1988 FIAT TEMPRA battery

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.

Job 12. Number plate light -
replacement.
lob 11. Side repeater indicators -
replacement. Job 13. Interior/courtesy light -
removal and refitting.
Job 11-2 |
G Step 1: Remove the
protective cover from under the

wing
to gain access to the back

of the
light unit.
G Step 2: Twist and remove

the
light lens.
G Step 3: Release the two
retaining clips on the light unit
body (arrowed). Withdraw the
light unit and unplug the
connector.
G Step 4: Refit in reverse
order.
PART A: TIPO MODELS
G Step A4:
Undo the two
screws to detach
the printed
circuit/bulb holder

(2) from
the
cluster (1).
G Step A5:
Reverse these
operations to refit.
PART B: TEMPRA MODELS
G Step B1: Disconnect the battery earth lead.
G Step B2: Undo the screw at the top and remove the lens.
IMPORTANT
NOTE: Some
types are held in
place with
screws, found
beneath the
G Step B3:
SALOON MODELS.

This is
the layout of

the
components.

See
Step B4.
G Step B4:
ESTATE MODELS.
Unplug the wiring
connector. Undo

the
three screws
(positions arrowed)

and
withdraw the

light
cluster.
G Step B5: Refit

in
reverse order.
Q Step 1: Remove
the battery earth
lead. Use a screw-
driver and carefully
prise off the interior
light lens.
Job 10-B3
Job 10-B4
• Step A1: Undo the six fixing screws (arrowed)...
• Step A3:
Unplug the wires
from the bulb
holders
(1)
and
the unit becomes
free.
PART B: TEMPRA MODELS
• Step B1: Release the number plate light securing clips
and withdraw the lights.
IG Step B2: Disconnect the wiring plug and remove the
lights.
O Step B3: Refit in reverse order.
• Step A2:
...and withdraw
the unit.
Job 10-A4
• Step 2: Release
the press clips, two
on each end
(arrowed) unplug
the connector and
withdraw the light.

Job 15. Central locking -
replacement off components.
Job 14. Fuel gauge sender unit
removal and refitting.
SAFETY FIRST!
• Carry out this work out of doors, away from sources
of ignition.
• Make the open aperture on top of the fuel tank air
tight as quickly as possible.
• You should carry out this job when the fuel is at a
low level.
VEHICLES WITH ELECTRIC FUEL PUMPS
(NOT ENGINE MOUNTED)
Job 16. Electric windows -
replacement of components.
courtesy light lens and/or panel. The connectors are on
the rear of the unit.
• Step 3: The estate car has a rear courtesy light which is
removed as in Step 1 and 2
LJ Step 4: Refit in the reverse order.
PART A: ELECTRONIC CONTROL UNIT
• Step A1: You
will find the
electronic control
unit
(1)
mounted
beside the
junction unit...
PART A: ELECTRONIC CONTROL UNIT
• Step A1: Disconnect the battery at the earth terminal.
• Step A2: The
electronic control unit
(1) is mounted directly
on the junction unit to
the left of the foot
pedals. To change it,
simply unplug it and
plug the new one in.
• Step A3:
Reconnect the battery.
PART B: DOOR LOCK SWITCHES AND MOTORS
• Step B1: Both door lock switches and motors are an
integral part of the lock assembly. Therefore, if a fault
develops in either, the complete unit will have to be changed.
See PARTI: BODYWORK AND INTERIOR
• Step A2: ...while the
circuit fuse (2) is on the
junction unit holder. First,
disconnect the battery
earth lead.
• Step A3: Disconnect
the electrical plugs, undo
the securing screws and
withdraw the unit.
• Step A4: Refit in
reverse order.
Q Step 1: Disconnect the battery earth lead.
Q Step 2: Lift the luggage compartment floor covering and
prise the round plastic cover from the floor to expose the
sender unit.
Q Step 3: Unplug the sender unit wires and position them
out of the way.
• Step 4: Using the
two opposing lugs on
the unit, (FIAT tool no.
1854045000 or similar
would be useful) twist
it in an anti-clockwise
direction and remove
it from the fuel pipe
housing.
C-) Step 6: Refit in the reverse order.
VEHICLES WITH
ENGINE MOUNTED
FUEL PUMPS
• Step 7: Where a
mechanical fuel pump is
fitted, the sender unit
looks like this. A ring nut
is use to secure it to the
top of the fuel tank.
• Step 5: Check
the condition of the
sealing ring and replace it if necessary.
Job 16-A1

Job 17. Diesel engines - Glow
plugs, checking and replacement.
LI Step 1: Disconnect the battery earth lead. Undo the
retaining nut at each plug top (a) and remove the bridging
strip (b) from between the glow plugs (complete glow plug -
inset).
• Step 2: With the
wire or connecting strap
removed, unscrew each
plug from the cylinder
head by just a couple of
turns using a ring spanner
(as shown) or socket.
H INSIDE INFORMATION: It is false economy to renew
only one glow plug at a time
-
we recommend a
complete set of new plugs if any one plug is in poor
condition. E9
• Step 6: Refit the glow plugs and tighten to their specified
torque
-
see Chapter 3, Facts and Figures. Over tightening a
glow plug can damage it!
• Step 7: Refit the bridging strip and connect the supply
lead.
17-1
PART B: WINDOW CONTROLS
Q Step B1: Disconnect the battery earth terminal.
Q Step B2: Undo the screw and remove the armrest trim,
then undo the screws fixing the armrest and withdraw it
enough to unplug the wiring. See PARTI: BODYWORK AND
INTERIOR.
• Step 3: Clean away
dirt from around the
plugs, then fully unscrew
and remove them. It's a
good idea to blank off
the plug hole with cloth
to prevent dirt from
entering.
• Step 4: Examine the condition of each plug by wiping
soot away and examining for erosion of the element sheath.
• Step 5: Check the internal resistance of each glow plug
by connecting across a resistance meter. You are looking for a
resistance of 5 ohms or less. If the reading is much higher
than this, or is infinity, the plug must be renewed.
Q Step B4: Refit in the reverse order.
PART C: COURTESY LIGHT/WINDOW LIFT INTERLOCK
SWITCHES
Q Step C3: Refit in reverse order.
PART D: WINDOW OPERATING MOTOR
Q Step D1: The motors are an integral part of the winding
mechanism and therefore can only be changed as a complete
assembly. Refer to PART I: BODYWORK AND INTERIOR
Q Step B3: From inside the armrest, undo the retaining

screws and
detach the control panel from the armrest.
G Step C1: Disconnect the battery earth lead.
Q Step C2: Take off the rubber dust cover (3), prise the
switch out of the panel and disconnect the wire.

PART F: FUEL AMD EXHAUST SYSTEMS
PART F: Contents
Job 1. Fuel system types. Job 9. Electric fuel pump, petrol engine (S.P.I.)
-

Job 2. Carburettor
-
removal and refitting. replacement.
Job 3. Petrol injection unit
-
removal and refitting. Job 10. Fuel tank
-
removal and refitting.
Job 4. Accelerator cable, carburettor engines
-
replacement Job 11. Hot air hoses/thermo-valves
-
general.
and adjustment. Job 12. Lambda sensor (S.P.I, engines)
-
replacement.
Job 5. Carburettor choke cable
-
replacement and Job 13. Fuel evaporation system.
adjustment. Job 14. Exhaust system
-
replacement.
Job 6. Accelerator cable, petrol injection engines -Job 15. Turbocharger, diesel engine
-
replacement.
replacement and adjustment. Job 16. Diesel injection pump
-
removal and refitting.
Job 7. Diesel engines. Accelerator cable
-
replacement and Job 17. Diesel injectors
-
remove and refit.
adjustment. Job 18. Bleeding Diesel fuel system.
Job 8. Mechanical fuel pump, petrol engine (carburettored) -
replacement.
Job 1. Fuel system types.
FACT FILE: FUEL INJECTION/ELECTRONIC
IGNITION PRECAUTIONS
OBSERVE THE FOLLOWING PRECAUTIONS
WHEN WORKING ON PETROL-ENGINED
VEHICLES WITH FUEL INJECTION - ELECTRONIC
IGNITION SYSTEMS:
• never start the engine when the electrical terminals are
poorly connected or loose on the battery poles;
• never use a quick battery charger to start the engine;
• never disconnect the battery from the car circuit with the
engine running;
• when charging the battery quickly, first disconnect the
battery from the vehicle circuit;
• if the vehicle is placed in a bodyshop drying oven after
painting at a temperature of more than 80 degrees Celsius,
first remove the injection/ignition ECU;
• never connect or disconnect the ECU multiple connector
with the ignition key in MARCIA position;
• always disconnect battery negative lead before carrying out
electrical welding on vehicle.
Note that some systems contain one memory that is always
active (stand-by memory) and that stores learnt self-adaptive
values. Because this data is lost when the battery is discon-
nected, this operation should be carried out as infrequently as
possible.
Refer to illustrations in Job 1 for typical layouts.
It's a good idea to familiarise yourself with the type of fuel
system fitted to your car. These are the main types.
• Type 1: This is the 1400/1600cc carburettored engines
fuel system.
SAFETY FIRST!
• The high pressure pipework on a petrol or diesel fuel
injection system can retain its pressure for days even
after the engine has been switched off.
• When you disconnect the pipework, a jet of fuel can
be emitted under very high pressure
-
strong enough to
penetrate the skin or damage the eyes.
• NEVER work on the fuel pipework when the engine is
running (except when bleeding Diesel injectors
-
see Job
18.
• ALWAYS place a rag over a union while it is being
undone until all the pressure has been let out of the
system.
• You must wear strong rubber gloves and goggles
when disconnecting the fuel injection system's high
pressure pipework. Always disconnect VERY slowly,
letting pressure out progressively.
• See Job 8 for details of how to depressurise the
system.
• Disconnect the battery negative earth before working
on the fuel system.
• Work outdoors and away from sources of flame or
ignition.
• ALWAYS wear rubber gloves
-
don't let your skin come
into contact with fuel.
1 - overflow pipe 2 - safety valve/roll over cut-off device 3 - fuel tank 4 - carburettor 5 - fuel supply, pump to carburettor 6 - mechanical fuel pump
7 - fuel filter 8 - fuel supply, tank to pump 9 - excess fuel return, carburettor to tank 10 - breather pipe, between highest and lowest Job
1-1

• Type 2: This is the fuel supply circuit for the 1400/1600cc
engines using the Bosch Mono-Jetronic S.P.I. System and
Bosch Monomotronic injection systems (1400cc type shown).
5 - fuel supply, pump to injector turret 6 - injector, turret mounted 7 - fuel pressure regulator, integral with turret 8 - fuel return, injector turret to tank — Job 1-2
1
-
fuel tank 2
-
electric fuel pump 3
-
gauze filter on pump inlet 4
-
main fuel filter
H INSIDE INFORMATION! The main fuel filter (4) is
protected by a rubberised shield which must be lowered
at one end for access. H
5 - fuel filter 6 - water bleed valve 7 - breather pipe, between highest and lowest parts of fuel tank 8 - safety valve/roll over cut-off device 9 - blow back pipe 10 - fuel tank Job 1-3
1
-
Bosch injection pump 2
-
fuel supply, filter to injection pump 3
-
excess fuel return, injection pump to tank 4
-
fuel supply, tank to filter
forget to check for these hoses, fitted to the underside of the
air filter housing.
• Step 2: Disconnect coolant hoses from the carburettor
body, and plug them.
Q Step 3: Disconnect the throttle and choke controls. See
Jobs 4 and 5.
Q Step 4: Disconnect the fuel lines from the carburettor
and plug the ends.
/ • E"sure thf ™ delivery
" (/ and return fuel lines are
identified for refitting in
their correct positions.
• Step 5: Unscrew the carburettor mounting nuts and
remove the unit from the intake manifold.
LI Step 6: Clean the mating flanges, fit a new carburettor
base gasket and refit/reconnect in the reverse order.
Job 3. Petrol injection unit -
removal and refitting.
IMPORTANT NOTE: No adjustment or fault diagnosis of
the petrol injection system is possible without the correct
diagnostic equipment. We show how to replace the
Single Point Injection (S.P.I.) turret, but we still
recommend taking your car to your FIAT dealer to have
an apparent fault diagnosed before changing the
injector turret.
Job 2. Carburettor - removal and
refitting.
Q Type 3: This is the fuel supply system for the 1700 and

1930cc
Diesel engines, (1700cc shown).
Q Step 1: Disconnect the battery earth lead, then remove

the air cleaner.
See Chapter 5, Servicing Your Car. Don't
Q Step 1A: The single-point injection unit looks rather like a
carburettor and is fitted on the inlet manifold. This view is
from the rear of the engine.

1 - injection control unit 15 - electric fuel pump 2 - butterfly valve angular protective fuse position sensor (potentiometer) 16 - heated Lambda sensor 3 - coolant temperature sensor protective fuse 4 - petrol vapour cut-out 17 - electric fuel pump solenoid valve 18 - Lambda sensor 5 - current restricter resistor for 20 - ignition switch injector 21 - battery 6 - electric fuel pump relay 23 - RPM and T.D.C. sensor feed 24 - Mono-Jetronic failure 7 - S.P.I, injection system relay warning light feed 25
-
fuel filter 9 - fuel injector 26 - active charcoal filter 10 - intake air temperature 27 - multi-purpose valve sensor 28 - tank ventilation and safety 11 - fuel pressure regulator valve 12 - engine idle adjustment motor and CUT-OFF micro switch 13 - ignition coil 14 - diagnostic socket
Q Step 1B: This is the Bosch Mono-jetronic S.P.I, injection system, used on the 1372cc (1400cc) engine.
1 - fuel tank 13 coolant temperature 2 - electric fuel pump sensor 3 - fuel filter 14 RPM sensor 4 - fuel pressure regulator, 15 electronic control unit integral with turret 16 - high tension coil 5 - injector 17 - system main relay 6 - atmospheric safety valve 18 - electric pump relay 7 - breather float, vent and 19 - Lambda sensor roll over cut-off valve 20 - ignition switch 8 - active charcoal filter 21 - battery 9 - petrol vapour cut out 22 - additional resistance solenoid valve 23 - system fuse 10 - air temperature sensor 24 - diagnostic socket 11 - butterfly valve opening 25 - warning light sensor (potentiometer) 26 - thermostatic duct 12 - engine idle adjustment motor and cut-off micro switch
Q Step 1C: This is the Bosch Monomotronic electronic injection system, used on the
1581
cc (1600cc) engine.
• Step 2: Disconnect the battery earth lead. Depressurise
the fuel system
-
see Job 9.
• Step 3: Remove the air cleaner assembly and the rubber
sealing ring from around the top of the injection unit.
Q Step 4: Disconnect all electrical connections from the
injector unit, making a written note of their positions.
Q Step 5: Release the clips and disconnect the fuel supply
and return hoses from the unit.
G Step 6: Disconnect the breather hose from the unit.
• Step 7: Release the clip securing the throttle link rod to
the injection unit throttle lever, then detach the link rod from
the lever.
Q Step 8: Release the four Allen-type through-bolts in the
top of the injection which retain it to the manifold, then lift
the unit and its base gasket from the manifold.
• Step 9: Refit in the reverse order, making sure mating
faces are clean and the base gasket is new.
• Step 10: Reconnect the battery earth lead.
Job 4. Accelerator cable,
carburettor engines -
replacement and adjustment.
• Step 1: From
under the bonnet,
Slide the outer cable
from its bracket (a)
and detach the
inner cable from the
quadrant (b).
118

over stop and will also reach its 'maximum speed' stop with
the pedal fully depressed.
Job 8. Mechanical fuel pump,
petrol engine (carburettored) -
replacement.
O Step 1: Disconnect the battery earth lead.
• Step 2: Find the pump on the forward facing side of the
cylinder block near the timing cover end. Disconnect the two
fuel lines from the pump and plug the ends, (labelling them
for correct refitment).
• Step 3: Undo the two
mounting bolts and
remove the pump (a) and
spacer block (b).
• Step 4: Clean off any
old gasket particles and
refit in reverse order using
new gaskets. Check that
the hose connections are
sound.
D INSIDE INFORMATION! Where the fuel pump is of the
pushrod type, the inner gasket should always be 0.3 mm
thick. The outer one is available in 0.3, 0.7 and 1.2 mm
thicknesses from your FIAT dealer, allowing for fuel
pressure adjustment. Pressure is higher with a thin
gasket and lower with a thick one, and the correct
pressure is 0.176 bar. Q
/ # lfyou h"ve a m/cromefer
ff (y - or a good vernier caliper,
clean the old gaskets,
measure their thickness, and fit new gaskets of the
same thickness.
Job 9. Electric fuel pump, petrol
engine (S.P.I.) - replacement.
• Step 2: Lift
the luggage
compartment
floor covering
and remove the
dust cover from
above the fuel
pump (arrowed). .
• Step 3:
Disconnect the
electrical plugs
from the pump and fuel gauge sender.
• Step 4: Unscrew the fuel gauge sender unit by twisting
the two opposing lugs anti-clockwise.
D INSIDE INFORMATION! FIAT use special tool for this
(see illustration Job
9-2,
inset) but it can be done
without, by using a little care. Use two vertically held
screwdrivers against the lugs and another levering
between them as low as possible. H
Q Step 5: Remove the safety plate and disconnect the fuel
supply pipe (the white union)...
Q Step 6: ...and the return pipe (the black union).
1-1 Step 7: Undo the large ring nut securing the pump to the
tank, ideally, using tool 1854041000 and a polygonal spanner
or by making up a tool of your own!
SAFETY FIRST!
• Do NOT drift the nut because of the risk of
causing

sparks.
Q Step 8: Remove the pump
from the fuel tank.
Q Step 9: Refit in reverse
order making sure all electrical
and fuel connections are sound
and correctly made.
• Step 10: Remember to
refit the fuel pump relay and
reconnect the battery.
SAFETY FIRST!
• Depressurise the fuel system before starting work
-
this
is important because fuel remains under pressure in the
system long after the engine has been switched off.
• Step 1A: Depressurise the fuel system by unplugging
the fuel pump relay (a) and running the engine until it
stops. The relay (b) is for the injection system; (c) and (d)
are fuses for the Lambda sensor and the fuel pump,
respectively.
• Step 1B: Switch off the ignition and disconnect the
battery leads, starting with the earth lead.