1988 FIAT TEMPRA Service And Repair Manual

IMPORTANT NOTE: Take care not to allow any dirt or grit
to get into the gearbox.
• Job 19. Check driveshaft gaiters.
45
B INSIDE INFORMATION: Make sure you have a 10 mm
Allen key that will fit, before you start. There's very little
room between gearbox and subframe. B
Q Job 17. Check auto, transmission fluid level.

The
automatic transmission fluid level should be checked with

the
car on level ground and the engine at normal running
temperature
-
the car should have been driven for about 4
miles. The level is checked by means of a dipstick next to the
battery.
IMPORTANT NOTE: i) It is especially important that the
fluid is at the correct level. If the system needs regular
topping up because of leaks, fix them as rapidly as
possible or have your FIAT dealer check the system,
ii) Wipe the dipstick only with a lint-free rag to avoid
clogging up transmission valves. Keep dirt out!
18B. The filter is
secured by one
central screw.
Undo this and pull
the filter down,
detaching its upper
fluid pipe in the
process. Remove
the filter, discard it
and fit the
replacement. Refit
the sump, using a
new gasket and
non-setting gasket
sealer.
Replace the drain plug and fill the gearbox through the
dipstick tube. {See Job
17.)

19A. Grasp and turn the
inner drive-shaft and
gaiters, checking for signs
of gaiter splitting or
damage that could allow
grease out or
-
worse still

-
water in. Ensure the
gaiter clips are secure.
Q INSIDE INFOR-
MATION: Inners tend to
leak, putting an oil
stain on the shaft, as
here. You can buy a
FIAT repair kit, with
bearing and
replacement gaiter, to
repair the leak. This
involves removing the
drive shaft
-
see
Chapter 6, Repairs
and Replacements. B
19B. Check the outer
gaiter as well. This moves
over a greater range and
is more prone to damage
and splits.
IMPORTANT NOTE:
Change a split, or
damaged gaiter as soon
as possible
-
preferably
before using the car
again.
If
necessary,
fresh Tutela CVT should be poured in through

the
dipstick tube, using a funnel in the tube or by using ATF

from
a dispenser with a small spout. You may have to leave

the fresh
oil to clear the tube before seeing a clear dipstick
reading.
G Job 18. Replace auto, transmission fluid and
filter.

As well as
Tutela CVT fluid, you will need a new, sump
gasket
and
a new gearbox oil filter, from your FIAT dealer. The
filter
should
be changed every time the oil is replaced.

18A.
Always drain the

fluid when
the trans-
mission
is
warm, such as

after a
run. Raise the

front
of the car on

ramps,
so the fluid

drains well
from the

drain
hole (C) at the rear
under-side of the 'box.

Remove
the drain plug

with an
Allen key or hexagonal socket adaptor, and allow the

fluid to
drain into a container beneath the transmission
-
allow

ten
minutes for complete drainage.
Underneath the car, remove the 13 transmission sump bolts.
H INSIDE INFORMATION: The sump is easily distorted,

so,
when refitting, tighten all bolts progressively and
evenly to the recommended torque
-
see Chapter 3,
Facts and Figures. B

17.
Check the level with the
engine idling and the gear
selector in the 'P' (PARK)
position. Pull out the dipstick

(A),
wipe it clean with paper
kitchen towel, re-insert it and
check the level. The upper

and
lower marks on the dipstick represent minimum and
maximum acceptable fluid levels.

• Job 20. Check/adjust clutch. CABLE OPERATED CLUTCH
The clutch mechanism is self-adjusting, although the cable
linkage can stretch over a period of time and may need
adjustment. The adjuster is on top of the gearbox, reached
from inside the engine bay.
20C. 'Work' the clutch pedal
(X) a few times, pull back the
carpet from under the pedal,
then measure the full travel of
the pedal, which should be
between 140 and 150 mm.

/
\
/ \
/ u / Xl
1 ' ' / . V y 2
Jdi V 1 \
X. 1 —

20C
HYDRAULIC CLUTCH
20B. Check the
pipework and slave
cylinder, on the
gearbox casing,
from beneath the
20D. If not, note that after
slackening the locknut, turning
the adjusting nut inwards
along the threaded rod
(arrowed) will increase pedal
travel. Tighten the lock-nut
against the inner nut after
adjustment.
• Job 21. Check auto, transmission selector cable.
It should only be possible to start the engine when the gear
selector is in the 'P' or 'N' position. Place it in each of the
other positions and try to start the car. If it starts, the fault
must be put right! Also check that, with the ignition off and
the selector lever in 'D' (Drive), 'L' (Low), 'R' (Reverse) or 'N'
(Neutral), the timed warning buzzer should sound. If it
doesn't, the selector cable adjustment may be faulty.
See Chapter
6,
Repairs and Replacements, PART B:
TRANSMISSION AND CLUTCH, Job 8 for adjustment details.
PART D: IGNITION AND ELECTRICS
See FACT FILE: DISCONNECTING THE BATTERY on page 36
SAFETY FIRST!
• You may minimise the risk of shock when the engine is running by wearing thick rubber gloves and by NEVER
working on the system in damp weather or when standing on damp ground. Read Chapter 1, Safety First! before
carrying out any work on the ignition system.
• ELECTRONIC IGNITION SYSTEMS INVOLVE VERY HIGH VOLTAGES! All manufacturers recommend that only trained
personnel should go near the high-tension circuit (coil, distributor and HT wiring) and it is ESSENTIAL that anyone
wearing a medical pacemaker device does not go near the ignition system.
• Stroboscopic timing requires the engine to be running
-
take great care that parts of the timing light or parts of
you don't get caught up in moving components!
• Don't have loose clothing or hair.
46
FACT FILE: CABLE OR HYDRAULIC
CLUTCH?
• Most earlier Tipos and Tempras had a
cable-operated clutch, while later ones
are hydraulic.
• 2 OA. You
can easily tell
which system
your car is
fitted with.
The hydraulic
pipe (if fitted)
runs almost
horizontally,
across the
back of the engine bay.
• There is no separate clutch fluid reservoir
-
it shares
the brake fluid reservoir.
• Clutch cables (when fitted) are inclined to break
without warning.
• It pays to keep the operating mechanism well lubri-
cated and renew the cable every few years.
car. If the pipe
appears cracked,
replace it. If the
slave cylinder
oozes fluid, replace
it, in both cases bleeding the system. See Chapter
6,
Repairs
and Replacements.

J Job 22. Check/clean/gap spark plugs. Q Job 23. Change spark plugs.
GENERAL. On all Tipo and Tempra petrol engines the spark

plugs
face forwards, allowing easy working access.
Carefully remove the
spark plug caps, being
careful to pull only on

the cap and
not the HT
lead. If you can't be

sure
to remember which

HT lead
belongs to
which spark plug,
number them from one

end
of the engine to the
other.
22B. If the electrodes of the
plugs look rounded and worn,

replace
the plugs. See page

154
for details of 'Reading
Your Spark Plugs. Nip' the

cap
tight with pliers, so that it
can't come loose.
Spark plugs 'tire' and lose efficiency over a period of time,
even if they look okay. See Job 22 for information on their
removal and replacement. Use good quality Champion or FIAT
plugs of the correct specification.
• Job 24. Check/dean HT leads and distributor
cap.
See SAFETY FIRST! at the start of this section and
Chapter 1, Safety First!
IMPORTANT NOTE: On latest models, there is no conven-
tional distributor and, for those cars, none of the
following should be attempted. Illustration to Job 28C
illustrates the type which should NOT be worked on
except for wiping off the outer surface, with the engine
not running.
Remove each plug lead from the spark plugs, pulling only on
the plug caps, not on the HT cables. Also, remove the large HT
lead from the coil and take off the distributor cap, either by
popping off its spring retainers if the distributor is on the side
of the engine (front of engine bay
-
see illustration 25A) or by
undoing the two retaining screws.
24A. On later
cars (Digiplex
ignition -
distributor
mounted
horizontally on
end of cylinder
head) unclip and
remove the
22A. Unscrew the plug

using
the correct type of
spark plug socket. Take

care
to keep the
spanner strictly in line
with the plug so as not to
crack the electrode.

22C.
it
is
essential

that the
plug is

gapped
correctly.

See Chapter 3,
Facts
and Figures.

Use a
feeler blade

of the
correct
thickness, sliding it

between
the
electrodes. It should

be a firm
sliding fit.

Use a
gapping tool

or
carefully wielded pliers to bend the curved electrode

towards
or away from the centre electrode. Take GREAT CARE

not to
damage the insulator near the tip of the plug.
H INSIDE INFORMATION: The spark plugs screw into
aluminium, which is easily damaged if the spark plugs do

not
engage their threads properly. Screw in the plugs by
hand initially
-
by, say, two or three turns
-
before using
the plug spanner. A light smear of copper grease on the

plug
threads will enable them to turn more freely and

also
make them easier to remove next time. Finally,
don't over-tighten the plugs
-
firm hand-pressure on the
spanner is sufficient. D
IMPORTANT NOTE: DO NOT
spray water dispellant or
apply lubricant to any part
of an electronic ignition
distributor. (It's okay to
clean the cap, as described,
however.)
shroud. Clean the
cap and cables of
either type with a clean rag, applying a little aerosol water-
dispellant spray to help shift oil and grime.
24B. Check each of the HT posts (a) inside the cap for burning
or damage, and the central carbon brush (b) to ensure that it's
not worn down and that the
spring loading is okay. Clean
the dust cover (c) and rotor
arm, and check the tip (d) for
burning.

• Job 25. Check ignition timing.
_ FACT FILE: IGNITION SYSTEM TYPES
Two different types of electronic ignition
systems have been fitted to the petrol
engines covered by this manual.
The earlier Breakerless Inductive Discharge System can
be adjusted. Its distributor is fitted as shown in illus-
tration 25A.
The later, Digiplex 2 system, has an integrated ignition
and fuel injection control system and any checks and
adjustments will need to be carried out by your FIAT
dealership with the appropriate diagnostic equipment.
See Job 28.
MAGNETI MARELLI BREAKERLESS INDUCTIVE
DISCHARGE IGNITION SYSTEM
CHECK VACUUM AND MECHANICAL ADVANCE SYSTEMS
25A. This is the
location of the break-
erless electronic
ignition components in
the car. The distributor
(1) is fitted to the front
of the block while the
ignition coil
(2)
is
alongside the battery.
25B. This type of distributor can be
identified by the electronic ignition
control module (a) and the vacuum
advance unit (b), not fitted to other
ignition types.
• the engine must be at
ature.
• the idle speed/mixture/CO adjustments must be correct

-
see Job 35.
• Start the engine and run it at between 750 and 850 rpm.
• Point the timing light at the crankshaft pulley timing mark
and ensure that the mark lines up with the 10 degrees Before
Top Dead Centre (BTDC) mark on the timing belt cover.
• If the reading is 'out' stop the engine and slacken the clamp
nut on the distributor so that the distributor can just be turned
with firm hand pressure.
• Turn the distributor a very small amount, restart the engine
and check again.
• Repeat the procedure until, with the engine running, the
crankshaft pulley timing mark lines up with the 10 degree
BTDC mark. Then tighten the nut securing the distributor to
the engine block.
You can now check the vacuum advance system as follows:
• increase the engine speed to approximately 2,000 rpm and,
with the timing light pointed at the timing marks, make a
mental note of the position of the mark on the crankshaft
pulley in relation to the timing belt cover. If the position is no
further advanced than 10 degrees BTDC, the mechanical
advance system inside the distributor is probably seized.
• stop the engine, reconnect the vacuum advance pipe and
repeat the procedure.
• you should see a further amount of advance taking place
and if not, the diaphragm inside the vacuum advance
mechanism is probably punctured.
• if either or both of these faults have occurred, your engine
will run uneconomical^ and inefficiently and it may pay you to
fit a new distributor.
MAGNETI MARELLI DIGIPLEX 2 ELECTRONIC
IGNITION
25D. This is the layout of the Digiplex ignition system, viewed
from over the engine looking towards the left-side of the car.
The ignition coil (1) is adjacent to the battery. The electronic
control unit (2) is nearer to the engine bay sidewall. The
distributor (3) is mounted on the end of the cylinder head and
the rpm and Top Dead Centre (TDC) sensor (4) is located on
the crankshaft cover on the flywheel side.
IMPORTANT NOTE: Before
checking the ignition timing,
you must be certain that:
• the pipe from the distributor
vacuum unit is disconnected
from the distributor and plugged.
its normal operating temper-
instructions. The
timing light should
always be connected
to No.
1
spark plug
lead
-
the one nearest
the timing belt end of
the engine.
48
25C. To check the ignition timing, connect up a stroboscopic
lamp, either as shown on the inset or in accordance with the
manufacturer's

FACT FILE: DIGIPLEX DISTRIBUTOR
REMOVAL
25E. If the distributor has to be removed
for any reason, it is ESSENTIAL that the
PRECISE position of the rotor arm in
relation to the distributor body and the
position of the distributor body (2) in relation to the
cylinder head
-
via the spacer (1)
-
are clearly marked so
that they can be
replaced in
EXACTLY the
same position.
Note that the
locator
(arrowed) only
gives an approx-
imate, not a
precisely correct
location of the
spacer.
25F. D INSIDE
INFORMATION:

Use
touch-up
paint
and
let it
dry before
removing the
unit. D
SETTING THE RPM AND TDC SENSOR POSITION
25G. This job can not
be carried out without
the FIAT special tool
illustrated. The sensor
is correctly positioned
when the engine is
produced and to
prevent accidental
tampering, one of the
two bolts holding the
sensor in place is a
shear bolt and will have to be renewed if removed.
IMPORTANT NOTE: The slots in the distributor body are
NOT used to alter the advance setting, as on a conven-
tional distributor. This operation is carried out by the
position of the TDC sensor
-
see later.
CHECKING THE IGNITION ADVANCE can be carried out in an
approximate manner using the same method as described in

25C.
However, you must make sure that the following steps

are
taken:
•
the
vacuum pipe between the electronic control unit and

the
inlet manifold must remain connected and be in good
condition
-
neither blocked nor split.
•
the
engine must be at its normal operating temperature.
•
the
idle speed/mixture/CO adjustments must be correct
-

see Job 35.
•
with
the engine idling at between 800 and 900 rpm, the

mark on
the crankshaft pulley should be at approximately 12
degrees BTDC.
IMPORTANT NOTE: The only marks are for 0, 4 and 10
degrees BTDC, so you will have to make a guess at the
correct position for 12 degrees.
FACT FILE: TIMING MARKS
y-; • It appears that some earlier engines
H. j may be fitted with different types of
J timing marks. There might be a metal
pointer fitted to the timing belt cover.
Other engines may have their timing marks in the
flywheel housing, so that you need to take out a rectan-
gular rubber bung and look out for the fixed timing
mark on the flywheel housing and the timing settings

on
the flywheel itself.
• It always helps to paint all of the timing marks with
white paint or typists' correction fluid so that they are
easier to see when the timing light is operating.
1. Line up the mark on the crankshaft pulley with the 0
degrees (TDC) mark on the timing belt cover. See 25C.
2. Without moving the crankshaft from this position, undo the
screws holding the rpm and TDC sensor to the sensor carrier
plate. Fit the tool no. 1895898000 in place of the sensor.
Check that the flywheel pin or lug (3) must fit in the groove of
the tool and the bolts must tighten easily. If not, carry out the
following procedure:
3. Slacken the bolts securing the carrier plate behind the
sensor.
4. Move the plate so that the tool slips freely into the sensor's
hole and the bolts tighten easily.
5. Tighten the bolts holding the sensor carrier plate in place.
6. Remove the tool and refit the sensor.
ON BOTH TYPES: As the distributor is turned (clockwise to
advance, anti-clockwise to retard), the timing mark on the
flywheel will be seen to move relative to the pointers. Move
the distributor so the timing marks are aligned correctly, and
retighten the clamp nut or bolts.
• Job 26. Check/adjust drive belt/s.
26A. Depending on
your Tipo or Tempra
model, access to the
alternator belt and
adjustment fixings will
probably be possible
from the engine bay.
V-BELTS ONLY
Check the belt, and if there is any sign of cracking, 'polishing',
fraying or severe wear on the inner face, replace it. The belt
should deflect by about 10 mm when firm thumb pressure is
applied to the belt between the pulleys in the direction of the
arrow. Too little tension and the belt might slip; too much,
and belt and bearing wear will increase.

26B. If adjustment is
necessary, slacken the
tensioning nut (A) and
the alternator pivot (B),
on all models. (These
are two typical
layouts.)
Use a length of wood
to pivot the alternator
away from the engine
block but take great
care not to damage the
alternator casing.
Tighten the nuts/bolts
when the tension is correct.
RIBBED BELTS ONLY
If your vehicle is fitted with a ribbed belt, pivot the alternator
as described above and tighten it when you can just twist the
belt by 1/4 turn in the middle of its longest run.
IMPORTANT NOTE:
• Belt tension should only be adjusted when the engine
is cold.
• After adjustment, run the engine for 15 to 30 seconds,
to allow the belt to bed-in, then check again.
• Experience mechanics claim that belts often go slack
when the engine heats up, producing belt squeal.
• If this happens on your vehicle, adjust the belt again
when the engine is hot. Wear industrial leather gloves
and long-sleeved overalls and take very great care not to
burn yourself on the hot engine or exhaust.
If there is an auxiliary unit, such as an air conditioning pump,
driven by a separate drive belt, examine and adjust it as
described here.
Q Job 27. Check electric fan operation.
Drive the car until it is at normal operating temperature. Park
outdoors and, with the gearbox in neutral (or 'P' in the case of
an automatic) leave the engine running. At just above normal
temperature the electric cooling fan should come on, and
then go off again when the temperature drops. Refer to your
temperature gauge, if fitted. If the fan doesn't behave, check
the thermo-switch on the radiator, along with all connections
and wires in its circuit with the fan motor. See Job 13 and
Chapter
6,
Repairs and Replacements.
• Job 28. Run diagnostic ignition/injection test.
DIAGNOSTIC TEST
28A. Have your FIAT dealer
carry out a diagnostic test,
plugging his tester into the
diagnostic socket tucked away
at the front of the passenger-
side footwell.
EMISSIONS TESTS
Vehicles fitted with the Mono-Jetronic fuel injection system
are not fitted with adjustment screws. The system is self-
regulating. However, specified annual checks carried out with
an exhaust gas analyser will provide essential information on
the condition of the injection/ignition system, the catalytic
converter and the engine itself.
28B. The checks are carried out twice: once with the test
sensor at least 300 mm into the end section of the exhaust
pipe (a). (If the shape of the end section of the exhaust pipe is
such that the sensor cannot be completely introduced, a
special extension pipe must be added ensuring that the joint
with the car's tail-pipe is sealed.); the second after undoing
the cap or nut on the exhaust pipe upstream of the catalytic
converter (b).
The following table shows the test limits for carbon monoxide,
unburned hydrocarbons (in parts per million) and carbon
dioxide:
CO (%) HC (p.p.m.) C02(%)
Upstream of the catalyzer (a) 0,4 -h 1 500/600* >12
Downstream of the catalyzer (b)
=£
0,35 =s 90 >13
* FIAT's figures vary.
IMPORTANT NOTE: The engine must be at its normal
operating temperature and normal tick-over speed.
• if the percentage concentration of CO upstream of the
catalytic converter is not within the limits in the table,
check:
• the Lambda sensor
-
see Job 37.
• air penetration around the Lambda sensor housing.
• faults in the ignition or injection systems. (First try
renewing the spark plugs, distributor cap and HT leads.)
If, at the same time, the concentration of hydrocarbons
is not less than 500/600 parts per million (FIAT'S figures
vary), check:
• the ignition timing (see Job 25).
• the valve clearances (see Job 9).
• the valve gear timing (see Job 12).
• the engine compression. (You will need to remove the
spark plugs, fit a compresson tester to each plug
aperture in turn and crank the engine. See the FACT FILE
on page 51.)

28C. With very latest
'distributorless' system,
disconnect the multi-plug
from the base of the 'black
box'.
28D. With the two earlier
systems, disconnect the
multi-plug leading to the
distributor/control unit
from the ignition coil
behind the battery.
FACT FILE: CRANKING AN ENGINE
WITH ELECTRONIC IGNITION
Severe damage can be
caused to the ignition
system if the engine is
cranked with plugs/leads
removed
-
and a severe
electric shock can be
experienced.
PART E: FUEL AND EXHAUST
SAFETY FIRST!

Always
wear impervious gloves so that fuel cannot

come
in contact with your
skin.
It can induce cancer.
Q Job 29. Check fuel pipes for leaks.
Check the fuel lines from the fuel tank and into the engine
compartment, looking for signs of chafing, splits and perishing

of the
rubber and plastic parts. Ensure any worm-drive hose

clips used
on the connections are firm and secure.
Q Job 30. Change petrol air filter.
IMPORTANT NOTE: If the HC reading when measured at
the end of the exhaust pipe is outside of the recom-
mended limit while that measured upstream of the
catalytic converter is OK, the cat. is almost certainly
faulty. Have it double-checked by your dealer before
replacing it
-
an expensive component!
30C. Pull on the
tabs
-
and watch
that the springs
don't fall on the
floor as you release
the catches!
30D. Lower the
filter cover and lift
out the filter
element.
31B. If you want to
take the cover right
off, you will have to
unscrew the air
hose clamp
(arrowed). Remove
and replace the
filter element (A).
• Job 31.
Change diesel
air filter.
31A. Take out the
four screws
(arrowed) and lift
off the cover (B). 30B. ...and release

the two
fasteners

(a) and the
two

spring clips
(b).
30A. Unscrew the

two
screws
(arrowed)...
51

• Job 32. Change petrol fuel filter. IMPORTANT NOTES:
• Wear plastic gloves and goggles and have a large rag
and a suitable fire extinguisher ready.
• Place a container beneath the filter to catch fuel
spillage.
• After fitting the new filter in place, refit the casing,
ensure no traces of fuel are left, reconnect the battery and
restart the engine.
• Check carefully to ensure there are no leaks before
refitting the cover.
• Job 33. Drain diesel fuel filter.
IMPORTANT NOTE: Some models are fitted with a water-
in-fuel sensor. Drain the filter when the warning light
comes on. Unplug the sensor from the base of the filter,
first.
FUEL INJECTION
MODELS
32A. The filter is under the
car, ahead of the fuel tank.
E3 INSIDE INFORMATION:
Remove the visible screws
holding the flexible
plastic cover in place.
You can now pull the
front down and out of
the way. E3
32B. Undo the clamp,
remove the outer
casing and renew the
special paper filter,
from your FIAT
dealership. There is
an arrow on the
casing to remind you
which way round it
must be fitted.
33. The fuel filter is
located in the rear of
the engine
compartment. Water
carried in the fuel
accumulates in the
bottom of the filter,
and should not be
allowed to build up.
To drain it position a receptacle under the filter, then unscrew
the knurled tap at the bottom of the filter by a couple of turns.
Do so at the recommended interval, or if the panel indicator
comes on. (See Chapter
2,
Getting to Know Your
Car.)
H INSIDE INFORMATION: Plastic fuel pipes become
brittle and snap. Extra care needed! E3
SAFETY FIRST!
• The high pressure pipework on a 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).
• ALWAYS place a rag over a union while it is being
undone until all the pressure has been let out of the
system.
• You are recommended to 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 Chapter 6, PART F: 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.
IMPORTANT NOTE: All Tipo/Tempra diesel engines are
self-bleeding and there should be no need to bleed air
out of the system manually.
• Job 34. Change diesel fuel filter.
Drain the fuel filter. Unscrew the complete filter canister from
its head, in the same way that you would an engine oil filter.
First undip the sensor plug (if fitted) from the base of the unit.
^ 34A. If it is too tight to
^^ - unscrew by hand, use an oil
filter wrench on the lower,
flatted zone (C). Wipe the underside of the filter head,
fill the new filter
with fuel...
34B. ...lightly
lubricate its seal
with fuel, then
screw it onto the
filter head. Once it
is 'nipped up',
tighten it as far as
possible by hand,
without
'murdering' it
-
so
that you CAN
remove it next
time!