headlights (as appro-
priate) is situated in the engine
bay: adjacent to the left-hand
strut, behind the battery...
5B. ...and behind the
coolant expansion
tank on diesel
models, as illustrated
here.
• Job 6. Tyres
-
check pressures and condition
(road wheels).
/
6A. Check the tyre
pressures using a
reliable and accurate
gauge. Note that the
recommended
pressures (see
Chapter
3,
Facts and
Figures) are given for ^^
iH^KKSEI ^ "'

COLD tyres. Tyres
warm up as the car is used
-
and warm tyres give a false (high)
reading. You should also check for wear or damage at the
same time.
SAFETY FIRST!
• If a tyre is worn more on one side than another,
consult your FIAT dealer or a tyre specialist. It probably
means the tracking needs re-setting, though it could
indicate suspension damage, so have it checked.
• If a tyre is worn more in the centre or on the edges,
this indicates incorrect tyre pressures.
• Incorrectly inflated tyres wear rapidly, can give
dangerous handling, and can worsen fuel
consumption.
Every three months,
raise each wheel off
the ground and turn it
slowly between your
36
6B. Every few weeks, examine the tyre treads for wear using a
tread-depth gauge. This will help you keep safe and on the
right side of the law!
Check treads visually
every time you check
the pressures.

26B. If adjustment is
necessary, slacken the
tensioning nut (A) and
the alternator pivot (B),
on all models. (These
are two typical
layouts.)
Use a length of wood
to pivot the alternator
away from the engine
block but take great
care not to damage the
alternator casing.
Tighten the nuts/bolts
when the tension is correct.
RIBBED BELTS ONLY
If your vehicle is fitted with a ribbed belt, pivot the alternator
as described above and tighten it when you can just twist the
belt by 1/4 turn in the middle of its longest run.
IMPORTANT NOTE:
• Belt tension should only be adjusted when the engine
is cold.
• After adjustment, run the engine for 15 to 30 seconds,
to allow the belt to bed-in, then check again.
• Experience mechanics claim that belts often go slack
when the engine heats up, producing belt squeal.
• If this happens on your vehicle, adjust the belt again
when the engine is hot. Wear industrial leather gloves
and long-sleeved overalls and take very great care not to
burn yourself on the hot engine or exhaust.
If there is an auxiliary unit, such as an air conditioning pump,
driven by a separate drive belt, examine and adjust it as
described here.
Q Job 27. Check electric fan operation.
Drive the car until it is at normal operating temperature. Park
outdoors and, with the gearbox in neutral (or 'P' in the case of
an automatic) leave the engine running. At just above normal
temperature the electric cooling fan should come on, and
then go off again when the temperature drops. Refer to your
temperature gauge, if fitted. If the fan doesn't behave, check
the thermo-switch on the radiator, along with all connections
and wires in its circuit with the fan motor. See Job 13 and
Chapter
6,
Repairs and Replacements.
• Job 28. Run diagnostic ignition/injection test.
DIAGNOSTIC TEST
28A. Have your FIAT dealer
carry out a diagnostic test,
plugging his tester into the
diagnostic socket tucked away
at the front of the passenger-
side footwell.
EMISSIONS TESTS
Vehicles fitted with the Mono-Jetronic fuel injection system
are not fitted with adjustment screws. The system is self-
regulating. However, specified annual checks carried out with
an exhaust gas analyser will provide essential information on
the condition of the injection/ignition system, the catalytic
converter and the engine itself.
28B. The checks are carried out twice: once with the test
sensor at least 300 mm into the end section of the exhaust
pipe (a). (If the shape of the end section of the exhaust pipe is
such that the sensor cannot be completely introduced, a
special extension pipe must be added ensuring that the joint
with the car's tail-pipe is sealed.); the second after undoing
the cap or nut on the exhaust pipe upstream of the catalytic
converter (b).
The following table shows the test limits for carbon monoxide,
unburned hydrocarbons (in parts per million) and carbon
dioxide:
CO (%) HC (p.p.m.) C02(%)
Upstream of the catalyzer (a) 0,4 -h 1 500/600* >12
Downstream of the catalyzer (b)
=£
0,35 =s 90 >13
* FIAT's figures vary.
IMPORTANT NOTE: The engine must be at its normal
operating temperature and normal tick-over speed.
• if the percentage concentration of CO upstream of the
catalytic converter is not within the limits in the table,
check:
• the Lambda sensor
-
see Job 37.
• air penetration around the Lambda sensor housing.
• faults in the ignition or injection systems. (First try
renewing the spark plugs, distributor cap and HT leads.)
If, at the same time, the concentration of hydrocarbons
is not less than 500/600 parts per million (FIAT'S figures
vary), check:
• the ignition timing (see Job 25).
• the valve clearances (see Job 9).
• the valve gear timing (see Job 12).
• the engine compression. (You will need to remove the
spark plugs, fit a compresson tester to each plug
aperture in turn and crank the engine. See the FACT FILE
on page 51.)