1988 FIAT TEMPRA steering

G Step 17: Now repeat this operation on the remaining
valves.
G Step 18: Wash the whole cylinder head again using
paraffin and an old brush, making sure that all traces of
grinding paste are removed, then dry off. Use compressed air

if
available.
SAFETY FIRST!
•
Treat
compressed air with respect. Always wear

goggles
to protect your eyes.
•
Never
allow the airline nozzle near any of the body Sep apertures.
H INSIDE INFORMATION! Check the height of the valve
springs against new ones if possible, but if not, compare
them with each other. If any are shorter than the others,
play safe and replace the complete set. They are bound
to have suffered fatigue which could cause premature
valve failure. H
G Step 19: To install the valves, start from one end.
Lubricate a valve stem with fresh engine oil and slide it in to its
guide.
G Step 20: Locate a new valve stem seal over the stem of

the valve
(if applicable) and push down into contact with the
guide. Position the seal on its seat using a suitable metal tube.
G Step 21: Refit the flat washer and spring seat.
G Step 22: Position the inner and outer springs and the

spring
cap.
G Step 23: Re-apply the valve spring compressor and

compress
the springs enough to allow you to engage the split
collets
in
the stem grooves.
D INSIDE INFORMATION! Grease the grooves so that the
collets will 'stick' in place. The collets are easily fitted by
'sticking' the backs of them onto the end of a screw-
driver with some grease and feeding them into
position. B
G Step 24: Carefully release the spring compressor and

check
that the collets are correctly located. Tap the end of the

stem with
a hammer, to bed them in.
G Step 25: Fit the remaining valves.
Job 5. Petrol engine -
dismantling.
G Step 1: Familiarise yourself with the layout of the engine.

Refer to
illustration Job
2-1
for an exploded view of the

engine
components.
G Step 2: Drain the engine oil. Remove the cylinder head.
See
Job 2.

G Step 3: Remove the distributor. See PART D: IGNITION
• Step 4:
Remove the petrol
pump and spacer
block, if the
mechanical type
(a). (Electric fuel
pumps are in the
fuel tank.)
• Step 5:
Remove and
discard the oil filter
illustration Job
5-4,

• Step 6: Remove the water pump complete with its distri-
bution pipe, and the power steering pump (if fitted).
Q Step 7: Remove the alternator, the crankshaft pulley, the
crankshaft and camshaft sprockets, the cam belt tensioner
and the cam belt cover backplate.
• Step 8:
Remove the
auxiliary shaft
sprocket...
• Step 9: ...the
end plate and
seal, and remove
the auxiliary shaft.
• Step 10:
Undo and remove
the clutch, and
then the flywheel.
• Step 11: Turr
engine assembly c
remove the sump
and remove the crankcase breather (see
part b) with its pipe.

• Step 16: Unbolt

the
lower suspension

arms
(arrowed)...
• Step 17:

...remove
the

drive
shaft

assemblies
from
their housings in

the
gearbox...
• Step 15: Undo

and
remove the
suspension strut to

stub axle
nuts and

bolts
(arrowed
-
two

each side).
Pull the

tops
of the stub axles

clear
of the struts.
• Step 12:
Disconnect both
trackrod ends from

their
steering arms.
• Step 13:

Remove
the fixing

bands
(arrowed) on

the
protective boots

on the
inner ends of

the
drive-shafts.
• Step 14: Unplug

the brake
pad wear

sensors
(a) if fitted.
Unbolt (see arrows)

the
complete caliper
support bracket.

Hang
each caliper

and
bracket in their
wheelarches, taking

care
not to strain or

damage
the hydraulic
hoses.
• Step 21:
Remove the nuts (1)
holding the centre
support to the
gearbox, and those
(2) holding the
flywheel shield.
• Step 22:
Remove the centre
support/mounting (a)
and the flywheel
shield (b).
• Step 18: and
remove each
complete front hub,
drive-shaft and brake
disc assembly.
Job 8-18
Q Step 20: Support the power unit, just keeping its weight
off the mountings.
E3 INSIDE INFORMATION! This can be done from under-
neath with a trolley jack and piece of wood on its pad to
prevent damage
-
or by means of a hook from above. B
• Step 19:
Disconnect the gear
selector linkage and
place it out of the
way, in the lower
part of the engine
compartment.
Job 8-19
Job 8-13
expert22 fl/ia http://rutracker.org
I

Job 13. Diesel engine. Timing belt
- replacement and adjustment.
• Step 1: Undo
the bolts and remove

the
top timing belt
cover.
Q Step 2: Securely
support the car and

remove
the right

hand
front wheel for

access
to the wheel

arch
dust shield.

Undo
the fasteners
(arrowed) and

remove
the shield.
• Step 3: Slacken the power steering pump support

bracket securing
bolts (arrowed).
Q Step 4: Slacken

the bolts
holding the

power steering
pump

to the
bracket
(arrowed)
• Step 5: and
remove the drive
belt, allowing it to
hang on the engine
support bracket
(arrowed).
• Step 6: Slacken the alternator mounting bolts, and
remove the drive belt.
• Step 7: Ensure
that the notch on the
crankshaft
pulley/damper
(arrowed) is aligned
with the ridge on the
lower half of the
timing belt cover
(arrowed),
M
V// Job 13-7
• Step 8: .... then
undo the securing
bolts (arrowed) and
remove the cover
(inset).
• Step 9: Undo
the bolts (arrowed)
and remove the
flywheel cover guard
(inset).
IMPORTANT NOTE: From now on, one of two different
procedures will be required, depending upon the age of
your diesel engine, as modifications were made from
engine No. 1723291-on to allow fine adjustment of
camshaft timing. Both procedures require the use of FIAT
special tooling, which it may be possible to hire from
your local specialist
-
otherwise you will have to make
your own tools or have the work carried out for you.
85

• Step 4:
Disconnect the
brake servo
pipe from the
vacuum pump
(a) and all the
water hoses
from the
thermostat (b).
• Step 5:
Disconnect the
heater supply hose
from the cylinder
head.
• Step 6: Unplug
the temperature
warning light
connector from the
cylinder head.
• Step 7:
Disconnect the glow
plugs, supply lead
(arrowed).
Q Step 8: Disconnect and remove the fuel delivery pipes (a)
- from the pump (b) and from the injectors (c).
• Step 9: From the
hoses leading to the
expansion tank and
the coolant pump.
• Step 10: Undo
the bolts (arrowed)
and remove the
power steering pump
cover.
• Step 11: Undo
the bolts securing
the pump to the inlet
manifold (arrowed)
and tie the pump
clear.
• Step 12: Undo
the bolts (arrowed)
and remove the
power steering pump
support bracket.
88
cylinder head, disconnect the coolant
Job 14-10
Job 14-12
Job 14-11

Job 17. Diesel engine.
Valve clearances - adjustment.
D INSIDE INFORMATION! After carrying out Job 16,
valve clearance measurement and adjustment is now
needed. Both measurement and shim replacement are
carried out in the same manner as for the petrol engine

(.Job
7), so refer to this and also to Chapter 3, Facts
and Figures for specifications. B
Job 18. Diesel engine - removal.
moving parts with engine oil during assembly. See Chapter 3,

Facts
and Figures for specified tightening torques.
luei suppiy diiu leium pipe;>
at the injection pump...
• Step 9: ...and the stop
control supply cable. Also
disconnect the cable from
the injection pump hydraulic
advance control sensor and
the alternator cables.
• Step 10:
Disconnect the oil
feed and return
pipes between the
thermostatic valve
and the radiator
and tie clear.

I

This should
be read in connection with Job 8
Q INSIDE INFORMATION! • The turbo and non-turbo
diesel engines are essentially similar.
• The under-bonnet scene is in some ways different
because of the extra plumbing required when a turbo is
fitted.
• Locations and shapes of various items may differ, or
not exist at all on the non-turbo unit.
• As most complexity is found with the turbo engine,

I

the
following illustrations are mainly of this version.
• The power units are removed from under the car,
therefore make sure you can raise the car enough to
achieve this. Support the car firmly and safely on axle
stands. D
Q Step 1: Disconnect the negative lead from the battery

and drain
the cooling system. Q Step 2: Remove the bonnet lid.
• Step 3: Drain the transmission oil.
Q Step 4: Disconnect and remove all pipes and hoses.
Q Step 5: Undo all electrical connection and label them

with masking
tape. Write matching numbers on each male

and female
connection to assist reconnection, later.
Q Step 6: Disconnect the power steering pump pipes

(where fitted),
catching any spilt fluid and tie them clear. See

Job 14.

• Step 7: Part the
connection for the

electronic
speedometer
magnetic impulse

generator
(when fitted).
Q Step 11: Disconnect the clutch cable, adjacent earth lead
and reversing light switch other cable connection from the top
of the gearbox.
• Step 12: Disconnect the leads from the oil pressure
warning light from the oil filter mounting, and the oil level
warning light switch.
• Step 13: From under the car, remove the exhaust front
section from the manifold and from its support brackets.
O Step 14: Remove the front road wheels and the access
panel from each wheel housing.
• Step 15: Remove the brake pad wear sensor cables,
when fitted.
Q Step 16A: On the turbo version, undo the six 'Allen'
screws securing the inboard end of each drive-shaft. Undo the
two pinch bolts that fix each stub axle to the suspension struts
and pull them clear. Ease the drive-shafts clear of the trans-
mission casing

-
take care
not to
damage the
protective
boots.

• Step 2: Remove the bonnet. Disconnect and remove the
battery.
0 Step 3: Drain the oil from the transmission.
0 Step 4: Disconnect the clutch cable or remove the slave
cylinder, if hydraulic, from the top of the gearbox.
• Step 13: Disconnect the
gearchange rods at the gearbox
(arrowed).
O Step 14: Remove the trans-
mission mounting and bracket
assembly.
Job 2. Transmission refitting
(with engine in car).
/ a 5tep1S: • SLjpp°n the
'' £/ gearbox in such a way that
when disconnecting, it can
be withdrawn smoothly and without 'hanging' on the
engine. A trolley jack might do the job nicely.
• Step 16:
Undo the gearbox
to engine fixing
bolts...
• Step 17: ...slide the
box back until it's clear of
the clutch and lower it to
the ground using a
hydraulic stand or trolley
jack.
IMPORTANT NOTE: Refer to PART A: ENGINE, Jobs 8
and 9 in connection with this Job.
• Step 1: Refitting is the reverse of the removal work
carried out in Job 1 but bear in mind the following:
Q Step 2: Centralise the clutch driven plate, if it has been
disturbed. See Job 3.
• Step 3: NON-HYDRAULIC CLUTCHES ONLY. Adjust the
clutch cable. See Job 4
Q Step 6: Raise the front of the car and support securely on

axle stands.
Remove the road wheels and the previously
slackened hub nuts.
Q Step 7: Remove the wheel arch protective shields.
Q Step 8: Disconnect the speedometer cable from the
gearbox. (If digital instrumentation, disconnect the wiring

from
the sender unit.)
Q Step 9: Disconnect and remove the starter motor and

unplug
the reverse light connector and the earth lead from

the
transmission housing.
Q Step 10: Undo the trackrod ends securing nuts and use a
suitable 'splitter' tool to part the balljoints from the steering

arms.
Slacken the drive-shaft inner boot securing clips. Undo

the pinch
bolts fixing the stub axles to the suspension struts,

pull
the stub axles clear and extract the drive-shafts.
0 Step 11: Support the engine at the gearbox end, just

taking
the weight as described in Step 1.
Q Step 12: Remove the central power unit support (a), the
flywheel guard (b) and the exhaust bracket (c).
• Step 5: With

the
car
still
on the
ground, loosen

the nuts
fixing the
constant velocity

joints
to the hubs.
These require an
enormous force

to be
tightened or
released (see

Chapter 3,
Facts and Figures) and they will have been
staked. There is a severe risk of pulling the car off supports if

you
attempt to undo these nuts while the car is raised off the
ground. Slacken the front wheel nuts.
Job 1-14

Job 9. Drive-shaft - removal
and refitting.
IMPORTANT NOTE: For removal of the diesel Turbo's
drive-shaft, see also PART A: ENGINE, Job 18, Step 16A.
G Step 1: Drain the transmission oil.
• Step 8B: Diesel turbo
models have a bolt-on inboard
flange.
• Step 9: Withdraw the shaft
from the transmission (illus-
tration Job
9-8A,
part b).
G Step 2: Ask a helper to apply the footbrake very firmly
while
you
slacken the drive-shaft-to-hub nut, using a long bar
for
good
leverage after
opening out the
staking on the nut, as
far
as
possible. DON'T

do so
with the car off

the
ground because

the
very large force
needed could pull it off

its stands.
Remove the

nut
after the car has
been raised.
Job 10. Drive-shaft (outer)
constant velocity joint -
G Step 8A: Undo the

inboard
gaiter retaining

clip
(a) and release the
gaiter.
• Step 11: Refill the
transmission with oil.
See Chapter
3,
Facts
and Figures.
G Step 3: Slacken the hub nuts on the side to be worked

on.
Jack up the front of the car and support on axle stands.
Remove the roadwheel.
G Step 6: Remove the

hub
carrier securing

bolts
(arrowed) from the

base
of the front
suspension strut and tap

the
carrier down and out

of the
clamp. Pull the

top
outwards.
G Step 7: Push

or tap
the drive-

shaft
splines
(arrowed) out of

the hub
carrier,

taking
care not to

damage
the
thread.
Q Step 1: Remove the drive-shaft from the car. See Job 9. G Step 4: Unbolt the
brake hose support clip

from
the suspension strut.
G Step 5: Disconnect the
track rod end from the
steering arm using a
suitable splitter tool.
• Step 2: Remove
the gaiter retaining
clip...
Q Step 3: ...and pull
the gaiter clear.
• Step 4: Remove
the circlip and pull the
CV joint from the shaft.
Q Step 5: Thoroughly clean the joint with petrol or other
agent and dry. Check that the balls and their seats are still in a
good, unbroken shiny condition
-
no score marks. Fit a new
joint if in doubt.
• Step 6: Fit the new gaiter onto the shaft, followed by the
CV joint and circlip. Pack the joint with the grease supplied or
with FL Tutela MRM2 grease.
Q Step 7: Pull the gaiter over the joint and secure with the
retaining band or new screw-type clip. The drive-shaft
assembly is now ready for refitting.
• Step 10: Refit in the
reverse order, using a new
drive-shaft nut tightened to the
specified torque. See
Chapter
3,
Facts and
Figures Stake the nut
into the drive shaft
groove, as shown.

Job 11. Drive-shaft inner spider
joint - replacement.
• Step 3: Replace the (split) rubber mounting and refit the
weight.
Job 13. Front hub/bearings -
replacement.
Job 11-1
a - distance - 305 mm b - spider joint c - inner gaiter d - inner bearing seal e
-
vibration damper f
-
outer gaiter
g - circlip h - outer u.j. i - hub mounting spline
• Step 1: Note the arrangement of the inner spider joint
and drive-shaft components.
Q Step 2: Remove the
drive-shaft from the car. See
Job 9.
• Step 3: Remove the
circlip and pull or press the
spider joint from the drive-
shaft.
• Step 4: Remove the inner gaiter (illustration Job
11-1,

part c) from the seal bearing (Job
11-1,
partd). Check the
bearing for wear and smooth operation.
Q Step 5: Replace it if necessary by using a standard type
puller to remove it from the shaft, driving the new one into
position with a suitable length of tubing.
Q Step 6: After obtaining a new spider joint, if necessary,
(available as a complete replacement item from your FIAT
dealership), fit the new gaiter and its retainer to the shaft,
followed by the spider joint and circlip. No lubrication is
required prior to refitting the drive-shaft.
• Step 7: E9 INSIDE INFORMATION! The turbo diesel
uses an inboard CV joint similar to the outer one except
that it has a flange for attachment to the transmission.
(See PART A: ENGINE, Job 18, Step 16A ) Inspect and
replace in the same way as the outer one. The interme-
diate shaft can only be inspected for wear in its bearing
which cannot be removed separately. Therefore, the
whole unit must be changed if defects are found. Q
Job 12. Drive-shaft damper -
replacement.
Refer to Job
11,
Step 1
Q Step 1: A damper is fitted to the right-hand drive-shaft to
prevent vibration in what is a long drive-shaft. The rubber
mounting can disintegrate or become damaged.
Q Step 2: Use an Allen key to separate the two halves of
the weight.
s * You ™yfind *
" U ' necessary to pull out
gently

on the stub axle and at
the

same time tap lightly (so you don't damage the
thread) on the end of the shaft to knock it through.
• Retrieve the stub axle/hub assembly.
Q Step 7: Use a large vice or a press to push the hub out of
the stub axle.
• Step 8: You may have to remove the bearing inner track
from the hub if it comes out with it.
• Step 2: Partly dismantle the front suspension as described
in Job 9. Steps 2 to 6.
• Step 3: Unbolt the brake caliper and support bracket and
tie it clear.
• Step 1: Take note of the components illustrated here.
Also, see PART G: STEERING AND SUSPENSION, Job
12

where this work is described in more detail.
Q Step 4: Unbolt the brake disc and shield.
• Step 5: Undo the track control arm to stub axle pinch
bolt and
withdraw the
balljoint pin from
the stub axle.
• Step 6: Ease
the stub axle
(illustration Job

13-1,
parts d
and c, combined)
off the drive-
shaft splines (Job

11-1,
parti)
leaving the
inboard end of the
mission.
drive-shaft still attached to the trans-