Fiat barchetta Engine

Cooling system

1 Lower vehicle and drain coolant. Loosen

collars and disconnect top coolant sleeve.
Remove bolts retaining fan to radiator and
connections, then remove fan unit.
P3W17AXO1

2. Remove lower bolts retaining condenser

to radiator unit.
3. Remove lower bolts retaining air shroud.
4. Unscrew upper bolts retaining condenser
to radiator, then move to take out radiator
unit.

Reverseremoval operations to refit.

---
~~~\ ~ ..~~

P3W17AXO3

Copyright Fiat Auto 17

Engine Fiat barchetta
Replacing auxiliary belt

REMOVING-REFITTING AUXILIARY COMPONENT BELT

Position the vehicle on a lift, disconnect bat-

tery negative lead, then proceed as follows:

1 Loosen nuts retaining right front wheel,

2. Raise vehicle and remove right front

wheel. Unscrew the bolts fastening pas-
senger side wheel arch lining and remove
from vehicle.

Check tension and condition of aux-

iliary unit drive belt and in particular
for cracks,tears,surfacewear (which
looks smooth and shiny) and dry or
hardenedparts that could lead to loss
of grip. If one of the above defectsis
found, replace the belt.

3 3. View of auxiliary drive belt fitted to vehi-

(5)~7f::::==~~=~==
-

0~
I cle:
1. Alternator
2. Automatic tensioner
3. Of crankshaft pulley
4. Air conditioner compressor pulley
5. Fixed tensioner
6. Power steering pump pulley
7. Auxiliary component belt
..1,

'\E A void the belt coming into contact

with oil or solvent that could impair
L the flexibility of the rubber with a
consequentloss of grip
P3W18AXO1

18 Publication no. 506.586/01

Fiat barchetta Engine
Replacing timing belt

~i I 1"'-,1/
P3W19AXO1

1. Slacken belt tension by turning central au-

tomatic tensioner nut anticlockwise in or-
der to release pressure on the spring inside
the device.
2. Prise off the auxiliary drive belt while
keeping the tensioning device slack.

Reverse disassemblyinstructions in
order to fit a new belt. Thepreloaded
automatic tensioner spring will en-
sure belt tension is correct after turn-
ing the crankshafta few times.

REMOVING-REFITTING TIMING BELT

Before removing the timing belt, first

remove the auxiliary drive belt as de-
scribed in the previous section.
3. Remove the fixed belt pulley to permit re-
moval of the timing belt guard.
4. Remove the lower bolts retaining the tim-
ing belt guard.

Co/Jvril1ht Fiat Auto 19

 Engine Fiat barchetta
Replacin~ timing belt

1. Unscrew top timing belt cover retaining

bolts, then remove the cover from the en-
gine bay.
2. Remove the ignition coil cover by un-
screwing the bolts shown in the figure.
Hexagonal-headed socket screws (1)
may be exposed by removing oil filler cap.
3. Disconnect supply leads to ignition coils,
earth lead (1) and pipe (2) for recovery of
oil vapour from the cylinder head cover.
4. Disconnect the electrical connection
shown in the figure from the air condition-
er compressor.
5. Remove the cylinder head cover by undo-
ing the retaining bolts shown in the figure.

P3W20AXO3

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P3W20AXO4 P3W20AXO5

20 Publication no. 506.586/01

~
Fiat barchetta Engine
Replacing timing belt

P3W21 AXO1 P3W21 AXO2

"!=:::[--~~ 1. Removethe spark plugs using an appro-

-s-l~= priate wrench.

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2. Position the guage against cylinder no. 1,
then use tool 1895879000 to turn the
crankshaftto t.d.c.
3. Removethe 2nd intake end camshaftcap
9~ and the 3rd exhaust end camshaft cap as

~ shown in the figure.

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Mark camshaftcapsafterremovalto
ensurethey are refitted in the correct
position. Otherwise camshafts may
operate inefficiently.

P3W21 AXO3

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4. Position and retain pair of tools
1860847000 on caps removed previously.

Tool pair 1860847000 must follow

camshaft cam profile exactly.
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Copyright Fiat Auto 21

 Engine Fiat barchetta
Replacing timing belt

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P3W22AXO1 P3W22AXO2

3 \ 1. Remove the protective cover on the bell

housing shown in the figure, then position
2. Remove auxiliary drive pulley on the
flywheel retainer 18

]":J
A\ crankshaft.
~I ~II\ 0
~ 0
3. Check that the locating dowel on the
-- crankshaft drive gear is positioned low
down in line with the engine. Then re-
move the inspection cover on the bell
'" housing and check that the reference mark
on the flywheel coincides with the mark
on the bell housing, as shown in the box.

4-5. Slacken drive belt tension by undoing

the nut shown in the figure, then prise
off the belt.

P3W22AXO5

22 Publication no. 506.586/01

~
 Engine
Replacing timing belt

Refitting timing belt

1. To facilitate timing belt positioning,

loosen intake end camshaft pulley bolt by

applying leverage with tool 1860831 000.

This pulley is slotted to permit correct

belt-pulley coupling.

2. Fit the belt, observing the following fitting

order:
- crankshaft drive gear (1);
- fixed pulley (2);
- exhaust end camshaft pulley (3);
- intake end camshaft pulley (4);
- automatic tensioner guide pulley (5);
- coolant pump pulley (6).

NOTE Take care not to kink the belt when

fitting because this could damage
the belt material.

Fit the belt so that the arrow on the

belt points in the direction of engine
rotation.
P3W23AXO2

Copyright Fiat Auto 23

Engine Fiat barchetta
Replacing timing belt

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P3W24AXO1

~
3 Tensioning timing belt
/'~~ 1. Fit tool 1860845000 into the hole on the
automatic tensioner mount. Turn the tool
to exercise a force on the automatic ten-
(\}@~
'",~ ~ sioner. Adjust to maximum tension and
/ ...5 r'( then tighten nut retaining tensioner to
mount.
6) 2. Tighten bolt retaining intake end camshaft
pulley to a torque of 11.8 daNm. Apply
leverage using tool 1860831 000.
3. Remove tool pair 1860847000 and repo-
~ sition camshaft caps (marked upon re-
moval) correctly. Tighten to a torque of
1.5 daNm. Remove the flywheel retainer
and turn crankshaft through two turns in
its direction of rotation.

Loosen belt tensioner retaining nut and usetool 1860845000 to align mobile belt tensionerpointer (1)
with fixed reference (2) on engine block. Tighten belt tensioner retaining nut to a torque of 2.5 daNm
and then refit parts removed previously.

24 Publication no. 506.586/01

 Fiat barchetta Engine
Removing-refitting cylinder head

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P3WO5AXO4
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REMOVING-REFITTING CYLINDER HEAD

Disconnect battery negative lead, re-

move auxiliary drive belt and timing
belt as indicated in the previous sec-
tions, then proceed as follows:
1. Drain coolant by loosening lower radiator
sleeve temporarily.
2-3. Remove air intake shrouds by undoing
fastenings shown in the figure.
4. Remove the coolant expansion tank after
disconnecting the hoses.
5. Disconnect upper coolant sleeve.

P3WO6AXO4

Copyright Fiat Auto 25

~
 Engine Fiat barchetta
Removin~-refitting cylinder head

1 Remove car alarm ECU/siren retaining

nuts, then position unit to one side of the
engine bay without disconnecting the
electrical wiring.

2. Remove the battery after disconnecting

the positive lead.
3. Disconnect the air intake line between
butterfly valve case and debimeter by un-
doing fasteners shown.
4. Disconnect the accelerator cable from the
lever on the butterfly valve case.
5. Disconnect the protection on the exhaust
manifold by undoing the three nuts
shown.

"

--
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"
P3W26AXO1
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P3WO3AXO5

26 Publication no. 506.586/01

~
 Fiat barchetta Engine
Removing-refitting cylinder head

1 2

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:::::::::::::::::::,~
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P3WO5AXO1

Disconnect the lambda Probe electrical con-

nector, raise the vehicle and proceed as fol-
lows:
1. Remove the nuts retaining the exhaust
pipe to the catalytic converter.
2. Undo the bolts retaining the exhaust pipe
to the manifold.
3. Remove the first exhaust pipe section after
removing the support bracket shown in
the figure.
4. Remove the bracket connecting the en-
gine block to the inlet manifold by undo-
ing the fasteners.
5. lower the vehicle and remove the exhaust
manifold (1), dipstick (2) and rigid
coolant pipe (3) after disconnecting the
sleeves connected to the pipe.

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\ P3W27AXO2
P3W27AXO1

Copyright Fiat Auto 27

~
Engine Fiat barchetta
Removing-refitting cylinder head

1 Disconnect electrical connections from

the following parts:
- Injectorsand timing variator(1);
- coolant temperaturesensor on thermo-
stat (2);
- coolant temperaturesensoron head (3);
- gearboxend earth point (4);
- idle adjustment actuator (5);
- throttle valve position sensor (6);
- ignition power module (7);
- engine timing sensor (8);
- timing end earth point (9).

2. Undo the two screws retaining the injec-

tion wiring to the intake manifold and

move the wiring out of the way.

3. Disconnect the fuel inlet and outlet lines

at the points indicated.

4. Disconnect the evaporation control sys-

tem lines from the intake manifold.

28 Publication no. 506.586/01

Fiat barchetta Engine
Removing-refitting cylinder head

1 \\
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P3W29AXO1 P3WO7AXO5

1. Unscrewboth screwsretainingthermostat
assemblyto cylinder head and move the
assemblyout of the way, taking care not
to damageconnected sleeves.
2. Disconnect vacuum pipe from brake ser-
vo.
3. Disconnect butterfly valve case by undo-
ing bolts retaining it to intake manifold.
4. Unscrew the bolts retaining the cylinder
head to the engine block using tool
1852154000,then hoist cylinder headto-
gether with intake manifold and remove
using a lift sling.
5. Place the assemblyonto a service bench
and separatethe intake manifold by undo-
ing the retaining bolts.

\ ~r, "'-.

P3W29AXO3
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Copyright Fiat Auto 29
 Engine Fiat barchetta
Removing-refitting cylinder head

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P3W30AXO2

Refitting
1. Position cylinder head gasket with the
wording "ALTO" facing the operator.
m The cylinder head gasket is AS-
~ T ADUR type. This type of gasket is

3 , " made from a special material which

undergoes a process of polymerisa-
~\
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\ tion while the engine is running and
therefore hardens considerably during

~~ use. The following conditions must be

satisfied in order to ensure polymeri-
sation occurs:
- keep the gasket sealed in its plastic
bag;
::: - take out of the bag shortly before
fitting;
- do not oil the gasket or contami-
-::::-J. nate with oil. Ensure cylinder head
and crankcase surfaces are thor-
~~ J/
"/
oughly clean.
2. Position the cylinder head, then tighten
. --,- ,i'? ff /'/7 I retaining screws to torque. Note that the
tightening pattern is as shown in the fig-
ure for each tightening stage.
3. Oil the screws and washers and leave to
drain for at least 30 minutes. Screw in
bolts to a torque of 2 daNm and then
tighten to a torque of 4 daNm by means of
wrench 1852154000.
4. Angle tighten screws through 270° in
three different stages (90° + 90° + 90°)
using wrench 1852154000 and
1895897000.

Refit parts removedpreviously by re-

versing disassemblyinstructions. Fit
timing and auxiliary belts and tension
as described in the previous para-
graphs.

~O Publication no. 506.586/01

~
Fiat barchetta Engine
Removing-refitting cylinder head

REMOVING-REFITTING COOLANT PUMP

Before removingthe coolantpump,

remove the auxiliary and timing belts
as describedin previous sections.
1. Remove the inlet end camshaft by exert-
ing leverage using tool 1860831 000.
2. Remove covers shown in the figure.
3. Remove the coolant pump by undoing re-
taining screws.
4. Refit parts removed previously and tighten
inlet end camshaft pu!.ley retaining bolts to
a torque of 11.8 daNm, exerting leverage
using tool 1860831000. Position timing
and auxiliary belts and tension as de-
P3W31 AXO2 scribed in previoussections.

P3W24AXO2

CoDvriaht Fiat Auto 31