Fiat Bravo Quiz
Engine

1.6 L engine

In this manual: Engine
Dear Reader — 1Engine — 35Engine lubrication — 3Engine cooling — 10Ignition/spark plugs — 14Fuel system — 10Petrol fuel injection — 13Diesel injection system — 13Exhaust system — 7Clutch — 7Transmission / Gearshift / Automatic Transmission — 5Front Axle — 11Rear axle — 4Steering — 9Wheel alignment — 1Brake system — 22Wheels and tyres — 10Body — 34Heating — 6Electrical system — 39Lighting system — 14Instruments — 7Windscreen wiper system — 8Vehicle care / tools — 6Jump Starting / Towing the Vehicle — 3Jacking up the vehicle — 1Fiat Bravo / Brava Maintenance Schedule — 1Maintenance — 38Wiring diagrams — 5
6steps
~36min
2/5difficulty
070140210280350220162N·mlb·ft
Tightening torque found on this page
Done 0 of 6
Removal

  • Disconnect the negative (-) battery cable. Caution: this may erase electronic memories, such as the radio code. Observe the notes in the chapter "Removing and installing the battery".

  • Mark the position of the right front wheel relative to the wheel hub with paint. This allows the balanced wheel to be refitted in the same position. When loosening the wheel bolts, the vehicle must be standing on the ground. Raise the vehicle, then remove the front wheel.

  • Remove the V-belt for the power steering pump and the poly-V belt, see page 58.

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  • Remove the intake duct from the timing belt cover.

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  • Turn the engine until mark - 1 - on the crankshaft pulley is aligned with mark - 2 - on the rear timing belt cover. At the upper transmission inspection window - 3 - the flywheel must align with the "0" mark; see detail.

  • The Fiat workshop checks the TDC position of the piston in cylinder 1 with a dial gauge as follows.

    To do this, remove the spark plugs; see page 298.

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  • Screw a dial gauge with a suitable holder into cylinder 1; the gauge plunger rests on the piston. Cylinder 1 is on the timing belt side of the engine.

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  • From underneath the vehicle, remove the flywheel cover plate (arrows) and lock the flywheel with a suitable tool so the crankshaft does not turn when the pulley bolt is loosened.

    The illustration shows the Fiat tool, which can also be made from sheet metal. Instead of the tool, the flywheel can be locked with a screwdriver; an assistant is required.

  • Remove the crankshaft V-belt pulley with a 36 mm socket (SW 36), arrow in illustration t-10218.

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  • Remove the timing belt cover bolts (arrows) and take off the cover.

    The illustration shows the lower bolts.

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  • Mark the position of the camshaft gears relative to each other with a coloured pencil or scribe - 1 -. Note: these marks are essential, as no other markings are present. Fiat workshops lock the camshafts with special tools when the timing belt is removed. This is only necessary if a basic engine setting is carried out or new parts are installed. The illustration does not show the Fiat engine.

  • To refit the timing belt exactly, also count the number of timing belt teeth between the 2 marked positions - a - of the two camshaft gears and note the number.

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  • Loosen the nut -arrow- on the automatic belt tensioner.

    Press the tensioner pulley away from the timing belt.

  • Remove the timing belt, then do not change the position of the gears any more.

Note: the following precise fixing of the engine must only be carried out if there are doubts about the correct position of the engine. Various special Fiat tools are required for this. If the camshaft has to be turned through a larger angle, make sure that no piston is at top dead centre (TDC), otherwise valves or pistons may be damaged. If necessary, set the crankshaft approx. 90 (1/4 revolution) before or after TDC.

However, do not turn the pulley more than 90° in total.
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  • Fiat workshops lock the camshafts with special tools when the timing belt is removed. To do this, first unscrew the ignition coils, then the rear camshaft covers -arrows-.

    Remove the ignition coils, see page 86.

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  • Screw Fiat tools 1860874000 on instead of the covers; a key spring - 1 - on the tool engages in the camshaft - 2 -. The camshafts are then locked in TDC position.

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  • At the Fiat workshop, the crankshaft pulley is fitted with an angle disc and a pointer on the engine block. The pointer is screwed in in place of the V-ribbed belt tensioner.

  • Remove the crankshaft locking tool and turn the crankshaft 10 to the left and 10 to the right in each case. Observe the dial gauge at the spark plug thread of cylinder 1: it must deflect equally in both directions, otherwise TDC is not in the centre. Turn the crankshaft until the dial gauge pointer shows the same value to the left and right when turning the crankshaft. The exact TDC is in the centre.

  • Lock the crankshaft flywheel again at the exact TDC position determined.

Installation
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  1. Crankshaft

  2. Oil pump

  3. Idler pulley

  4. Intake camshaft

  5. Exhaust camshaft

  6. Tensioner pulley

  • Fit the timing belt so that the arrow on the timing belt points in the direction of engine rotation.

    Start at the crankshaft gear - 1 - and fit the timing belt following the numbering in the illustration. Viewed from the right-hand side of the vehicle, the engine rotates clockwise.

Note: when fitting the timing belt, neither the camshaft nor the crankshaft position may be changed.

Otherwise, serious engine damage may occur, or the engine will no longer deliver its full output. After the timing belt has been tensioned, check the camshaft and crankshaft marks again; they must line up as they did before removal.
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  • Unscrew the bolt at position - 1 - on the upper left of the tensioner pulley and screw in the Fiat tool, see illustration. The tool's function is to press the tensioner pulley towards the timing belt. It can also be made yourself using the illustration.

  • Push the tensioner pulley aside with the tool until the pointer is at the right-hand stop, see detail in the illustration. The tensioner pulley is then at maximum tension.

    Tighten the tensioner pulley fixing nut.

  • Note: if used, unscrew the dial gauge from the spark plug thread of cylinder 1. Remove the locking tools from the camshafts. Remove the angle disc and pointer from the crankshaft gear.

  • Insert the key into the crankshaft, slide on the crankshaft pulley and tighten the nut SW 36 to 220 N·m with the crankshaft locked.

  • Remove the crankshaft locking tool.

  • Refit the flywheel cover plate.

  • Turn the crankshaft 2 revolutions in the direction of engine rotation (clockwise). This distributes the timing belt tension evenly.

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  • Carefully loosen the tensioner pulley fixing nut with a ring spanner, holding the tensioner pulley with the special tool; otherwise the timing belt will slacken again.

    Release the tensioner pulley and position the movable pointer - 1 - opposite the mark - 2 -. In this position, tighten the timing belt tensioner nut with a torque wrench to 25 N·m.

  • Turn the crankshaft twice in the direction of engine rotation and check the setting again. The marks on the camshaft gears must align, and at the same time the mark on the crankshaft gear, see illustrations under "Removal". As a check, count the timing belt teeth between the 2 positions marked on the two camshaft gears during removal. The number must match the number noted during removal.

  • If the match is not exact, slacken the timing belt, offset it accordingly on the belt pulleys and tension it again.

  • Unscrew the timing belt tensioning tool and instead screw the plug back into the engine block.

  • Screw on the 2 camshaft end covers, see illustration T-10223 under "Removal".

  • Fit and connect the ignition module to the cylinder head, see page 86.

  • Fit the spark plugs, see page 298.

  • Fit the timing belt cover and tighten the screws.

  • Route the air intake pipe along the timing belt cover.

  • Fit and tension the power steering pump V-belt and the V-ribbed belt, see page 58.

  • Clip the poly-V belt cover into the wheel arch and bolt it in place.

  • Position the right front wheel so that the marks made during removal line up. Before fitting, lightly grease the wheel centering seat and the conical surface of the wheel bolts with wheel bearing grease. Do not grease or oil the wheel bolt threads. Fit the wheels and lower the vehicle, then tighten the wheel bolts in a crosswise sequence to 90 N·m.

  • Connect the battery earth cable (-). Set the clock.

    Program the radio stations.

Test yourself

A quick Fiat Bravo quiz: every answer comes with an explanation and a link to the manual page.