steering FIAT TEMPRA 1988 Service And Repair Manual

• Repeat this operation three more times until the
complete code number has been entered, if the code
has been entered in correctly LED B will start flashing.
• Release button A (see illustration
1B).
Red LED B
flashes for 8 seconds indicating the new remote unit's
code has been stored.
IMPORTANT NOTE: If the LED does not illuminate
when remote unit button (illustration 1B, button
O is pressed, change the remote unit's battery.
• Insert the emergency key A into the emergency switch
slot in the glove compartment turn the key to the left to
switch the alarm off (see inset).
• Turn the key back towards its original position to
switch the alarm system back on.
IMPORTANT NOTE: As the alarm system absorbs
energy, if you are not planning on using the car
for a long period of time, turn the alarm exclusion
key to the off position, so as not to run the vehicle
battery down.
• 2. IGNITION SWITCH AND
STEERING COLUMN LOCK
IGNITION SWITCH
2. The ignition/steering column lock key, once inserted
in the ignition lock, can be placed in any of the
following four positions:
• PARK
-
With the key in this
position the side and tail lights
can be turned on, the steering
column locked and the keys
can be removed. Press button
A to turn the key to PARK.
• STOP
-
When the key is
turned to the STOP position the steering column will be
locked, and the keys can be removed.
• MAR
-
This is the driving position. When the key is in
this position all the electrical devices are energised.
• AW
-
Turning the key to this position starts the
engine.
STEERING COLUMN LOCK
• LOCKING
-
To apply the steering wheel lock turn the
steering wheel slightly to the left or right when the key is
at STOP or PARK.
• UNLOCKING
-
Rocking the steering wheel gently back
and forth while turning the ignition key to MAR unlocks
the steering wheel.
• 3. PANEL INDICATORS
INSTRUMENT DISPLAY PANEL
3. These are the instrument panel warning LED indicators
for all FIAT Tipo/Tempra models. Your vehicle will only
have Panel Indicators relevant to your particular car.
• 4. ELECTRONIC CHECK PANEL
4. The electronic check panel is not fitted to models
with basic trim.
IMPORTANT NOTE: The check panel will not
indicate if the tail light fuses blow at the same
time, or if there is a circuit failure within the panel
display.
SIDE AND HATCHBACK DOORS
When the ignition key is at MAR, the check panel LEDs
g, h, i, I, m and n monitor the light bulbs and fuses.
LEDs a, b, c, d, and e monitor incomplete closure of
the side doors and hatchback.
• Never remove the key when the car is moving.
If you do, the steering wheel will lock the first
time you turn it.
• If the ignition lock has been tampered with or
shows any sign of damage (e.g. attempted theft),
have the lock checked at your nearest FIAT
Service Centre.
M Choke Oil pressure warning
Direction indicators (®) Handbrake engaged
-X: Side lights m Rear window defroster
10 High beam head
lights '•y Injection system warning light
<1* Rear fog lights • Battery warning
A Hazard warning lights A Seat belts not
buckled
m ABS brake warning a Automatic transmission fluid warning
o Brake pad wear warning a Doors not properly closed
Turbo pressure warning Trailer direction indicators
10 Front fog lights a Diesel fuel filter condenstate warning
•515" Diesel heater/glow •515" plugs 3
SWITCHING OFF THE ALARM
1C. Some models
are fitted with an
alarm exclusion
switch, which can
be found inside
the glove
compartment. If
the alarm is faulty
or the remote control batteries are flat:

CONTROLS
• 6. LIGHTS AND INDICATORS
DIRECTION INDICATORS AND REAR FOG LIGHT
SWITCH
The lights operate when the key is at the MAR position.
6A. The symbols on
the stalk all
illuminate when the
side or headlights
have been switched
on.
• 3
-
Continuous operation (when the stalk is released
the wiper turns OFF).
WINDSCREEN WASHER/WIPER (REAR)
6C. • Turn switch B
from position 4 to
position 5 to turn on
the rear window
wiper.
• Pull the stalk
toward the steering
wheel to turn on the
rear window washer and wiper (continuous operation).
Both the washer and wiper stop operating when the
stalk is released.
REAR WINDOW DEFROSTER The defroster can only be operated when the key is in
MAR:
LOW BEAM HEADLIGHTS
• Turn the knurled switch from position C to B, for low
beam headlight.
HIGH BEAM HEADLIGHTS
• When the knurled switch pointer is at position B, pull
the stalk towards the steering wheel to switch the
headlights to high beam.
• The panel full headlight beam LED will light up.
• Flick the stalk towards the steering wheel again to
switch off the high beam headlights (the low beam
headlights will remain on).
REAR FOG-GUARD LIGHTS
•
Turn
the knurled switch to B (low beam) and then
press the rear fog switch A at the tip of the stalk to
turn the rear fog-light on.
DIRECTION INDICATORS Move the left-hand column stalk (from its centre
position): • Up = right turn. • Down = left turn.
The panel direction indicator light flashes when the
direction indicators are operating. The stalk returns to
the centre position after completing the turn.
WINDSCREEN WASHER/WIPER CONTROLS
6B: WINDSCREEN WASHER/WIPER (FRONT)
The washer and wiper only operate when the key is
positioned at MAR.
When the windscreen washer
stalk is positioned at:
• 0
-
The windscreen wiper is
off.
•
1 -
Intermittent operation
(adjustable by turning switch C,
from II to III).
• 2
-
Continuous high speed
operation.
Press switch A at the tip of the right-hand stalk to turn
on the rear window defroster. The rear defroster LED
panel indicator will illuminate.
HAZARD WARNING LIGHTS
6D. Press the hazard
light switch (arrowed)
to turn on the hazard
warning lights. All the
directional indicator
lights and the panel
indicator will flash. The
hazard warning lights
work whether the key is inserted or not.
FRONT FOG LIGHTS Press the front fog light switch (key at
MAR, headlights on). The fog light panel
indicator will illuminate.
PANEL LIGHT DIMMER (DIGITAL
INSTRUMENTS)
Press the panel light dimmer switch to
adjust the panel backlighting level (key at
MAR, headlights on).
FUEL CUT-OFF SWITCH
6E. Some models are fitted with a fuel cut-off device,
which cuts the fuel supply off to the engine if the car is
involved in a collision.
• If there are
no signs of fuel
leaks and the
vehicle is in
good enough
condition to
start again,
reactivate the
fuel feed
system by
pressing button A (arrowed), which is located
underneath the passenger's seat.
• Turn the left-hand
column stalk's
knurled switch from
0 to C. The panel
indicator sidelight display will illuminate.

• 9. DOOR MIRROR ADJUSTMENT
• 7. STEERING WHEEL
HEIGHT ADJUSTMENT
7. On some versions the
height of the steering
wheel can be adjusted -
ONLY WITH VEHICLE
STATIONARY!
• Pull lever A, positioned
under the steering wheel, towards you.
• When you have adjusted the wheel to a comfortable
height push the lever back to its original position.
MANUAL TYPE 9A. Move the internal
knob B (attached to the
door mirror A) to adjust
the mirror.
Move it from position 1
to position 2 from
outside the car if extra
clearance is needed.
INDIVIDUAL SETTINGS POWER ADJUSTMENT
9B. When the key is at
MAR, use the 4-way
switch A (near the
handbrake) to adjust the
mirror and switch B to
select left/right mirror.
On some models mirrors are demisted/de-iced
whenever you turn on the rear demister.
• 8. FRONT SEAT ADJUSTMENT
LEGROOM
ADJUSTMENT
8A. Lift lever 1
and exert body
pressure in the
direction desired
to set the seats
fore-and-aft
position:
• Release lever 1, ensuring that the seat is locked in the
desired position.
FRONT SEAT ANGLE ADJUSTMENT
To adjust the angle of the front seats backrest cushion:
• MODELS FITTED WITH A LEVER (ILLUSTRATION 8A, 3):
lift to recline the seat.
• MODELS FITTED WITH AN ADJUSTABLE KNOB (8B, 4):
rotate to recline the seat.
DRIVER'S SEAT HEIGHT ADJUSTMENT
On models with driver's seat height adjustment,
depending on which type you have:
EITHER, pull up lever 2
(illustration &4):
• Move forward to
raise the seat.
• Move backward to
lower the seat.
8C: • OR, pull lever 5
out so that it is at its
full extension.
• Move lever 5 up or
down to adjust the
height of the seat.
After the seat has been adjusted to the required height
slide the extended lever back to its original collapsed
position.
• 10. ELECTRIC WINDOWS
operate the front electric windows (if fitted) when the
key is at MAR:
• A
-
Closes left window.
• B
-
Closes right window.
• C
-
Opens left window.
• D
-
Opens right window.
• E
-
Locks and unlocks the rear electric windows.
• F and G
-
Open and close the rear side windows.
Some models are fitted with two buttons in the front
passenger's armrest to open and close the passenger-
side front window.
• 11. AIR BAG
AIR BAG SAFETY DEVICE
As an extra safety device, some models are fitted with
an air bag, which is stored in the steering wheel. The air
bag inflates immediately to protect the drivers chest and
face in the event of a head on collision.
IMPORTANT NOTE: All diagnosis, repair and
replacement of the air bag device is a specialist job
and is potentially dangerous. It must only be
carried out by your FIAT Service Centre.
I

SAFETY FIRST!
If an air bag has been fitted to your vehicle:
• DO NOT apply stickers or any other objects to
the steering wheel as this may restrict the
operation of the air bag.
• NEVER travel with anything on your lap or in
front of your chest
• NEVER drive with a cigarette, pipe, pen or any
other object in your mouth.
• 12. INTERIOR LIGHTS
COURTESY LIGHT
On most models the courtesy light is positioned in the
centre of the roof.
• With the light switch in the central position the light
turns on when either of the front doors is opened.
• When the switch is in the right position the light
remains on.
• With the switch in the left position the light is
switched off.
• 13. SUNROOF OPERATION
14B. Positioned at the front of the bonnet is a release
catch B. Lift catch up to release.
14C. Lift the
bonnet and pull
the support rod
C out of its
holder.
When the
• 15. LUGGAGE COMPARTMENT
INCREASING THE CARGO AREA
FOLDING THE BACK SEATS
-
Use the following
procedure to fold the rear seat forwards:
• Pull the strap at the centre of the backseat cushion in
an upwards direction to swing up the seat cushion.
15A. On models fitted with lever A, pull the lever up to
release the seat backrest.
15B. Models fitted with a lockable lever B, turn the key
to position 2 to unlock (1 to lock), then lift the lever in
the direction arrowed.
• Fold the backrest cushion forwards.
BONNET AND LUGGAGE
L 2 . fj§
• 14 .BONNET
OPENING THE BONNET
14A. Pull the bonnet release lever A, toward the
steering wheel to release the bonnet catch.
To repositioning the back seats
-
reverse the order
described above.
WHEEL CHANGING
• 16. CHANGING THE WHEEL IN AN
EMERGENCY
CHANGING A WHEEL
Whenever possible park the car on firm level ground.
Put the car into reverse gear and pull on the handbrake.
Keep chocks or pieces of wood in the boot of your car,
which can be wedged in front and behind the
diagonally-opposite wheel to the one being removed to
prevent the car from rolling. If you haven't got a piece
of wood handy, use large rocks or stones.
The location of the spare wheel, jack and tools for most
models is in the luggage compartment under the mat.
However on some models the spare wheel and tools are
located in a storage container within the side walls of the
rear luggage compartment.
bonnet is fully
raised, place the
tip of the rod in
the recess B located in the bonnet.
• Pull handle A down
and turn anti-clockwise,
slides back.
13B. To operate a
sunroof with
electric controls:
13A. SUNROOF CONTROLS
As an optional extra
some models are fitted
with a sunroof. To
operate the manually
operated sunroof:
The sunroof lifts up and then
• Press rocker
switch C either at
the front or back
edge to open or close the sunroof.
Z3

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

October 1991 2.0 i.e. 16v introduced, with 1995cc, 16 valve
high-performance DOHC engine, catalytic converter, sports
suspension, front and rear disc brakes. ABS available as
option.
January 1992 Existing Tipo models lightly facelifted and
redesignated 1.4 Formula, 1.45, 1.6S, 1.6SX, 1.9TD SX,
1.8 i.e. SX. 1.7D discontinued. SX versions with digital
instruments.
Tempra 1.9 TDS (turbo diesel) Station Wagon introduced. 1.4
and 1.9D saloons discontinued.
May 1992 Tempra 1.8 i.e. SX Saloon and Station Wagon
discontinued.
June 1992 Tempra 2.0 i.e. SX saloon and station wagon
models introduced, with high performance 1995cc DOHC fuel
injected engine, catalytic converter and disc brakes front and
rear.
Tipo 1.4 and all Tipo and Tempra 1.6 models (except Selecta)
now with a catalytic converter and fuel injection in place of
Weber twin-choke carburettor. Designated i.e. in badging.
December 1992 Tipo 1.8 i.e. and 1.6 Selecta discontinued.
February 1993 Tipo 2.0 i.e. GT introduced. Slightly lower
performance and spec, version of the 16v model.
July 1993 Tipo 1.4 now available as a 3-door or 5-door
hatchback. 2.0 i.e. 16v now only available as 3-door. Tipo 2.0
i.e. GT replaced by similar spec. 2.0 i.e. SLX.
Tempra 2.0 i.e. SX saloons and estates now only available
with auto, gearbox. Otherwise, SX models become known as
SLX, with colour-coded mirrors and ABS brakes. Most Tempras
now with body-coloured bumpers. 1.9D (non turbo Diesel re-
introduced).
All Tipo and Tempra models now with revised front-end
styling
-
narrower headlights and revised grille. Improved crash
protection, including side impact beams, safety steering wheel
and uprated brakes. Power steering, central locking, electric
windows all standard.
February 1994 Tipo 1.7 non-turbo diesel re-introduced as
1.7 DS.
May 1994 Tempra 1.9DS Station Wagon introduced.
September 1994 Most models available with driver's airbag,
fire prevention system and seat belt pre-tensioners.
December 1994 Tempra 1.6 i.e. versions get M.P.I, engine.
February/March 1995 All models with VIN number window
etching and immobiliser standard on all Tempra petrol models.
October 1995 Immobiliser fitted to Tempra D and TD models.
End of 1995 Tipo discontinued.
Mid-1996 Tempra discontinued.
PART B: VITAL STATISTICS
All Tipo models
-
55 litres, except petrol with catalytic converter
- 51
litres.
All Tempra models
-
65 litres, except petrol with catalytic converter
-
62 litres.
Wheels and Tyres
ENGINE PRESSED STEEL RADIAL TYRE PRESSURES (cold)
WHEEL RIM TYPE TUBELESS FRONT REAR
TYRE TYPE average load heavy load average load heavy load
TIPO MODELS
1.4 and 1.6 Petrol 5.00B x 13H 165/70R13S 2.0 bar/29 psi 2.0 bar/29 psi 1.9 bar/28 psi 2.2 bar/32 psi
1697 Diesel 5.00B x 13H 165/70R 13S 2.1 bar/30 psi 2.1 bar/30 psi 1.9 bar/28 psi 2.2 bar/32 psi
Turbo D 5.5J x 14H
175/65 R
14T 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
1.4 i.e./1.6 i.e. (1993-on) 5.5J x 14H
165/65 R
14T 2.0 bar/29 psi 2.0 bar/29 psi 1.9 bar/28 psi 2.2 bar/32 psi
1.7D (1993-on) 5.5J x 14H 165/65R 14T 2.1 bar/30 psi 2.1 bar/30 psi 1.9 bar/28 psi 2.2 bar/32 psi
Option
-
certain models 5.5J x 14AH2 185/60R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
TEMPRA MODELS
Early 1.4 and 1.6
Saloons 5.00B x 13H 165/70R 13S/T 2.0 bar/29 psi 2.0 bar/29 psi 2.0 bar/29 psi 2.2 bar/32 psi
1.6 SX Saloon 5.5J x 14H 165/65R 14T 2.0 bar/29 psi 2.0 bar/29 psi 2.0 bar/29 psi 2.2 bar/32 psi
1.9D/1.9 TD Saloon
and Late 1.6 i.e. 5.5J x 14H 175/65R 14T/H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
1.6/1.9D/1.9TD
Station Wagons 5.5J x 14H 175/65R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 3.0 bar/44 psi
Option for Station 5.5J x 14H or AH2 185/60 R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 3.0 bar/44 psi
Wagons (alloy)
SPARE WHEEL
-
ALL TIPO AND TEMPRA MODELS (speed limit 50 mph)
Tempra TD Saloon and
ALL Station Wagons 4.00B x 14H 105/70 B14 4.2
bar/61
psi
All other models 4.00Bx14H 135/80 B14 2.8
bar/41
psi

Handbrake Control
Screw with broad flange retaining handbrake and gear lever to body (M8)
Bolt retaining handbrake and gearlever to body (M8)
Screw with normal flange retaining handbrake lever bracket to plate (M8)
Screw with normal flange retaining handbrake cable slide plate to
floorpan (M6)
Screw with long flange for fastening handbrake cable reaction bracket to
floor (M8)
Screw with broad flange retaining pedal unit to dashboard (M8)
Self-locking nut for bolt retaining brake servo to pedal unit (M8)
Nut for through screw joining brake and clutch pedals to pedal unit (M8).
Self-locking nut retaining accelerator pedal to pedal unit (M6)
Nut retaining brake pump to brake servo (M8)
Steering
Self-locking nut retaining steering link ball pin to cast iron pillar (M10 x 1.25)..
Bolt retaining steering and/or power steering box to front beam (M10 x 1.25).
Nut for side steering link (M12 x 1.25)
Self-locking nut retaining steering shaft universal joint forks (M8)
Self-locking nut retaining steering wheel to column (M16 x 1.5)
Bolt retaining steering column mount to body (M6)
Self-locking nut for steering wheel position adjustment device (tighten nut
to specified torque with lever in locked position) (M12 x 1.25)
Nut for screw retaining steering column to support (M8)
Self-locking nut with polyamide ring retaining damper to steering box (M8)
Union for oil delivery fitting from pump to power steering, on power
steering (M14 x 1.5)
Union for adjustable oil delivery fitting from pump to p.s., on power
steering (M16 x 1.5)
Union for oil delivery fitting from power steering to reservoir (M12 x 1.5)
Union oil return fitting from reservoir to pump (M18 x 1.5)
Front Suspension
Screw with broad flange retaining front of front beam to body
(M12 x 1.25)
Screw with normal flange for nut retaining rear of front beam to body
(M10
x
1.25)
Screw with flat and tapered washer for nut retaining front and rear ext.
of wishbone connection plates to beam (M10 x 1.25)
Screws with flat and tapered washer for nut retaining front and rear inner
swinging arm connection plates to beam (M10 x 1.25)
Flanged nut fastening top of damper to block (M12 x 1.25)
Screw with broad flange retaining top damper block to body (M8)
Self-locking nut retaining damper to pillar (M10 x 1.25)
Self-locking nut for screw retaining wishbone head and joint to pillar
(M10
x
1.25)
Screw with tapered and flat safety washer retaining stabilizer bar
support plate to beam (M8)
Self-locking nut retaining end of anti-roll bar to rod (M10 x 1.25)
Self-locking nut retaining bar to front suspension arm (M10 x 1.25)
Nut retaining front wheel hub to coupling
(M22 x 1.5)i
(M24
x
1.5)
Wheel stud (M12 x 1.25).....
Rear Suspension
Screw with broad flange retaining front flexible block to rear subframe
(M12 x 1.25)
A B C D E Torque (Nm)
• • • • • 28
• • • • • 15
• • • • • 28
8.5
35
32
15
32
4.4
20 .
A B C D E Torque (Nm)
• • • • • 34
70
34
• • • • • 20
50
7.4
24
24
15
30
35
20
34
A B c D E Torque (Nm)
108
80
69
69
100
40
70
70
40
70
31
• • • • • •
24
28
86
A B c D E Torque (Nm)
108

Please read the whole of the CHAPTER 1, SAFETY FIRST! before carrying out any work on your car.
fUADTCSA I En Hr
GETTIIMG THROUGH THE MOT
This chapter is for owners in Britain whose
vehicles need to pass the 'MoT' test.
Obviously, you won't be able to examine
your car to the same degree of
thoroughness as the MoT testing station.
But you can reduce the risk of being one of
the 4 out of 10 who fail the test first time by
following this check-list.
iMFTri
The checks shown below are correct at the
time of writing but do note that they are
becoming stricter all the time. Your local
MoT testing station will have the latest
information, should you need it.
1 p Chapter Contents -
Page No. Page No.
PART A: INSIDE THE CAR 28 PART C: VEHICLE RAISED OFF THE GROUND 30
PART B: VEHICLE ON THE GROUND 29 PART D: EXHAUST EMISSIONS 31
PART A: INSIDE THE CAR
Steering Wheel and Column
O 1. Try to move the steering wheel towards and away from you and then from side to side. There should be no appreciable movement or play. Check that the steering wheel is not loose on the column.
02 . Lightly grip the steering wheel between thumb and finger and turn from side to side. Cars with a steering rack: free play should not exceed approximately 13 mm (0.5 in.), assuming a 380 mm (15 in.) diameter steering wheel. Cars fitted with a steering box: free play should not exceed approximately 75 mm (3.0 in.), assuming a 380 mm (15 in.) diameter steering wheel.
Ob . If there is a universal joint at the bottom of the steering column inside the car, check for movement. Place your hand over the joint while turning the steering wheel to-and-fro a little way with your other hand. If ANY free play can be felt, the joint must be replaced.
04. Ensure that there are no breaks or loose components
on the steering wheel itself.
Electrical Equipment
OS . With the ignition turned on, ensure that the horn works okay.
OE . Check that the front wipers work.
07 . Check that the windscreen washers work.
o 8. Check that the internal warnings for the indicator and hazard warning lights work okay.
Checks With An Assistant
O9 . Check that the front and rear side lights and number plate lights work and that the lenses and reflectors are secure, clean and undamaged.
o 10. Check the operation of the headlights (you won't be able to check the alignment yourself) and check that the lenses are undamaged. The reflectors inside the headlights must not be tarnished, nor must there be condensation inside the headlight.
o 11. Turn on the ignition and check the direction
indicators, front and rear and on the side markers.
o 12. Check that the hazard warning lights operate on the
outside of the vehicle, front and rear.
o 13. Check that the rear fog light/s, including the warning
light inside the car, all work correctly.
o 14. Check that the rear brake lights work correctly. These checks are carried out all around the vehicle with all four wheels on the ground.
o 15. Operate the brake lights, side lights and each indicator in turn, all at the same time. None should affect the operation of the others.
SAFETY FIRST!
• Follow the Safety information in CHAPTER 1, SAFETY FIRST! but bear in mind that the vehicle needs
to be even more stable than usual when raised off the ground.
• There must be no risk of it toppling off its stands or ramps while suspension and steering components
are being pushed and pulled in order to test them.

Windscreen and Mirrors
O 16. In zone 'A' of your windscreen, no items of damage larger than 10 mm in diameter will be allowed. In the rest of the area swept by the windscreen wipers, no damage greater than 40 mm in diameter will be allowed, nor should windscreen stickers or other obstructions encroach on this area.
o 17. Check that the exterior mirror on the driver's side is in good condition.
o 18. There must be one other mirror in good condition, either inside the car or an external mirror on the passenger's side.
Brakes
O 19. You cannot check the brakes
properly without a rolling road brake
tester but you can carry out the
following checks:
O 20. Pull on the handbrake. It should be fully ON before the handbrake reaches the end of its travel.
O 21. Knock the handbrake from side to side and check that it does not then release itself.
O 22. Check the security of the handbrake mountings and check the floor around it for rust or splits.
o 23. Check that the brake pedal is in good condition and that, when you take hold of it and move it from side to side, there is not too much play.
o 24. Push the footbrake down hard, with your foot. If it creeps slowly down to the floor, there is probably a problem with the master cylinder. Release the pedal, and after a few seconds, press down again. If the pedal feels spongy or it travels nearly to the floor, there is air in the system or another MoT-failing fault with the brakes.
o 25. Check the servo unit (when
fitted) as follows: Pump the pedal
several times then hold it down hard.
Start the engine. As the engine starts,
the pedal should move down slightly.
If it doesn't the servo or the vacuum
hose leading to it may be faulty.
Seat Belts and Seats
O 26. Examine all of the webbing (pull out the belts from the inertia reel if necessary) for cuts, fraying or deterioration.
o 27. Check that each inertia reel belt retracts correctly.
o 28. Fasten and unfasten each belt to ensure that the buckles work correctly.
o 29. Tug hard on each belt and inspect the mountings, as far as possible, to ensure that all are okay.
IMPORTANT NOTE: Checks apply to
rear seat belts as much as front
ones.
O 30. Make sure that the seat runners and mountings are secure and that the back rest locks in the upright position.
Doors and Door Locks
O 31. Check that both front doors latch securely when closed and that both can be opened and closed from both outside and inside the car.
PART B: VEHICLE ON THE GROUND
Electrical Equipment
See Part A: INSIDE THE CAR for checks on the operation of the electrical equipment.
O 1. Examine the wiper blades and replace those that show any damage.
Vehicle Identification
Numbers (VIIU)
O 2. The VIN (or chassis number on older vehicles) must be clearly displayed and legible.
O 3. Number plates must be secure, legible and in good condition with correct spacing between letters and numbers. Any non-standard spacing will not be accepted.
Braking System
O 4. Inside the engine bay inspect the master cylinder, servo unit (if fitted), brake pipes and mountings. Look for corrosion, loose fitting or leaks.
Steering and Suspension
OS . While still in the engine bay, have your assistant turn the steering wheel lightly from side to side and look for play in steering universal joints or steering rack mountings and any other steering connections.
OE. If your vehicle is fitted with power steering, check the security and condition of the steering pump, hoses and drivebelt, in the engine bay.
O 7. Look and reach under the car while your assistant turns the steering wheel more vigorously from side to side. Place your hand over each track rod end in turn and inspect all of the steering linkages, joints and attachments for wear.
o 8. Go around the vehicle and
'bounce' each corner of the
vehicle in turn. Release at the lowest
point and the vehicle should rise and
settle in its normal position without
continuing to 'bounce' of its own
accord.

PART C: VEHICLE RAISED OFF THE GROUND
Bodywork Structure
01
.
Any sharp edges on the external bodywork, caused by damage or corrosion will cause the vehicle to fail.
02 . Check all load bearing areas for corrosion. Open the doors and check the sills inside and out, above and below. Any corrosion in structural metalwork within 30 cm (12 in.) of seat belt mounting, steering and suspension attachment points will cause the vehicle to fail.
Wheels and Tyres
Under the Front of the
Car
You will need to support the front of the car on axle stands with the rear wheels firmly chocked in both directions.
OE . Have your helper turn the steering from lock to lock and check that the steering turns smoothly and that the brake hoses or pipes do not contact the wheel, tyre or any part of the steering or suspension.
TWI
Ob . To pass the test, the tread must be at least 1.6 mm deep throughout a continuous band comprising the central three-quarters of the width of the tread. The Tread Wear Indicators (TWI) will tell you when the limit has been reached, on most tyres.
IMPORTANT NOTE: Tyres are past their best, especially in wet conditions, well before this point is reached!
04 . Check that the front tyres match and that the rear tyres match each other
-
in terms of size and type but not necessarily make. They must be the correct size for the vehicle and the pressures must be correct.
05 . With each wheel off the ground in turn, check the inside and the outside of the tyre wall for cuts, lumps and bulges and check the wheel for damage. Note that tyres deteriorate progressively over a period of time and if they have degraded to this extent, replace them.
07 . Have your assistant hold down the brake pedal firmly. Check each brake flexible hose for bulges or leaks.
o 8. Inspect all the rigid brake pipes underneath the front of the vehicle for corrosion or leaks and also look for signs of fluid leaks at the brake calipers. Rigid fuel pipes need to be checked in the same way.
09 . At each full lock position, check the steering rack rubber gaiters for splits, leaks or loose retaining clips.
o 10. Check the track rod end dust covers to make sure they are in place.
o 11. Inspect each constant velocity joint gaiter
-
both inners and outers
-
for splits or damage. You will have to rotate each wheel to see the gaiters all the way round.
O 12. Check all of the suspension rubber mountings, including the anti-rollbar mountings (when fitted). Take a firm grip on each shock absorber in turn with both hands and try to twist the damper to check for deterioration in the top and bottom mounting bushes.
o 13. Underneath the front wheel arches, check that the shock absorbers are not corroded, that the springs have not cracked and that there are no fluid leaks down the body of the shock absorber.
o 14. While under the front end of the car, check the front of the exhaust system for security of fixing at the manifold, for corrosion and secure fixing to the mounting points.
o 15. Preferably working with a helper, grasp each front road wheel at the 12 o'clock and 6 o'clock positions and try rocking the wheel. Look for movement or wear at the suspension ball joints, suspension mountings, steering mountings and at the wheel bearing
-
look for movement between the wheel and hub. Repeat the test by grasping the road wheel at 3 o'clock and 9 o'clock and rocking once more.
o 16. Spin each wheel and check for noise or roughness in the wheel bearing and binding in either the wheel bearing or the brake.
IMPORTANT NOTE: Don't forget that on front wheel drive cars, the gearbox must be in neutral. There will be a certain amount of noise and drag from the drivetrain components.
O 17. If you suspect wear at any of the suspension points, try levering with a screwdriver to see whether or not you can confirm any movement in that area.
o 18. Vehicles fitted with other suspension types such as hydraulic suspension, torsion bar suspension etc. need to be checked in a similar way with the additional point that there must be no fluid leaks or damaged pipes on vehicles with hydraulic suspension.
Underneath the Rear
of the Car
O 19. Inspect the rear springs for security at their mounting points and for cracks, severe corrosion or damage.
o 20. Check the rear shock absorbers in the same way as the checks carried out for the fronts.
o 21. Check all rear suspension mounting points, including the rubbers to any locating rods or anti-rollbar that may be fitted.
O 22. Check all of the flexible and rigid brake pipes and the fuel pipes just as for the front of the vehicle.
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