1988 FIAT TEMPRA wheel size

and explosions. Do not allow resin or 2-pack adhesive hardener,
or that supplied with filler or 2-pack stopper, to come into
contact with skin or eyes. Read carefully the safety notes
supplied on the can, tube or packaging and always wear
impervious gloves and goggles when working with them.
Fluoroelastomers
Fluoroelastomers are commonly used for oil seals, wiring and
cabling, bearing surfaces, gaskets, diaphragms, hoses and '0'
rings. If they are subjected to temperatures greater than 315
degrees C, they will decompose and can be potentially
hazardous. Some decomposition may occur at temperatures
above 200 degrees C, and it is obvious that when a car has
been in a fire or has been dismantled with the assistance of a
cutting torch or blow torch, the fluoroelastomers can
decompose in the manner indicated above.
According to the Health and Safety Executive, "Skin contact
with this liquid or decomposition residues can cause painful and
penetrating burns. Permanent irreversible skin and tissue
damage can occur". Damage can also be caused to eyes or by
the inhalation of fumes created as fluoroelastomers are burned
or heated.
After a vehicle has been exposed to fire or high temperatures:
1. Do not touch blackened or charred seals or equipment.
2. Preferably, don't handle parts containing decomposed
fluoroelastomers, but if you must, wear goggles and PVC
(polyvinyl chloride) or neoprene protective gloves whilst doing
so. Never handle such parts unless they are completely cool.
3. Contaminated parts, residues, materials and clothing,
including protective clothing and gloves, should be disposed of
by an approved contractor to landfill or by incineration
according to national or local regulations. Oil seals, gaskets and
'0' rings, along with contaminated material, must not
be burned.
1. Always have a fire extinguisher of the correct type at arm's
length when working on the fuel system. If you do have a fire,
DON'T PANIC. Use the extinguisher effectively by directing it at
the base of the fire.
2. NEVER use a naked flame anywhere in the workplace.
3. KEEP your inspection lamp well away from any source of
petrol (gasoline) such as when disconnecting a carburettor float
bowl or fuel line.
4. NEVER use petrol (gasoline) to clean parts. Use paraffin
(kerosene), white spirits, or, a proprietary degreaser.
5. NO SMOKING. There's a risk of fire or of transferring
dangerous substances to your mouth and, in any case, ash
falling into mechanical components is to be avoided.
FACT FILE: FOUR WHEEL DRIVE CARS
• Whenever you have to raise a wheel off the
ground and turn it by hand, always ensure that
the opposite-side's wheel to the one being lifted is
also off the ground and free to turn and that both wheels remaining
on the ground are held by the parking brake (if possible) and
securely chocked in both directions.
• ALWAYS have the gearbox in neutral (or 'N' in the case of
automatics). In the case of
some
4 wheel drive automatics and those
with permanent 4WD, it is necessary to disengage the 4WD system
by special means.
• Consult your handbook or seek advice from your main dealer.
6. BE METHODICAL in everything you do, use common sense,
and think of safety at all times.
ENVIRONMENT FIRST!
The used oil from the sump of
just
one car
can
cover
an
area of
water the size of two football pitches, cutting off the oxygen
supply
and
harming swans, ducks, fish and other river lift.
When you drain your engine oil
-
don't oil the drain!
Pouring oil
down the
drain will
cause
pollution. It is
also an
offense.
Don't mix used
oil with other
materials, such
as paint and
solvents,
because this
makes
recycling
difficult.
Take used oil
to an oil
recycling bank.
Telephone
FREE on 0800 663366 to find the location of your nearest oil
bank, or contact you local authority recycling officer.
OIL POLLUTES WATER
USE YOUR BRAIN-
NOT THE DRAIN!

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

PART F: TORQUE WRENCH SETTINGS
Key for engine types and sizes: A
-
1372cc; B
-
1581cc;
C
-
1697cc Diesel; D
-
1929cc Diesel; E
-
1929cc Turbo Diesel.
Engine
Screw retaining caps to crankcase (M10 x 1.25)
Screw retaining intermediate and central caps to crankcase (M12 x 1.25)...
Self-locking screw retaining front and rear caps to crankcase (M12 x 1.25)
Bolt, cylinder head to engine block (M10 x 1.25)
IMPORTANT NOTE: All torque settings shown in
Newton-meters (Nm). Bolt, nut or screw sizes in
brackets in left-hand column.
Bolt, cylinder head to engine block (M12 x 1.25)
Bolts, top to bottom cylinder head (M8)
Nut for connecting rod cap retaining bolt (M9 x 1)
Screw, connecting rod cap (M10 x 1)
Screw retaining engine vent to crankcase
(M8)
(M8)
Screw retaining front cover to crankcase
(MlOx 1.25)
(M8)
Bolt retaining rear cover (flywheel side) to crankcase (M6)
Nut retaining inlet and exhaust ducts to cylinder head
(M8)
(M8)
Screw, flywheel to crankshaft
(M10x 1.25)
(M12
x
1.25)
Lower belt cover retaining screw (M8)
Screw, damping flywheel to drive gear (M8)
Nut retaining auxiliary drive pulley to crankshaft (M20 x 1.25)
Screw retaining drive shaft to crankshaft (*) (M14 x 1.5 left)
Screw, timing gears
(M10x 1.25)
(M12x 1.25)
Belt tensioner retaining bolt
(M8)
(M10x 1.25)
Fixed belt tensioner retaining screw (M10 x 1.25)
Screw retaining auxiliary component driven gear (oil pump) (M10 x 1.25)
Nut for camshaft cap retaining stud (M8)
Nut retaining camshaft and air vacuum pump end mounts (M8)
Combustion prechamber retaining ring (M32 x 1.5)
Nut, injection pump stud (M8)
Screw, injection pump (M8)
Nut fastening flexible block to coolant pump case (M12 x 1.25)
Nut, injection pump gear (M12 x 1.75)
Screw retaining reaction bracket to oil filter support and injection pump (M8).
Top retaining screw or nut, oil filter support and injection pump (M12 x 1.25)
Lower retaining screw, oil filter support and injection pump (M10 x 1.25)
Complete injector (M24 x 2)
Glow plugs (M12 x 1.25)
Nuts retaining fuel delivery line to injection pump and injector (M12 x 1.25)...
Bolt, coolant pump to engine block (M8 x 1)
Bolt retaining cover and bracket to coolant pump case (M8)
Oil pressure switch (M14 x 1.5)
Coolant temperature sender unit
(M16 x 1.5 tapered)
(M18x 1.5 tapered)
Coolant temperature thermal switch (M16 x 1.5 tapered)
(*) The bolt need not be greased.
A B C D E Torque (Nm)
• • 80
• • • 113
• • • 113
• • 40
+
90 degrees
+ 90 deqrees
• • • 100
+
90 degrees
+ 90 deqrees
• • 28
• • 51
• • • 25 + 50 deqrees
• •
• • •
25
20
• • 50
25
• 10
• •
• • •
28
25
• •
• • •
83
142
• • 25
• • • 28
• • 155
• • • 190
• •
• • •
83
118
• •
• • •
25
44
• • • 44
• • 83
• • • 19
• • • 19
• • • 118
• • • 25
• • • 25
• • 80
• • • 49
• • • 29
• • • 98
• • • 71
• • • 55
• • • 15
• • • 29
• • • 25
• • • 23
32
• •
• • • 34
30
• • 30
expert22 fl/i* http://rutracker.org 23

PART C: VEHICLE RAISED OFF THE GROUND
Bodywork Structure
01
.
Any sharp edges on the external bodywork, caused by damage or corrosion will cause the vehicle to fail.
02 . Check all load bearing areas for corrosion. Open the doors and check the sills inside and out, above and below. Any corrosion in structural metalwork within 30 cm (12 in.) of seat belt mounting, steering and suspension attachment points will cause the vehicle to fail.
Wheels and Tyres
Under the Front of the
Car
You will need to support the front of the car on axle stands with the rear wheels firmly chocked in both directions.
OE . Have your helper turn the steering from lock to lock and check that the steering turns smoothly and that the brake hoses or pipes do not contact the wheel, tyre or any part of the steering or suspension.
TWI
Ob . To pass the test, the tread must be at least 1.6 mm deep throughout a continuous band comprising the central three-quarters of the width of the tread. The Tread Wear Indicators (TWI) will tell you when the limit has been reached, on most tyres.
IMPORTANT NOTE: Tyres are past their best, especially in wet conditions, well before this point is reached!
04 . Check that the front tyres match and that the rear tyres match each other
-
in terms of size and type but not necessarily make. They must be the correct size for the vehicle and the pressures must be correct.
05 . With each wheel off the ground in turn, check the inside and the outside of the tyre wall for cuts, lumps and bulges and check the wheel for damage. Note that tyres deteriorate progressively over a period of time and if they have degraded to this extent, replace them.
07 . Have your assistant hold down the brake pedal firmly. Check each brake flexible hose for bulges or leaks.
o 8. Inspect all the rigid brake pipes underneath the front of the vehicle for corrosion or leaks and also look for signs of fluid leaks at the brake calipers. Rigid fuel pipes need to be checked in the same way.
09 . At each full lock position, check the steering rack rubber gaiters for splits, leaks or loose retaining clips.
o 10. Check the track rod end dust covers to make sure they are in place.
o 11. Inspect each constant velocity joint gaiter
-
both inners and outers
-
for splits or damage. You will have to rotate each wheel to see the gaiters all the way round.
O 12. Check all of the suspension rubber mountings, including the anti-rollbar mountings (when fitted). Take a firm grip on each shock absorber in turn with both hands and try to twist the damper to check for deterioration in the top and bottom mounting bushes.
o 13. Underneath the front wheel arches, check that the shock absorbers are not corroded, that the springs have not cracked and that there are no fluid leaks down the body of the shock absorber.
o 14. While under the front end of the car, check the front of the exhaust system for security of fixing at the manifold, for corrosion and secure fixing to the mounting points.
o 15. Preferably working with a helper, grasp each front road wheel at the 12 o'clock and 6 o'clock positions and try rocking the wheel. Look for movement or wear at the suspension ball joints, suspension mountings, steering mountings and at the wheel bearing
-
look for movement between the wheel and hub. Repeat the test by grasping the road wheel at 3 o'clock and 9 o'clock and rocking once more.
o 16. Spin each wheel and check for noise or roughness in the wheel bearing and binding in either the wheel bearing or the brake.
IMPORTANT NOTE: Don't forget that on front wheel drive cars, the gearbox must be in neutral. There will be a certain amount of noise and drag from the drivetrain components.
O 17. If you suspect wear at any of the suspension points, try levering with a screwdriver to see whether or not you can confirm any movement in that area.
o 18. Vehicles fitted with other suspension types such as hydraulic suspension, torsion bar suspension etc. need to be checked in a similar way with the additional point that there must be no fluid leaks or damaged pipes on vehicles with hydraulic suspension.
Underneath the Rear
of the Car
O 19. Inspect the rear springs for security at their mounting points and for cracks, severe corrosion or damage.
o 20. Check the rear shock absorbers in the same way as the checks carried out for the fronts.
o 21. Check all rear suspension mounting points, including the rubbers to any locating rods or anti-rollbar that may be fitted.
O 22. Check all of the flexible and rigid brake pipes and the fuel pipes just as for the front of the vehicle.
30

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