radiator cap FIAT TEMPRA 1988 Service And Repair Manual

Please be sure to read the whole of this Chapter before carrying out any work on your car.
SAFETY FIRST!
You must always ensure that
safety is the first consideration
in any job you carry out. A
slight lack of concentration, or
a rush to finish the job quickly
can easily result in an accident,
as can failure to follow the
precautions outlined in
this manual.
Be sure to consult the
suppliers of any materials and
equipment you may use, and
to obtain and read carefully
any operating and health and
safety instructions that may
be available on packaging or
from manufacturers
and suppliers.
Raising the Car Safely
ALWAYS ensure that the vehicle is properly supported when
raised off the ground. Don't work on, around, or underneath
a raised vehicle unless axle stands are positioned under
secure, load bearing underbody areas, or the vehicle is driven
onto ramps, with the wheels remaining on the ground
securely chocked to prevent movement.
NEVER work on a vehicle supported on a jack. Jacks are made
for lifting the vehicle only, not for holding it off the ground
while it is being worked on.
ALWAYS ensure that the safe working load rating of any
jacks, hoists or lifting gear used is sufficient for the job, and
that lifting gear is used only as recommended by the
manufacturer.
NEVER attempt to loosen or tighten nuts that require a lot of
force to turn (e.g. a tight oil drain plug) with the vehicle
raised, unless it is safely supported. Take care not to pull the
vehicle off its supports when applying force to a spanner.
Wherever possible, initially slacken tight fastenings before
raising the car off the ground.
ALWAYS wear eye protection when working under the
vehicle and when using power tools.
Working On The Vehicle
ALWAYS seek specialist advice unless you are justifiably
confident about carrying out each job. The safety of your
vehicle affects you, your passengers and other road users.
DON'T lean over, or work on, a running engine unless it is
strictly necessary, and keep long hair and loose clothing well
out of the way of moving mechanical parts. Note that it is
theoretically possible for fluorescent striplighting to make an
engine fan appear to be stationary
-
double check whether it
is spinning or not! This is the sort of error that happens when
you're really tired and not thinking straight. So...
...DON'T work on your car when you're over tired.
ALWAYS work in a well ventilated area and don't inhale dust
- it may contain asbestos or other harmful substances.
NEVER run the engine indoors, in a confined space or over
a pit.
REMOVE your wrist watch, rings and all other jewellery before
doing any work on the vehicle
-
and especially when working
on the electrical system.
DON'T remove the radiator or expansion tank filler cap when
the cooling system is hot, or you may get scalded by escaping
coolant or steam. Let the system cool down first and even
then, if the engine is not completely cold, cover the cap with
a cloth and gradually release the pressure.
NEVER drain oil, coolant or automatic transmission fluid when
the engine is hot. Allow time for it to cool sufficiently to avoid
scalding you.
ALWAYS keep antifreeze, brake and clutch fluid away from
vehicle paintwork. Wash off any spills immediately.
TAKE CARE to avoid touching any engine or exhaust system
component unless it is cool enough not to burn you.

—I Job 13. Check cooling system.
SAFETY FIRST!
• The coolant level should be checked
-
and the
cooling system worked on, ONLY WHEN THE
COOLANT IS COLD. If you remove the pressure cap or
bleed screws when the engine is hot, scalding coolant
will spurt out.
• Keep anti-freeze away from children. If it is acciden-
tally swallowed or contacts skin or eyes, rinse
immediately with plenty of water and seek immediate
medical help.
Examine the cooling system hoses, looking for signs of
splitting, chafing and perishing. Squeeze the top and bottom
radiator hoses. Any hard, brittle areas or crackling sounds tell
you that the hoses are decomposing from the inside
-
replace-
ments needed!
SAFETY FIRST!
If
a
clearance is outside the tolerances shown in Chapter 3,

Facts
and Figures, the relevant shim will have to be changed.
New
shims
are available from your FIAT dealer. This work is
fully described in Chapter
6,
Repairs and Replacements.
10E. You must
always use a new
gasket, especially in
view of the oil level
mentioned earlier.
Clean the housing

and
cover faces and

use
the gasket dry.

11.
Examine the

belt
for wear. If
there
is
any
cracking, or if the
toothed side
10F.H INSIDE
INFORMATION:
The cover is 'anti-
crush'
-
you CAN'T
tighten beyond
the lugs pointed
out here
-
so
there's no point
trying! H
0 Job 11. Check camshaft timing belt.
Remove the camshaft belt outer cover. See Chapter 6,

Repairs
and Replacements, PART A: ENGINE.
FACT FILE: VALVE IDENTIFICATION:
T
—
Remember that clearances for inlet and
3™ exhaust valves differ. See
Chapter
3,
Facts and Figures. Counting from the
—^ timing belt end the valves are:
1.1,1.2 8-valve AND DIESEL ENGINES:
EXHAUST -1, 3, 6, 8. INLET
-
2, 4, 5, 7.
1372cc AND 1581cc ENGINES: EXHAUST -1, 4, 5, 8.
INLET
-
2, 3, 6, 7.
1.2 16-valve Hydraulic tappets
-
non-adjustable.
13. If original FIAT hose
clips (a) are fitted, cut them
off (taking great care not to
damage the stub beneath!)
and replace with screw-
tight clips, when fitting a
new hose. Ensure that hose
clips are secure and firm but
not over-tightened.
Check that the wires to the
cooling fan switch (b) are in
good shape. Also, refer to
Job
27

• Job 14. Change engine coolant.
• See SAFETY FIRST! at the start of Job 13.
appears worn, or
any 'teeth' are
missing, replace
the belt straight
away. If the belt

breaks
the valves may collide with the pistons, causing serious
engine damage. Camshaft belt replacement is described in

Chapter 6,
Repairs and Replacements, or you may wish to

have
your FIAT dealer carry out the work for you. If you can
twist the belt through more than 90 degrees, it needs re-
tensioning. Also see Chapter
6,
Repairs and Replacements.
m
AUtOKAlIC CtMAU s/
b
14A. Remove the expansion tank filler cap. Move the heater
control (a) to the red (open) position or, on automatic
systems, press the TEMP button (b) on the dash until HI
appears on the display (c).
—i Job 12. Change camshaft timing belt.

It is
ESSENTIAL that you renew the camshaft drive belt at the
recommended interval. See the Service Interval Chart at the

start
of this chapter. Chapter
6,
Repairs and Replacements
explains how to carry out the work.
14B. Loosen the
worm-drive clip
(arrowed) and
pull off the
bottom radiator
hose.

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.)

Job 19. Diesel engine - refitting.
• Step 18: Remove the brackets and plate (arrowed).
Q Step 19: Remove the electric radiator cooling fan.
• Step 1: Follow the instructions for removal in reverse
order, referring to Chapter
3,
Facts and Figures for torque
settings and adjustments, lubricant and coolant types and
capacities.
IMPORTANT NOTE: Where the drive-shafts have been
withdrawn from the hubs, new nuts must be used and
staked into their grooves after tightening to the correct
torque.
• Step 16B: D INSIDE INFORMATION!
On the non-turbo version, it is necessary
to undo the drive-shaft-to-hub nuts. These
are very tight and you will require plenty
of leverage while a helper applies the
footbrake very firmly to prevent hub
rotation. Separate the hubs and
suspension struts by removing the pinch
bolts and pulling the hubs clear. Push the
drive-shafts out of the hubs
-
leaving
them fixed at the inboard ends. E3
• Step 17:
Disconnect the
three gearchange
control rods from
the gearbox
brackets.
H INSIDE INFORMATION! For separation and
reconnection of the engine/transmission, see Jobs
21

and 22 Q
• Step 20: Support the power unit (by means of a hook
from above, or from underneath with a trolley jack and a
protective piece of wood on its pad), and raise it just enough
to take the weight off the mountings. Undo the fixing bolts
(arrowed) and remove the mountings.
• Step 21:
Lower the
power unit to
the ground,
preferably onto
a trolley, and
retrieve from
under the car.
Job 18-16B

extend their life by fitting new seals, when necessary. Note that
you will need to use internal circlip pliers to remove the circlip
from the pushrod on the master cylinder in order to dismantle it.
When you need to bleed the clutch hydraulic system, follow
the procedure described for brake bleeding in PART H:
BRAKES, Job 17. Because the circuit is far simpler, the
procedure itself is likely to be both simpler and quicker to carry
out. Note that the bleed screw (f) is normally covered by a cap
(e) which must be removed before the bleed screw can be
slackened.
PART C: COOLING SYSTEM
PART C: Contents - ' B SI s |§w ^ - -
-
silt Job 1: Component positions. Job 4. Thermostat
-
replacement.
Job 2. Radiator and cooling fan
-
replacement. Job 5. Coolant pump
-
replacement.
Job 3. Thermostatic switch
-
testing and replacing.
Job 1. Component positions.
1 - bottom hose - radiator to pump 2 - top, hose - radiator to thermostat 3 - radiator
4 - thermostat 5
-
water pump 6 - thermostatic switch 7 - cooling fan
Type 1
1 - expansion tank 2 - hose, tank to pump 3 - bottom hose, radiator to thermostat 4 - top hose, thermostat to radiator 5 - hose, radiator to expansion tank
6 - thermostat/housing assembly 7 - delivery pipe, thermostat to pump 8
-
water pump 9 - cooling fan 10
-
thermostatic switch 11 - radiator core Type 2
Type 2: ...and these the diesel engine's components. Type 1: These are the components of the petrol engine
cooling system...
Job 2. Radiator and cooling fan -
replacement.
• Step 1: Unplug the electrical connections from the fan
motor and thermostatic switch.
• Step 2: Drain the cooling system and disconnect all
hoses from the radiator.
Q Step 3: Undo the mounting bolts and remove the
radiator/fan assembly from the car.
• Step 4: Undo the fan
mounting fixing bolts and
remove the complete
assembly from the radiator.
Also see illustration Type 1
(petrol), or Type 2
(diesel).
Q Step 5: Refit in reverse
order.
H INSIDE INFORMATION! The fan assembly can be
removed from the car without disturbing the radiator if
required. New fan units are supplied by FIAT complete
with the mounting bracket, ready to bolt on. D
Job 3. Thermostatic switch -
testing and replacing.
• Step 1: The thermostatic switch which controls the fan is
located in the radiator header tank. See illustration Type
1,

part 6 (petrol), or Type 2, part
10
(diesel) .
• Step 2: To remove, drain the cooling system, disconnect
the switch and unscrew it from the radiator.
• Step 3: H INSIDE INFORMATION! Test the switch
using a test bulb and two leads. Connect one to a
battery terminal and the other to one of the switch
terminals. Now connect a wire between the remaining
switch and battery terminal. (9

A Accelerator linkages and cables 118,119 Aerial 112 Airbag 14, 63, 128 Air cleaner/filter 51 Air Conditioning 12,41 Alternator, drive belt . . 49, 50, 110 Antifreeze 43, 44 Anti-roll bars 131 Auto-Biography 1 Automatic transmission fluid 45 gear selector cable 102
B Ball-joints steering and suspension 57 Battery disconnecting 36 electrolyte 36 safety 7 Bellows, steering gear (see 'Gaiters') Bonnet 15, 143 Brakes 59 to 62, 134 to 142 bleeding 141 caliper 59 to 61, 135, 137 cylinder (master) 138 discs, front 59, 135 discs, rear 61, 137 drums 60, 136 fluid, check level 35,36 handbrake 61, 142 hoses/pipes 62, 141 pads 59, 135, 137 pressure regulating/proportioning . . . valve (ABS) 140 pressure regulating/proportioning valve (Non-ABS) 139 RPM sensors (ABS systems) .... 140 safety 7 servo 138 shoes 135 wear sensors (non-ABS) 60 Bulb renewal (see 'Lights') Bushes 57 Bumper removal and refitting. 146
c Cables accelerator 118,119 automatic transmission ... 101, 102 choke 119 clutch 46, 101 handbrake 61 Caliper, brakes (see 'Brakes') Camshaft belt 43, 66 Capacities 19,154 Carburettor adjustment 53 removal 117 Catalytic converter 54, 55 safety 6 Central locking 114 Choke 119 Clutch adjustment 46, 100 hydraulic 46, 105 replacement 100 cable 46, 101 Coil, ignition 47, 107, 108 Coil spring 57 Constant Velocity (C.V.) joints (see 'Driveshaft') Contents 4 Controls and switches ... 10 to 14 Cooling system .. 35, 43, 106 to107 change coolant 43 radiator pressure cap 35 Crankcase ventilation system 42 Cylinder head Diesel 87 to 93
Petrol 67 to 73
D Data 17 to 27 Diesel bleeding the system 126,127 fuel filter 52 glow plugs 115 injection pump 56,124 injectors 126 Disc, brakes (see 'Brakes') Distributor 108, 109 cap 47 Marelli Breakerless 48 Marelli Digiplex 2 48, 49 Doors hinges 62 locKs and handles 147 to 150 removal and refitting 147 trim panels 146 Drivebelts alternator 49, 50, 110 camshaft 43 Driveshaft C.V. joints 103 gaiters 45, 103 removal and refitting 103 Drum (see 'Brakes')
E Electrical system 110 to 115 Electronic control module 54 safety 7 Emergency starting 16 Emissions 31, 51 to 56 control 53, 54 legal limits 31 Engine bay layouts 34 Engine dismantling Diesel 95 Petrol 73 Engine mountings Diesel 95 Petrol 83 Engine oil (see 'Oil') check level 34 Engine refitting Diesel 94 Petrol 82 Exhaust manifold 56 Exhaust 56 system 56, 122 Expansion tank 35
F Facts & Figures 17 to 27 Fan 50, 106 Fast idle carburettor 53, 54 fuel injection 54 diesel 55 Filter air 51 diesel 52 petrol 52 oil (see 'Oil filter') pollen 63 Fire Extinguisher . 6 Fluoroelastomers, safety 8 Fuel cut-off switch 13 Fuel gauge 114 Fuel injection 52, 54, 55, 117 Fuel lines/pipes 51 Fuel pump electric 120 mechanical 120 Fuel system 51 to 56 evaporation control system . 54,122 Fuel tank 121 Fumes, safety 6 Fuses 40
Gearbox (transmission) .... 44 to 46 oil (automatic) . . 45 oil (manual) 44 Generator drive belt (see 'Alternator, drive belt')
H Handbrake 61, 142 Headlights (see 'Lights') adjustment 62 bulb replacement 37 Headrest 153 Heater 11 Hoses/pipes (see 'Pipes and hoses') HT leads 47 Hub front 104 rear 134
I Identification numbers 27 Idle speed adjustment (see 'Carburettor') Ignition system 46 to 51, 107 to 109 coil 47,48 safety 7 Ignition timing 19, 48 to 50 Instruments 110 panel lights 10 Intercooler 123, 124
J Jacking safety 5 wheelchange 15, 16 Jump leads (Jump starting) 16
L Lambda sensor ... 54, 55, 121, 122 Lights fog lights 13, 38 hazard warning 13 headlights 13,37 indicators 13, 37 interior 15, 39, 40 MoT 28 number plate 39 rear lights 38 reversing lights 39 sidelights 13, 37 Locks and latches 9, 10, 62 Lubricants 154
m Manifold fixings 56 Mirrors 14, 150 Mixture adjustment (see 'Carburettor') Model years 17, 18 MoT, getting through 28 to 31
m Number plates (lights) . . 28, 39, 145
o Oil change disposal 7, 8 engine 41, 42 transmission 44, 45 safety 7 Oil filler cap 35 Oil filter 41 Oil level engine 34, 35 gearbox 44, 45 topping up 35
P-Pads, brake (see 'Brakes') Pipes and hoses brakes 62, 138, 141 hot air 121 radiator (cooling system) 43 Plastics, safety 7 Production changes 17, 18
ft Radiator .* 106 Raising the car 5 Repair data 20 Road test, brakes and steering ... 63 Rotor arm 47, 49
s Safety First! 5 to 8 Seats 14, 151 to 153 mountings 62 Seat belts mountings 62 pretensioners 151, 152 Servicing Your Car 32 to 63 Shock absorbers 57,131 Shoes, brake (see 'Brakes') Sidelights (see 'Lights') Spark plugs 47, 154 Specifications (see 'Facts & Figures') Speedometer cable 110 Starter motor 110 Steering 57, 58, 127 to 131 lower wishbone 127, 130 power steering 58, 130 rack gaiters 58, 133 Steering wheel 128 Sun roof 151 Suspension ... 57 to 59, 127 to 134 front 57, 127, 131 rear 58, 59, 128, 133 strut 57, 131
T Tailgate wiper (see 'Windscreen wipers') Tailgate and strut 144 Thermostat 107 Throttle cable and pedal (see 'Accelerator, linkage and cables') Timing belt 43 Diesel 85 to 87 Petrol 65, 66 Torque wrench settings ... 23 to 27 Track control arm (inner bushes). . 57 Track rod ends 57, 58, 128 Transmission. . 80 to 83, 95, 98 to 106 removal 80 to 82 separation and reconnection (Diesel). . 95 separation and reconnection (Petrol). . 83 Transmission fluid 44, 45 Turbocharger replacement 122 to 124 Tyre checking 30, 36 pressures 18,36
u Universal joints 28, 58 Using your car 9 to 16
¥ Vacuum unit, distributor 48 Valve clearances 42, 43, 79, 93 Valve grinding 72 Vehicle Identification Numbers (VIN) 27
w Washer fluid reservoir 36 Water pump 107 Wheel alignment 28 Wheel bearings 57, 58 Wheel bolts 59 Wheel changing 15,16 Wheel cylinder 137 Wheel sizes 18 Windscreen, damage 29,162 Window regulator 147 to 149 Windscreen washers 112 Windscreen wipers 13,111 Wiring diagrams 155 to 174
Gaiters 30, 57
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