1988 FIAT TEMPRA radiator

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withdrawn from the hubs, new nuts must be used and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

Job
9-2

Job 7. Windscreen washer pump -
replacement.
Job 10. Rear light cluster
replacement.
Job 8. Radio aerial - replacement.
• Step 1: Refer to Job 13 and remove the interior light.
Q Step 2: Now disconnect the aerial lead from the exposed
base and undo the securing nut.
• Step 3: Remove the aerial from outside the car.
Q Step 4: Reverse the process to refit but ensure that the
seal is good between the aerial and the roof to prevent water
ingress.
Job 9. Headlight cluster -
replacement.
• Step 1: Remove the radiator grille
-
see PARTI: BODY
AND INTERIOR
PART A: TIPO MODELS
O Step A1: Disconnect the
battery.
• Step A2: Raise the
tailgate and undo the fixing
screws (arrowed).
• Step A3: Withdraw the
cluster and disconnect the
wiring plug.
• Step 2:
Disconnect the
battery. Unplug all
the wires serving
the light cluster.
Undo the fixing
bolts (arrowed)...
• Step 3: ...and
withdraw the
complete
assembly.
Q Step B6: From inside, undo the mounting bolts and
remove the motor.
Q Step B7: Refit in reverse order.
O Step 1: Disconnect the
battery earth terminal.
• Step 2: Locate the
pump (arrowed), which is a
push fit in the washer fluid
reservoir and disconnect the
electrical plug.
• Step 4: Refit
in the reverse way
and have the
beam alignment
checked by your
local FIAT service
agent.
• Step 3:
Withdraw the
pump and
disconnect the
tubing. This, for
reference, is the
layout of the
headlight washer
pipes and the
headlight wiper
motor.
• Step 4: Check the condition of the seal before refitting in
reverse order.

PART I: BODY AMD INTERIOR
PART 1: Contents
Job 1. Bonnet
-
removal and refitting. Job 8. Tempra boot lid locking mechanism
-
removal and
Job 2. Bonnet locking mechanism
-
replacement and refitting.
adjustment. Job 9. Front bumper and grille
-
removal and refitting.
Job 3. Radiator grille
-
removal and refitting. Job 10. Rear bumper
-
removal and refitting.
Job 4. Tipo/Tempra tailgate
-
removal and refitting. Job 11. Door trim panel
-
removal and refitting.
Job 5. Tipo tailgate locking mechanism
-
removal and Job 12. Door component
-
removal and replacement
refitting. Job 13. Door removal, replacement and adjustment.
Job 6. Tempra estate tailgate locking mechanism
-
removal Job 14. Door mirror
-
replacement.
and refitting. Job 15. Sun roof
-
removal and refitting.
Job 7. Tempra boot lid
-
removal and refitting. Job 16. Front seats
-
removal and refitting.
-Job 17. Rear seats
-
removal and refitting.
Job 1. Bonnet - removal and
refitting.
Job 2. Bonnet locking mechanism
- replacement and adjustment.
• Step 1: Note the bonnet hinges, support and stops.
G Step 2: Use the prop and hold the bonnet open. Outline
the hinge positions on the bonnet with masking tape for
accurate refitment.
G Step 3: Ask an assistant to support the bonnet. Undo the
two hinge fixing bolts. Carefully lift the bonnet clear.
if refitting the bonnet, put a
piece of cloth under each
rear corner to protect the bodywork.
• Step 1: This drawing shows left and right hand drive
layouts. Select which is right for your car.
• Step 2: The two screws (illustration Job 2-3 arrowed)
used to fix the locking pin/safety catch assembly to the bonnet
are also used for fore and aft adjustment. This is best done a
little at a time until smooth operation is achieved.
• Step 3: Height
adjustment (levelling with
the wings) is achieved by
screwing the bump stops
(inset, arrowed) up or
down. Then slacken the
G Step 5: When refitting, tighten the bolts just enough to
grip the hinges, then carefully lower the bonnet to check for
correct alignment all round
-
equal gapping.
When the alignment is satisfactory, tighten the bolts to their
correct torque, See Chapter 3, Facts and Figures
[G Step 4: To remove the lock/striker assembly, separate the
cable eyelet from the operating lever hook, see illustration Job
2-1, parts 13 and 14
1 - lock/striker assembly, front panel 2 - locking pin/safety catch, bonnet 3 - release lever. (Also fitted other side, some R/H drive cars) 4 - cable, L/H drive 5 - cable, R/H drive
and secondary cable, R/H drive 7 - screw 8
-
washer 9 - bolt 10 - bolt
11 - cable clip 12 - cable fixing screw 13 - cable eyelet 14 - operating lever hook Job 2-1
locking nut (hidden
behind the locking pin
spring) and screw the
locking pin up or down
until the bonnet will shut
when dropped from 30 cm height and then have no
movement on the lock. Don't forget to tighten the locknut.

Job 3. Radiator grille - removal
and refitting.
Job 5. Tipo tailgate locking
mechanism - removal and
refitting.
Job 4. Tipo/Tempra tailgate -
removal and refitting.
Q Step 5: Undo the securing bolts (see illustration Job
2-1,

part
10)
and remove the lock.
Q Step 6: Refit in reverse order.
Q Step 7: Replace a cable by disconnecting it at each end
and releasing it from any securing clips. Run the new cable
along the same route and re-connect and secure.
• Step 1: Undo the
two fixing screws
(arrowed)...
Q Step 2: ...and pull
out at the top of the grille
to release it from the
securing clips. Withdraw
the grille.
• Step 3: Refit in
reverse order.
• Step 1:
Disconnect the
battery negative
terminal.
• Step 2A: Take
note of this
exploded view of
the Tipo tailgate.
• Step 2B: This is
the Tempra estate
layout.
IMPORTANT
NOTE: While these
instructions are for
the Tipo, the
Tempra estate is
very similar.
• Step 1:
Study this
exploded view of
the locking
mechanism to
help you under-
stand the job.
• Step 2:
Remove the five
bolts (a) securing
the lock
assembly...
• Step 3: ...and
carefully lever off the five
buttons (see illustration
Job
5-2,
arrowed). The
lock assembly (fitted to
the inside of the cover) is
now free.
• Step 6: TIPO ONLY:
Remove the semi-circular
safety spring from the gas
strut balljoints and pull the
socket off the ball.
TEMPRA SW ONLY:
Unbolt the tailgate from the
hinges.
• Step 7: Extract the circlips retaining the hinge pins with
pliers. Support the forward end of the tailgate and knock out
the hinge pins (arrowed), and remove the tailgate.
WARNING! At all costs, avoid loosening the Tipo's hinge
bolts on the body or tailgate
-
or they will have to be
replaced, according to FIAT.
• Step 8: H INSIDE INFORMATION! • When removing
and when refitting, particular attention must be paid
when inserting the stop engagement teeth to avoid
breaking and replacing the stops.
• To refit, insert the upper tooth, then turn the stop
downwards and insert the lower tooth. B
Q Step 9: Continue to re-assemble in reverse order.
Job 5-1
• Step 3:
Disconnect all the
electrical connec-
tions and the washer tubing.
• Step 4: Remove the left cable duct (left-side) and
withdraw the cables from the body shell. Its 'twin', on the
other side, is a plain stop. See Step 8
• Step 4: Unplug the
lock servo control
connector from inside the cover and remove the lock assembly
from the car.
Q Step 5: Disconnect the control rod (see illustration Job

5-1,
part 6) and remove the speed fasteners (Job
5-1,
part
5).

• Step 5: Support the weight of the tailgate with a suitable
length of timber and protective pad.
• Step 6: Remove the two screws (illustration Job
5-1,

parts 4, 9 and
10)
and the closing device (Job
5-1,
part
7).

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

Diagram 13: Models: DGT1100
-
1400 and 1600
-
Engine Radiator Cooling
-
Car Interior Ventilation
-
Available for Radio -
Cigar Lighter
-
Courtesy Light
Diagram 14: Model: 1697 Diesel ('93 Range) Super
-
Engine Cooling System
-
Car Interior Ventilation
-
Provision for Car
Radio
-
Cigar Lighter
-
Courtesy Light
NB
-
Early/non-Super models similar, but no items 47A, 295, and 60A. Item 95 has 40A fuse on DGT Models

Diagram 15: Model: 1930 Turbo Diesel DGT
-
Engine Radiator Cooling
-
Car Interior Ventilation
-
Available for Radio -
Cigar Lighter
-
Courtesy Light