Fiat Brava - Page 617

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Bravo-Brava Bodywork

Replacing structural body panels

70.

Welding the spare part

Carry out the specific welds as shown in the diagram.

Carry out the welding for filling.

3. Remove and level the weld residues, using an abrasive grinder.

155

Main Page

Service Manual Composition2
Workshop Manual Composition4
Preface14
Foreword15
Graphic Representations and Symbols16
Electrical System18
Contents18
Alarm18
Location of Components of Alarm System19
Introduction20
Receiver20
Remote Control20
Emergency Key Switch21
Operation21
Programming21
Switching off the Alarm21
Simplified Programming22
Programming Country Code22
Closing the Memory23
Programming with Closed Memory24
Opening Memory and Memorization of a New Remote Control24
Replacing Alarm Control Unit24
Analytical Charts25
Electrical Equipmentfault Diagnosis25
Fault Diagnosis28
Wiring Diagrams28
Parking Lights and Warning Lamp - Dipped Beam Headlamps - Main Beam Headlamps and Warning Light - Parking Lightsnumber Plate Lights28
Location of Components29
Components Key29
Trim Level: S - SX46
Electric Front Windows46
Table of Contents48
Not OK48
At the Electric Windows Relay48
Bridge the N Coloured Cable OK51
Not OK51
Check for Voltage at the R Not OK51
Coloured Cable at the Elec51
Fault Diagnosis Analytical Charts51
55D53
Trim Level: el - ELX - GT - HGT54
Check for a Short Circuit in the System and Replace the Fuse56
Restore the Continuity of the R Coloured Cable between56
Restore the Continuity for the56
Check for Voltage at the R56
Not OK56
Coloured Cable for the Left56
Electric Window Control57
Restore the Continuity of the R Coloured Cable between57
Trasound Welding57
Restore the Continuity of the N Coloured Cable between57
Panel 7358
Bridge the N Coloured Cable OK58
Not OK58
Bridge the BG Coloured Ca OK58
Bridge the ZG Coloured Ca OK58
Control Panel 73 and the Ul59
Trasound Welding59
Tor 3659
Window Motor 7760
Trim Level: el - ELX62
Electric Rear Windows62
Extract the Connector for the OK68
55D70
Not OK71
Version Without Alarm: S - SX - GT72
Central Locking72
Tween the Control Unit 11274
And the Ultrasound Welding74
Restore Continuity of the N74
Coloured Cable between the74
Ultrasound Welding74
Not OK76
Bridge the RV/ZB & C/BR76
Not OK77
Version: el - ELX - HGT84
Central Door Locking and Car Doors Not Shut Warning System84
Check the Condition of the Not OK87
Fuse 1087
Check for Voltage at the R Not OK87
Bridge the N Coloured Cable OK87
Check for a Short Circuit in the System and Replace the Fuse87
Ultrasound Welding87
Restore the Continuity of the N Coloured Cable between87
Not OK88
The Control Unit 112 and the91
Restore the Continuity for the H/G Coloured Cables be96
Trim Level: el - ELX - HGT100
Direction Indicators and Warning Light - Hazard Warning Lights and Warning Light - Braking Lights - Reversing Lights100
Vehicle Interior Lights - Ideogram Lights124
Electrical Equipment146
Electrical System: Contents147
Electrical Symbols149
Explanation to Reading Wiring Diagram152
Key to References152
Connector Blocks153
Instrument Panel Connections153
Model: 1910 75 BHP166
Air Conditioner166
Model: 1910 100 BHP168
Windscreen Wash/Wipe - Rear Window Wash/Wipe - Electric Horns - Heated Rear Window and Warning Light - Headlampwasher170
Version Without Air Conditioner172
Engine Cooling System - Water Temperature Gauge - Car Interior Ventilation172
Version: 1910 75 BHP174
Tarting System - Recharging System and Warning Light - Low Engine Oil Pressure Warning Light - Heater Plugs Warninglight - Fuel Injection Fault Warning Light - Fiat CODE Fault System Warning Light - Rev Counter174
Starting System - Recharging System and Warning Light - Low Engine Oil Pressure Warning Light - Heater Plugs Warninglight - Fuel Injection Fault Warni176
Interpretation of the Codes on the Connector Blocks180
Cable Colour Codes180
How to Read the Wiring Diagrams191
Side Lights and Warning Lamp - Dipped Beam Headlamps - Main Beam Headlamps and Warning Light - Parking Lights - Number Plate Lights192
Front Fog Lamps and Warning Light - Rear Fog Lamps and Warning Light 7 7 7 7 7194
Version with Air Conditioner196
Engine Cooling System - Water Temperature Gauge196
Version with Air Conditioner Engine Cooling System - Water Temperature Gauge197
Anti-Lock Braking System (A.B.S.) and Fault Warning Light - Hand Brake On/Low Brake Fluid Level Warning Light 11 11 11 11 11198
Fiat-CODE System and Fault Warning Light 13 13 13 13 13200
Tarting - Electronic Ignition and Fuel Injection - Recharging and Warning Light - Low Engine Oil Pressure Warning Light - Fuel Injection Fault Warning202
Model Without Air Conditioner204
Ngine Coaling System - Water Temperature Gauge - Car Interior Ventilation204
Ersion: S - SX206
Direction Indicators and Warning Lamp - Hazard Warning Lights and Warning Lamp - Stop Lights - Reversing Lights 19 19 19 19 21206
Courtesy Light - Symbol Illumination 29 29 29 29 29216
Diagnostic Socket Connections 35 35 35 35 35222
Electrical Equipment: Contents226
Instrument Panel228
Removing-Refitting228
Instrument Panel for S, SX Versions229
Front of Control Panel229
Wiring Diagram229
Rear Side (Showing the Connector Sockets)230
Instruments for EL, ELX Versions231
Instrument Panel for GT Version233
Instrument Panel for HGT Version236
Fuel Level Gauge239
Fuel Level Gauge Wiring Diagram239
Engine Coolant Temperature Gauge239
Warning Lights for S, SX Versions240
Warning Lights for EL, ELX Versions240
Warning Lights for GT Version240
Warning Lights for HGT Version240
Fuse, Relay and Control Units241
Front View of Fuse and Relayunit and Identification of Fuses242
Rear View of Fuse and Relayunit and Location of Relays242
List of Fuses and Main Protected Circuits243
Diagram of Fuse and Relay Unit Internal Connections244
Location of Fuel Injection/Ignition Control Unit245
Location of Elecrohydraulic Control Unit for Anti-Lock Braking System245
Front Lights Cluster with Direction Indicator246
Replacing Bulbs on Front Lights Cluster247
Side Light Bulbs247
Direction Indicators Bulb247
Replacing Rear Lights Cluster Bulbs248
Removing-Refitting Rear Lights Cluster249
Replacing Rear Light Cluster251
Replacing Tail Light Cluster252
Additional Stop Light255
Front Fog Lamps256
Replacing Front Fog Lamp Bulb257
Number Plate Light258
Courtesy Lights258
Replacing Courtesy Light Bulbs259
Removing-Refitting Glove Compartment Light and Replacing Bulb259
Removing-Refitting Windscreen Wiper Motor260
Replacing Windscreen Wiper Blades261
Rear Window Wiper Motor262
Replacing Rear Window Wiper Blade262
Windscreen/Rear Window Washer Pump263
Stalk Unit264
Wiring Diagram of Stalk Unit265
Front View of Stalk Unit265
Rear View of Stalk Unit265
Identification of Connector Terminals266
Stalk Unit Right Lever266
Windscreen Washer267
Rear Window Wiper267
Rear Window Washer267
Headlamp Washer267
Ignition Switch268
Removing-Refitting Ignition Key269
Removing-Refitting Ignition Switch Contact Block269
Tailgate Electrical Contacts270
Removing-Refitting (on Tailgate)270
Removing-Refitting (on Body Shell)270
Stop Lights Switch271
Removing-Refitting Radiator Fan272
Fuel Gauge Sender Unit273
Fuel Gauge274
Grunding AD 182 L Radio and Cassette Player275
Rear View of Radio276
Codes Relating to the Various Wave Bandsor Ranges276
Adjusting Digital Clock277
Radio Cassette Model AD 182 H278
Radio Section278
Cassette Section278
Compact Disc Section278
Description of the Controls279
Description of the Operation of the Radio Model AD 182 H280
Radio on280
Switching on / off with Engine Started /Stopped280
Pause Function281
Adjusting the Volume281
Adjusting the Tone281
Adjusting the Balance (between Right and Left Speakers)282
Adjusting the Fader (Balance between Front and Rear Speakers)282
Loudness Function283
Mute Function283
Radio Function284
Selecting the Function284
Selecting the Band284
Manual Search Tuning284
RDS Function (Radio Data System)285
Programming the Last Station Listened to285
Automatic Programming in RDS2 Band (AUTOSTORE)285
Manual Station Programming286
Listening to Stations Programmed286
TP Function (Traffic Programme)286
Pre-Setting Volume Level for TP Function (Traffic Programme)287
EON Function (Enhanced Other Network)288
Scanning Programmed Stations (SCAN Function)288
Stereo Transmitters288
Cassette Player289
Automatic Equalizing Selection289
Cassette Reproduction289
Changing Cassette Side290
Fast Forward / Rewind291
Listening to the Radio Whilst Fast Fowarding / Rewinding the Tape291
Searching for Previous / Next Track (Music Search System Function)291
Dolby B Function292
Ejecting the Cassette292
Compact Disc Player Function293
Filling the Compact Disc Loader293
Inserting Loader in Compact Disc Player293
Operation of the CD Player294
Extracting Loader from Compact Disc Player294
Extracting Compact Discs from Loader294
Possible Error Messages295
Selecting Disc295
Track Search (Forwards/Backwards)295
Scanning Tracks on the Compact Disc (SCAN Function)296
Track Repetition (REPEAT Function)296
CD Repetition (REPEAT Function)297
Random Playing of Tracks (RRANDOM Function)297
Clock Function298
Display Modes298
Selecting Display Modes298
Setting the Exact Time299
Switching Priority - Time/Frequency299
Disconnecting from the Supply299
Anti-Theft Protection300
Secret Code300
Entering the Secret Code300
Initial Entering of Secret Code300
Re-Entering the Code301
Eliminating Anti-Theft Protection301
Checking the Activation State of the Code301
Technical Information302
Partial View of the Rear of the Radio302
Location of Radio System Components for Model AD 182 H303
Removing Radio Model AD 182 L304
Radio Equipment305
Removing Radio Model AD182H305
Refitting Radio Models AD 182 L - AD 182 H306
Replacing Radio Models AD 182 L - AD 182 H306
Opening/Closing Cassette Housing Flap307
Refitting Cassette Housing Access Flap308
Speakers in Dashboard309
Rear Speaker309
Loudspeakers on Front Door310
Engine Control Unit312
Fiat CODE Control Unit313
Perspective View of the Fiat CODE Control Unit and Relevant Connectors314
Identification of Connector Pins314
Electronic Keys314
Aerial315
CODE Card315
Warning Light of the Fiat CODE System316
First Key Memorization316
Key Memorization with Unused System316
Key Memorization Procedure with USED Fiat CODE and Electronic Fuel Injection Control Units321
Connection between Fiat Code Control Unit and Engine Control Unit324
Unused System and Ignition on325
Fault Diagnosis with Fiat Lancia Tester326
Unused Fiat CODE Control Unit and Ignition on326
Parameters326
Emergency Starting Procedure327
Error327
Emergency Starting with Fiat Lancia Tester327
Emergency Starting Procedure Using Accelerator Pedal327
Replacing Transponder329
Flow Charts of Fault Repairs on Fiat Code System331
Master Key331
Loss of Main Key331
Mechanical Breakage of Main Key (Not in Notch)332
Electronic Fault (Transponder) Main Key332
Mechanical Breakage of Main Key in Door / Bonnet Lock Notch333
Mechanical Breakage of Main Key in Ignition Switch Notch334
Aerial on Ignition Switch Faulty335
Loss of Code Card335
CODE Warning Light Not Working335
Fuel Injection Fault Warning Light Not Working335
Wiring Diagram of Fiat Code System (Petrol Versions)336
Wiring Diagram of Fiat Code System (Diesel Versions)337
How Wire Safety Device339
Diagram of Hot-Wire Device340
Operation341
Noise Detector Safety System341
Location of Components and Wiring Loom343
Air Bag346
Electronic Control Unit348
Fault Memory350
Crash Memory350
Driver's Side Air Bag Module352
Passenger's Air Bag Module356
Device with Spiral Cable (Clock Spring)356
Diagnosis Using a Fiat/Lancia Tester358
Interventions on Vehicle360
Replacing an Air Bag (Due to Defects or Warranty Expiry)362
Replacing Control Unit362
Action Following an Accident364
Accidents with or Without Activation of the Air Bag System364
Accidents Involving Activation of the Air Bag System364
Painting Operations364
Danger to Health366
Effects of Over-Exposure366
Safety Regulations for Handling Air Bag Modules366
Disposing of Used Air Bag Modules370
Foreign Markets370
Ordering Procedure370
Wiring Diagram372
Removing Driver's Side Air Bag374
Operation Sequence374
Removing Clock Spring376
Preliminary Operations376
Removing the Steering Wheel378
Removing Watch Spring380
Refitting Clock Spring384
Refitting the Steering Wheel386
Completing Assembly390
Refitting Air Bag392
Side Repeater394
Rear Lights Cluster394
Wiring Diagram Showing Connection of Headlamp Alignment Device395
Electric Headlamp Adjuster396
Location of Components and Wiring Loom for Electric Headlamp Adjuster396
Headlamp Alignment397
Vertical Alignment397
Horizontal Alignment397
Manual Adjustment of Front Fog Lamps397
Removing-Refitting Passenger Side Air Bag398
Safety Measures398
Replacing Passenger Side Air Bag Trim400
Removing-Refitting Control Unit Air Bag System401
Operation Sequence for Fitting Control Unitearth Lead Braid402
Removing-Refitting External Rearview Mirror404
Recharging405
Battery405
Alternator405
Checking Current Intensity406
Checking Voltage406
Removing-Refitting (137012V)407
Overhauling408
Checking Diodes409
Dismantling409
Checking Inductor (Rotor) Winding Resistance at the Slip Rings410
Checking Stator Winding Insulation410
Removing-Refitting (1580 16V Version)411
Removing-Refitting (1747 16V Version)413
Removing-Ref Itting (1998 20V Version)415
Starting418
Removing-Refitting (1370 12V Engine)418
Removing-Refitting (1580 16V Engine)419
Overhauling at the Bench420
Starter Motor Components422
Removing-Refitting (1747 16V Engine)423
Removing-Refitting (1998 20V Engine)425
Checks426
Starter Motor Operational Fault Diagnosis426
Alarm427
Emergency Key427
Introduction427
Switching on - Switching off428
Excluding the System428
Surveillance428
Alarm State428
Operation428
Simplified Programming431
Start of Simplified Programming (First Remote Control)432
Protected Programming-Manual Closing of the Memory436
Entering the Password436
Checking that the Memory Is Closed439
Programming Codes with Manual Access440
Start of Manual Opening of the Memory (Entering a Known Password)440
Electronic Auto-Switching on Function444
Notes and Special Features444
Location of Alarm System Diagnostic Socket444
Fault Diagnosis with the Fiat-Lancia Tester444
Autodiagnosis Display445
Signalling Cause of Alarm445
Manual Diagnosis445
Main Wiring Diagram446
Input and Output Signals from the Anti-Theft Device Control Unit447
Alarm Control Unit Input and Output Signals447
Wiring Diagram448
Receiver Connector449
Removing-Refitting Alarm Control Unit449
Location of Preheating Components in Car450
Preheating Electronic Control Unit450
Introduction450
Changes in Preheating Time of the Glow Plugs451
Preheating Control System452
Checking Glow Plugs452
Main Operating Faults in the Preheating System452
COPYRIGHT Fiat a U T O S452
Engine Cut-Out Solenoid453
Checking Operation of Engine Cut-Out Solenoid (on Fuel Injection Pump)453
Front Bumper455
Rear Bumpers (5D)456
Rear Bumpers (3D)457
Adjusting Front Door458
Adjusting Position of Door Lock Striker458
Removing-Refitting Front Door458
Adjustments458
Removing-Refitting Door Panel and Protective Lining459
Removing-Refitting Outer Door Handle460
Replacing Door Lock Barrel460
Removing-Refitting Door Opening Mechanism461
Removing-Refitting Lowering Window Glass462
Removing-Refitting Window Opening Device462
Removing-Refitting External Rear View Mirror463
Removing-Refitting Door Rear Pillar Trim464
Rear Door465
Removing-Refitting466
Bonnet Lid467
Removing-Refitting Bonnet Lid467
Adjusting Bonnet Lid Position467
Adjusting Bonnet Lid Closing Device467
Removing-Refitting Bonnet Lid Striker468
Removing-Refitting Front Grille468
Removing-Refitting Windscreen Washer Pipes468
Rear Tailgate469
Removing-Refitting Tail-Gate (5D)469
Removing-Refitting Tail-Gate (3D)470
Adjusting Position of Tailgate Buffers471
Adjusting Horizontal Position of Tailgate471
Adjusting Position of Tailgate Lock Striker471
Adjustments471
Removing Refitting Tailgate Lock472
Replacing Lock Barrel ( 5 D )472
Replacing Lock Barrel (3D)473
Removing-Refitting Seat Front474
Dismantling-Fitting Front Seat Covers475
Seats476
Removing-Refitting Front Seat Guides478
Removing-Refitting Seat Raise Device479
Removing-Refitting Rear Seat480
Dismantling-Fitting One-Piece Rear Cushion481
Dismantling-Fitting One-Piece Rear Squab481
Removing-Refitting Rear Side Panel ( 3 D )483
Interior Fittings484
Roof Lining484
Roof Panel Trim for Versions with Sun-Roof488
W I T H Sun-Roof488
Removing-Refitting Dashboard490
Removing-Refitting Rear Seat Belts496
Seat Belt Pre-Tensioner497
Introduction497
Operation497
Removing Bracket498
Fitting Seat Belt with Pretensioner499
Safety Rules for Handling Seat Belt Unit with Pretensioner500
Bodywork Operations501
Ordering Instructions501
Removing-Refitting502
Equipment505
Composition of Kit505
Window Glasses505
Introduction505
Thermal Knife506
Vibrating Knife507
Window Glasses508
Wire508
Instructions for Using Wire Contained in Kit508
Replacing Front Window Glass (Windscreen)509
Removing Vehicle Trims and Protection509
Preparing the Windscreen Housing510
Preparing the Windscreen510
Replacing Rear Window Glass (Rearscreen)513
Replacing Rear W I N D O W Glass (3D)513
Replacing Rear W I N D O W Glass (5D)513
Replacing Third Fixed Winsow517
Removing Trim and Protection from Vehicle517
Sun Roof519
Introduction519
Removing Trim520
Removing-Refitting Complete Roof521
Dismantling-Reassembling Complete Roof522
Adjustments During Refitting523
Adjustment of Opening Device523
Adjusting the Window523
Adjusting the Spoiler523
Replacing Body Panels524
General Instructions for the Repair524
Introduction524
Graphic Index525
Symbols526
Front Wing527
Protection of Repaired Parts538
Preparation and Painting Procedure538
Replacing Rear W I N G (3D)541
Replacing Rear W I N G (5D)541
Removing off Cuts and Preparing Edges of Bodyshell542
Adjusting the Replacement Part542
Preparing the Spare Part and Checking that It Is Correctly Positioned on the Bodyshell543
Welding the Spare Part543
Finishing Operations544
Protections544
Adjusting Replacement Part and Finishing the Edges of the Bodyshell546
Replacing Vehicle Roof Panel549
Positioning the Replacement Part551
Replacing S T R U C T U R a L Panels554
Replacing Structural Body Panels565
Graphic Index565
Symbols566
Replacing Front Pillar577
Replacing Rear Wheel Arch593
Typical Measurements597
Measuring Windscreen Housing and Engine Compartment Dimensions597
Measuring Dimensions of Centre and Rear Pillar Housing (5 Door Version)598
Measuring Door Housing Dimensions599
Measuring Dimensions of Centre Pillar Housing and Door Housings (3 Door Version)600
Measuring Rear Tailgate Housing Dimensions (5 Door Version)602
Figures for Adjusting Moveable Parts (5 Door Version)603
Squaring Body605
Diagram for Checking the Floorpan605
Body Shell606
Diagram for Checking the Underbody606
Graphic Index607
Partial Replacement of a Side Member618

Fiat Brava - Page 617

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