1988 FIAT TEMPRA brakes

Mains Electricity
Avoid the use of mains electricity when working on the vehicle,
whenever possible. Use rechargeable tools and a DC inspection
lamp, powered from a remote 12V battery
-
both are much
safer. However, if you do use mains-powered equipment,
ensure that the appliance is wired correctly to its plug, that
where necessary it is properly earthed (grounded), and that the
fuse is of the correct rating for the appliance. Do not use any
mains powered equipment in damp conditions or in the vicinity
of fuel, fuel vapour or the vehicle battery.
Always use an RCD (Residual Current Device) circuit breaker
with mains electricity. Then, if there is a short, the RCD circuit
breaker minimises the risk of electrocution by instantly cutting
the power supply.
Ignition System
Never work on the ignition system with the ignition switched
on, or with the engine being turned over on the starter, or
running and you are recommended never to do so.
Touching certain parts of the ignition system, such as the HT
leads, distributor cap, ignition coil etc., can result in a severe
electric shock or physical injury as a hand is pulled sharply away.
Voltages produced by electronic ignition systems are much
higher than those produced by conventional systems and could
prove fatal, particularly to people with cardiac pacemaker
implants. Consult your handbook or main dealer if in any
doubt.
Cooling Fan
On many vehicles, the electric cooling fan can switch itself on
even with the ignition turned off. This is especially likely after
driving the car and parking it before turning off, after which
heat rises to the top of the engine and turns the fan on,
suddenly and without warning. If you intend working in the
engine bay, it's best to do so when the engine is cold, to
disconnect the battery, or keep away from the fan, if neither of
these are possible.
Battery
Never cause a spark, smoke, or allow a naked light near the
vehicle's battery, even in a well ventilated area. Highly explosive
hydrogen gas is given off as part of the charging process.
Battery terminals on the car should be shielded, since a spark
can be caused by any metal object which touches the battery's
terminals or connecting straps.
IMPORTANT NOTE: Before disconnecting the battery earth
(ground) terminal read the relevant FACT FILE in Chapter 5
regarding saving computer and radio settings.)
When using a battery charger, switch off the power supply
before the battery charger leads are connected or disconnected.
If the battery is not of the 'sealed-for-life' type, loosen the filler
plugs or remove the cover before charging. For best results the
battery should be given a low rate trickle charge overnight. Do
not charge at an excessive rate or the battery may burst.
Always wear gloves and goggles when carrying or when
topping up the battery. Acid electrolyte is extremely corrosive
and must not be allowed to contact the eyes, skin or clothes.
Brakes and Asbestos
Obviously, a car's brakes are among its most important safety
related items. ONLY work on your vehicle's braking system if
you are trained and competent to do so. If you have not been
trained in this work, but wish to carry out the jobs described in
this book, we strongly recommend that you have a garage or
qualified mechanic check your work before using the car.
Whenever you work on the braking system components, or
remove front or rear brake pads or shoes: i) wear an efficient
particle mask; ii) wipe off all brake dust from the brakes after
spraying on a proprietary brand of brake cleaner (never blow
dust off with compressed air); iii) dispose of brake dust and
discarded shoes or pads in a sealed plastic bag; iv) wash your
hands thoroughly after you have finished working on the
brakes and certainly before you eat or smoke; v) replace shoes
and pads only with asbestos-free shoes or pads. Note that
asbestos brake dust can cause cancer if inhaled; vi) always
replace brake pads and/or shoes in complete 'axle' sets of four
-

never replace the pads/shoes on one wheel only.
Brake Fluid
Brake fluid absorbs moisture rapidly from the air and can
become dangerous resulting in brake failure. You should
change the fluid in accordance with your vehicle manufacturer's
recommendations or as advised in this book. Never store (or
use) an opened container of brake fluid. Dispose of the
remainder at your Local Authority Waste Disposal Site, in the
designated disposal unit, not with general waste or with waste
oil.
Engine Oils
Always wear disposable plastic or rubber gloves when draining
the oil from your engine, i) Note that the drain plug and the oil
are often hotter than you expect. Wear gloves if the plug is too
hot to touch and keep your hand to one side so that you are
not scalded by the spurt of oil as the plug comes away; ii) There
are very real health hazards associated with used engine oil. In
the words of one manufacturer's handbook "Prolonged and
repeated contact may cause serious skin disorders, including
dermatitis and cancer." Use a barrier cream on your hands and
try not to get oil on them. Always wear gloves and wash your
hands with hand cleaner soon after carrying out the work. Keep
oil out of the reach of children; iii) NEVER, EVER dispose of old
engine oil into the ground or down a drain. In the UK, and in
most EC countries, every local authority must provide a safe
means of oil disposal. In the UK, try your local Environmental
Health Department for advice on waste disposal facilities.
Plastic Materials
Many of the materials used (polymers, resins, adhesives and
materials acting as catalysts and accelerators) contain dangers in
the form of poisonous fumes, skin irritants, and the risk of fire

CHAPTER 3
FACTS ARID FIGURES
This chapter provides you with
all the information you will
need about your car, especially
in connection with servicing and
repairing it. First, you'll need to
identify the engine type. If you
don't know it already, see
Chapter 6, Repairs and
Replacements.
Before buying parts, be sure to
take your vehicle's chassis and
engine numbers with you
-
see
Auto-Biography on page 1
and PART G: IDENTIFICATION
NUMBERS in this chapter.
Chapter Contents
• -< Page No. Page No.
PART
A:
MAJOR MILESTONES 17 PART E: REPAIR DATA 20
PART
B:
VITAL STATISTICS 18 PART
F:
TORQUE WRENCH SETTINGS 23
PART C: CAPACITIES 19 PART G: IDENTIFICATION NUMBERS 27
PART
D:
SERVICE DATA 19
•
IMPORTANT NOTE: Many detail changes have taken place over the years, and there have been many different Special
Editions and Options available. The following information will be true of most cases but can only be taken as a general
guide. Consult your local FIAT dealer for confirmation.
PART A: MAJOR MILESTONES
Overview Although the Tipo and Tempra were presented as
separate models, they are essentially the same cars, with detail
differences. However, all Tipos are 5-door hatchbacks (apart
from some 3-door 1.4 and the relatively rare 2.0 i.e. 16v, both
from 1993); all Tempras are 4-door saloons (with a boot) or
5-door estates. Apart from the rear bodywork and very slight
differences in rear suspension rates, both models are the
same, although years of production and options available
(including some engine options and some model names) are
not necessarily the same, and changes were not always
introduced to both model names at the same time
-
if at all.
All models come with front disc, rear drum brakes, except the

Tipo
2.0 i.e. 16v (but NOT the 2.0 i.e. GT), and the Tempra 2.0
i.e. SXand SLX models, which have discs front and rear.
IMPORTANT NOTE: This manual does NOT cover 1.8 and
2.0 litre Tipo or Tempra models.
June 1988 Tipo range introduced, as 1.4, 1.4 DGT, 1.6 DGT
and 1.6 DGT SX models with 1372ccand 1580cc petrol
engines. Also 7.97".dswith 1929 turbo diesel engine DGT and
Ids with digital instruments. All models with galvanised steel
body.
October 1988 Tipo 1.7D diesel version launched.
April 1990 Formula and S versions of Tipo 1.4 introduced.
April 1990 Also 1.6 DGT Selecta version introduced with CVT
gearbox.
July 1990 Tempra 1.4 and 1.6 (petrol) and 1.9D, (non-turbo
diesel), and 1.9 TD5 and TD5X (turbo diesel) 4-door saloon
models introduced. CVT auto-transmission available on 1.6
petrol models only
-
same as Selecta on Tipo models, but not
named as such. Tempra 1.8 i.e. SX with high performance
1756cc double-overhead camshaft (DOHC) fuel-injected
engine introduced. Tempra 1.4 and 1.6 basic and 5 models
with regular, analogue instruments; Tempra SXand SX i.e.
with digital instruments.
Tipo 1.8 i.e. DGT model, with high performance 1756cc fuel
injected, DOHC petrol engine introduced.
June 1991 Tempra Station Wagon introduced, as 1.6 or 1.8
i.e. models, with 2-part horizontally split tailgate and high-
roof styling.

October 1991 2.0 i.e. 16v introduced, with 1995cc, 16 valve
high-performance DOHC engine, catalytic converter, sports
suspension, front and rear disc brakes. ABS available as
option.
January 1992 Existing Tipo models lightly facelifted and
redesignated 1.4 Formula, 1.45, 1.6S, 1.6SX, 1.9TD SX,
1.8 i.e. SX. 1.7D discontinued. SX versions with digital
instruments.
Tempra 1.9 TDS (turbo diesel) Station Wagon introduced. 1.4
and 1.9D saloons discontinued.
May 1992 Tempra 1.8 i.e. SX Saloon and Station Wagon
discontinued.
June 1992 Tempra 2.0 i.e. SX saloon and station wagon
models introduced, with high performance 1995cc DOHC fuel
injected engine, catalytic converter and disc brakes front and
rear.
Tipo 1.4 and all Tipo and Tempra 1.6 models (except Selecta)
now with a catalytic converter and fuel injection in place of
Weber twin-choke carburettor. Designated i.e. in badging.
December 1992 Tipo 1.8 i.e. and 1.6 Selecta discontinued.
February 1993 Tipo 2.0 i.e. GT introduced. Slightly lower
performance and spec, version of the 16v model.
July 1993 Tipo 1.4 now available as a 3-door or 5-door
hatchback. 2.0 i.e. 16v now only available as 3-door. Tipo 2.0
i.e. GT replaced by similar spec. 2.0 i.e. SLX.
Tempra 2.0 i.e. SX saloons and estates now only available
with auto, gearbox. Otherwise, SX models become known as
SLX, with colour-coded mirrors and ABS brakes. Most Tempras
now with body-coloured bumpers. 1.9D (non turbo Diesel re-
introduced).
All Tipo and Tempra models now with revised front-end
styling
-
narrower headlights and revised grille. Improved crash
protection, including side impact beams, safety steering wheel
and uprated brakes. Power steering, central locking, electric
windows all standard.
February 1994 Tipo 1.7 non-turbo diesel re-introduced as
1.7 DS.
May 1994 Tempra 1.9DS Station Wagon introduced.
September 1994 Most models available with driver's airbag,
fire prevention system and seat belt pre-tensioners.
December 1994 Tempra 1.6 i.e. versions get M.P.I, engine.
February/March 1995 All models with VIN number window
etching and immobiliser standard on all Tempra petrol models.
October 1995 Immobiliser fitted to Tempra D and TD models.
End of 1995 Tipo discontinued.
Mid-1996 Tempra discontinued.
PART B: VITAL STATISTICS
All Tipo models
-
55 litres, except petrol with catalytic converter
- 51
litres.
All Tempra models
-
65 litres, except petrol with catalytic converter
-
62 litres.
Wheels and Tyres
ENGINE PRESSED STEEL RADIAL TYRE PRESSURES (cold)
WHEEL RIM TYPE TUBELESS FRONT REAR
TYRE TYPE average load heavy load average load heavy load
TIPO MODELS
1.4 and 1.6 Petrol 5.00B x 13H 165/70R13S 2.0 bar/29 psi 2.0 bar/29 psi 1.9 bar/28 psi 2.2 bar/32 psi
1697 Diesel 5.00B x 13H 165/70R 13S 2.1 bar/30 psi 2.1 bar/30 psi 1.9 bar/28 psi 2.2 bar/32 psi
Turbo D 5.5J x 14H
175/65 R
14T 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
1.4 i.e./1.6 i.e. (1993-on) 5.5J x 14H
165/65 R
14T 2.0 bar/29 psi 2.0 bar/29 psi 1.9 bar/28 psi 2.2 bar/32 psi
1.7D (1993-on) 5.5J x 14H 165/65R 14T 2.1 bar/30 psi 2.1 bar/30 psi 1.9 bar/28 psi 2.2 bar/32 psi
Option
-
certain models 5.5J x 14AH2 185/60R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
TEMPRA MODELS
Early 1.4 and 1.6
Saloons 5.00B x 13H 165/70R 13S/T 2.0 bar/29 psi 2.0 bar/29 psi 2.0 bar/29 psi 2.2 bar/32 psi
1.6 SX Saloon 5.5J x 14H 165/65R 14T 2.0 bar/29 psi 2.0 bar/29 psi 2.0 bar/29 psi 2.2 bar/32 psi
1.9D/1.9 TD Saloon
and Late 1.6 i.e. 5.5J x 14H 175/65R 14T/H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 2.4 bar/35 psi
1.6/1.9D/1.9TD
Station Wagons 5.5J x 14H 175/65R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 3.0 bar/44 psi
Option for Station 5.5J x 14H or AH2 185/60 R 14H 2.2 bar/32 psi 2.4 bar/35 psi 2.2 bar/32 psi 3.0 bar/44 psi
Wagons (alloy)
SPARE WHEEL
-
ALL TIPO AND TEMPRA MODELS (speed limit 50 mph)
Tempra TD Saloon and
ALL Station Wagons 4.00B x 14H 105/70 B14 4.2
bar/61
psi
All other models 4.00Bx14H 135/80 B14 2.8
bar/41
psi

Weights and Dimensions. All weights in kg. All sizes in mm.
All figures are given for 1993 model-year. Other years may vary.
ALL TIPO AND TEMPRA MODELS: Maximum roof load
-
80 kg (all models). Maximum weight on towball, when fitted - 75 kg.
VEHICLE
TIPO MODELS
1.4
1.6 manual
1.6 auto.
1.9 Turbo D
1.7 Diesel
UNLADEN WEIGHT
1030
1050
1080
1160
1060
MAXIMUM
LADEN WEIGHT
1530
1550
1580
1660
1560
TOWABLE LIMITS WITHOUT WITH BRAKES BRAKES
400
400
400
400
400
1100
1100
1100
1200
1100
OVERALL LENGTH
3958
OVERALL WHEEL FRONT WIDTH* BASE TRACK * not including mirrors
1700
All models:
2540 1436
REAR TRACK
1415
HEIGHT (unladen)
1445
TEMPRA MODELS
1.4 Saloon 1075 1575 400 1100
1.6 Saloon 1080 1580 400 1200 Saloons:
1.6 Auto Saloon 1120 1620 400 1100 4354 1695 2540 1425 1415 1445
1.9 D Saloon 1170 1670 400 1200
1.9 TD Saloon 1210 1710 450 1300
1.6 Station Wagon 1140 1705 400 1200
1.6 Auto Station Station Wagons:
Wagon 1180 1750 400 1100 4472 1695 2450 1425 1415 1500*
1.9 D Station (* roof bars - add 40 mm)
Wagon 1230 1800 450 1300
1.9 TD Station
Wagon 1270 1840 450 1300
PART C: CAPACITIES
See RECOMMENDED EL LUBRICANTS on page 154.
PART D: SERVICE DATA
All setting in mm. unless stated otherwise.
Engine
FIRING ORDER: All petrol models 1-3-4-2
INJECTION ORDER: All diesel models 1-3-4-2
IGNITION TIMING in degrees Before Top Dead Centre
-
BTDC:
850 rpm: 1372cc-8to 12 degrees. 1580/1581cc- 10 to 14
degrees.
CO CONTENT AT IDLE (MAX): Petrol only
-
0.5 to 1.5%
Exhaust VALVE CLEARANCES (mm) Inlet
(Checked when engine cold)
Petrol engines
Diesel engines
Other settings
0.4
+/-
0.05
0.3
+/-
0.05
0.5
+/-
0.05
0.35
+/-
0.05
SPARK PLUG TYPES AND GAPS
Model FIAT
1372cc V4LSR

1580/1581
cc V45LSR
Champion Gap (mm)
RN9YC
RN7YC
IDLE SPEED:
Petrol: 800 to 850 rpm
Turbo Diesel: 880 to 920 rpm
Non-turbo Diesel: 740 to 780 rpm
0.7 to 0.8
0.7 to 0.8
CLUTCH ADJUSTMENT: No pedal free-travel. Adjustable pedal
height (see Chapter 5, Job 20).
BRAKE DISC PAD MINIMUM THICKNESS: Front (all models)
and Rear (models with ABS)
-
Brake pad wear warning light on
dash, but also check visually
-
minimum 1.5.
BRAKE SHOE FRICTION LINING MINIMUM THICKNESS: Rear
(when applicable)
-
minimum 1.5.
TYRE PRESSURES: See page 18

1372 OHC 1580/1581 OHC 1697 Diesel 1929 D 1929 Turbo D
Brakes
GAP
-
SERVO PISTON PUSHROD FROM SUPPORT PLATE (d):
22.45-22.65 22.45-22.65 22.45-22.65
MINIMUM ALLOWED FRONT DISC THICKNESS (mm):
NON-ABS: 9.2 NON-ABS: 9.2 NON-ABS: 9.2
ABS: 10.2 ABS: 10.2
MINIMUM ALLOWED REAR DISC THICKNESS
-
when applicable
-
(mm):
9.2 9.2 9.2
MINIMUM ALLOWED BRAKE DRUM INTERNAL DIAMETER
-
when applicable
-
(mm):
181.35 A: 181.35
B: 230
Running gear/suspension - front
CAMBER (not adjustable):
-20' to 40' -20' to 40'
A: 181.35
B: 230
-20' to 40
22.45-22.65
10.2
ABS: 9.2
230
22.45-22.65
10.2
(TdsX: 10.8)
ABS: 9.2
230
-20' to 40' -20 to 40'
(TdsX: 25'
+/-
30')
FRONT CASTER (not adjustable):
1 degree 50'-2 degrees 50'
1
degree 50'-2 degrees 50'
1
degree 50'-2 degrees 50'
1
degree 50'-2 degrees 50' 1 degree 50'-2 degrees 50'
(TdsX: 2 degrees 50')
TOE-IN (adjustable)

-1
to
1
mm
-1
to
1
mm
-1
to
1
mm
-1
to
1
mm
FRONT SPRING HEIGHT RELEASED (mm):
432 EARLY: 432 461 EARLY: 489
TEMPRA: 444 LATE: 444 LATE: 472
TEMPRA: 489
FRONT SPRING: when the given load in Nm is applied, the spring height should equal 191 mm:
3020-3330 3020-3330 3310-3590 3600-3900
REPLACEMENT FRONT SPRING COLOURS: If new springs fail to give the above heights, YELLOW SPRINGS give LOWER heights;
GREEN springs give HIGHER. ALWAYS use them in pairs of same colour.
Rear suspension
CAMBER (not adjustable):
TOE-IN (not adjustable):

-1
to
1
mm
EARLY: 489
LATE: 472
TEMPRA: 493
3600-3900
-1 degree 30' to -30' -1 degree 30' to -30' -1 degree 30' to -30' -1 degree 30' to -30'

-3
to
1
mm
-3
to
1
mm
-3
to
1
mm -3 to
1
mm
-1 degree 30' to -30'
(TdsX: 1 degree 30' +/-15'

-3
to
1
mm
(TdsX:
-2
to 2 mm)
REAR COIL SPRING HEIGHT, RELEASED (mm):
3270 3270 3270 3270 3270
TEMPRA: 3390 TEMPRA: 3390 TEMPRA: 3390 TEMPRA: 3390
REAR COIL SPRING HEIGHT, LOAD in NM REQUIRED TO COMPRESS TO 195 mm.
2930-3170 2930-3170 2930-3170 2930-3170 2930-3170
TEMPRA: 3120-3380 TEMPRA: 3120-3380 TEMPRA: 3120-
3380 TEMPRA: 3120-3380
REPLACEMENT REAR SPRING COLOURS: If new springs fail to give the above heights, YELLOW springs give LOWER heights;
GREEN springs give HIGHER. ALWAYS use them in pairs of same colour.
(*) The bolt need not be greased

Lubrication and Cooling Circuit
Self-locking nut for screw fastening radiator support bracket to body (M6)....
Flanged screw, radiator support beam to body (M8)
Flanged screw retaining heater (M6)
Clutch
Screw with split safety washer retaining clutch mechanism
(M8)
(M6)
Gearbox Differential
Tapered threaded plug for filling gear case with oil (M22 x 1.5)
External Gearbox Control
Oil pressure switch (M10 x 1.25 tapered)
Braking System
Bolt retaining brake carrier plate to rear suspension arm
(rear drum brakes) (M8)
Bolt retaining caliper support to rear top arm (rear disc plate) (M8)
Bolt retaining rear brake caliper to plate (rear disc plates) (M10 x 1.25)
Screw retaining front brake caliper to pillar (M10 x 1.25)
Bolt retaining front brake disc and rear brake drum or disc to hub (M8)
Fitting connecting hose to front brake caliper (M10 x 1)
Bleed screw on front brake caliper (M8)
Fitting connecting hose to rear brake caliper (rear disc plates) (M10 x 1)
Bleed screw on rear brake caliper (rear disc plates) (M7)
Bolt with split safety washer retaining brake system bracket assembly (M8)....
Bolt retaining cylinder to rear drum brake carrier plate (M6)
Bleed screw on rear drum brake cylinder (M8)
Male fitting for hoses with flared ends fastening rigid pipe to front and
rear hoses (M10 x 1)
Male fitting for hoses with flared ends fastening rigid pipe to hose on
rear axle (M10 x 1)
Bolt retaining brake fluid reservoir to body (M8)
Nut retaining brake fluid reservoir to body (M6)
Bolt retaining brake fluid reservoir to body (M6)
Male fitting for flared hoses fastening rigid pipe to rear drum brake
cylinder
(M1
Ox 1)
Male fitting for flared hoses fitting brake pipe to pump and cast iron Ip valve
(M10
x
1)
(M12
x
1)
Male fitting for flared hoses fitting brake pipe to 4-way control valve and
aluminium load prop, valve

(M10 x
1)
(M12
x
1)
Load Proportioning Valve Fasteners
Bolt retaining load proportioning valve to bracket (M6)
Self-locking nut for bolt retaining valve spring bracket to rear
anti-roll bar (M6)
Bolt retaining square lever for load proportioning valve adjustment (M8)
Bolt retaining load prop, valve to rail (for Girling ABS) (M8)
Bolt retaining square lever for load prop, valve adjustment (M6)

Windscreen and Mirrors
O 16. In zone 'A' of your windscreen, no items of damage larger than 10 mm in diameter will be allowed. In the rest of the area swept by the windscreen wipers, no damage greater than 40 mm in diameter will be allowed, nor should windscreen stickers or other obstructions encroach on this area.
o 17. Check that the exterior mirror on the driver's side is in good condition.
o 18. There must be one other mirror in good condition, either inside the car or an external mirror on the passenger's side.
Brakes
O 19. You cannot check the brakes
properly without a rolling road brake
tester but you can carry out the
following checks:
O 20. Pull on the handbrake. It should be fully ON before the handbrake reaches the end of its travel.
O 21. Knock the handbrake from side to side and check that it does not then release itself.
O 22. Check the security of the handbrake mountings and check the floor around it for rust or splits.
o 23. Check that the brake pedal is in good condition and that, when you take hold of it and move it from side to side, there is not too much play.
o 24. Push the footbrake down hard, with your foot. If it creeps slowly down to the floor, there is probably a problem with the master cylinder. Release the pedal, and after a few seconds, press down again. If the pedal feels spongy or it travels nearly to the floor, there is air in the system or another MoT-failing fault with the brakes.
o 25. Check the servo unit (when
fitted) as follows: Pump the pedal
several times then hold it down hard.
Start the engine. As the engine starts,
the pedal should move down slightly.
If it doesn't the servo or the vacuum
hose leading to it may be faulty.
Seat Belts and Seats
O 26. Examine all of the webbing (pull out the belts from the inertia reel if necessary) for cuts, fraying or deterioration.
o 27. Check that each inertia reel belt retracts correctly.
o 28. Fasten and unfasten each belt to ensure that the buckles work correctly.
o 29. Tug hard on each belt and inspect the mountings, as far as possible, to ensure that all are okay.
IMPORTANT NOTE: Checks apply to
rear seat belts as much as front
ones.
O 30. Make sure that the seat runners and mountings are secure and that the back rest locks in the upright position.
Doors and Door Locks
O 31. Check that both front doors latch securely when closed and that both can be opened and closed from both outside and inside the car.
PART B: VEHICLE ON THE GROUND
Electrical Equipment
See Part A: INSIDE THE CAR for checks on the operation of the electrical equipment.
O 1. Examine the wiper blades and replace those that show any damage.
Vehicle Identification
Numbers (VIIU)
O 2. The VIN (or chassis number on older vehicles) must be clearly displayed and legible.
O 3. Number plates must be secure, legible and in good condition with correct spacing between letters and numbers. Any non-standard spacing will not be accepted.
Braking System
O 4. Inside the engine bay inspect the master cylinder, servo unit (if fitted), brake pipes and mountings. Look for corrosion, loose fitting or leaks.
Steering and Suspension
OS . While still in the engine bay, have your assistant turn the steering wheel lightly from side to side and look for play in steering universal joints or steering rack mountings and any other steering connections.
OE. If your vehicle is fitted with power steering, check the security and condition of the steering pump, hoses and drivebelt, in the engine bay.
O 7. Look and reach under the car while your assistant turns the steering wheel more vigorously from side to side. Place your hand over each track rod end in turn and inspect all of the steering linkages, joints and attachments for wear.
o 8. Go around the vehicle and
'bounce' each corner of the
vehicle in turn. Release at the lowest
point and the vehicle should rise and
settle in its normal position without
continuing to 'bounce' of its own
accord.

O 23. Have your assistant press down firmly on the brake pedal while you check the rear brake flexible hoses for bulges, splits or other deterioration.
o 24. Check the fuel tank for leaks or corrosion. Remember also to check the fuel filler cap
-
a correctly sealing filler cap is a part of the MoT test.
O 25. Examine the handbrake mechanism. Frayed or broken cables or worn mounting points, either to the bodywork or in the linkage will all be failure points.
o 26. Check each of the rear wheel
bearings as for the fronts.
o 27. Spin each rear wheel and check that neither the wheel bearings nor the brakes are binding. Pull on and let off the handbrake and check once again to make sure that the handbrake mechanism is releasing.
SAFETY FIRST!
• Only run the car out of doors.
• Beware of burning yourself on a hot exhaust system.
o 28. While you are out from under the car, but with the rear end still raised off the ground, run the engine. Hold a rag over the end of the exhaust
pipe and listen for blows or leaks in the system. You can now get back under the car and investigate further if necessary.
o 29. Check the exhaust system mountings and check for rust, corrosion or holes in the rear part of the system.
o 30. Check the rear brake back plate or calipers (as appropriate) for any signs of fluid leakage.
o 31. Check the insides and the outsides of the tyres as well as the tyre treads for damage, as for the front tyres.
PART D: EXHAUST EMISSIONS
This is an area that is impossible to
check accurately at home. However,
the following rule-of-thumb tests will
give you a good idea whether your car
is likely to fail or not.
H INSIDE INFORMATION: If you
feel that your car is likely to fail
because of the emission test, have
your MoT testing station carry out
the emission part of the test first so
that if it fails, you don't waste
money on having the rest of the
test carried out. Q
O 1. PETROL ENGINES BEFORE 1 AUGUST 1973 AND DIESEL ENGINES BEFORE 1 AUGUST 1979 only have to pass visible smoke check. Rev the engine to about 2,500 rpm (about half maximum speed) for 20 seconds and then allow it to return to idle. If too much smoke is emitted (in the opinion of the tester) the car will fail.
O 2.DIESEL ENGINES FROM 1 AUGUST 1979 The engine will have to be taken up to maximum revs several times by the tester, so make certain that your timing belt is in good condition, otherwise severe damage could be caused to your engine. If the latter happens, it will be your responsibility!
FACT FILE: VEHICLE EMISSIONS

PETROL
ENGINED VEHICLES WITHOUT
CATALYSER

Vehicles first used before 1 August 1973

• visual smoke check only.

Vehicles first used between 1 August 1973 and 31 July 1986

• 4.5% carbon monoxide and 1,200 parts per million, unburned
hydrocarbons.

Vehicles first used between 1 August 1986 and 31 July 1992

• 3.5% carbon monoxide and 1,200 parts per million, unburned
hydrocarbons.
PETROL ENGINED VEHICLES FITTED WITH
CATALYTIC

CONVERTERS
i

Vehicles first used from 1 August 1992
(K-registration on)

• All have to be tested at an MoT Testing Station specially equipped to
handle cars fitted with catalytic converters whether or not the vehicle
is fitted with a 'cat'. If
the
test, or the garage's data, shows that the
vehicle was not fitted with a 'cat' by the manufacturer, the owner is
permitted to take the vehicle to
a
Testing Station not equipped for
catalysed cars, if he/she prefers to do so (up to 1998-only). Required
maxima are
-
3.5% carbon monoxide and 1,200 parts per million,
unburned hydrocarbons. The simple emissions test (as above) will be
supplemented by a further check to make sure that the catalyst is
maintained in
good
and efficient working order.
• The tester also has to check that the engine oil is up to a specified
temperature before carrying out the test. (This is because 'cats' don't
work properly at lower temperatures
-
ensure your engine is fully
warm!)
DIESEL ENGINES'EMISSIONS
STANDARDS

• The Tester will have to rev your engine hard,
several times. If it is not in good condition, he is
entitled to refuse to test it. This is the full range of
tests, even though all may not apply to your car.

Vehicles first used before 1 August, 1979

• Engine run at normal running temperature; engine speed taken to
around 2,500 rpm (or half
governed
max. speed, if lower) and held for
20 seconds. FAILURE, if engine emits dense blue or black smoke for
next 5 seconds, at tick-over. (NOTE: Testers are allowed to be more
lenient with pre-1960 vehicles.)

Vehicles first used on or after 1 August, 1979

• After checking engine condition, and with the engine at normal
running temperature, the engine will be run up to full revs between
three and six times to see whether your engine passes the prescribed
smoke density test. (For what it's worth
-
2.5k for non-turbo cars; 3.0k
for turbo diesels. An opacity meter probe will be placed in your car's
exhaust pipe and this is not something you can replicate at home.)
Irrespective of the meter readings, the car will fail if
smoke
or vapour
obscures the view of other road users.
• IMPORTANT NOTE: The diesel engine test puts a lot of stress on the
engine. It is IMPERATIVE that your car's engine is properly serviced,
and the cam belt changed on schedule, before you take it in for the
MoT test. The tester is entitled to refuse to test the car if
he
feels that
the engine is not in serviceable condition and there are a number of
pre-Test checks he may carry out.