1988 FIAT TEMPRA coolant capacity

FACT FILE: DIESEL ENGINES AND SPECIAL TOOLS
• As the
construction and
assembly of the
diesel engine is,
for the best part,
the same as the
petrol engines,
this section details
only those proce-
dures which are
specific to the
diesel.
• Major differ-
ences lie in the
areas of the
cylinder head and
camshaft drive
belt.
• Where
inspection of
components such
as crankshaft,
camshaft, pistons,
conrods, cylinder
head face, flywheel
etc. is not detailed
within this
section, refer to
the relevant infor-
mation in the
Petrol Engine
section, Job 6,
under Checking
for wear -
information which is common to all engine types.
• In view of the complexity of the diesel engine's camshaft drive arrangement, the need for special tooling and the
accuracy required in adjusting camshaft
timing and injection pump timing, we
strongly recommend that any work involving
disturbance of the timing belt or injection
pump is entrusted to a FIAT dealer.
• The following information is provided only
for those who have technical experience of
diesel engines, along with access to the
required tooling.
• Familiarise yourself with this drawing,
showing the cylinder head, block and other
major components referred to in the
following text.
1
-
cylinder block 2
-
sump 3
-
cylinder head 4
-
injection pump mounting 5
-
oil pick-up and pump 6
-
threaded bush 7
-
rear crank seal carrier 8
-
front cover/oil seal 9
-
plate
10
-
head gasket 11
-
camshaft rear bearing 12
-
camshaft front bearing 13
-
exhaust manifold 14
-
intake manifold 15
-
coolant pipe 16
-
water pump 17
-
cam cover 18
-
gasket
19-seal 20
-
valve 21
-
valve guide 22
-
spring seat 23
-
thermostat housing 24
-
oil filler cap 25
-
compression washer
1
-
strainer with gauze filter 2
-
geared oil pump 3
-
oil pressure relief valve 4
-
total capacity cartridge oil filter with safety valve to cut out filter element becomes blocked 5
-
main oil delivery pipe supplying various / components 6
-
oil delivery pipe to camshaft
IHSupply circuit I
I Return
circuit
a
-
camshaft b
-
vacuum pump c
-
bucket tappets d
-
valve guides e
-
valves f
-
piston g
-
gudgeon pin assemblie; h
-
conrod i
-
crankshaft j
-
crank journal k
-
flywheel

are very clean, and great care is taken, it is possible to take an
average protrusion measurement based on measuring the
protrusion at each side (A) and (B) of the piston crown, using
a steel straight-edge and feeler gauges. Use the HIGHEST
average measurement of the four pistons as your working
figure.
Q Step 2: Now,
referring to the illus-
tration, select the
appropriate one of the
three available cylinder
head gasket thicknesses
as follows:
Measured protrusion
Up to 1.05 mm
1.05
-
1.20 mm
Over 1.20 mm
B INSIDE INFORMATION! The cylinder head gasket is of
the special 'ASTADUR' type and polymerises during
engine use, becoming much harder. It should only be
removed from its wrapping immediately before fitting
and then should be kept free of contamination by oil,
grease or water. Fit only between clean and dry cylinder
head and block surfaces. B
• Step 3: Discard the old gasket and thoroughly clean the
cylinder block mating surface and dry off. Make sure that the
bores are free of gasket particles.
B INSIDE INFORMATION! It is important to be sure that
all the cylinder head bolt holes in the block are clear
right down to their bottoms. The bolts and washers
should be cleaned, lubricated with engine oil and then
drained for at least 20 minutes before fitting. B
• Step 4: Clean the cylinder head, taking care not to gouge
the aluminium surface
-
use a straight edge that isn't too
sharp.
Q Step 5: Place the new gasket on the cylinder block with
the word 'ALTO' facing upwards.
• Step 6: Lower the head into position and screw all the
bolts in finger tight.
LI Step 7: Note the numbered tightening order of the ten
main cylinder head bolts. Using a suitable torque wrench,
proceed to tighten the ten main bolts in the following
sequence:
Stage i) Tighten to 50 Nm.
Stage ii) Tighten to 100 Nm.
• Step 8: Using
a suitable bar,
continue to tighten
IN EXACTLY THE
SAME ORDER AS
BEFORE, as
follows:
• Step 9:
Finally, using a
torque wrench,
Tighten the five
remaining smaller
bolts to 30 Nm.
Q Step 10: Now reverse the remaining steps in Job
74
to
reinstate all items removed or disconnected during removal of
the cylinder head. See Chapter
3,
Facts and Figures for
relevant torque figures and the coolant mixture and capacity.
• Step 11: Bleed the fuel system
-
refer to PART
F: FUEL

AND EXHAUST
• Step 12: Prior to initial start up, check that everything is
properly connected and secured. Run the engine to normal
working temperature, switch off and check all fuel lines and
coolant hoses for leaks. Allow to cool and check the coolant
level.
Gasket identification
No notches (1.65 mm gasket)
One notch (1.80 mm gasket)
Two notches (1.95 mm gasket)
Stage iii) Tighten
each bolt through
ninety degrees
(one quarter turn).
Stage iv) Tighten each bolt through a further ninety degrees.

gjpjgjjl 'READING' YOUR SPARK PLUGS
Champion explain how the condition of spark plug firing ends can act as a guide to the state of tune and general condition of the engine. The examples shown are assumed to be the correct grade for the engine.
NORMAL
Core nose lightly coated with grey-brown deposits. Electrodes not burning unduly
-
gap increasing by about 0.01 mm every 1,000 miles approximately (with the use of unleaded fuel). Spark plugs correct for engine.
OIL FOULING
Deposits can short-circuit firing end, weakening or eliminating spark. Causes: worn valve guides, bores or piston rings, or while new engine is running-in. Replace spark plugs. Cure oiling problem.
SPLIT CORE NOSE
(May first appear as hair-line-crack). Probably caused by: Over-advanced ignition timing. Faulty distributor advance mechanism. Use of low octane fuel. Weak mixture. Manifold air-leaks. Cooling system problems. Incorrect gap-setting technique.
HEAVY DEPOSITS
Possible causes: Fuel or oil additives. Excessive upper cylinder lubricant. Worn valve guides. Unvarying speed (stationary engine). Replace spark plugs.
OVERHEATING
Likely causes are: Over-advanced ignition timing, or faulty distributor advance mechanism. Use of low octane fuel. Weak mixture. Discard spark plugs showing signs of overheating, and cure the cause.
CARBON FOULING
Look for dull black sooty deposits. (Unleaded fuel carbon fouling can appear similar to oil fouling). Deposits can short circuit the firing end, weakening or eliminating the spark. Check for: Over-rich mixture, faulty choke or clogged air filter. Replace spark plugs.
INITIAL PRE-IGNITION
Caused by serious overheating. Causes are those listed for overheating, but may be more severe. Corrective measures are urgently needed before engine damage occurs. Discard plugs in this condition.
FACT FILE: CORRECT INSTALLATION
• Make sure seating areas are perfectly clean.
• Insert plug finger tight to seat. Ensure plug 'spins' freely.
• PLUGS WITH SEATING GASKET: Tighten to relevant torque setting.
• PLUGS WITH TAPER SEATS: Tighten a further l/16th turn ONLY - no further!
• Overtightening can damage cylinder head or make taper seat plugs impossible to remove.
RECOMMENDED FL LUBRICANTS
FOR YOUR FIAT TIPO ARID TEMPRA
COMPONENT/ TIPO & TEMPRA TIPO SELECTA & TEMPRA SELECTA TIPO & TEMPRA DIESEL CAPACITY 1.4 and 1.6 1.6 and 1.6 i.e. 1.7 D, 1.9 Dand 1.9 TD
ENGINE SELENIA 20K SELENIA 20K SELENIA TURBO DIESEL CAPACITY 3.8 L 3.8 L/4.2 L 5.0 L
MANUAL TRANSMISSION TUTELA ZC80/S -TUTELA ZC80/S CAPACITY 2.0 L -2.0 L
AUTOMATIC TRANSMISSION -TUTELA CVT -CAPACITY -3.5 L (a) -
DIFFERENTIAL(S) FROM GEARBOX FROM GEARBOX FROM GEARBOX CAPACITY ---
STEERING BOX TUTELA K854 TUTELA K854 TUTELA K854 CAPACITY 80 g (b) 80 g (b) 80 g (b)
CONSTANT VELOCITY JOINTS TUTELA MRM2 TUTELA MRM2 TUTELA MRM2 CAPACITY 95 g (each) 95 g (each) 95 g (each)
BRAKE FLUID RESERVOIR TUTELA PLUS 3 TUTELA PLUS 3 TUTELA PLUS 3 CAPACITY (NON-ABS) 0.40
L
(c) 0.40 L (c) 0.40
L
(c)
COOLANT PARAFLU 11 PARAFLU 11 PARAFLU 11 CAPACITY 6.5 L(d) 6.5 L(d) 8.8
L
(d)
WINDSCREEN WASHER TANK AREXONS DP1 AREXONS DP1 AREXONS DP1 CAPACITY 5.0 L 5.0 L 5.0 L
NOTES: (a) DRAIN/REFILL CAPACITY (b) IF MODEL FITTED WITH POWER ASSISTED STEERING USE 0.75 L TUTELA Gl/A (c) IF ABS BRAKING IS FITTED USE 0.52 L TUTELA TOP 4 (d) COOLING SYSTEM AT A CONCENTRATION OF 50% COOLANT TO 50% WATER
CHANGE PERIODS: See Chapter 5, Service Intervals
154