Fuses (903, 999, 1116, 1299/1301 and 1301 cc Turbo ie) (continued)
Fuse No. Rating Circuit
Supplementary fuses at side of main fuse block:
A 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front fog lamps
B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling fan (Turbo ie models)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injector cooling fan (Turbo ie models)
D 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
E 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (Turbo ie models)
Fuses (later 903, 999, 1108, 1372 ie and 1372 cc Turbo ie)
Fuse Rating Circuit
1 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH tail, RH front parking, rear number plate lamps and check panel
2 7.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH tail, LH front parking, cigar lighter illumination, clock light, heater
control illumination and map reading light
3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp main beam
4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp main beam and warning light
5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cooling fan (except Turbo ie models) and horn
6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigar lighter, courtesy lamps, digital clock, stop-lamp switch, clock
and radio
7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH headlamp dipped beam
8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH headlamp dipped beam
9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear fog lamp and warning lamp
10 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated rear screen and warning lamp
11 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument panel, stop-lamps, direction indicators, reversing lamps,
warning module and carburettor cut-off (FIRE models only)
12 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater fan, heater/ventilation control illumination lights and digital
clock light
13 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen wiper, windscreen washer pump and rear wiper/washer
(where fitted)
14 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horns and relay
15 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning light and indicator light
Supplementary fuses at side of main fuse block:
A 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric windows
B 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Central locking (where fitted)
C 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector cooling fan (where fitted)
D 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp washers (where fitted)
E 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foglamp and warning lamp
F - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare
G 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump (fuel injection models)
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated Lambda sensor
Supplementary fuses on steering column relay bracket:
-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid monitor circuit (where fitted)
-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antiskid supply circuit (where fitted)
Steering and suspension
General
1301 cc Turbo ie
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1º 55’ to 2º 35’ positive
Number of turns of steering wheel, lock-to-lock . . . . . . . . . . . . . . . . . . 3.42
Later models
Steering angles:
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30’ ± 30’
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2º10’ ± 15’
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 2.0 mm
1301/1372 cc Turbo ie
Steering angles of roadwheels:
Inner wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36º 43’
Outer wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31º 27’
Torque wrench settingsNm lbf ft
Anti-roll bar clamp bolts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . . . . 25 18
Anti-roll bar end fixing nuts (1301 and 1372 cc Turbo ie) . . . . . . . . . . . 15 11
13•16 Supplement: Revisions and information on later models
Starter motor brushes
(later models) - renewal#
25When renewing the starter motor brushes
on later models, the old brushes will need to
be crushed (in a vice or with a hammer) and
their leads then soldered to the new brushes.
Fuses - later models
26The fuse arrangement is slightly different
on later models, but the circuits protected are
still identified by a symbol. Refer to the
Specifications Section for full details. Note
also the terminal block with plastic cover,
which can be used to isolate the battery from
the electrical system by disconnecting the
leads from the terminals (photos).
Relays (Turbo ie models) -
general
27On Turbo ie models, the relays mounted
in the fuse block are as shown in Fig. 13.103.
Additional relays are located as follows:
Headlamp relay - on lead under main fuse
blockFuel injection system main control relay -
adjacent to airflow meter
Headlamps later models
28The headlamp units fitted on later models
differ according to model, but the bulb and
unit replacement details are generally the
same as described for previous models in
Chapter 9. Note that the rubber cover can
only be fitted with the tab to the top as shown
(photo).
Headlamp beam adjusters for
load compensation - later
models
29Some later models are fitted with
headlamp beam adjusters which allowtemporary resetting to be made (such as
when the car is fully loaded). Access to these
adjusters is made by lifting the bonnet (photo).
30Turn the adjusters anti-clockwise to lower
the beam to the normal level or clockwise to
raise the beam (when the car is unloaded).
Repeat the procedure on the opposite
headlamp unit an equal amount.
31Other later models have separate
horizontal and vertical beam adjusters,
positioned as shown (photos). A load
compensating lever is attached to the
adjusters to enable temporary resetting of the
headlamp beams, without changing the
normal adjustment. Turn the lever to the
appropriate side (right or left) to make the
adjustment as required. The normal setting
Supplement: Revisions and information on later models 13•105
15.26B Battery lead terminal block on the
1301 cc Turbo ie model15.23B Starter motor and wiring
connections on the 1372 cc ie engine
15.31B Headlamp vertical beam alignment
adjuster screw on a 1372 cc ie model. Note
the load compensator lever which is set in
the “O” (normal load) setting position15.31A Headlamp horizontal beam
alignment adjuster screw on a 1372 cc ie
model
15.29 Headlamp beam adjuster on the
999 cc Turbo ie model15.28 Headlamp unit fitted to the 1372 cc ie
model
15.26A Fuse block on the 1301 cc Turbo ie
model
13
Fig. 13.103 Auxiliary fuses and relays on
1301 cc Turbo ie models (Sec 15)
1 Horn relay
2 Heated rear screen relay
3 Foglamps relay
4 Radiator fan relay
5 Electric windows relay
6 Foglamps fuse
7 Radiator fan second speed fuse
8 Fuel injector fan fuse
9 Electric windows fuse
10 Electric fuel pump fuse
83Refitting is a reversal of the removal
procedure. Reset the clock on completion.
Central door locking system
84Certain later models, equipped with a
central door locking system, have an infra-red
remote control for opening the door locks.
85It is important that the battery used in the
hand control is renewed when necessary with
one of identical type (Duracell 7H34). This is
only available as a FIAT spare part (No
7595393).
86The remote control door lock receiver unit
can be removed by carefully prising it free
from the roof panel and disconnecting the
wiring connector (photo).
87If either this unit or the hand control are
renewed at any time, recoding will be
necessary and this is a task best entrusted to
a FIAT dealer.
Cigar lighter
(later models) -
removal and refitting
Á
88Pivot back the cover and lift out the ashtray.
89Undo the retaining screws and remove
the trim together with the lighter unit. Detach
the wiring connector and release the lighter
unit from the panel.
90Refit in the reverse order of removal.
Electrically operated windozw
switches -
removal and refitting
Á
91The window regulator switches on later
models are located in the door pull trim. To
remove a switch, prise it free from the trim by
inserting a thin-bladed screwdriver under the
switch flange, then lever it free from its
aperture (photo). Take care not to damage thetrim. Detach the wiring connector to fully
remove the switch.
92Refit in the reverse order of removal and
then check the operation of the switch.
Windscreen wiper motor
(later models) -
removal and refitting
ª
93Disconnect the battery negative lead.
94Remove the bonnet as described in
Chapter 12.
95Remove the wiper arm and blade as
described in Chapter 9, then unscrew and
remove the pivot nut (photo).
96Undo the air inlet grille retaining screws
noting that two are not fitted with washers.
Where applicable, remove the washer
reservoir filler cap from the reservoir neck
protruding through the grille. Carefully prise
free and lift the air inlet grille clear of the body.
Supplement: Revisions and information on later models 13•109
15.81 Roof-mounted spotlamp switch
removal15.80B Roof-mounted spotlamp bulb
removal15.80A Prising free the roof-mounted
spotlamp
15.96B . . . and detach the windscreen
washer hose15.96A Release the air grille from its fixing
points . . .15.95 Unscrewing the wiper pivot nut
15.91 Prising free the window regulator
switch from the armrest15.86 Remote control receiver unit removal15.82 Roof-mounted clock retaining screw
removal
13
push it towards the windscreen; the ball
socket will release (photo).5Extract the screws from the mounting plate
(photo).
6When refitting the mirror, engage the front
of the socket on the ball and then twist the
mirror rearwards and upwards.
Exterior
7On models without remotely-controlled
type exterior mirrors, the ball-jointed mirror is
held in position by the two self-tapping
screws which secure the triangular trim plate
inside the car (photos).
8To dismantle the mirror, extract the balljoint
fixing screw, but take care as considerable
force is exerted by the interior coil spring
(photo).
Door armrestÁ
9A redesigned armrest is used on somemodels. This is simply secured by two
self-tapping screws (photo).
Tailgate (Turbo ie model) -
component
removal and refitting
Á
10The tailgate on these models is of plastic
injection-moulded type, with a bonded
window glass.
11Renewal of the glass or repair of the
tailgate should be entrusted to your FIAT
dealer or a specialist repairer, due to the need
for special products and techniques.
12To remove the tailgate lock and handle,
open the tailgate and extract the lock handle
screws.
13Prise off the link rod socket from the
ball-pin (photos). Unbolt and remove the
handle and lock.
14A remote type of tailgate release is fitted,
with a control handle located by the driver’s
seat. Access to the handle can be obtained by
removing the seat and sill trim, and peeling
back the carpet.
15If a new cable is to be fitted, disconnect it
from the tailgate latch, tape the new cable to
the old one, and draw it carefully around the
side panel and sill trim (photo).
16To remove the tailgate wiper motor, first
take off the wiper arm and blade.
17Extract the plastic clips and take
off the wiper motor protective cover.
Disconnect, unbolt, and remove the wiper
motor (photo).
13•112 Supplement: Revisions and information on later models
17.17 Tailgate wiper motor17.15 Tailgate release cable (arrowed)17.13 Tailgate handle link rod (arrowed)
17.9 Door armrest17.8 Extracting the mirror balljoint screw
17.7B Withdrawing the exterior mirror
17.7A Exterior mirror trim plate17.5 Interior mirror mounting plate17.4 Interior mirror base
18Refitting of all components is a reversal of
removal.
Radiator grille (1301 cc
Turbo ie model) -
removal and refitting
Á
19The grille is secured by a central screw
and two upper clips. Use a screwdriver to
prise the tabs on the upper clips downwards
(photos).
20Lift the grille upwards and forwards to
disengage its lower mountings (photo).
21Refitting is a reversal of removal.
Radiator grille (1372 cc ie
and 1372 cc Turbo ie
models) - removal
and refitting
Á
22The radiator grille on these models is
secured by screws at the top edge (photo).
Raise and support the bonnet. Undo the
retaining screws, then lift the grille clear.
23Refit in the reverse order of removal.
Bumpers (1301 cc Turbo ie,
1372 cc ie and 1372 cc
Turbo ie models) -
removal and refitting
Á
Removal - front
24Remove the radiator grille as previously
described, to provide access to the bumper
upper mounting screws (photo).
25The ends of the bumpers are secured withbolts and captive nuts but to reach them, the
underwing shields must be released and
pulled away.
26Disconnect the leads from the auxiliary
lamps which are mounted in the spoiler, and
then lift the bumper/spoiler from the car.
Removal - rear
27Open the tailgate to provide access to the
bumper upper mounting screws.
28Disconnect the leads from the rear
number plate lamp. Unscrew the lower
mounting nuts (photo).
29Disconnect the bumper end fixings, which
are accessible under the rear wing edges
(photo).
Refitting - front and rear
30Refitting either front or rear bumpers is a
reversal of removal.
Rear hinged windows -
removal and refittingª
31These have toggle-type catches and
hinges bolted directly through the glass
(photo).
32To remove the window glass, have an
assistant support it, and then unscrew the
cross-head hinge screws and the toggle catch
anchor plate screws. Lift the glass away. If the
toggle catch must be removed from the glass,
first drive out the handle pivot pin and then,
using a pin wrench or circlip pliers, unscrew
Supplement: Revisions and information on later models 13•113
17.20 Removing the radiator grille from a
1301 cc Turbo ie model17.19B Prising down a radiator grille clip17.19A Extracting a radiator grille screw
17.31 Rear window toggle-type catch17.29 Unscrewing a bumper end fixing nut
17.24 Front bumper upper mounting screw
(arrowed)17.22 Radiator grille screw removal on a
1372 cc SX ie model
17.28 Rear bumper lower mounting nut
13
the ring nut which secures the handle to the
glass.
33When refitting the screws or ring nut to
the glass, make sure that the insulating
washers are in good condition to prevent
metal-to-glass contact.Door trim panel
(Turbo ie model) -
removal and refitting
Á34The operations are similar to those
described in Chapter 12, Section 11, except
that electric windows are fitted instead of aconventional mechanical regulator and
handle. Before the trim panel can be
withdrawn, the window control switches
must be disconnected from the wiring plug,
and the plug fed through the panel aperture
(photos).
13•114 Supplement: Revisions and information on later models
17.34C Door interior showing electric
window motor (arrowed)17.34B Disconnecting an electric window
regulator switch plug17.34A Armrest electric window switches
Wiring diagrams 14•1
14
Component key for wiring diagrams 1 to 29
Note: Not all the items listed will be fitted to all models
No Description
00200 Alternator with built-in regulator
00500 Battery
01001 Starter motor
01202 Rear front electric window motor
01203 Left front electric window motor
01206 Windscreen wiper motor
01207 Rear screen wiper motor
01252 Right front door locking motor
01253 Left front door locking motor
01254 Right rear door locking motor
01255 Left rear door locking motor
01400 Windscreen washer pump
01401 Rear screen washer pump
01420 Electric fuel pump
01500 Engine cooling fan
01502 Injector cooling fan
01504 Ventilation fan
02001 Engine cut-out solenoid on injection pump
02010 Fuel injector
02011 Fuel injector
02012 Fuel injector
02013 Fuel injector
02015 Supplementary air valve
02210 Accelerator pump outlet cut-out solenoid on
carburettor
02215 Supplementary air valve
02400 Ignition coil
02405 Ignition coil with electronic control unit
02490 Static advance ignition control unit
02492 Microplex ignition system control unit
03000 Insufficient engine oil pressure switch
03002 Right front door ajar switch
03003 Left front door ajar switch
03004 Right rear door ajar switch
03005 Left rear door ajar switch
03006 Handbrake ‘on’ warning switch
03007 Brake stop-lamp switch
03008 Reversing light switch
03028 Radiator thermostatic switch
03029 Coolant overheating warning light thermostatic switch
03034 Injector cooling fan thermostatic switch
03035 Accelerator pump outlet cut-out solenoid thermostatic
switch
03036 Radiator thermostatic switch with two operating ranges
03053 Map reading light switch
03059 Foglamps switch
03060 Rear foglamp switch
03110 Heated rear screen switch
03114 Ventilation fan switch
03123 Air pressure switch
03142 Choke warning light switch
03144 Reset switch
03145 Display switch
03305 Right front door open light push button
03306 Left front door open light push button No Description
03319 Horn push button
03500 Ignition switch
03505 Butterfly valve cut-off switch
03506 Throttle position switch
03530 Right front electric window switch
03531 Left front electric window switch
03546 Rear screen wash/wipe switch
03550 Hazard warning lights switch
04010 Steering column switch unit, direction indicators
04022 Steering column switch unit, headlamps, main beam
and dipped, side lights
04032 Steering column switch unit, windscreen wash/wipe
04214 Fuel injection system control relay
04215 Antiskid system failure relay
04225 Radiator fan 2nd speed engagement relay feed
04241 Foglamps relay feed
04260 Electric windows motor relay feed
04283 Antiskid system relay
04291 Horn relay feed
04292 Heated rear screen relay feed
04441 Dim-dip cut-out 04600 Ignition distributor
04700 Coolant temperature sender unit
04701 Electronic injection coolant temperature sender unit
04720 Oil pressure sender unit
05008 Right headlamp, main beam and dipped with side light
05009 Left headlamp, main beam and dipped with side light
05013 Abnormal fuel consumption sensor
05015 Right foglamp
05016 Left foglamp
05410 Right front direction indicator
05411 Left front direction indicator
05412 Right front side direction indicator
05413 Left front side direction indicator
05640 Rear number plate lamp
05690 Right rear light cluster, sidelight, direction indicator,
brake light, rear foglamp
05691 Left rear light cluster; side light, direction indicator,
brake light, rear foglamp
06000 Centre courtesy light
06026 Map reading light
06076 Ideogram fibre optic light
06080 Heater controls light
06084 Instrument panel light
06300 Sidelights warning light
06305 Main beam headlamps warning light
06310 Rear foglamps warning light
06311 Foglamps warning light
06315 Hazard warning lights warning light
06320 Direction indicators warning light
06335 Insufficient brake fluid level warning light
06336 Handbrake ‘on’ warning light
06343 Insufficient engine oil pressure warning light
06344 Insufficient brake fluid level warning light
06345 Fuel reserve warning light
06350 Coolant overheating warning light
Wiring diagram 15 - central door locking and electric windows
(S and SX models)
Wiring diagram 16 - headlamp dim-dip system (1987-on models)
14•10 Wiring diagrams