1988 FIAT TEMPRA battery

Job 10. Fuel tank - removal and
refitting.
Job 11. Hot air hoses/thermo-
valves - general.
SAFETY FIRST!
Job 12. Lambda sensor
(S.P.I, engines) - replacement.
• We recommend that you carry out all of this work
out of
doors.

I
IMPORTANT NOTE:
• Read Chapter 1, Safety First! before carrying out

this
work!
• Plan ahead! Run the fuel in the tank as low as possible
before you start this job.
Q Step 1: Disconnect the battery leads starting with the
earth lead.
• Step 2: Syphon any remaining fuel from the tank and
into a suitable closed container.
Q Step 3: Disconnect the fuel sender wiring and any fuel

hoses
from within the boot (model-dependent
-
see Job 9 and
PARTE: ELECTRICAL AND INSTRUMENTS, Job 14).
• Step 4: Disconnect the filler and breather hoses from the

tank,
working from underneath the car.
a - Lambda sensor b - connector to ECU c - sensor heater power supply Job 12-2
Q Step 5: Support the tank while undoing the strap
securing bolts at the rear of the tank...
Q Step 6: ...and at the front.
Q Step 7: Lower the tank a very small amount at a time,
enough to check whether any hoses remain attached, then
lower it fully to the ground.
Q Step 8: Refit in the reverse order, making sure all connec-

tions are
sound. Reconnect the battery leads.
• Step 1: H INSIDE INFORMATION: The good
operation of the thermostatic valve in the air cleaner
where the heated air pipe from the manifold enters the
air filter) relies on air hoses that are in good condition.
Replace any that are doubtful before suspecting the
valve to be faulty. These valves usually give little trouble
and usually only suffer from sticking, caused by dirt.
Try cleaning the flap and hinge before assuming the
worst! Q
• Step 1: The Lambda sensor
can be found screwed into the
exhaust just behind the point
where the down pipes run into
one (arrowed).
Q Step 2: Trace the wiring
back from the sensor and
disconnect the two plugs,
(b and c).
a - air filter b - injection unit c - inlet manifold d - cool air intake e - heated air intake - from exhaust manifold f
-
thermostatic valve flap g - thermostatic valve
Job 11-1

Job 14. Exhaust system -
replacement.
FACT FILE: LAMBDA SENSOR
• The Lambda sensor is very fragile and
should not be knocked or dropped.
• We recommend that a new one is fitted
only by your FIAT dealer, who can test the
old one to see whether it is working properly.
• No cleaners should be used on the sensor.
Q Step 3: Before refitting, check that the sensor sealing ring
is in good condition, and lubricate the thread of the sensor
with a high-temperature anti-seize compound.
Job 13. Fuel evaporation system.
a - fuel tank b - two way safety valve c - multi purpose valve d
-
active charcoal filter e - petrol vapour cut out valve
f - electronic control unit g - crankcase blow by pick up h - thermostatic air filter vacuum pick up i - fuel filter
• Point 1: A complex control system exists to prevent
evaporative losses of fuel vapour to the atmosphere, and to
control fuel tank pressure under different temperature condi-
tions.
—) Step 1: Exhaust systems are similar in principle
-
and
mostly in appearance
-
between engine types but differ in that
some have a Lambda sensor, and a catalytic converter. This is
a typical system.
• Step 2: If a Lambda sensor is fitted, see Job
12
for
important information regarding removal.
• Step 3: Undo the downpipe to manifold flange bolts.
• Step 4: With a helper to support the weight, release the
exhaust system from its mountings along its length and lower
it to the ground.
O Step 5: Separate the sections if only part of the system is
being replaced. Take care not to damage the catalytic
converter if this is staying.
• Step 6: Refit by starting at the front and fitting the down
pipe using a new gasket, just nipping up the flange bolts.
• Step 7: Continue fitting loosely towards the rear until all
is in place, using new gaskets and sealing compound, as
required, for each of the joints.
• Step 8: Working from the front, align the system, tight-
ening each flange or joint as you go.
• Step 9: Reconnect the Lambda sensor if fitted.
• Point 2: The system comprises a charcoal canister which
absorbs fuel vapour from the fuel tank, mostly while the
vehicle is standing, then re-injects it when the engine is
running. The valves which regulate the system are controlled
by the engine's electronic control unit.
• Point 3: Other than occasional replacement of the
charcoal canister, no system maintenance is needed. However,
a fault with the system can lead to running problems, and
diagnosis and rectification must be left to your FIAT dealer.
Job 15. Tlurbocharger, diesel
engine - replacement.
• Step 1:
Disconnect the
battery earth lead.
• Step 2: Undo
the two clips
(arrowed
-
one at
each end of the
pipe) and remove
the compressed air
supply pipe, from
intercooler to inlet
manifold.
expert22 fl/i* http://rutracker.or

Q Point 1B: This version shows the anti-lock braking system
and has discs replacing drums at the rear. One of two makes
is used
-
Lucas or Bosch
-
and both are similar in design.
Shown here is the Bosch ABS system in left hand drive form.
Apart from checking that the hydraulic and electrical connec-
tions are sound, anti-lock brakes are not repairable. Individual
components and friction materials can be replaced but
otherwise, you should consult your FIAT dealer for diagnosis
of system faults (with specialised equipment) and rectification.
SPECIAL NOTES: • Unplug the electronic control unit
(ECU) before any electric welding is carried out.
• When oven drying paint, the ECU cannot withstand 95
degrees Celsius for more than a few minutes or 85
degrees Celsius for more than 2 hours.
• Disconnect the battery earth before removing the
hydraulic control.
• When reconnecting the battery, make sure the connec-
tions are firm and sound.
Q INSIDE INFORMATION: When disconnecting brake
pipes or hoses, it is essential to minimise brake fluid loss.
This can be done by unscrewing the master cylinder
reservoir cap, laying a sheet of plastic across the opening,
and refitting the cap. This will prevent atmospheric
pressure from pushing the fluid out of opened lines. D
Job 2. Front brake pads -
replacement.
Changing and checking the Tipo's and Tempra's brake pads
are virtually identical jobs. See Chapter 5, Servicing Your
Car, pages 59 and 60
Job 3. Front brake caliper -
replacement.
Carry out this work with reference to Chapter 5, Servicing
Your Car, Job 49, pages 59 and 60.
Q Step 1: Slacken the front road wheels, jack up the car
and support on axle stands. Remove the wheels.
Q Step 2: Unplug
the brake pad wear
sensor (a
-
arrowed)
and ease the fluid
pipe/hose from the
bracket (b
-
arrowed)

on
the shock absorber
leg.
Q Step 3: Undo the brake fluid pipe union from the caliper
body and plug the end to prevent too much fluid loss.
Q Step 4: Undo the bolts and remove the caliper.
D INSIDE INFORMATION! The caliper securing bolts must
always be replace by new FIAT ones when loosened or
removed. They are of a special self-locking type. B
Q Step 5: Refit in reverse order and bleed the brakes, see
Job 17
Job 4. Front brake disc -
replacement.
Q Step 1: Carry out Steps 1 to 4 in Job 3.
• Step 2:
Undo the
securing bolts
and remove
the caliper
support
bracket.
• Step 3:
Undo the disc
fixing bolts
and withdraw
the brake
disc.
Q Step 4: Refit the remaining parts in reverse order of
removal. See Chapter 5, Servicing Your Car.
Carry out this work with reference to Chapter 5, Servicing
Your Car, Job 50, pages 60 and 61.
Job 5. Rear brake shoes -
replacement.
H INSIDE INFORMATION! It often helps to work on one
side at a time, completing all the work on that side of
the car and using the other side as a reference before
you start dismantling it. Q
• Before refitting the disc,
ensure that the mating
surfaces
-
hub to disc, are
clean and undamaged.
• Spin the disc to be sure there is no 'run out' before
proceeding further.
Job 4-2

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).

Job 15. Sun roof - removal and
refitting.
PART A: GENERAL
E3 INSIDE INFORMATION! If an electric sunroof fails to
work, it can be operated manually with the aid of a key
positioned behind the cover panel in the roof light
assembly. By engaging the key in the exposed drive pin,
you can turn it and adjust the roof position. Q
• Step A1: SPECIAL NOTE. Here we cover the
replacement of the electric motor (where fitted) and the
glass roof panel. We strongly recommend that any
further work, which could involve the removal of the
headlining, should be entrusted to your FIAT agent or
body specialist.
PART B: TO REMOVE THE MOTOR:
• Step B1: Close the sunroof fully and then disconnect the
battery earth lead.
Q Step B2: Carefully lever out the panel cover and remove
the roof light lens.
Q Step B3: Undo the screws and lower the panel...
G Step B4: ...then unplug the two connectors from the
other side of the panel.
O Step B5: Unplug the connector from the motor cable,
once exposed...
• Step B8: Refit by reassembling in reverse order.
PART C: TO REMOVE THE GLASS PANEL:
• Step C1: Position the glass in the fully tilted mode and
remove the mouldings (arrowed) by sliding them rearwards.
• Step C2: Undo the
mounting bolts (two
per side) found behind
the mouldings...
• Step C3: and
raise the glass to
remove it from the
frame.
• Step C4: Refit in
the reverse order.
Job 16. Front seats - removal and
refitting.
PART A: SEATS WITHOUT PRETENSIONERS
• Step A1:
Undo the screws
(arrowed) and
remove the seat
mounting cover
from both sides.
• Step A2:
Undo the four
bolts
-
two per
side of each seat
-

fixing the runners
to the floor and
remove the seat.
PART B: SEATS WITH SEAT BELT PRETENSIONERS -
REMOVAL
IMPORTANT NOTES: i) In a collision, the pretensioners
are activated whether the belt is buckled or not. They
cannot be reset and must be replaced! If the seat belt
was buckled, it too, must be replaced,
ii) Read Safety First! Steps B2 and B3.
he motor.
SAFETY FIRST!
• Handle pretensioners with extreme care
-
don't drop.
• Never cause impact to the tensioning device
-
which
could set off the pre-loaded spring.
• The components must be fitted with care to avoid
knocking or jarring.
• Detach the pretensioner if working on the seat.
• Always insert the blue safety clip before removing or
refitting the seat
• Never attempt to service or dismantle the unit
• Never grasp the buckle or the power unit
• Step B6:
...then undo the
mounting screws
(arrowed).
D INSIDE
INFORMATION:
The relay is
found here
(a).H
• Step B7: You
can now withdraw

IMPORTANT NOTE: Not all of the components listed here are fitted to all models.
CHAPTER 7
WIRING DIAGRAMS
IMPORTANT NOTE: Not all of the components listed here
are fitted to all models.
IMPORTANT NOTES:
3. We have sometimes shown the wiring diagram for a
'highest' spec, model, in the knowledge that 'lower'
spec, models are usually similar with the deletion of
certain components.
1. There are several hundred FIAT wiring diagrams for
the whole TIPO range. This is a representative selection,
covering the majority of applications. However, in the
event that your car's details are not covered here,
consult your nearest FIAT dealer.
2 All of the following are Tipo wiring diagrams. Tempra
saloons and estates are essentially similar.
4. 'EEC Stage 2 Engines' In late 1994, Tipo 1.4 and 2 -
Litre and Tempra 1.6 MPI vehicles were modified to suit
new emission regulations. These changes were NOT only
engine-related. Vehicles covered by this manual are Tipo
1.4 (with engine code no. 836A4.000) and Tempra 1.6
(with engine code 159B9.000). See Page 27 for location
of codes.
KEY:
1 Left front light cluster 2 Reversing light switch 3a Left horn 4 Electric cooling fan 5 Dual contact coolant thermal switch 6 Right longitudinal cable connection 7 Right front earth 8 Right front light cluster 9 Right horn 10 Screen/rear window washer pump 11 Left brake pad wear sensor 11A Right brake pad wear sensor 12 Ignition coil 12A Ignition coil with power module 12B Ignition coil with H.T. points 13 Digiplex electronic ignition control unit 13A Digiplex electronic ignition lead connection 13C Diagnostic socket for Digiplex electronic ignition 14 Left front earth 15 Battery earth 16 Engine coolant temperature sender unit 17 Battery 18 Ignition distributor 19 Sparkplug 20 Spark plug 21 Sparkplug 22 Spark plug 23 TDC sensor 24 Alternator 25 Oil pressure switch 26 Connector block 27 Brake fluid level sensor 28 Left side turn signal 30 Idle cut-out device 31 Starter motor 32 Throttle valve sensor 33 Pulse generator for speedometer signal 34 Windscreen wiper 35 Right side turn signal 36 P.T.C. resistor for heating fuel duct 37 Thermal switch for PTC 38 Vacuum sensor for vacuum gauge 39 Fuse and relay control unit E2 Turn signal and hazard warning light flasher E4 Fog light relay E5 Horn relay E6 Heated back window relay E7 Switch discharge connector E9 Windscreen wiper intermittent function E10 Rear fog light relay E11 Dipped beam relay E12 Main beam relay E13 Side light control relay E14 Central locking electronic control unit E1-E3-E8-E15-available (unused)
40 PTC resistor activation relay 41 20A fuse for inlet duct heater circuit 42 25A fuse for electric window ECU 43 Junction between facia cable and heater cable 44 Earth on left hand side of facia 45 Junction between facia cable and left front door
G Horn button H Windscreen wiper stalk I Back window wash/wipe selector L Heated rear windscreen switch M Rear screen wash/wipe switch N Windscreen wiper speed switch cables 56 Junction: facia cable and r.h. rear door cables Electric window control unit 57 Glove compartment light bulb Provision for left front speaker 58 Facia cable coupling with right front door cables Provision for left rear speaker 59 Facia cable coupling with right front door cables Supplementary earth point 60 Provision for right front speaker Instrument panel 60A Provision for right rear speaker A Direction indicators warning light 61 L.h. button for courtesy light and electric window B Side lights warning light 62 Junction between rear cable and left rear door C Main beam headlights warning light cables D Heated rear windscreen warning light 63 Junction between rear cable and left front door E Rear fog lights warning light cables E1 Fog lights warning light 64 Left front door lock motor and left front door F Hazard warning lights warning light open warning light G Battery recharging warning light 65 Left front electric window motor H Insufficient engine oil pressure warning light 66 Electric front window control buttons I Trip counter 67 Cigar lighter J Left brake lining wear warning light 68 Braking light switch J1 Seat belt undone warning light 69 Passenger compartment courtesy light K Handbrake on and low brake fluid level 69A Passenger compartment courtesy light with door warning light lock remote control receiver L Choke warning light 70 Hand brake warning light switch M ABS failure warning light 71 Passenger compartment ventilation fan switch N Instrument panel light bulbs 71A Passenger compartment ventilation control 0 Fuel level gauge 72 Passenger compartment ventilation fan speed P Coolant temperature gauge regulation resistor P1 Engine oil pressure gauge 73 Passenger compartment ventilation fan P2 Engine oil temperature gauge 74 Heater controls light bulbs Q Clock 75 Right front door lock motor and right front door R Heater plugs warning light open warning light S Speedometer 76 Right front electric window motor S1 Speed warning light 77 Right front electric window control button T Rev counter 78 R.h. button for courtesy lights and window U Trailer turn signal warning light 79 Luggage compartment lighting X Water in fuel filter warning light 80 Left rear earth Y Excessive turbocharging air pressure warning 80A Right rear earth light 81 Rear cable connection Y1 Lambda probe failure warning light 82 Left tail-light cluster Z Excessive automatic transmission fluid 83 Left rear door lock motor temperature warning light 84 Fuel level gauge Z1 Injection system failure warning light 85 Tailgate lock/release motor Ignition switch 86 Left number plate light Available for radio 87 Right number plate light Available for radio 88 Rear window wiper motor Hazard warning lights switch 89 Heated rear windscreen Stalk unit 90 Right tail-light cluster A Rear fog lights switch 91 Right rear door lock motor B Exterior lighting selector 92 Glow plug preheating system ECU c Control lighting bulb 93 Glow plugs D Light flasher button 94 Engine cooling fan first speed additional resistor E Turn signal stalk 95 30A fuse for engine cooling fan F Dipped/main beam headlight selector 96 Switch for automatic advance
155

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.

A Accelerator linkages and cables 118,119 Aerial 112 Airbag 14, 63, 128 Air cleaner/filter 51 Air Conditioning 12,41 Alternator, drive belt . . 49, 50, 110 Antifreeze 43, 44 Anti-roll bars 131 Auto-Biography 1 Automatic transmission fluid 45 gear selector cable 102
B Ball-joints steering and suspension 57 Battery disconnecting 36 electrolyte 36 safety 7 Bellows, steering gear (see 'Gaiters') Bonnet 15, 143 Brakes 59 to 62, 134 to 142 bleeding 141 caliper 59 to 61, 135, 137 cylinder (master) 138 discs, front 59, 135 discs, rear 61, 137 drums 60, 136 fluid, check level 35,36 handbrake 61, 142 hoses/pipes 62, 141 pads 59, 135, 137 pressure regulating/proportioning . . . valve (ABS) 140 pressure regulating/proportioning valve (Non-ABS) 139 RPM sensors (ABS systems) .... 140 safety 7 servo 138 shoes 135 wear sensors (non-ABS) 60 Bulb renewal (see 'Lights') Bushes 57 Bumper removal and refitting. 146
c Cables accelerator 118,119 automatic transmission ... 101, 102 choke 119 clutch 46, 101 handbrake 61 Caliper, brakes (see 'Brakes') Camshaft belt 43, 66 Capacities 19,154 Carburettor adjustment 53 removal 117 Catalytic converter 54, 55 safety 6 Central locking 114 Choke 119 Clutch adjustment 46, 100 hydraulic 46, 105 replacement 100 cable 46, 101 Coil, ignition 47, 107, 108 Coil spring 57 Constant Velocity (C.V.) joints (see 'Driveshaft') Contents 4 Controls and switches ... 10 to 14 Cooling system .. 35, 43, 106 to107 change coolant 43 radiator pressure cap 35 Crankcase ventilation system 42 Cylinder head Diesel 87 to 93
Petrol 67 to 73
D Data 17 to 27 Diesel bleeding the system 126,127 fuel filter 52 glow plugs 115 injection pump 56,124 injectors 126 Disc, brakes (see 'Brakes') Distributor 108, 109 cap 47 Marelli Breakerless 48 Marelli Digiplex 2 48, 49 Doors hinges 62 locKs and handles 147 to 150 removal and refitting 147 trim panels 146 Drivebelts alternator 49, 50, 110 camshaft 43 Driveshaft C.V. joints 103 gaiters 45, 103 removal and refitting 103 Drum (see 'Brakes')
E Electrical system 110 to 115 Electronic control module 54 safety 7 Emergency starting 16 Emissions 31, 51 to 56 control 53, 54 legal limits 31 Engine bay layouts 34 Engine dismantling Diesel 95 Petrol 73 Engine mountings Diesel 95 Petrol 83 Engine oil (see 'Oil') check level 34 Engine refitting Diesel 94 Petrol 82 Exhaust manifold 56 Exhaust 56 system 56, 122 Expansion tank 35
F Facts & Figures 17 to 27 Fan 50, 106 Fast idle carburettor 53, 54 fuel injection 54 diesel 55 Filter air 51 diesel 52 petrol 52 oil (see 'Oil filter') pollen 63 Fire Extinguisher . 6 Fluoroelastomers, safety 8 Fuel cut-off switch 13 Fuel gauge 114 Fuel injection 52, 54, 55, 117 Fuel lines/pipes 51 Fuel pump electric 120 mechanical 120 Fuel system 51 to 56 evaporation control system . 54,122 Fuel tank 121 Fumes, safety 6 Fuses 40
Gearbox (transmission) .... 44 to 46 oil (automatic) . . 45 oil (manual) 44 Generator drive belt (see 'Alternator, drive belt')
H Handbrake 61, 142 Headlights (see 'Lights') adjustment 62 bulb replacement 37 Headrest 153 Heater 11 Hoses/pipes (see 'Pipes and hoses') HT leads 47 Hub front 104 rear 134
I Identification numbers 27 Idle speed adjustment (see 'Carburettor') Ignition system 46 to 51, 107 to 109 coil 47,48 safety 7 Ignition timing 19, 48 to 50 Instruments 110 panel lights 10 Intercooler 123, 124
J Jacking safety 5 wheelchange 15, 16 Jump leads (Jump starting) 16
L Lambda sensor ... 54, 55, 121, 122 Lights fog lights 13, 38 hazard warning 13 headlights 13,37 indicators 13, 37 interior 15, 39, 40 MoT 28 number plate 39 rear lights 38 reversing lights 39 sidelights 13, 37 Locks and latches 9, 10, 62 Lubricants 154
m Manifold fixings 56 Mirrors 14, 150 Mixture adjustment (see 'Carburettor') Model years 17, 18 MoT, getting through 28 to 31
m Number plates (lights) . . 28, 39, 145
o Oil change disposal 7, 8 engine 41, 42 transmission 44, 45 safety 7 Oil filler cap 35 Oil filter 41 Oil level engine 34, 35 gearbox 44, 45 topping up 35
P-Pads, brake (see 'Brakes') Pipes and hoses brakes 62, 138, 141 hot air 121 radiator (cooling system) 43 Plastics, safety 7 Production changes 17, 18
ft Radiator .* 106 Raising the car 5 Repair data 20 Road test, brakes and steering ... 63 Rotor arm 47, 49
s Safety First! 5 to 8 Seats 14, 151 to 153 mountings 62 Seat belts mountings 62 pretensioners 151, 152 Servicing Your Car 32 to 63 Shock absorbers 57,131 Shoes, brake (see 'Brakes') Sidelights (see 'Lights') Spark plugs 47, 154 Specifications (see 'Facts & Figures') Speedometer cable 110 Starter motor 110 Steering 57, 58, 127 to 131 lower wishbone 127, 130 power steering 58, 130 rack gaiters 58, 133 Steering wheel 128 Sun roof 151 Suspension ... 57 to 59, 127 to 134 front 57, 127, 131 rear 58, 59, 128, 133 strut 57, 131
T Tailgate wiper (see 'Windscreen wipers') Tailgate and strut 144 Thermostat 107 Throttle cable and pedal (see 'Accelerator, linkage and cables') Timing belt 43 Diesel 85 to 87 Petrol 65, 66 Torque wrench settings ... 23 to 27 Track control arm (inner bushes). . 57 Track rod ends 57, 58, 128 Transmission. . 80 to 83, 95, 98 to 106 removal 80 to 82 separation and reconnection (Diesel). . 95 separation and reconnection (Petrol). . 83 Transmission fluid 44, 45 Turbocharger replacement 122 to 124 Tyre checking 30, 36 pressures 18,36
u Universal joints 28, 58 Using your car 9 to 16
¥ Vacuum unit, distributor 48 Valve clearances 42, 43, 79, 93 Valve grinding 72 Vehicle Identification Numbers (VIN) 27
w Washer fluid reservoir 36 Water pump 107 Wheel alignment 28 Wheel bearings 57, 58 Wheel bolts 59 Wheel changing 15,16 Wheel cylinder 137 Wheel sizes 18 Windscreen, damage 29,162 Window regulator 147 to 149 Windscreen washers 112 Windscreen wipers 13,111 Wiring diagrams 155 to 174
Gaiters 30, 57
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