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Fiat Spider - 2000
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SERVICE NETWORK
When your car needs Service lookfor the sign which identifies all autho -rized Fiat Dealers where trained per-sonne!, specially designed equipmentand faciiities are available.
Our organization is at your fülldisposal for any Suggestion or adviceyou may need.
SPARE PARTS
Authorized FIA T parts are the bsstguarantee for top Performance andsatisfactory Operation of all compo-nents.
When ordering, p/ease quote (seepage 2) :
— Car Model.
— Nurnber for Spates.
— PartNumber(s) of Spare (s) Ordered.
BREAK-IN RECOMMENDATIONS
Current progress in design andmanufacturing technology is so ad-vanced that no hard-and-fast ruleneed be given for break-in, However,a few simple rules should be fol-!owed for the first 1000 mües:
Avoid fierce accelerations soon afterstarting and allow time for theengme to warmup (a good habiteven after break-in).
Do not fully depress the accele-rator pedal and avoid high enginespeeds, when operating in thelower gears, that is, never allowthe tachometer pointer to moveinto the yellow sector indicatinghfgh rpm rates.
Change your road speed occasion-ally, especially on long trips. Avoidlong drives at constant high orIow speeds,
Downshift whenever necessary tocope with driving conditions onroute: you will avoid engine lug-ging at excessively iow rpm.
Avoid, if possible, severe stops atsustained speeds during the firstfew hundred miles: brakes willset properly and improve their lifeand effectiveness.
Remember that satisfactory Oper-ation and iong life are dependent to agreat extent on the care with whichthe car is handled during break-in.
Fiat Spider 2000This Manual provides the Informationnecessary for satisfactoryOperation and maintenanceof your car.
We wish you pieasant motorinyand trust the Information providsdwill help to ensure thefang Ufe and safety of your car.
Operation maintenance specifications
KEYS
Each vehicle is provided with twokeys in duplicate; quoting the numberstamped on each key is essential toobtain a replacement from FIAT'sSales Organization.
A For ignitron switch
B For door and trunk locks.
B
IDENTIFICATIONDATA
• Manufacturer's Plate
A - Name of manufacturer
B - Vehicls identification code
C - Chas&is Number
D - Engine type
E - Version code
F - Number for spares
G - Space reserved for Diesel vehicles
50022
o1 -2-
MOTOFtE-ENGINE
YEFSIONF- VERSION
N'PERRICAMBI-NäFDR SPAR£S
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0
i i
1 1— J39090
• Engine Type (132 C3.031) andIdentification Number - Punchedon crankcase, near oil filter mount.
• Chassis Type (124 CS2} andIdentification Number - Punchedon engine compartment bulkhead(permanent structure) right side.
• F.M.V.Safety Standard 115TagType of vehicle and chassis number,located on panel top between instru-ment cluster and windshield.
• F.M.V.Safety Standard 110TagTire data and car capacity, locatedon R.H. door pillar, above striker.
• A) F.M.V. Safety Standard Con-formity Tag - Month and yearof manufacture, gross vehicle weightrating, gross axle weight rating,chassis number and car type, locatedon left door pillar.
• B) Vehicle Emission Control In-formation Label - Located on leftdoor pillar.
• E.P.A. and California Regula-tions Conformity Tag - Air pollutioncontrol specifications for correct enginetuneup and adjustments, located inengine compartment, on cowl.
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
32 31 30 2735 34 33
INSTRUMENTS AND CONTROLS
1 lighting switch, three-position
2 Turn signal lights switch levei
3 High/Low beams change-overswitch lever
4 Inspection lamp receptacle
5 Instrument cluster
6 Horn button
7 Steering lock ignition switch
8 Windshield washer and wiperswitch lever, three-position
9 Air outlets
10 Windshield wiper sweep rate knob
11 Low brake fluid level/hand brakeON indicator
12 «EX. GAS SENSOR)) indicator
13 Fasten belts indicator
14 Knob switch and rheostat forinstrument cluster lighting
15 Glove compartment
16 Glove compartment lock
17 Utility recesses (two)
18 Power window switches housing
19 Courtesy light with switch
20 Vehicular hazard warning signalindicator and switch
21 Gearshift lever
22 Lever controlling air flow throughoutlets 9 and/or under dash
23 Cigar lighter
24 Optional radio housing blankinglid
25 Ash tray
26 Hand brake lever. To release thelever press in button on top ofhandgrip
27 Two-speed heater fan switch,three-position
28 Air volume control lever
29 Air temperature control lever
30 Accelerator pedal
31 Service brake pedal
32 Clutch pedal
33 Fusebox
34 Hood release emergency cable
35 Hood catch release lever
a b
n i m nInstrument Cluster
a) Fuel Reserve Indicator (Red) -Warning that the fuel supply avail-able in the tank is between 5and 7.5 liters {173to2 Gals).
b) Fuel Gagec) Speedometer - This instrument
(which includes the odometer) isfactory-sealed: any tampering byunauthorized persons will invali-date the warranty.
o p q f sd) Odometer (Totalizer)
e) Trip Recorder
f) Engine Water TemperatureGage - If the pointer enters thered area it means that the engine isoverheating: it will then be neces-sary to immediately rev down theengine to idle speed (do not $witchoff). Should the pointer remainon the red area, contact the nearest
FIAT Dealer for a cooling systemcheck (including fan circuitry).
g) Tachometer - Electronically-op-erated from the ignition distribu-tor. The yellow area indicates ma-ximum engine speed for all gearswhereas the red area showsdangerous engineoperating speeds.
h) Type of Fuel Used (see page 33)
i) Cluster Panel Mounting Knobs(Four)
I) Parking and Tail Lights Indi-cator (Green)
m) Turn Signal Arrow Indicator(Flashes green)
n) High Beams Indicator (Blue)
o) Trip Recorder Zeroing Knob -Turn knob clockwise but neverwhen car is running.
p) Battery Charge Indicator (Red)With engine inoperative, and ig-nition key in position MAR, thecharge indicator is on and mustgo out when engine is started;
should indicator turn on whileengine is running, this is a warn-ing of a fault in the battery re-charging system: turn immedia-tely to a FIAT Dealer for assist-ance.
q) Insufficient Oil Pressure In-dicator (Red) - The light shouldgo off when oil pressure is suffi-cient to ensure adequate enginelubrication,
r) Clock Reset Knob - Push andturn clockwise making sure thatit springs back when released.
5) Quartz Crystal Clock
Lighting Switch
Up = All lights OFF.
With Ignition Key at MAR:Down — Parking and tail lights,headlight low or high beams andflashers (main beams).
With Ignition Key Removed:Center (night parking oniy) = Park-ing and tail lights.Down = All lights OFF.
Fasten Belts Indicator (Red) andBuzzer - Both are operative for afew seconds when a starting attemptis made with seat belts (driver and/orpassenger) unfastened.
Low Brake Fluid Level/Hand BrakeON Indicator (Red)
With ignition key at MAR the indicatorlights up to warn the driver that thebulb is efficient. In case the indicatorremains ON it means either that thehand brake lever is pulled upwards(brake applied) or that the brake fluidlevel is too low.
Should the indicator turn on whilethe vehicle is moving, stop and checkthe fluid level in reservoir. If the levelis too low, great care should be takenwhen applying the brakes and thenearest FIAT Dealer contacted for abrake system check.
Vehicular Hazard Warning SignalSwitch - Turns ON (independently ofkey position in lock switch) the frontand rear turn signal lights which will allflash simultaneously to warn of the pre-sence of the vehicle stopped on the road.
38003
EXHAUST GAS SENSORINDICATOR (red)
Lights up:
— Every 30 000 miles to warn ownerof need to replace exhaust gassensor (Lambda probe);
— On starting; it should go out whenengine is started.
Steer ing Lock Ign i t ion S w i t c h (*)(See page 16 for starting procedureinstructions)
MAR (Run) = Engine ignition ON andaccessories energized
AW (Start) = Engine starting
ST [Stop) = Steering post antr-theftlock in. Key removable
Remove Key Buzzer - Operateswhen the steering wheel side door isopened to leave the car and the igni-tion key is forgotten in the lock switch.Gearshiftirtg Pattern - To engagereverse (R), press the lever and shiftas indicated by the gating pattern.
Note: The use of fifth gear over 4B mphimproves fuel economy.
The total or partial removal oi key will lock the steering post even if car is in motion.To facilitate the disengagement of steering post lock, slightly rock the steering wheelwhile rotating the key. Key must not be left in position MAR when engine is inoperativeand must be removed only when leaving the car, especially if unattended.
(*) Even with key removed (position ST) the following circuits are stifl energized : courtesylights; horns; cigar lighter and housing indicator; vehicular hazard warning signal; removekey buzzer; clock; inspection lamp receptacle.
Windshield Wiper/Washer SwitchLever
a = Wiper off
b = Wiper On-Off intermittently (par-ticularly useful in drizzly weather)
c = Wiper on continuously
Lifting the lever towards steeringwheel, whatever its position, will switchon the washer.
Windshield Wiper Sweep RateKnob - Provides high or low sweeprates in either wiper continuous orintermittent operation, depending onthe position of wiper lever switch.
25947
High/Low Beams Change-OverSwitch Lever {With lighting switchdown and ignition switch at MAR)
I = Low beamsII = High beams
By lifting the lever towards steer-ing wheel headlight high beam flashesare obtained even with all lights out(Daylight signals).
Inner Rear View Mirror - Collap-sible, with anti-glare (Day/Night) po-sition controlled by a lever. If themirror comes off its seat, followingan impact, refit by engaging spring Bon stud A — make sure the twolocation dowels are properly registeredwith relevant seats — and presson base C. Engagement is of thesnap-on type.
Outer Rear View Mirror A onsteering wheel side door is adjustablefrom driver's seat, by means of lever B.
Turn Signal Lights Switch LeverAutomatically trips back to OFF.
R = Right turn Left turn
DOORSOpening
From outside - Unlock and pull thehandle.
From inside - Pull up lever A.
Locking
From outside - Both doors are pro-vided with key-operated locks. Step-ping out of the car on the curb sideis thus also possible. Always use thekey; never lever A.
From inside (safety latch) - Withdoor already shut set the lever A down.The lever will thus first insert thesafety latch and then snap back torest.
Note: Lubrication of lock cylinders is notrecommended. At most, blow some gra-phite powder into the cylinder keyhole.In cold climates it is recommended tosquirt in some special antifreeze fuild forlocks. Repeat the operation every timethe car is washed or at least every 15 days,if insertion of key in the frozen lock provesdifficult, simply warm up the key.
SEATS
Seats may be adjusted for leg reachafter moving control lever A downwards.
Once the desired position is found,release the lever and make sure theseat has locked.
The position of the backrest is ad-justed by turning knob B.
10
For access to the rear compart-ment push down lever C and tiltbackrest downward.
On top of each seat backrest is fitteda headrest: to re-set height pull upor push down as required.
The headrest must be adjusted soas to support the head and not theneck of the occupant.
39078
SEAT BELTS
Seat belts provided as standardoriginal equipment are of the 3-pointlap type.
Pull belt fully out from retractorswithout stopping as otherwise it willbe necessary to return the belt to thestowed position to release the re-tractor stop mechanism.
To fasten, fit tongue A into buckleB until a sharp click is heard.
Adjust the belt snugly around thehips, not the waist, allowing excesswebbing to be pulled back into re-tractor.
To free yourself from the beltrestraint: simply press in bucklebutton C.
Warning
Before fastening the belts make surethe seats and headrests are properlypositioned.
Each belt is intended for use byone adult or one child over 6 yearsof age.
Occasionally, check that webbingis in good condition.
In the event of an accident evenif the belt you were wearing is appa-rently undamaged it is suggestedthat you replace it with a new beltassembly of the same type.
To keep belts clean, wash only,using warm water and mild soap.Rinse and dry thoroughly. Do notuse strong detergents and avoid anychemical that may weaken the equip-ment.
Users are warned to consult theManufacturers in case of doubt andnot to make any alterations of, oradditions to, seat belt assembliesand/or anchorages.
11
VENTILATION AND HEATING Ventilation and heating are adjusta-ble according to seasonal requirements.
To ensure best comfort to occu-pants it is important to become familiarwith system controls and operation.
Admission of Heated or Fresh Air
Heater fan switch C is ener-gized only when ignition key is inposition MAR.
Pressed in forward = High speed
Intermediate position = Off
Pressed in backward = Low speed
390 68
12
Lever D controls the air tempera- Defrosting end Demistingture.
Pulled all back - No heating of air
Pushed allforward - Maximum heatingof afr
Lever E controls the air volume.
Pulled all back - Maximum air flow
Pushed all forward - No admissionof air
Intermediate positions are usedespecially when outdoor temperatureis low to limit the flow of cold airaround heater core.
Lever F controls the amount of airflowing through windshield outlets Aand into front lower area throughconsole outlets B.
Pulled all back - Air flows throughoutlets A only
Pushed all forward - Air flows throughoutlets A and B
For quick defrosting of windshield,pull back completely lever F, pushforward lever D and set lever E in anintermediate position. Turn on theheater fan by switch C.
Door window ventilators areopened by pulling lever G and tur-ning upward lock H.
Frost Precautions
If during cold weather the car mustremain inactive for some time at freez-ing temperatures and the coolingsystem is not protected with antifreezemixture, it will be necessary whiledraining the radiator and Jacketsto empty also the heater core byshifting lever D all forward.
Note: If heating proves inadequate,operation of the thermostat on the linefrom cylinder block to radiator must bechecked.
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SiFOLD-AWAY TOP
To lower the folding top, proceed asfollows:
— Wind down the door windows.
— Pull down the two latch levers Aand release clamps B from latches Csecuring the top to windshieldframe.
Push the top to the rear, makingsure the back window is not pinch-ed by the metal frame.
Free the rubber strap from the pegon body side and strap the foldedtop as shown in the figure.
14
Place cover F on the folded topwell by fitting rear eyelets D onhooks E (page 14) then catches G
in detents H, spring hooks I inholes L and snap on the buttonfasteners M.
15
38000
STARTING THE ENGINE
Cold Starts With ManualTransmission
— Move gearshift lever to neutral.
— Depress clutch pedal, especially incold climates.
— Insert and turn ignition key clock-wise to the stop, that is positionA W . As soon as engine is startedrelease key which will snap back toposition MAR.
Should the engine fail to startreturn ignition key back to ST posi-tion and repeat starting attempt.
— Do not step on accelerator pedaluntil the engine is running smoo-thly.
— Avoid sudden acceleration whenengine is cold.
Do not continue with repeated start-ing attempts. If the engine fails tostart or stalls at idling have the fuelinjection and ignition systems checkedas soon as possible.
Cold Starts With AutomaticTransmission
Move the selector lever to HI or PEngine starting is not possible withthe selector lever in any other po-sition.Then proceed according to manualtransmission instructions.
Hot Starts
For vehicles with manual and automatictransmission turn ignition key withouttouching accelerator pedal.
16
DRIVING THE CAR
Never maintain nor exceed themaximum allowed speeds and donot drive with tachometer pointersteadily on the yellow sector.
Do not travel steadily for longintervals at top speed in any gear.
All red indicator lights should beout while driving.
Do not coast downhill with theclutch pedal depressed, the transmis-sion in neutral or the engine off, as themarginal saving in fuel consumptionwhich may be derived from suchpractice does not compensate for theresulting loss in brake lining life anddriving safety which is provided by thebraking effect of the engine.
Remember that upon switching offthe engine, the brake servo isdeactivated and, therefore, brakingrequires more effort.
Do not allow the engine to lug,particularly when driving up steephills, but shift down in good time tobenefit from maximum engine pullingpower.
Do not ride the clutch, otherwiseslippage and damage will result.
Ensure that both the foot andhand brakes are efficient at all times.After a car wash apply the foot-brakea few times so as to restore fullbrake effectiveness.
Always apply the foot brake pro-gressively. Remember that wheel lock-ing, especially with an unladen car,will result in dangerous skidding. Incase of emergency the hand brake maybe used to stop the car.
On wet or slippery roads hardbraking will increase the likelihood ofwheel locking and consequent inevi-table loss of handling control. Instead,use the engine braking effect by
engaging a gear lower than wouldnormally be required. Braking, if abso-lutely unavoidable, should be gentleand progressive and, in any case,simultaneous with engine braking.
On icy roads drive slowly, turnthe steering wheel very gently, avoidusing the brakes, change gear smoothlyand do not drive with the clutchpedal depressed. If the car startsskidding release the accelerator pedal,do not brake, but steer smoothly inthe direction of skid; as the car re-gains its course straighten the wheelsand accelerate gently.
Always use tire chains or snowtires before starting a journey on iceor snow covered roads and rememberthat while snow chains can be fittedto the driving wheels only, studdedtires should be fitted to all wheels.
When driving in mist or fog duringdaylight switch on the parking andtail lights: do not use the high beams.
17
Before turning or changing lanes,in addition to giving the correct signalsglance in the mirrors to ascertain theintentions of the drivers behind you.Before cutting back into your laneafter overtaking a vehicle wait untilit appears in your inner mirror.
At night when meeting oncom-ing traffic, keep your eyes on theright side of the road rather thanlooking straight into the approachingheadlights or other light sources: youwill avoid being blinded.
RECOMMENDEDSHIFTING SPEEDS
1st-2nd 2nd-3rd 3rd-4th 4th-5th
15 mph 25 mph 40 mph 45 mph
Note: In any case the maximum speedlisted on page 62 should never be exceeded.
PARKING
Always apply the hand brake whenparking and if on a grade, for addedsafety also shift into first or reversedepending on whether the car isheading up- or downhill.
When the car is left in dark areasalways turn on the parking lights:lighting switch pressed halfway inat bottom.
18
AUTOMATICTRANSMISSION(Optional Extra)
OPERATIONTo obtain any ratio move selector
lever A to the desired position.When shifting from P to R, R to P,
N to R, D to N or 2 to 1 lift trigger Bsimultaneoulsy. When shifting from Dto 2 and viceversa do not operatetrigger B, Light C indicates the selectedposition.
Selector Lever PositionsP. Park - R. Reverse - M. Neutral -D. Drive - 2. Intermediate - 1. Low.
Selector Lever Positions
Park
In this position the transmission ismechanically locked but engine startingis possible. Park should not be selectedwhen the car is in motion or stationaryin busy car parks where shunting islikely to occur.
Use of the Park position is recom-mended when parking on flat andsloping ground and before servicing.
Reverse
To select Reverse bring the car to Qdead stop and release the acceleratorpedal (engine idling).
Neutral
In this position the engine can bestarted.
Drive
This position is used for normaldriving.
The transmission starts in low gearand automatically changes up or downat suitable road speeds according tothe position of the accelerator pedaland the demands made by the driver.For quick down-shifting depress theaccelerator pedal through its hard spot(kickdown position).
Kickdown permits down-shiftingfrom third to second below 59 to 64mph or into first below 31 to 34 mph.
Normal change-down from D to 2and D to 1 can be obtained by meansof the selector lever below 70 mphand 43 mph respectively, without de-pressing the accelerator pedal.
Intermediate
Operation is as described under Dbut no up-shift into third is possible.This may be advantageous when drivingover hilly or difficult roads requiring
19
consistent pull and moderate enginebraking.
o Low (Lock-up in First)
To be selected when driving up anddown very steep hills, especially witha trailer on tow, and when maximumengine braking is desired.
When the selector lever is moved to1 the transmission changes to, andremains in first, regardless of enginespeed.
Note: With the engine idling and D,2, 1 or R selected the car may tend tocreep forwards or backwards. Thistendency can be obviated by lightlyapplying the foot brake and may wellbe advantageous for difficult parkingmaneuvers.
Starting
Before starting the engine move theselector lever to l\l or P.
Engine starting is not possible withthe selector lever in any other position.
Starting instructions not describedhere are as given on page 19.
Depress the brake pedal withoutaccelerating at all, and move theseSector lever to 1, 2, D or R asdesired.
Release the hand brake and the footbrake.
Depress the accelerator pedal pro-gressively. In D the car will move offin first gear and automatically changeup as speed is increased,
For maximum acceleration depressthe pedal through its hard spot. Thiscauses up-changes to occur at higherroad speeds than under part-throttledriving {approximately 40 to 43 mphfrom first to second and approximately65 to 70 mph from second to third).
Exceptionally, when maneuveringin confined areas or for hill-holdingthe driver will find it convenient touse the left foot on the brake pedaland, using this pedal in conjunctionwith or without the accelerator pedal,a high degree of control is obtained.
During normal driving both theaccelerator and the brake pedals shouldbe operated with the right foot only.
Towing by Another Vehicle
Proving the transmission isoperating satisfactorily, the car maybe towed in N over distances up to
30 miles and at road speeds notexceeding 30 mph, otherwise gearboxdamage may result. If the car is tobe towed over long distances, or ifthe transmission is defective, the carmust be towed with the rear wheelsraised from the ground or propellershaft disconnected.
Warning
To prevent dangerous over-revvingdo not exceed the prescribed shiftingspeeds.
Stopping
To stop the car release the accele-rator pedal and apply the brakes.
No further action is needed forshort stops, as first gear will be auto-matically re-engaged when movingoff again. On upgrades, hold the carexclusively by pressing the brake pedal.
For long stops, move the selectorlever to hi and apply the handbrake.
When leaving the car unattendedshift the selector lever to P aftercoming to rest. Thus, the transmissionwill be locked.
20
38821
WHEEL CHANGING
If possible, place the car on levelground and lock rear wheels by thehand brake.
Release strap B and take out jack Aand spare wheel C in trunk.
The jack is completed by handlever D and extension E,
Extension E has two drives: a hex.shank for the jack hand lever and ahex. socket to manipulate both the jackand wheel bolts.
To Remove the Wheel
— Slacken about one turn the fourwheel fixing bolls using extensionE and lever D.
— Place the jack under the car at thebracket nearest the wheel to beremoved.
— Fit extension E to jack shank, andturn handwheel F until the jackcontacts the lift bracket under floor.
— Make sure the ground is sufficientlyhard (that is, jack base does notsink during the lift action).
3BS24
Fit the hand lever to extension Eand actuate the lever to and fro untilthe wheel is clear of the ground.
Back out completely the bolts andremove trim and wheel.
Keep the bolts in a clean place toprevent the threads from gettingfouled with dirt, a frequent causeof difficulties at reassembly.
To Fit the Wheel
— Fit the spare wheel seeing that thelocation dowel fits into the locationhole in wheel disk.
— Refit trim and refit and tightenuniformly the wheel fixing bolts incriss-cross sequence.
— Remove the jack hand lever andactuate handwheel F of extensionE and lower the car.
— Fully tighten the wheel bolts incriss-cross sequence.
— Check that the newly fitted tire isinflated to the correct pressure.
When repositioning the jack in thetrunk make sure extension E is properlyhoused and Jack, bag and hand lever Dare correctly fastened by strap B.
JACKING UP ANDTOWING
When either the front or rear endof car must be raised with a garagejack, it is necessary to fit jack headunder front suspension cross rail, in-terposing a suitably thick (abt. 3 cm- I'A in.) wooden block, or rearaxle bulge.
If car needs towing with a ropethis must be attached to the spe-cially provided front brackets.
34975
22
MAINTENANCE
This section includes all periodicalmaintenance operations essential forcontinued effectiveness of the car.
The lubrication, cleaning, inspect-ion and adjustment operations recom-mended in relation to given mileagesare listed on a General MaintenanceSchedule. Reference is made to thepages where each operation is descri-bed.
The Owners Warranty and ServiceBook contains a free service coupon.This service should be performed at1 500 miles.
Failures, other than those resultingfrom defects in material or workman-ship, which arise solely as a result ofowner abuse and/or lack of propermaintenance are not covered by war-ranty.
Particular stress is laid onimportance of reporting to aFIAT Dealer for all the main- "tenance operations so marked :
For oil grades not mentioned here,seethe Fill-up Data Table.
EMISSION CONTROLSYSTEMS
The maintenance operations ne-cessary to ensure the proper function-ing of the vehicle emission controlsystems are printed in red for im-mediate identification both in theGeneral Maintenance Schedule andin the paragraphs of this section.
The engine tuneup and adjustmentspecifications are also listed on theE.P.A. and California Regulations Con-formity Tag. located in the enginecompartment (see page 3).
For oil these operations it is alsorecommended to refer to the instruc-tions specified in the Owners Warrantyand Service Book,
NOTICE
Besides the routine maintenanceoperations listed in the Schedule,this section describes other operationswhich must be performed only inspecial cases of defective operation ofmechanical units.
23
MAINTENANCE
GENERAL MAINTENANCE SCHEDULE
We recommend that all operations so marked be entrusted to the Fiat service network
OPERATIONS
V a l v e c l e a r a n c e : Check and adjust if necessary
A i r c l e a n e r : Renew filtering element . . . .
Spark plugs : Changs
Alternator and water pump drive belt; C/ieck tension and state of wear; Adjust andjorrenew as necessary
Oxygen sensor (Lambda probe): Renew , ,
Brakes; Check state of wear of seals, lines and check hand brake efficiency, renew or adjustas necessary ,
Transmission (manual and automatic) and differential: Change oil
Clutch: Check pedal height and adjust if necessary
Suspensions, steering and drive line: Check components
Wheel bearings: Check lubrication
Body: Lubricate door locks and hinges
See page
26
27
27
28
32
38
39
39
41
41
43
Every15 000miles
• *
o •
•
Every30 000miles
0
o
o
Every45 000miles
1 These operations are not obligatory but only recommended when the car is used frequently in abnormal traffic conditions or on sandyand dusty roads.
24
SPECIAL MAINTENANCE
OPERATIONS See page
Engine oil -.Check level , , 26
Engine oil and filter; Change 26
Cooling system : Check coo/ant level 37
Brakes: Check brake pads and front discs 38
Automatic transmission (where fitted): Check oil level 40
Tires: Check pressure 41
Battery: Check electrolyte level, terminals and clamps 44
Every500miles
(orweekly)
0
Every3 000miles
•
Every7 500miles
Lubricant Designations
FIAT
VS +
ZC90
INTERNATIONAL
Single-grade low-ash content de-tergent oils - API Service SE, toMIL-L.46152 and above :he CCMCEuropean Sequence
SAE SOW/90 Oil with anti-wearadditives, for manual transmission
FIAT
Gl/A
W90/M
Jotai
MR 3
INTERNATIONAL
A.T.F. - DEXRON II Typefor automatic transmission
SAE 30 W/90 EP Oil to MIL-L-2105 B
Lithium-base Grease N.L.C.I. Mo. 1
Lithium-base Grease N.L.G.I. No. 3
25
ENGINE
Engine Oil
Every 500 miles or weekly -With engine cold, check oil level whichmus1 always be between the Minand Max marks on dipstick, and topup if required.
Every 7 500 miles or every sixmonths at most - Replaceoil with engine well warmed up.
Drain all used oil through plug B.Oil should of course be changed
also in relation to the grade used andoutdoor temperature (Singiegrade orMultigrade) as shown in the Fill-upData Table,
Engine Oil Filter
Every 7 500 miles or at every en-gine oil renewal - Unscrewfilter A from its support oncrankcase, and replace.
Before fitting a new filter on thesupport, wet its seal with engine oil.Screw on the filler: once the sealcontacts the support, tighten 3/4 turnmore.
Tappet Clearance
Every 15 000 miles or whenevervalve operation becomes noisy.Check clearance between tap-pets and cams. Specified
clearance, with cold engine, is .41 10.49 mm (.016 to .019 in) for intakeand .46 to .54 mm (.018 to .021 in)for exhaust valves.
.
37995
Air Cleaner
Every 30 000 mi les (*) : Change f i l -tering element. To gain accessto filtering element A undofasteners C using a screwdriver
and remove cover B.
Change the filtering element, refit coverand secure with fasteners C.
Reinstall fasteners by pressing oncurved section.
Spark P/ugs
Every 30 000 mi les ( * ) : Changespark plugs. To disassemblespark plugs, withdraw terminalsA and back off using a suita-
ble wrench.
New spark plugs must be of the typespecified (see page 62}; if their thermalrating is incorrect engine malfunctionand/or failure may occur.
(*) It is recommended thai air cleaner andspark plugs be replaced every 15 000 milesif the vehicle is frequently driven in heavytraffic conditions or sandy or dusty areas.
27
Alternator and Water PumpDrive Beit
Every 30 000 mi les ( * ) ; Check belt
for wear and if necessary renew,
Also check belt tension andadjust if necessary,
Belt sag should he 1 to 1.5 cm (1/3to 1/2 in.) when firm thumb pressureis applied. To adjust tension of belt
driving water pump A and alternatorB, slacken nuts C and D and movealternator outwards and then retightenthe nuts.
Do not exceed the tension since thiswould result in abnormal stress on thebearings.
(') It is recommended that [hese operationsbe carried out every 15,000 miles if thevehicle is frequently driven in heavy trafficconditions or In sandy and dusty areas.
37991 |
Ignition Timing
Spark advance is set in the factoryand no further adjustment is requiredduring the life of the vehicle.
Ignition timing must be checked only ifthe ignition distributor is removed.To adjust proceed as follows:
— For vehicles fitted with manualtransmission, engage top gear andmove vehicle until cylinder no. 1 isin compression phase and the markon the crankshaft pulley is alignedwith the fixed timing mark A indi-cating 10u B.T.D.C.
Ignition timing:v.);B = 5°(Adv.);C-0°(TDC)
For vehicles fitted with automatic trans-mission use a suitable wrench to adjustthe nut D securing crankshaft pulleyuntil above conditions are obtained.
— Remove distributor cap and turnshaft manually until rotor is posi-tioned against contact for firing ofcylinder no. 1.
38113
Without moving distributor shaft, insertdistributor1 in its seat and secure.Connect leads going to coit, installcap and check that the leads arecorrectly connected to spark plugs,
Connect the rev counter and the stro-boscopic lamp to the engine usingspark plug lead for cylinder no. 1.
— Start engine and check ignitiontiming with the stroboscopic lamp.Ignition timing should be 10"B.T.D.C. at 800 to 850 rpm forvehicles with manual transmissionand 10" B.T.D.C. at 700 to 750 rpmfor vehicles with automatic trans-mission,
— If distributor calibration is not cor-rect, slacken and rotate manuallyuntil correct calibration is obtained,then tighten it.
If distributor removal is not required,proceed from this point.
EMISSION CONTROLSYSTEMS
Vehicle emissions are controlled byvarious devices that make up the crank-case emission control system, theexhaust emission control system andthe fuel evaporative emission controlsystem.
Any modification of the emission con-trol systems is subject to federal lawsand regulations and may incur penal-ties.
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Crankcase Emission ControlSystem
This is a closed system designed toprevent any emission of blow-by gasesand oil vapours into the atmosphere.
These gases and vapours are pipedto an orifice downstream of the throt-tle and are then drawn into the engineIn any rpm condition.
1. Emission feedback port
2. Throttle valve
3. Flame trap
4. Intake manifold
5. Sump-to-air cleaner line
6. Cyclone liquid/vapor separator
7. Oil drain line into sump
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38004
Fuel Evaporative EmissionControl System
The fuel evaporative emission controlsystem is designed to prevent air pol-lution caused by evaporative tossesfrom the fuel system.This is accomplished by a proper sys-tem which prevents the release into theatmosphere of fuel vapors from thefuel tank.The fuel vapors from the fuel lank ftowinto the activated charcoal carbon can-ister where they are absorbed andstored when the engine is not opera-ting.When the engine is running, the fuelvapors retained in carbon canister arepurged through a line which conveysthem to intake manifold.
The system consists essentially of:
— Sealed filler cap.— Limited-filling tank,— Vapor-liquid separator.— Two-way valve.— Vapor vent line.— Carbon canister.— Purge line.
39069
1. Fuel pressure regulator - 2. Cold start solenoid injector - 3. Solenoid injectors -4. Activated carbon canister - S. Two-way valve - 6. Fuel tank vapor vent fine - 7. Fuelreturn line - 8. Fuel delivery line - 3. Fuel filter - 10. Electric fuel pump - 11. Sealed fillercap - 12. Vapor-liquid separator.
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Ftief Injection SystemGeneral
This is an electronically controlledintermittent low pressure injectionsystem.
The fuel is injected upstream of theintake vaives by means of solenoidinjectors supplied at constant pressure.Flow is controlled by means of varia-tion in the opening time of the injectors.
The main factor controlling flow isthe direct measurement of drawn airby a special sending unit which trans-mits the most important informationfor fuel metering to the electroniccontrol unit.
The system is also provided with acertain number of measuring sensorswhich provide the electronic controlunit with the information required tooptimize the composition of the mix-ture in all engine operating conditions.
Exhaust Gas Emission ControlSystem
For the control of exhaust gas emis-sions, the injection system is fitted with
an oxygen sensor {Lambda probe)which measures the oxygen content ofthe exhaust gases and transmits anyadjustment of the air-fuel mixture tothe control unit. It is thus possiblewith the aid of a catalytic converterfitted to the exhaust pipe, to reduce toa minimum the harmful residues con-tained in the exhaust gases.
Oxygen Sensor {Lambda probe)
Every 30,000 miles: Renew oxygensensor. An indicator on theinstrument panel lights up oncompletion of 30,000 miles
(see page 7) signifying that the sen-sor must be replaced.
To renew sensor proceed as follows:
— Disconnect probe cable A.
— Back off probe B from its seat Con exhaust manifold.
— Fi 1 new probe lubricating threadedpart with anti-seize, ami-rust grease.
— Reconnect cable A.
— Press button to zero indicator. I79H9
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18
Vacuum
Components con rlHttiO nS
•Systam components
3800S
ELECTRONIC FUELINJECTION DIAGRAM
1. Battery
2. Relay set - Operates electroniccontrol unit 3 and motor driven fuelpump 1 7.
3. Electronic control unit
Receives information about oil quan-tity, coolant temperature and tempe-rature of cylinder head, position ofthrottle valve, starting phase as wellas engine rpm and injection point.
it processes this information and trans-mits electric pulses to the solenoidinjector.
It is connGcted with the individualcomponents by means of a multipleconnection plug and associated con-necting cables.
4. Coil
In addition to its normal function, ittransmits the number of engine rpm orthe injection point to the control unit.
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5. Air measuring instrument
This supplies information to electroniccontrol unit of quantity of air drawnand activates fuel supply pump,
6. Supplementary air valve
Supplies extra air during engine heat-ing stage, depending on temperaturelevel.
7. Throttle switch
Signals idle and full load to electroniccontrol unit.
8. Temperature sensor
Signals coolant temperature at the cy-linder head outlet
9. Cold starting solenoid injector
During starting in low temperatures,injects extra fuel into intake line.
10. Solenoid injectors
Inject fuel in intake port of cylinders.
11. Delay thermal switch
This automatically controls injectionof cold starting solenoid injector.
12. Fuel pressure regulator
Keeps fuel pressure constant in fuellines.
13. Fuel delivery line
14. Excess fuel exhaust line
15. Ignition switch
16. Fuel filter
Is fitted on fuel supply line for fuelfiltering.
17. Motor driven fuel supplypump
Delivers a constant supply of fuel tosolenoid injector.
18. Fuel tank
19. Oxygen sensor {Lambda probe).
Measures the oxygen content of ex-haust gases and transmits any adjust-ment of air-fuel mixture to control unit.
20. Catalytic converter
Reduces harmful residues containedin exhaust gases to a minimum.
Note: You are advised to take thefollowing precautions:
— Never start the engine if the batteryis not properly connected.
— Do not use charger with batteryleads disconnected.
— Never disconnect battery leads withthe engine running.
— When charging battery, disconnectclamps.
— If temperature is above 80° C(special body work) disconnectelectronic control unit from vehicle.
— Never remove or insert control unitharness connector with ignitionswitched on.
— Jf car is to remain out of service forsome time, add 10% of engine oil tothe fuel tank.
Idling Speed
Any adjustment to idling speed mustbe carried out with a warm engineand with gearshift lever in neutralposition for mechanical versions andin D (drive) position for automaticversions.
The engine is warm when the radiatorelectric cooling fan has been activatedat least twice.
To adjust idle the electric fan must beoff.
To adjust, turn bypass screw A.
idling speed is S50 _L 50 rpm formanual transmission and 750 ± 50 rpmfor automatic transmission.
Idle CO Setting
The idle co setting is factory adjustedand sealed. No additional adjustmentis required when tuning up engineduring the useful life of the vehicle.
WARNING
Fuel Refilling
Strictly adhere to the label on instru-ment panel and on filler cap.
UNLEADED FUEL ONLY
Leaded fuel will damage the catalyticconverter beyond repair, Alwais refillat Service Stations which carry unlea-ded fuel (small pump nozzle).
35
COOLING SYSTEM
Coolant Circuit
Every 500 miles or weekly - Checkthe coolant level in system expansiontank, with cold engine: the level must3lways be abt. 7 cm (2y.F in) above theM!N mark on tank.
When engine is very hot the levelmight rise noticeably: this could afsohappen immediately after stopping theengine.
Should the coolant level drop belowthe tank MIN mark, top up by removing
expansion tank cap and pouring incoolant, seeing that its level is asspecified.
Warning: Do not remove radiator orexpansion tank caps on a hot engineto avoid possibly scorching your hands;wait until engine has cooled down.Do not top up a hot engine withcold water.
Should more than 2 conse-cutive top-ups be required atshort intervals, or after limited
mileages (500 miles), the system needschecking, This applies also whenwater temperature gage pointer stayson the red sector (see page 6).
To drain cooling system, movelever D to the left {see page 12),open the cocks on radiator lower sideand on cylinder block, and disconnectexpansion tank hose.
To fill the system:— Connect expansion tank hose, close
radiator cock and remove plug A.— Pour in water siowly through radia-
tor filler port until water overflows,then refill the expansion tank.
— Refit radiator and expansion tankcaps and plug A then run theengfne so as to favor a thoroughmixing of the fluid in the system.
— Stop the engine, slacken plug A,wait for a proper system bleedingand refit the plug.
— With engine cold check the levelin expansion tank and, if nee. top up.
Antifreeze Mixture
The cooling system is filled with anantifreeze mixture effective down to— 35 "C (—32 (1F). In case of coolantchange or topping-up FIAT recom-mends the use of a 50-50 mixture ofwater and Paraflu 11 fluid {or equi-valent), which allows the use of hardor chlorinated water and incorporates
oxidation, corrosion, foam and scaleinhibiting properties and is effectivedown to — 35"C (—32° F). See Fill-upData Table.
This mixture shall subsequently bereplaced after 45 000 miles or everytwo years, whichever occurs firstthus reducing the need for any ser-vicing action on the cooling system.
When this mixture is used, plainwater may be added only in emergen-cies (sudden heavy coolant losses).
As soon as possible repair thefault and refill the systemwith the recommended coolant.
BRAKES
Brake system with front and rearindependent circuits.
If pedal free travel has becomeexcessive, if braking unbalanceon one wheel is appreciable
or if pedal sponginess is felt withconsequent reduced brake effective-ness, a complete inspection of thesystem is needed.
Fluid Reservoir
The « Low Brake Fluid Level » in-dicator (see page 7), controlled bya float and switch assembly on brakefluid reservoir, warns the driver of asudden drop in brake fluid.
A - Front brake fluid sectionB - Rear brake fluid section
Every 15 000 miles - Top up brakefluid reservoir. Use exclusively DOT 3MotorVehicle Brake Fluid (conformingto F.M.V.S.S. No. 116). Avoid usingany other type of fluid which woulddamage the special rubber parts in thesystem.
Front Brakes
Every 7 500 miles - Check that brakelinings are not worn down to less than1.5 mm (.06 in). Replace if required.
Lines and Fittings
Every 15 000 miles - Check hosesand fittings for leakages and tightness.
Bleeding
Bleeding is a delicate operationrequiring the necessary know-how and should only be needed
when air has entered either one orboth brake circuits (line disconnection,
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fluid drainage, etc.). This is indicatedthrough pedal sponginess and reducedbraking effectiveness.
Hand Brake
Every 15 000 miles or sooner ifhand lever stroke is excessivelylong, pull up the lever threenotches and adjust through
the appropriate tensioner (see fi-gure below).
Then release the lever and checkthat the wheels are not locked.
POWER TRAIN
Clutch
The clutch is mechanically controlled,with automatic wear take up and nopedal free travel.
Every 15 000 miles
Check pedal height and adjustif necessary.
After repeated adjustments, checkclutch facings for excessive wear:replace if required.
Manual Transmission OH
Every 30 000 miles
Renew oil. Let drip thoroughlyfrom plug B before refilling. The correctlevel is up to the opening of filterplug A.
sk i s
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Automatic Transmission(Where fitted)
If defective transmission oper-ation is detected contact yournearest FIAT Dealer.
Every 3 000 miles
Check the fluid level. Correct levelis between the MIN and MAX markson dipstick A.
Before checking the fluid leveldrive about 6 miles to reach normaloperating temperature, stop the caron level ground but keep the engine
running at idling speed, and move thegear selector lever to P or N.
If necessary, top up to the MAXmark through filler B using Fiat GI/Aor equivalent grade of automatic trans-mission fluid. Do not overfill.
The utmost care should be takento ensure that both the containers andthe funnel used for topping up areabsolutely clean.
Following emergency topping-upafter a sudden leak, owners arerecommended to contact the nearestFIAT Dealer for a general inspectionof the transmission.
Every 30 000 miles or two years -Renew the fluid with a warm trans-mission. If the fluid is found to beheavily soiled, also renew the filter inthe valve assembly, together with theassociated seal.
To renew the fuild remove plug A.To renew the filter remove sump B.
Axle Oil
Every 30 000 miles
Renew oil after thorough drainingthrough plug B. The correct level isup to the opening of filler plug A.
mmMIIS Hii
m
SUSPENSIONSAND STEERING
Front Suspension [SteeringArticulation Boots and Caps
Every 15 000 miles or wheneverunderbody inspections are carried out,check the condition of ball joint rubbercaps and steering gear rack rubberboots.
If they are damaged, replace.The new caps should be packedwith grassofiat MR 3 prior
to their installation.
At the same time inspect ball jointsfor excessive play. If evidence oflooseness exists, replace the bail joint.
Proper joint maintenance is essen-tial for car safety.
Front and Rear Suspensions
Check rubber mounts for properefficiency.
Front Wheel Bearings
Every 30 000 miles - Check bearingsfor play and adequate lubri-cation. Adjust and lubricatewith grassofiat MR 3, if nee-ded.
TIRES
Every 500 miles or weekly - Checkpressure with a gage not forgettingthe spare wheel (see page 56 forpressures}.
Make sure pressure is exactly thesame in each pair of tires. In hot cli-mates, do not reduce pressure as thiswould only increase tire temperature.
MISCELLANEA
Windshield Washer
Every 7 500 miles approximatelyCheck level in the bottle located
in left headlamp compartment.In case of incorrect jet aiming:
Clean the jet squirt hole accurately (bya needle).
Check also electric pump terminals.To re-aim jets: Turn the complete
body with a screwdriver and then thelateral pin so as to direct the watersquirt to top of wiper sweep arc.
Windshield Wiper
Every 7 500 miles approximately
Check for proper efficiency.
To remove a wiper blade, tilt outthe arm, free blade mount A from itslock dowel B on arm and extract theblade upwards.
Note - When adjusting wiper armsposition on windshield ensure thatthe distance from windshield base towiper arm fulcrum is:
driver's side = 55 to 75 mmpassenger's side = 70 to 90 mm
2546Q
BODY
Every 15 000 milesLubricate the following items as
required using the recommended pro-ducts:
Door lock cylinders with gfaphitepowder.Door locks through the speciallyprovided hole (near lock) blankedby a plastic plug, door hinges andlimiter, and front seat reclinablebackrest control with engine oil.Window venti-pane joints and hin-ges with glycerine (2-door ver-sion).Trunk lids and engine hood catchesand hinges with petroleum jelly.Seat guide rails with grassofiatJotai.
Tool Kit
The tool box contains:Wrench, socket, spark plugsWrench, double end, 8x10 mmWrench, double end, 13x17 mmScrewdriver, double-tippedPunch, straightWrench, wheel bolts
The jack is stored in trunk, on right-hand side.
41
Exterior Body Care
Wash the bodywork frequently withcold or lukewarm water. Sponge downusing a good quality car shampoo -Deterlux or equivalent. Never usehousehold soap or detergent, otherwisethe paintwork may be adversely affec-ted.
If a hose is used avoid directing itat full force against the body. Rinsethoroughly and dry off with a cleanchamois leather.
Do not wash your car in thesunshine, especially in hot climates orwhen the hood is still hot.
When cleaning the windshield raisethe wipers clear, and do not force themsideways.
An occasional light polish with anapproved silicone car polish will give
the paintwork extra protection. Also
remove any stain promptly.
Grease and tar should be removed
using a clean and soft kerosene- or
gasoline-moistened cloth. Subsequen-
tly, apply a fresh coat of polish.
To clean the windows use a goodquality spray type window polish -DP 1 or equivalent - and wipe dry withwater-absorbing paper.
Chromium-plate and any otherbright decorative metal parts are bestcleaned with either cold or tepid water,or any reputable make of car chromecleaner.
To preserve the rubber seals of
doors, hood and trunks use silicone
grease. This will also prevent squeaking,
particularly during the cold season.
interior Body Care
Dust the interior, preferably using avacuum cleaner.
To remove grease spots from clothlining use a good brand of stainremover (petroleum ether or light gaso-line) apply talc liberally, allow to soakand brush off.
To remove dirt from the seats or anyother imitation leather-lined part use adamp sponge and a neutral or blandsoap. Subsequently, rinse with a cieandamp sponge and dry off usingchamois leather.
Textile fiber mats should be cleanedusing a moistened cloth with goodquality detergent.
Rubber mats or floor lining shouldbe washed with a damp sponge andneutral detergent or water and soap.
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PROLONGED INACTIVITY
If the car is to remain inactive overlong periods it is advisable to carryout the following operations:
— Store the car in a covered, dry andventilated place.
— Ensure that the handbrake is re-leased.
— Do not empty the cooling system:in cold climates, if necessary,replace the coolant with a reliablehigh grade anti-freeze mixture.
— Check the tire inflation pressuresperiodically.
— Re-charge the battery about everysix weeks.
— Switch off any electrical loads andremove the ignition key.
— Protect the finish with a coat of
good silicone wax.
— Coat all bright metal parts with areputable make of car chromepreservant.
— Remove the wiper blades to pre-vent the rubber from distorting.
— Protect the car using a non-plasticscar cover.
If the car is to be left in the openspray the underside and the entireengine compartment with an approvedengine preservant, PROT V or equi-valent. Do not spray a hot engine.
Before starting a sprayed engineopen the hood and wait for at leastten minutes.
Prior to using the car following aprolonged period of inactivity performthe following operations:
— Remove the chrome preservant fromall bright metal parts.
— Wash the car.
— Renew the engine oil.
— Recharge the battery,
— Refit the wiper blades.
— Check the tire inflation pressures(including that of the spare wheel).
ELECTRICAL SYSTEM
Battery
Located in trunk.Every 3 000 miles or monthly -With battery at rest and cold, checkthe electrolyte level.In hot climates, check the levelmore often.
When liquid additions are needed,add distilled water (battery cold), neverelectrolyte fluid (which contains sul-phuric acid) as only water evaporatesfrom the battery in service, neverthe acid.
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WARNING - The battery containssulphuric acid. Avoid contactwithskrn,eyes or clothing.
Externalantidote: Flush with water.
Internal antidote: Drink large quan-tities of water or milk.
Follow with milk of magnesia,beaten egg or veg. oil.
Call physician immediately.
Eyes: Flush with water for 15minutes and get prompt medical atten-tion.
Batteries produce explosive gases.Keep sparks, flame, cigarettes away.
Ventilate when charging or usingin enclosed space.
Always shield eyes when workingnear batteries.
Keep out of reach of children.
Every 3 000 miles
Check posts and clamps for tight-ness and cleanliness.
Except in particular service condi-tions the battery does not require anyperiodical recharge.
As your car is fitted with electronic devicesnever run the engine - even for a veryshort while - with battery disconnectedfrom the alternator or wrongly connected(positive ground) otherwise serious da-mage will result.
Fuses
Nine 8-Amp. and three 16-Amp.fuses in a box under dash, driver'sside, and two 8-Amp. and 16-Amp.fuses in separate holders.
Before replacing a blown fuse tracethe cause and remedy accordingly.
Unprotected Circuits
Alternator, starting and starter refay,ignition high beams relay coilr batterycharge indicator, radio set {wherefitted), electronic fuel injection system.
44
Protected Circuits•
A (8 Amps)Turn signal lamps and indicatorStop lampsOH pressure gage and insufficient pres-
sure IndicatorEngine coolant temperature gageFuel gage, with reserve indicatorEngine tachometerLow brake fluid level and hand brake
ON indicatorBack-up lampsFast idle electrovalveFasten belts indicator and relay for
buzzerDelay circuit for fasten seat belts indi-
cator and buzzerSelected gear indicator light (autom.
transmission)30 000 miles pick-up and indicator
B (8 Amps)Windshield wiper motorHeater fan motorWindshield washer pumpWindshield wiper sweep rate rheostat
C (8 Amps)Left headlight high beamsHigh beam indicator
D (8 Amps)Right headlight high beams
E (8 Amps)Left headlight low beam
F (8 Amps)Right headlight iow beam
G (8 Amps)Front right parking lampRear left tail lampFront right/rear left side marker lampsLicense plate lamp (right)
H {8 Amps)Front left parking lampParking and tail lamps indicatorRear right tail lampFront left/rear right side marker lampsLicense plate lamp (left)Cigar lighter housing indicatorTrunk lightInstrument cluster lightIdeogram illumination optical fibers
light sourceVehicular hazard warning signal switch
light
I (8 Amps)Quartz crystal clockCourtesy lightHazard warning flasher and indicatorInspection lamp receptacleRemove key and fasten belts buzzer
L (16 Amps)HornsEngine fan motor
Wl (16 Amps)Power window motor {Left-if fitted)
N (16 Amps)Power window motor (Right - if fitted)
In separate holder (8 Amps)Cigar lighter
In separate holder (16 Amps}Fuel pumpSupplementary air valve
45
Lights
Headlights
Alignment
For aiming the headlights,screw 6 (vertically) and C(horizontally) are readily acces-sible after removing retainingring G.
Removal
Turn off screw E and removeretaining ring 6. Slacken 4screws Dand,byturning counter-clockwise remove headlight unitL. Then pull off terminal socket I.
Caution: Replace blown bulbsexclusively with bulbs of the sametype and wattage. Weaker bulbswill diminish visibility whereasstronger bulbs will draw a greateramount of current and overworkthe alternator, resulting in progressi-ve battery discharge. For bulb speci-fications see page 63.
Installation
Center headlight unit L on bodyby aligning locating dowel H with itsseat. Turn the unit clockwise and tigh-ten screws D. Refit retaining ring Gby tightening screw E in hole F.
Front Parking and Turn SignalLamps
A Lens mounting screws
B Lens
C Bayonet-coupled bulb, double fila-ment
D Positioning tabs
46
Rear Turn Signal, Stopand Back-up Lamps
The bulbs are accessible from insidetrunk after removing panel A.
To remove the panel free it fromthe arrowed lugs.
The bulbs are of the bayonet type. Side Marker Lamps
B Turn signal light
C Stop light
D Tail light
E Back up light
The rear bulb holders are accessiblefrom inside the trunk.
To remove the bulb, disconnect bulbholder A from seat B by turning coun-terclockwise.
Bulb C is of the plug-in type.
822
47
Front bulbs are accessible from in-side fenders.
To remove or refit follow the proce-dure given for the rear bulbs.
Courtesy Lamp
A Spring plates (two) unit mounting
B Switch
C Bulb, pressure mounted
D Lens and body unit
License Plate Lamps
To withdraw bulb holder remove reta-ining nuts from inside the trunk.
A Body retaining screws
B Body and lens
C Bulb holder
D Bayonet-coupled bulb
E Gasket
1^824
43
Advicefor bodyworkmaintenance
Protection from Atmospheric Agents
FIAT has introduced a series of measures to protect the auto-mobile from the various factors that can cause damage andcorrosion.Briefly summarized, these factors are:— Atmospheric pollution (urban environments and industrial
zones)— Airborne salts (marine areas, particularly those with warm
and humid climates)— Seasonal and ambiental humidity conditions (use of salt on
roads during the winter).The paintwork and body shell underside can be subjected notonly to the chemical action caused by the factors mentionedabove, but also to the abrasive actron of airborne dust andsand, mud, and loose gravel thrown up by passing cars as wellas the damaging action of salt spread on the roads in winter.FIAT's answer to this problem can be summarized as follows:— Corrosion and abrasion resistant paints and painting
systems.— Widespread use of pre-treated and highly corrosion resistant
sheet metal.— Spraying of the underside of the floor plan, engine compart-
ment, wheel boxes, and the various box sections with highlyadhesive protective waxes.
— Adequate covering or protective spraying with setting plasticof such particularly exposed parts as the door sill panels,wing interiors, borders, and so on.
— Use of enamels with greater resistance to polluted andindustrial atmospheres.
50
Obviously the factors we have described act in different waysin different cases, according to the environmental conditionsand the use of the car. Equally obvious is the fact that theowner who cares about hfs car and maintains it properly canmake it last longer. We would like to list a few useful hints andpieces of advice which, though obvious, often pass unobservedfor that very reason. The FIAT Service Network will be happyto supply more details on request.
Body Paintwork
Needless to say, the paintwork does not serve only an aestheticfunction, but also covers and protects the metal on which it isdeposited.
Therefore, any abrasion or deep scratches that expose thesheet metal should be retouched immediately to avoid pittingby rust.
This retouching should always be done with original products(see paint indentification plate).
Washing the car is the greater part of normal paint maintenance.
The frequency or washing depends not only on the frequencyof use, but also on the nature of the car's surroundings: washingshould be more frequent in more polluted areas, or if the caris often parked under trees which produce harmful resins.
A correct wash should be done as follows: First the car shouldbe wet down with water at low pressure and sponged downwith a light (2 - 4%) detergent solution. Rinse the sponge fre-quently. Rinse the car with a spray of water to carry away theloosened dirt, then dry with an air jet or chamois leather.
51
Be particularly careful to dry the less visible areas, such as thedoor frames, hood and headlight housings, where standingwater can collect more easily. Similarly, avoid putting the carin a closed space immediately after washing, so that air circu-lation can help evaporate any trapped water.
Do not wash the car after it has been parked in the sun, or ifthe hood is still hot, as this could adversely affect the brilliancyof the paint.
The occasional use of a silicone car wax wilt give the paint-work extra protection and keep it shiny. If the paintwork beco-mes cloudy due to smog accumulation, a slightly abrasive lightwax polish can be used.
Body Underside
The less accessible areas of the underside and frame boxsections have already been treated to ensure longer duration.
Regular check-ups should be made on the car. The aim of theseis to survey the soundness of the body and mechanical compo-nents, as well as to repair any damage. Particular attentionshould be paid during check-ups to the drainage holes in theunderbody box frames and door frame undersides. These holesserve to drain any water that may accumulate while driving thecar in the rain or while washing it, and so should be kept clear.
52
In harsh environmental conditions, periodic supplementary pro-tective treatments to the box sections and door interiors arerecommended.
These treatments must be done with special products andtechniques, and so should be left to experts. It should be doneat least every two years, and, in more severe cases, annually,preferably at the beginning of winter.
Car Interior
The maintenance of the passenger compartment is no less im-portant than that of the exterior. The same care should bedevoted to it.
Check to see that there is no standing water under the mats orfloor lining, as this could cause rusting. Dust the seats andcloth parts with a brush or vacuum cleaner.
To remove grease spots use petroleum ether or light gasoline,apply talc and brush off.
To clean seats in imitation leather, use a damp sponge and aneutral or bland soap. Rinse several times with a clean dampsponge.
While cleaning perforated seat covers, be particularly carefulthat water does not seep through the holes to the padding.
53
Windows
To ensure perfect visibility, windows should be cleaned with agood quality glass cleaner and then wiped dry. Always use aclean cloth to avoid scratching the glass.
To clean the inside of the windshield, where more obstinategrease deposits are to be found, use sulphur ether as a solvent.
The inside of the rear window can be cleaned in the same way,but particular care should be used to avoid damaging the dem-ister wires embedded in the glass.
Engine Compartment
The engine compartment should be well washed at the end ofevery winter to avoid damage caused by salt on the roads.
Chromium Trim
Chromium parts should be coated occasionally with car chromepreservant to protect them from atmospheric agents.
54
Cleaning Plastic Parts
Exterior plastic parts should be washed in the same way as thecar itself. If traces of dirt remain, use special plastic cleaners,following the manufacturer's instructions. Interior plastic partscan be cleaned in the same way. Do not use paint cleaners.
Cleaning the Convertible Top
To properly clean the convertible top, use the following proce-dure:• Do not perform cleaning procedure in direct sunlight.
• Thoroughly wet down the entire vehicle with water.— Keep vehicle wet through entire cleaning operation.
Caution: Make sure soap and cleansers do not run onto a drybody finish since it may cause streaks or stains if allowed to dry.• Apply a mild foaming cleanser to the entire top.— Use a Lestoil and Fantastic mixture with clean warm water
in a 2 to 1 ratio.For example:— 1 pint Lestoil— Vs pint Fantastic— y2 gallon clean water
55
• Scrub the top with a small medium-soft bristle brush addingwater, as necessary, until the cleanser forms a soapy con-sistency.
• Remove the first accumulated dirt from the top with a cloth(towel} or sponge before it can be rubbed back into the fabrictop.
• Apply a fresh mixture of cleanser and clean water to top.Scrub top with brush until the top is clean.
• Thoroughly rinse the top with clean water to remove alltraces of cleanser.
If any dirt spots are still on the top, apply Lestoil directly to thewet top, utilizing the same scrub brush and a final rinsing withclean water.
Leaving the Car in the Garage
A car left in the garage is subject to damage by humidity, whichis generally greater in a closed space than in the open air.
Parking the car in the garage while wet or covered with snowwill increase humidity through slow evaporation. In such casesthe car should be dried. Do not store large quantities of waterin the garage. Make sure that the garage has windows or otheropenings to ensure adequate ventilation.
Prolonged Inactivity
If the car is to remain inactive over long periods, It is advisableto carry out the following operations:
• Clean and protect the painted areas with silicone wax, Coatthe bright metal parts with a standard chrome preservant.
• Store the car in a covered, dry and ventilated place.
• Ensure that the parking brake is released.
• Disconnect the battery terminals.
• Remove the wiper, blades and coat with talc.
• Open the door windows slightly.
• Protect the car using a non-plastic car cover. This shouldnot be waterproof.
• Check the tire inflation pressure periodically.
• Check the battery charge every iy2 month. When necessary,use a slow 24 hr. charge.
• Do not empty the cooling system.
57
SPECIFICATIONS
ENGINE
Type 132 C3.031Number of cylinders, in line 4Bore and Stroke . . . . 8 4 x 9 0 m m
(3.31 x 3.54 in.)Total piston displacement. 1995 cc
(121.74cu. in.)Compression ratio . . . 8.2 to 1Maximum power (SAE net) 102 HPat 5500 rpm
Value Gear
0, H.V.
Twin O. H. camshafts driven by toothedtiming belt with tensioner.
Intake
Exhaust
Opens; B.T.D.C.Closes: A.B.D.C.
Opens: B.B.D.C.Closes: A.T.D.C.
5°53°
53"
Tappet clearance adjust-ment, for valve timing .80 mm (.031 in.)
Final tappet operation clearance adjust-ment, cold engine:Intake .41 to .49 mm (.016 to .019 in.)Exhaust .46 to .54 mm (.018 to .021 in.)
Lubrication System
Forced circulation by gear pump.Pressure limiter valve on delivery circuit.Full-flow cartridge oil filter.
Fuel System
Electronically controlled fuel injection.4 injectors, one per cylinder plus one
auxiliary injector for cold starting, allsupplied at constant pressure.
Gasoline flow governed by variation fnopening time of injectors.
An air measuring instrument is used forflow variation.
Electric sensors optimise the mixture inall engine operating conditions, supplyinginformation to the electronic control unit.
Air cleaner installed before air measuringinstrument with paper cartridge.
Cooling System
Radiator and translucent expansion tank.Water circulated by centrifugal pump.Thermostat with controlled by-pass on
cylinder head water outlet duct.
Four-blade fan driven by electric motorcontrolled by thermostatic switch onradiator: cut-in temperature about 90° C.
Ignition System
1-3-4-2Firing orderBasic ignition timig— at 800 to 850 rpm (manual
transmission), at 700 to 750rpm (automatic transmis-sion) IQo ± 1.5BTDC
Automatic advance . . . . 18° ± 2 °
Spark PlugsType: Champion RN9YThread size: 14 x 1.25 mmGap: 0.7 to 0.8 mm (0.027 to 0.031 in)
POWER TRAIN
Clutch
Mechanically controlled, automatic weartake up no pedal free travel.
59
Manual Transmission
Five forward speeds (all synchronized)and reverse.
Gear ratios to 1 :
1st 2nd
3.667 2.100
3rd
1.361
4th
1
5th
.881
Reverse
3.244
Automatic Transmission(Optional Extra)
G. M. hydraulic torque converter-gearboxunit.
Transmission ratios:
First 2.40 to 1Second 1.48 to 1Third 1 to 1Reverse 1.92 to 1
Propeller Shaft
Tubular propeller shaft in two sections,with rubber mounted central pillow block.Front section connected to transmissionby flexible joint and slip yoke. Thesecond section is connected to the firstand to rear axle by universal joints.
Rear Axle
Final drive hypoid gear ratio: 10/39— with automatic transmission 12/43
BRAKES
Service
Hydraulically operated by pedal throughvacuum servo and tandem master cy-linder.
Disk type, with floating caliper and onecylinder to each wheel.
Independent front and rear circuits.Proportioning valve in rear circuit for
car load and deceleration rate variationcompensations.
Device for automatic wear take-up.
Parking
Mechanical, operating on rear brake.
SUSPENS/ONS
FrontIndependent wheels, by swinging arms,
with coil springs and hydraulic, double-acting telescopic shock absorbers. Sta-bilizer bar. Sealed-for-life articulations.
Rear
By rigid axle anchored to body through 5reaction rods - 4 longitudinal and 1 trans-versal. Coil springs, hydraulic double-
acting telescopic shock absorbers. Asym-metric wheel motions stabilized by elasticmounts of reaction rods.
STEERING AND WHEELS
Steering
Standard , L.H.D.Control; worm screw and roller, ratio 1/16.4.Steering shaft in three sections, incorporat-
ing two universal joints; breakawaymount.
Independent and symmetric track rods toeach wheel, with central link rod. Seal-ed-for-life articulations.
Hydraulic, double-acting damper on relaysupport.
Turning circle 10.4 m(34 ft 2 in.)
Front wheel camber,, measur-ed at rim 0 to 6 mm (.00 to .24 in.)
or 30' ± 30'Front wheel toe-in, measured
at rim 3 ± 2 mm(.118 to .079 in.)
The above data apply to cars laden tothe equivalent of 2 adults (300 lbs) plus130 lbs of luggage.
Wheels and Tires
Disk wheels, ventilated, withrim size 5 J x 13"
Radial-ply tires, size . . , 165SR-13"or185/60 R-14
60
ELECTRICAL SYSTEM Bulbs
Voltage 12 Volts
AlternatorContinuous current rating . 65 AmpsIncorporated current rectifiers.Automatic voltage regulator.Cut-in speed at starting of engine (with
users off),
BatteryWith grounded negative; capacity at 20-hr
discharge rate 60 Amp, hr.Cold (— 18'C) high-discharge
test current 255 Amp.
StarterPower rating 1.3 kWDirect engagement by solenoid and free-
wheeling pinion.
Heater Fan MotorP o w e r r a t i n g . . . . 20 W
Engine Radiator Fan MotorPower rating 110 W
Windshield Wiper MotorPower rating 28 W
FusesNine 8-Amp, three 16-Amp fuses and two8-Amp and 16-Amp fuses in separateholders.
Location
Headlights (high and low beams)Front lamps
turn signal . . . . . . . . . .parking
Rear lampsturn signalback-upstop
Rear lampstaillicense plate .
Courtesy lightIdeogram illumination optical fiber
light source«EX. GAS SENSOR)) indicatorSelected gear indicator light (aut.
transmissfon)Turn signal indicatorHeadlight high beam indicator . .Battery charge indicatorInsufficient oil pressure indicator .Fuel reserve indicatorParking and tail lamps indicator . .instrument cluster lightsFasten belts indicatorVehicular hazard warning signal in-
dicatorLow brake fluid level and hand brake
ON indicatorSide marker lightsVehicular hazard warning signal
switch lightTrunk lampCigar lighter housing indicator . .
SAEStandard
FIATStd. Part No.
« Sealed Beam )> headlight unit 4002
No. 1034 (32 cp)1/41461/90
No. 1063 (32 cp)1/41460/90
No. 67 (4 cp)1/41459/90
No. 158 (2cp)
12V-5/21WNorm. 1/41446/90
12V-21WNorm. 1/41481/90
Norm. 1/08577/90
12V-5WNorm. 1/08630/90
12V-3WNorm. 1/41439/90
Norm. 1/41458/90or Norm. 1/41439/90
12V-1.2WNorm. 1/41437/9012V-4WNorm. 1/41423/90
61
MAIN DIMENSIONS PERFORMANCE
mm
in.
520
20,5
847
33.4
1 013
39.9
1 120
44
1 250
49.2
1320
52
1350
53.2
1613
63.5
2 281
89.7
4141
163
Speeds
Maximum speeds after break-in,fully laden
1st gear . . .2nd gear . .3rd gear . . .4th gear . . .5th gear, over
Gradeabi'tity
Maximum grades climbable, fully laden
Manual T.
295076
104107
Auto-Transm
4776
104
1st2nd3rd4th
5th
gear .gear
gear .gear .gear ,
. •
• •
WEIGHTS
Curb weigh)• {
%53261611
9,5
%
452517
Overall height is measured with unladen car. Trunk volume: 180cu.dm (6.4 cu. (t).
manual , . . 2 360 lbsautomatic . . 2 400 lbs
Vehicle load capacity (total 430 lbs):2 adults (300 lbs) + 130 lbs of luggage
Gross weight f manual . . . 2 790 lbs(fully laden) \ automatic . . 2 830 lbsDesignated seating capacity . 2 personsOccupant distribution . . . . 2 in front
FiLLUP DATA
Fuel tank
Radiator, cylinder jackets andheating system
Engine sump and filter (:) .
Manual transmission . . . .
Automatic transmission . . .Rear axleSteering box
Hydraulic brake circuits . .
Windshield washer
dm3
It
43
8
4.125
1.65
2.801.30.215
.380
Kg
—
—
3.750
1.50
2.51.20.195
.380
U.S.units
11.4 Gals
B% Qts
47, Qts
if km3 Qts
21 PtIS r I
% Pt
Unleaded qasolint? with octane ratingof at least 91 (Research Method)
Antifreeze mixture (J)
Low-ash content detergent oils-APIService SE to M1L-L-46152 and abovethe CCMC European Sequence. SeeTable belowSAE BQW/90 oil containing specialantiuvoar additivesA X F , - Dexron typo fluid
l-EAE BOW/90 EP oil
DOT 3 Motor VehicleBrake Fluid to F.M.V.S.S.No. 116
J
Temperature Solvent in bottle
above 0"C (32* F) 3%downto—10nC (14"F)| 50%below —ICC (14"F)| 100%
Pure water plushigh qualitywindshield
washer solvent
Outdoor temperature
Minimum below —15°C (5"F)
Minimum between —15° and 0" C(5"F to 32° F)
Minimumabove O C
(32° F)
Max. up to 35" C (95° F)
Max. over 35" C (95° F)
oltofiat Single-grade
VS+10 WSAE10W
VS+20 WSAE20W
VS+30SAE30
VS+40SAE40
oliofiat Multigrade
VS+ 15 W/40SAE15W/40
Do not mix oils of different brands or grades.
C1) The system is filled with a 50-50mixture of water and Para-flu 11 fluid<S8B Page 36).
(:) Total capacity of sump, filter and linesis 4.35 kg (SVs Qts). The amount indica-ted is the requirement for periodical oilchanges,
Tire Pressure
Front and rear . . 28 psi
Mote: To obtain the required safetyin car performance strictly adhereto the pressure rating given. Tireinflation pressure should be checkedwith cold tires.
INDEX
General
Identification dataKeys
Page
22
Operation
Automatic transmission 19Doors 10Driving the car 17Fold-away top 14Instruments and controls 5Jacking-up and towing 22Parking •« 18Recommended shifting speeds . . . 1 8Seats 10Seat belts 11Starting the car 16Starting the engine 16Ventilation and heating 12Wheel changing 21
Maintenance
Advice for bodywork maintenance . 49Air cleaner 27Antifreeze 36Axle oil 39Battery 43Body care 42Brakes 37Brake fluid reservoir 37Brake system bleeding 39
64
Page
Clutch 38Coolant circuit 36Cooling system 36Crankcase emission control system . 30Emission control systems 23Electrical system 43Engine lubrication 26Engine oil filter 26Exhaust emission control system . . 32Fuel evaporative emission control
system 32Fuel filter 30Fuel injection diagram 33Fuel injection system 32Fuses 44General maintenance schedule . . . 24Hand parking brake 38Headlights 46Ignition timing . . . , , . . . . 2 8Inactivity 43Lights 46Lubricant designations 25Miscellanea 40Oxygen Sensor 32Power train 38Spark plugs 27Special maintenance 25
Page
Steering 40Steering articulations 40Suspensions 40Suspension articulations 40Tappet clearance 26Tires 40Toolki t 41Transmission oil 38Water pump drive belt 28Wheel bearings 40Windshield washer 40Windshield wiper 41
Specifications
Brakes 60Electrical system 61Engine 59Fill-up data 63Main dimensions , . 62Performance data 62Power train 59Steering and wheels 60Suspensions 60Weights 62
Important - All conversions are in U.S. units. They are given merely for Owners' con-venience and, though the closest approximation is sought, are normally rounded offfor practical reasons. It must therefore be understood that in case of any dis-crepancy the metric units are the only valid reference.
The information contained in llu's publication is intended to he of a general nature only. The Fiat Company may st any timeand from time t<f time, for technical or other necessary reasons, modify <wy of the details at specifications of the product describedin this publication. To be sure of getting accurate, detailed and up-to-date information, an intending buyer should consult
his nearest Fiat Denier or distributor or branch.
Ditezione Commercials - Assistenzs Teenies • 10134 TORINO (Italia) • Cnr;:<: E. Giambone, 33' Fin Ami} S pA 2nd Edition - Print No. S03.05.S38 - V-7380 - 4500 - Printed in Italy • Tipogrsfia Torinese S.p.A. - Torino
