Fiat barchetta Braking system

Front brakes
33.
REPLACING BRAKE
PADS

1. Disconnect the brake pad wear sensor

connector.
2. Undo the caliper nuts and bolts and sepa-
rate the caliper from its mounting bracket.
3. Remove the brake pads from the caliper
mounting and check that they are not less
than 1.5 mm thick; if they are, replace the
brake pads.
4. Compress the piston in the caliper case
using the tool shown in the figure below.

2 To fit the brake pads, it is advisable

to use a tool of the shape and di-
mensionsillustrated in the drawing,
to compressthe piston in the caliper
7 case.

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P3WOO1004

P3WOO1003 P3WOO1 D05

Copyright Fiat Auto 1

 Braking system
Front brakes

BRAKE CALIPER
1

DI

"
P3WOO2DO1 1. Disconnect the brake pad wear sensor ca-
ble and the rigid pipe at the points shown
in the figure, and remove the brake caliper
2 as shown on page 1 .
2. Place the brake caliper in a vice and re-
move the hose at the point shown in the
figure.
3. Dismantle the piston from the caliper case
by directing a jet of compressed air in the
;,-.. brake fluid inlet hole. After dismantling,
/~ undo the bleed screw as shown in the in-
sert.
4. The piston and caliper case must not show
signs of friction or seizure, otherwise the
caliper complete with piston will need to
be replaced.
./ At all events, the dust excluder and seal
should always be replaced; also ensure
that the bleed screw is not blocked.
" P3WOO2DO2

P3WOO2D04 P3WOO2DO3

2 Publication no. 506.586

~
 Fiat barchetta Braking system
Front brakes

-' ,
BRAKE DISCS
,'~

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1. Separate the brake caliper from its mount-
ing bracket as shown on page 1, then un-
P3WOO3DO1
do the bolts and remove the caliper
mounting.
2. Undo the bolts shown in the figure and re-
move the brake disc.
3. Check that the thickness is not less than
the permitted minimum (see Section 00 -
Technical data), otherwise the brake disc
should be replaced. In the case of damage
or deep scoring, the brake disc surfaces
must be skimmed by a grinder. After skim-
ming, the brake disc thickness must not be
less than the specified limits (see Section
00 - Technical data).
4. Check using a dial test indicator that the
disc is fitted correctly. If the instrument
measures 0.15 mm at a distance of 2 mm
from the disc's outer edge, vibration will
be felt on the brake pedal when it is ap-
plied.

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P3WOO3DO3

Copyright Fiat Auto 3

~
 Braking system Fiat barchetta
Rear brakes
33.
BRAKE CALIPER

NOTE Toreplacethe brakepads, follow the

procedure describedon page 1.

Removing - refitting
1 Disconnect the brake hose and undo the
bolts shown in the figure, then remove the
brake caliper.
P3WOO4DO1

2. Place the brake caliper in a vice, and use

tool 1856133000 to remove the piston
from its seating.
P3WOO4DO2

3. Remove the brake caliper seal using a

point.

'4 Publication no. 506.586

 barchetta
Rear brakes

Dismantling-refitting hose

1 Working as shown il 1 the figure, separate

the hose from the br,ake caliper. The hose
must not be swollen Ior cracked, otherwise
it will need to be rep laced. Both hoses on
the brake calipers ha've to be replaced.

2 Undo the bolts and remove the spring

from the brake caliper.

3. Brake caliper assembly

P3WOO5DO1

1. Dust excluder
2. Piston
3. Seal
4. Handbrake linkage spring
5. Caliper case
6. Bleed screw
7. Protective cap
8. Hose
Lubricate the parts concerned with
brake fluid before final assembly.

BRAKE DISCS

4. Separate the brake caliper from its mount-

ing bracket as shown in figure 1 on the
preceding page, then undo the bolts
shown in the figure and remove the
P3WOO5DO2
mounting bracket.

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p"wnn!;on" P3WOO5DO4

Copvri.qhtFiat Auto 5

~
Braking system Fiat barchetta
Rear brakes
33.

1. Undo the bolts shown in the figure and re-

move the brake disc.
When refitting, remove any traces of rust
on the contact surfaces of1he parts, to en-
sure that the disc is perfectly perpendicu-
P3WOO6DO1
lar to the hub.
2. If the thickness is less than the permitted
minimum (see Section 00 - Technical da-
ta), the brake disc should be replaced. If
the brake disc is damaged or deeply
scored, the surfaces may be skimmed by a
grinder. After skimming, the brake disc
thickness must not be less than the speci-
fied limits (see Section 00 - Technical da-
ta).
3. Undo the hub-phonic wheel assembly
nut; after refitting., tighten the hub nut to
the specified torque.
4. Check that the brake disc is fitted correct-
ly; if the out-of-true is over 0.15 mm at a
distance of 1 mm from the disc's outer
edge, vibrations may be felt on the brake
pedal when it is operated.

P3WOO6DO2

6 Publication no. 506.586

Fiat barchetta Braking system
Rear brakes
33.
PRESSURE REGULATOR
The pressure regulators are inserted in the
pipes which connect the master cylinder with
the rear brake control cyliders and have the
task of preventing the rear wheels from lock-
ing during emergency braking when the load
of the vehicle moves to the front axle as a re-
sult of the effects of the braking.
Two pressure regulators are needed for a
crossover type braking system.

Intervention conditions
Up to an operating pressure of 30 Kg/cm2,
the outlet pressure (Pu) corresponds to the
inlet one (Pe). The increase in the inlet pres-
P3WOO7DO1
sure, acting on the surfaces of the pressure
regulator internal piston, causes it to move,
decreasing the pressure in the rear circuit at a
ratio of 0.25 for each wheel.

Location of pressure regulators on the rear

suspension

~ /
~-
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~ Removing - refitting
Disconnect the piping, then undo the fixing
bolts and remove the pressure regulator in-
volved.
P3WOO7DO3

Copyright by Fiat Auto 7

Braking system Fiat barchetta
Rear brakes

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P3WOO8DO1 P3WOO8DO2

HANDBRAKELEVER

1. Remove the handbrake lever trim.

2. 3. Undo the bolts shown and remove the
handbrake lever cover.
4. Disconnect the connector for the hand-
brake warning light.
5. Loosen the handbrake operating cables.

P3WOO8DO3

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P3WOO8DO4 P3WOO8DO5

8 Print no. 506.586

Fiat barchetta Braking system
Rear brakes

LOAD PROPORTIONING VALVE FOR

REAR WHEELS

Location on vehicle of load proportioning

valves for rear wheels.

Removing - refitting
Disconnect the piping, release the operating
spring and then undo the fixing bolts and re-
move the load proportioning valve involved.

When the refitting is complete,

bleed the braking system.

Adjustment

- Let the rear suspension bed in

- position the vehicle (in running order, i.e.
with a full fuel tank, coolant, spare wheel
and accessories) on a horizontal plane with
the wheels on the ground;
- apply a load of 130 Kg in the luggage com-
partment, if possible over the rear axle;
- loosen the bolt (1) fixing the bracket;
- apply torque wrench 1895873000 to the
bracket eyelet (2);

P3WOO7DO5

Copyright by Fiat Auto 7/1

Fiat barchetta Braking system
Rear brakes

- apply a load of 5 daN to the torque wrench;

- keeping the bracket (3) in this position,
lock the bracket fixing bolt (1 )
- repeat the adjustment procedure for the
other load proportioning valve.

NOTE In the case of irregular operation, the

complete load proportioning valve
must be replaced.

~ Bleed braking system

Operation
The load proportioning valve for the rear
wheels, fixed to a bracket on the rigid rear
axle, differs the braking pressure in the rear
wheel brake circuit and that in the front
wheel brake circuit according to the vehicle
deceleration load conditions.
The variation in pressure is determined by the
position of the spring (4) connected to the
stabi)izer bar which acts on the load propor-
tioning valve piston.

The braking system is equipped with 2 load

proportioning valves, 1 for each rear wheel.

Section of load proportioning valve.

Copyright by Fiat Auto 7/2

Fiat barchetta Braking system
Hydraulic system

1 Undo the attachment bolts and remove

the handbrake lever.
ADJUSTING HANDBRAKE

To adjust the handbrake, proceed as follows:

- position the handbrake lever on the 4th
click starting from the rest position;
- hold the nut with a spanner and turn the
adjustment screw anti-clockwise until the
cable is tensioned;
- check that in these conditions the rear
wheels are locked;

- set the handbrake lever in the rest position.

P3WOO9DO1
The rear wheels should now be able to turn
freely;
~ operate the lever and check that the num-
ber of clicks on the sector gear is between 4
and 5. If not, repeat the adjustment.

REMOVING REFITTING SERVO UNIT

COMPLETE WITH PUMP

After removing the ABS control unit (see dis-

mantling procedure on page 14), proceed as
follows:
3. Undo the attachment bolts and remove
the ABS control unit mounting.

4. Disconnect the pipes connecting the tank

to the pump.

3 4
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P3WOO9DO2 P3WOO9DO3

Copyright Fiat Auto 9

 Braking system Fiat barchetta
Hydraulic system

- Undo the nuts (arrowed) and remove the

brake fluid reservoir from its seating.

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I - Disconnect the vacuum pipe.
P3WO10DO2

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- Undo the bolt (arrowed) and remove the

,,...

. ... air conditioner pipe mounting bracket.

P3WO10DO3

10 Publication no. 506.586

~
 Fiat barchetta Braking system
Hydraulic system

P3WO11 DO1

- Working from inside the vehicle, withdraw the servo unit push rod (1) from the brake pedal

Undo the attachment nuts on the pedal assembly, then remove the servo unit.
- Undo the nut (2) and remove the brake pedal.

Copyright Fiat Auto 1

 Braking system Fiat barchetta
Bleeding brakes
33.
BLEEDING AIR FROM THE HYDRAULIC
1
BRAKING SYSTEM
-::::::::::::::::::::::::::: ~
/...J 1 Bleeding air by the traditional method

..:.( ,/ y - fit a suitable bleed pipe on the bleed screw;

- unscrew the bleed screw by a few turns;
o~ - operate the brake pedal, pressing it quickly
and lifting it slowly, until the air bubbles in
the rubber pipe disappear;
- keep the brake pedal pressed;
- tighten the bleed screw and remove the
\\ rubber pipe;
- repeat the bleeding cycle twice, then refit
the protective caps on the bleed screws.

P3WO12DO1

-
2 A When bleeding the braking system,
follow the sequence described be-
-.~
low:
Front left caliper - front right caliper
- rear left caliper - rear right caliper.

\~e
Do not reuse old brake fluid: the lev-
el should be topped up with fresh
~'-
,.-:--1/ brake fluid.

L~ -'
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Bleeding air with
pneumatic device
II JOLLY FREN"

- Connectthe device's hoseto the brakeflu-

id reservoir;
P3WO12DO2

- bleed the air from the hydraulic system, fol-

lowing the instructions given in the de-
vice's operation and maintenance booklet.

II JOLLY FREN" pneumatic device

PJWO12DOJ

12 Publication no. 506.586

~
Fiat barchetta Braking system
Anti-lock braking system
33.

1/ 1
2
2
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P3WO13DO1 PJWO1JDO2

LOCATION OF COMPONENTS

The illustrations show the main components

v , of the anti-lock braking system.
"I::J
~ CJ 1. Electrohydraulic control unit for anti-lock
braking system (Bosch" ABS 2SH") and
~
.~
6 its diagnostic socket.
2. 60A fuse protecting power cables.
3. 10A fuse protecting ABS control unit.
4. Front wheel rpm sensor.
5. Rear wh~el rpm sensor.
6. Stop lights switch.
P3WO13DO3

Copyright Fiat Auto 13

Braking system
Anti-lock brakin~ system

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P3WO14DO1

REMOVING-REFITTING ABS ELECTRON-

IC CONTROL UNIT (Bosch "ABS 2SH")

1. Press on the spot shown in the figure and

disconnect the multi-connector.
2. Undo the attachment screw and remove
the protective cover.
3. Disconnect the supply connector.
4. Using a screwdriver, release the brake
pipe retaining clip.
5. Using tool 1856132000 disconnect the
brake pipes from the electrohydraulic con-
trol unit.

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P3WO14D04

111 Publication no. 506.586

 Fiat barchetta Braking system
Anti-lock braking system

1
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P3WO15DO1

1. Undo the nuts shown in the figure and

gently lift the electrohydraulic control
unit.
2. Undo the attachment nut and disconnect
the
, earth cable
. from the electrohydraulic
control unit.
3. Disconnect the connector shown in the
figure.
4. Undo the bolts shown in the figure and re-
move the electronic section from the con-
trol unit.

3 4

P3WO15DO3

Copyright Fiat Auto 15

~
Braking system Fiat barchetta
Anti-lock braking system

ELECTROHYDRAULIC CONTROL UNIT

In functional terms, the electrohydraulic con-

trol unit comprises two sections:
- electronic;
- hydraulic.

1. Electronic control unit

The electronic control unit is mounted on the
hydraulic control unit and is connected to the
components of the anti-lock braking system
by a multi-connector.
In functional terms, the electronic control
unit may be divided into two sections:
1. signal and logic processing sections;
2. safety circuits.

Both receive the same input signals which each processes on its own behalf, and only when the results
are identical does the electronic control unit issue the operating command to the hydraulic control unit.

Otherwise (if there is a fault in the anti-lock braking system) the device switches itself off, braking
takes place in the conventional manner and at the same. time the fault warning light on the instru-
ment panel comes on.
In the processing section, the signals transmitted by the speed sensors are converted into signals that
can be used by the logic section so that it can recognize the values for acceleration, deceleration and
"creep" between the individual wheels.

NOTE Theperipheralspeedof a braked wheel reducesmore than the car speed:with the wheelscom-
pletely locked under the braking action (peripheral wheel speed = 0) and the car still moving,
there is still the largest differencebetween these two speeds.
This differenceis called "creep" or skid coefficient when it is expressedas a percentage:
creep 0% = wheel free:
creep 100%= wheel locked and car moving.
During braking, the friction coefficient increaseswhen braking occurs with low creep (rolling)
and subsequentlydecreaseswhen the skidding of a tyre becomesincreasinglysevereuntil the
wheel locks.
A con,siderablenumber of practical testsand experimentshave shown that in general,it is pos-
sible to reach the maximumbraking effort with "creep" valuesof between 5% and 15%,with a
maximum valueof 20%. Thisdefinesan optimum range within which the anti-lock braking sys-
tem tends to control any type of vehicle.

The logic part compares the signals received and transmits the adjustment instructions to the four
solenoids located in the hydraulic control unit. In the absence of a braking action, the electronic control
unit recognizes the vehicle speed from the sensors' signals.
When the driver presses the brake pedal, the wheels decelerate, possibly each to a different extent, and a
reference value is processed from the combination of the individual wheel speeds. This reference value
is stored in memory and continuously updated, and gives an approximate indication of the vehicle speed
at each instant of braking.
The skid signals of each individual wheel are constantly monitored by comparing the individual wheel
speeds with the reference speed.
The braking force may increase until one wheel ~kids more than the others; when this situation arises
("split"), the electronic control unit issues a command to the solenoids of the electrohydraulic control
unit which have to intercept the braking force on the wheel that has reported a loss of grip. The wheel in
question thus accelerates again.

16 Publication no. 506.586