Fiat Bravo Quiz
Engine

Diesel engine only

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
5steps
~30min
2/5difficulty
010203040502015N·mlb·ft
Tightening torque found on this page
Done 0 of 5
Removal

The diesel cylinder head bolts are arranged in the same way as on the 1.4-L engine.

  • Remove the timing belt, see page 22.

  • Remove the cylinder head cover, see page 36.

  • Unscrew the rear timing belt cover from the cylinder head.

  • Remove the front exhaust pipe, see page 120.

  • Disconnect the fuel supply line and return line from the injection pump.

  • Disconnect the connector from the injection pump.

  • Disconnect the connectors from the temperature sensors on the thermostat housing and from the glow plugs.

  • Disconnect the vacuum hose for the brake booster from the vacuum pump on the cylinder head. If fitted, cut through the crimp clamp with side cutters and replace it with a screw clamp during installation.

  • Unhook the throttle cable and move it aside, see page 98.

  • Loosen all cylinder head bolts in a crisscross pattern by 1/2 turn using a Torx wrench, then unscrew the bolts completely and remove them. Keep the old cylinder head gasket for purchasing spare parts.

Installation

Installation is carried out in the reverse order of removal.

  • Always replace the cylinder head bolts during repairs.

  • Clean the cylinder head bolts and washers and oil them with engine oil. After oiling, let the parts drain for at least 30 minutes.

Caution: depending on piston protrusion, cylinder head gaskets of 3 different thicknesses are installed. The gasket thickness is identified by 0, 1 or 2 notches on the outer edge of the gasket. Take the removed gasket along when buying spare parts. When replacing, use only a gasket with the same number of notches as the one removed.

When placing the cylinder head, make sure that all pistons are at half height, i.e. no piston is at TDC (top dead center), otherwise engine damage may occur. If necessary, turn the crankshaft 1/4 turn further; after installation, turn it back to its original position. See also the chapter "Removing and installing the timing belt".

If the crankshaft, engine block, connecting rod or pistons have been replaced, the thickness of the cylinder head gasket must be determined again.

To do this, the piston protrusion must be measured (workshop work). 0 notches = thickness 1.60 mm, 1 notch = 1.70 mm, 2 notches = 1.80 mm.

  • Take the new cylinder head gasket out of its original packaging and place it on the cleaned sealing surfaces of the engine block and cylinder head. The marking "ALTO" must point up.

  • The cylinder head bolts are tightened in 5 steps.

    In each step, tighten the cylinder head bolts in the sequence 1 to 10, see figure T-10253 on page 40.

Tightening method for cylinder head bolts:

  1. Step: with torque wrench 20 N·m

  2. Step: with torque wrench 65 N·m

  3. Step: turn all bolts a further 90 (1/4 turn) with a rigid wrench

  4. Step: turn all bolts a further 90 (1/4 turn) with a rigid wrench

  5. Step: turn all bolts a further 90 (1/4 turn) with a rigid wrench

Caution: cylinder head bolts must not be retightened when the engine is warm.

Test yourself

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