1988 FIAT TEMPRA heating

Running The Vehicle
NEVER start the engine unless the gearbox is in neutral (or
'Park' in the case of automatic transmission) and the hand
brake is fully applied.
NEVER run catalytic converter equipped vehicles without the
exhaust system heat shields in place.
TAKE CARE when parking vehicles fitted with catalytic
converters. The 'cat' reaches extremely high temperatures and
any combustible materials under the car, such as long dry
grass, could be ignited.
Personal Safety
NEVER siphon fuel, antifreeze, brake fluid or other such toxic
liquids by mouth, or allow contact with your skin. Use a
suitable hand pump and wear gloves.
BEFORE undertaking dirty jobs, use a barrier cream on your
hands as a protection against infection. Preferably, wear
suitable gloves, available from DIY outlets.
WEAR IMPERVIOUS GLOVES for sure when there is a risk of
used engine oil coming into contact with your skin. It can
cause cancer.
WIPE UP any spilt oil, grease or water off the floor
immediately.
MAKE SURE that spanners and all other tools are the right size
for the job and are not likely to slip. Never try to 'double-up'
spanners to gain more leverage.
SEEK HELP if you need to lift something heavy which may be
beyond your capability. Don't forget that when lifting a heavy
weight, you should keep your back straight and bend your
knees to avoid injuring your back.
NEVER take risky short-cuts or rush to finish a job. Plan ahead
and allow plenty of time.
BE METICULOUS and keep the work area tidy
-
you'll avoid
frustration, work better and lose less.
KEEP children and animals right-away from the work area and
from unattended vehicles.
ALWAYS tell someone what you're doing and have them
regularly check that all is well, especially when working alone
on, or under, the vehicle.
Fire!
Petrol (gasoline) is a dangerous and highly flammable liquid
requiring special precautions. When working on the fuel
system, disconnect the vehicle battery earth (ground) terminal
whenever possible and always work outside, or in a very well
ventilated area. Any form of spark, such as that caused by an
electrical fault, by two metal surfaces striking against each
other, by a central heating boiler in the garage 'firing up', or
even by static electricity built up in your clothing can, in a
confined space, ignite petrol vapour causing an explosion.
Take great care not to spill petrol on to the engine or exhaust
system, never allow any naked flame anywhere near the work
area and, above all, don't smoke.
Invest in a workshop-sized fire extinguisher. Choose the
carbon dioxide type or preferably, dry powder but NEVER a
water type extinguisher for workshop use.
DON'T disconnect any fuel pipes on a fuel injected engine
without following the advice in this manual. The fuel in the
line is under very high pressure
-
sufficient to cause serious
injury. Remember that many injection systems have residual
pressure in the pipes for days after switching off. If necessary
seek specialist advice.
Fumes
Petrol (gasoline) vapour and that given off by many solvents,
thinners, and adhesives are highly toxic and under certain
conditions can lead to unconsciousness or even death, if
inhaled. The risks are increased if such fluids are used in a
confined space so always ensure adequate ventilation. Always
read the maker's instructions and follow them with care.
Never drain petrol (gasoline) or use solvents, thinners
adhesives or other toxic substances in an inspection pit. It is
also dangerous to park a vehicle for any length of time over
an inspection pit. The fumes from even a slight fuel leak can
cause an explosion when the engine is started.
v ,,, Oil;::;s

Fluid levels (if included) are monitored by LEDs f, o and
p, indicating the levels of the fluid reservoirs.
A red LED illuminates at the position on the check panel
corresponding to a side door or a hatchback/tailgate
that is not properly closed.
SIDE AND TAIL LIGHTS
When the side and tail lights are turned on, the check
panel monitors the light bulbs, fuses and circuits.
• LED g monitors the front side lights.
• LED i monitors the tail lights.
If one of the two fuses protecting the following bulbs
blows, LEDs g, i, and m illuminate.
NUMBER PLATE LIGHTS
• LED m indicates when one or both of the number
plate light bulbs have burnt out.
REAR FOG LIGHTS
• When the fog-guard lights are turned on, LED h
monitors the light bulbs.
• When the fuse blows or a circuit malfunction occurs,
LED h illuminates, but not the panel indicator.
STOP LIGHTS
If one or both stop lights burn out, the fuse blows or a
circuit malfunction occurs, LED I or n illuminates when
braking.
• LED n monitors the left stop light.
• LED I monitors the right stop light.
If both bulbs burn out at the same time or brake pedal
switch malfunction occurs, both LEDs I and n
illuminate.
ENGINE OIL LEVEL
• LED f illuminates when the engine oil level is low (key
at MAR,engine not running).
The oil level monitoring system does not operate when
the engine is running. If the oil level warning LED
illuminates when driving, a circuit sensor malfunction
has occurred.
When starting the car on a hill or within 10 minutes of
switching off the engine the warning light may
illuminate (event will be stored in system memory). Start
the engine again on level ground to ensure the oil level
is sufficient.
COOLANT
A low coolant level is indicated by LED o (key at MAR).
The LED also illuminates when a sensor or circuit
malfunction occurs.
WINDSCREEN AND REAR SCREEN WASH LEVELS
• LED p illuminates (key at MAR) when the level in the
windscreen or rear screen wash reservoirs are low.
• The LED also indicates when a circuit or sensor
malfunction occurs.
• 5. HE ATI IMG AMD VENTILATION
CONTROLS
5A. Air volume control
-
Adjust
the dynamic air flow (fan OFF)
by turning the knob up to I.
Continue turning the knob to
the right to increase the air
flow (i.e. fan ON).
5B. Air temperature control -
The temperature will increase
the further you turn the air
temperature knob to the right
(red zone).
HEATING
HEAT DISTRIBUTION
With the air temperature
knob (56) turned to the
red zone and the air
volume control knob (5A)
turned to the desired fan
speed, turn the air
distribution knob (5C) to:
• 2
-
In sunny, cold weather.
• 3
-
For heating to footwell vents.
• 4
-
Demist the windows.
• Also, turn the air volume control knob (5A) to level II
or III.
VENTILATION
• Turn the air distribution control to 5.
• Turn the air temperature adjustment knob fully anti-
clockwise to the blue zone.
• Turn the air volume control knob to the desired fan
speed.
• Turn the air distribution control to 5.
When the car is moving the volume of the air entering
the passenger compartment can be reduced by turning
the fan knob to the left of 1.
DUAL TEMPERATURE
• Turn the air temperature adjustment knob to an
intermediate position.
• Turn the air distribution control knob to 2.
The temperature decreases the
further you turn the temperature control knob to the
left (blue zone).
Warmer air is delivered to the footwell vents and cooler
air to the dashboard vents.

AIR CONDITIONING (EARLY MODELS)
Air conditioning is an optional extra fitted to some
models of Tipo and Tempra.
AIR CONDITIONING SWITCH
5D. When you turn on the air
conditioning it will initially operate at
the first fan speed even if set at
position 0.
AIR RECIRCULATION SWITCH
5E. When pressed, no outside air
enters the passenger compartment.
Use the recirculation feature for fast
cooling or heating. Select
recirculation whenever you drive in
heavy traffic, in a tunnel or under any conditions where
the air is heavily polluted.
Use the following settings for maximum cooling:
• Turn the air temperature adjustment knob to the blue
zone.
• Turn the air conditioner switch ON.
• Turn the air volume control knob to position Mil.
• Turn the air distribution control knob to 5.
AIR CONDITIONER HEATING
Turning the air temperature adjustment knob to the red
zone:
• Turn the air volume control knob to the desired fan
speed.
• Turn the air distribution control knob (illustration 50
to 2 cold, sunny weather or 3 heating.
IMPORTANT NOTE: The air conditioner and heater
may be used at the same time during winter or
whenever the weather is particularly humid, for
optimal demisting .
DEFROSTING THE WINDSCREEN AND WINDOWS
• Turn the air temperature adjustment knob (illustration
56) to the red zone.
• Select fan speed 3 or 4.
• Turn the air distribution control knob to 4.
• Press the air conditioner switch for efficient demisting.
VENTILATION
• Turn the air temperature control knob (illustration SB)
to the blue zone.
• Select the fan speed desired.
• Turn the air distribution control knob (illustration 50
to position 5.
AIR CONDITIONING (LATER MODELS)
5F. The air conditioning controls fitted as an optional
extra to some later models of Tipo or Tempra are
shown in illustration 5F
TEMPERATURE CONTROL
• Use the TEMP button to select the cabin temperature.
• Each time the TEMP button (up or down arrow) is
pressed the temperature will increase or decrease by 1°C.
• If the temperature displayed exceeds 32°C or is lower
than 18°C the words HI or LO will appear on the
display.
• When the ECON button is selected the temperature
will remain static until the outside temperature drops
sharply or until the ECON button is switched off.
AIR VOLUME CONTROL
• Press the AIR left or right arrow buttons to increase or
decrease the air flow into the passenger compartment.
AIR DISTRIBUTION CONTROL
5G. • Press the demisting button 1
to demist the windscreen and side
windows.
• Select button 2 to direct the air
flow to the passenger face vents.
• Press button 3 to direct the air
flow towards the footwell and face
vents.
• Selecting button 4 will direct the
air flow to the floor vents.
AIR RECIRCULATION SWITCH
• When the air recirculation button (illustration 5G, 5)
is selected no outside air enters the passenger
compartment.
AUTOMATIC OPERATION
• When both LEDs next to the AUTO button light up,
the system is fully automatic.
• When only one LED lights up the system is in manual
operation.
• When the OFF button is pressed the LED next to it will
light up and all of the systems other LEDs will turn off,
indicating that the air control system has been switched
off.
vh
5G

CRANKSHAFT
• Step 1: TURBO ONLY: Before fitting the crankshaft,
install the four piston sprays (a) and stake the retaining plates
(arrowed).
Q Step 2: Locate the main bearing shells so that they are
firmly seated and their tabs engage with the slots in the
journal webs.
• Step 3: Apply some grease to the smooth side of the
thrust washers and 'stick' them in position on both sides of
the rear main bearing web (at the flywheel end).
• Step 4: Oil the shells liberally with fresh engine oil and
lower the crankshaft into position.
• Step 5: Fit the remaining halves of the shells into the
bearing caps. Oil the journals and position the caps the right
way round and in the correct order.
• Step 6: Screw the bolts in finger-tight and check that the
crankshaft rotates freely and smoothly.
Q Step 7: Tighten the bolts evenly and progressively until
the specified torque setting is reached, see Chapter
3,
Facts
and Figures. Check again that the crankshaft rotates
smoothly.
• Step 19:

Lift
the crank-
shaft clear of the
cylinder block,
retrieve the
other halves of

the
bearing
shells...
• Step 20:

...and
the two

thrust
washers

from
the rear
main bearing
web.
• Step 21:
TURBO
ENGINES ONLY.
Unbolt and

remove
the four
piston cooling

sprays
(a) from

the
cylinder
block oil gallery.

The
bearing shell
positions are
arrowed.
Job 24. Diesel engine -
reassembly.
Before starting work, read the notes at the beginning of
Job 6 for petrol engine reassembly
-
the checks and
preparation being basically the same for diesel engines.
H INSIDE INFORMATION! TURBO ENGINES ONLY. The
piston cooling sprays must be checked for serviceability
before refitting. Each spray contains its own valve which

must
open at between 1.25 and 1.75 bar. Below this
figure could cause excessive oil burning and low oil
pressure. Above this figure might result in the piston
overheating and its subsequent failure. Have your FIAT
dealer carry out this check, and replace any faulty units if
necessary. Q
• Step 9: Fit new oil
seals to the two seal
carriers.
• Step 10: Fit the
rear oil seal carrier (with
its new seal), using a
new gasket. Lubricate
the seal (illustration Job

24-9,
part b) and
lightly oil the gasket (a).
• Step 11: Position Nos. 1 and 4 crank pins at Top Dead
Centre (TDC), then fit the flywheel with its TDC mark facing
the cylinder head surface. Screw in the fixing bolts and tighten
to their specified torque. See Chapter
3,
Facts and Figures
Job 23-21
Q Step 8: Turn and lever the crankshaft tight against the
timing end and check the crankshaft end float by using a
feeler gauge between the thrust washer on the timing side of
the web and the crankshaft. Thicker washers are available if
required. See Chapter
3, Facts and Figures.

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

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.

ll
s
0
fe-x-
p
X
rsj
r^i
saCD-
TTT-f
o> SCD^
®0>
—«-f • =1=61
Diagram 2: Model: 1600 DGT
-
Starting
-
Digiplex Electronic Ignition
-
Charging
-
Oil Pressure Warning Light
-
Choke Warning Light
(NB. 1400 is similar)
sIJa^VL
Or
n
lK\i
—H— a
s £
—1
—EE3-*'
—PTwvM'
—KA/Wj—>'
—fvWM—>'
j'TT'
' jE1^
si's*
WwWw sLvl/4/vL
—
Diagram 3: Model: 1930 Turbo Diesel
-
Starting
-
Charging
-
Plug Preheating System and Warning Light
-
Oil Pressure
Warning Light
158