10 (1) .1 Engine Fiat

Fíat barchetta Engine
Contents
10.
page
REMOVING-REFITTING POWER
UNIT
- Removing-refitting power unit •1
- Separating gearbox-engine 13
REMOVING-REFITTING RADIATOR 15
REMOVING-REFITTING AUXILIARY
CO.MPONENT BELT 18
REMOVING-REFITTING TIMING
BELT 19
REMOVING-.REFITTING CYLINDER
~EAD 25 ·
REMOVING-REFITTING COOLANT
PUMP 31
Copyright Fíat Auto

Removing-refitting power unit
10.
P3W01AX02
P3W01AX01
REMOVING-REFITTING POWER
UNIT
Start up vehicle engine and leave running
with air conditioner activated for at least 1 O
minutes, then open bonnet lid and discon-
nect battery leads.
1. Remove anti-resonance duct by discon-
necting rubber fitting and unscrewing
both screws indicated.
2. Connect quick-release fittings of Cleaner
134 device to air conditioning system nee-
dle valves and discharge.
3. Working from inside the passenger com-
partment, remove guard located beneath
facia glove compartment.
4. Unscrew retaining screws and remove
junction unit from body.
5. Remove earth lead located on the top of
the ECU and disconnect the four connec-
P3W01AX03
tors.
P3W01AX04 P3W01AX05
Copyright Fiat Auto

Engine Fíat barchetta
10.
P3W02AX01 P3W02AX02
1. Push rubber gasket on body aside in arder

to allow wiring to be taken into the engine
bay. When fitting, it is advisable to lubri-
cate gasket to facilitate installation.
2. Position the vehicle on a stand and, work-
ing from the engine bay, remove the air in-
take pipe by unscrewing both screws and
loosening collar fastening pipe to the air
cleaner.
3. Remove the car alarm ECU, together with
mount, by unscrewing both nuts indicat-
ed. .
4. Disconnect the three connectors located
on the car alarm ECU after removing pro-
tection indicated.
5. Remove battery from mount after un-
screwing nuts and screw indicated.
P3W02AX03
P3W02AX04 P3W02AX05
2 Publication no. 506.586

Fiat barchetta Engine
10.
P3W03AX01 P3W03AX02
1. Remove air sleeve connecting debimeter

to butterfly valve case by loosening the
two collars and pipe indicated.
2. Remove the battery mount after releasing
electrical wiring from the rear and un-
screwing the screws indicated.
3. Unscrew the nuts and bolt indicated by
white arrows located on the top of the air
cleaner and release connector indicated
by the black arrow.
4. Unscrew the retaining bolts on the top
part of the fan and disconnect the connec-
tor located close to the right hand light
cluster.
5. Remove protection on exhaust manifold
by unscrewing the three bolts indicated.
P3W03AX03
P3W03AX04 P3W03AX05
Copyright Fíat Auto 3

Engine Fiat barchetta
10.
P3W04AX01
1. Raise vehicle and loasen bolt indicated by

white arrow, which fastens left-hand end
of lower beam to body in arder to facilitate
removal of air cleaner plastic pin (A) from
seat (indicated by black arrow) on body
mount.
2. Push air cleaner upward in arder to release
plastic pin A, then move toward power
unit and lower. Open collar B retaining
both air conditioner pipes and take air
cleaner out from rear of vehicle.
3. Unscrew lower fan retaining bolts and
bolts retaining air conditioning system to
the beam.
4. Remove fan from the engine bay.
5. Disconnect lambda probe connector indi-
cated in the figure.
P3W04AX03
P3W04AX04 P3W04AX05

10.
2
P3W05AX01 P3W05AX02
1. Unscrew bolts on first exhaust pipe sec-

tion to catalytic converter.
2. Unscrew bolts retaining first exhaust pipe
section to exhaust manifold.
3. Remove front exhaust pipe section after
unscrewing nuts retaining mount bracket
to oil sump.
4. Loasen collar retaining lower coolant
sleeve to radiator.
5. Loasen power steering pipe fitting located
on steering box. Lower lift, remove lower
radiator sleeve and power steering system
fitting in arder to allow coolant to drain
from the cooling systems.
P3W05AX03
P3W05AX04 P3W05AX05
Copyright Fiat Auto 5

10.
1
P3W06AX01
A: compressor end
B: compressor end P3W06AX02
1. Disconnect both pipes from compressor

and remove pipe leading to evaporator.
2. Disconnect delivery and return pipes from
fuel manifold.
3. Disconnect fuel vapour recovery pipe
from intake manifold.
4. Remove coolant expansion tank after dis-
connecting return and delivery pipes.
5. Draw off rluid from the power steering
tank using a syringe; unscrew bolts retain-
ing unit to body, remove pipes and remove
from engine bay.
P3W06AX03
P3W06AX04 P3W06AX05

10.
P3W07AX01 P3W07AX02
1. Remove top coolant sleeve by taking off

the two collars indicated.
2. Unscrew screws retaining relay protection
in engine bay and remove.
3. Unscrew both nuts retaining relay carrier
plate to body and disconnect connectors
A and B indicated in figure.
4. Remove accelerator sheath and cable from
butterfly valve case.
5. Disconnect valve from brake servo.
P3W07AX03
P3W07AX04 P3W07AX05

10.
P3W08AX01 P3W08AX02
111 1. Remove coolant delivery and return lines
1g from radiator.
2. Release cable and sheath from clutch link-
age.
3. Release reaction rod by unscrewing nut
indicated. Remove gear engagement ca-
ble by disengaging gear selection ball
joint from mount bracket, after removing
clip A. Withdraw cable from mount.
4. Disconnect engine injection supply lead
connector.
5. Remove gearbox earth and disconnect re-
versing light connector.
P3W0SAX03
P3W0SAX04 P3W08AX05

10.
2
P3W09AX01 P3W09AX02
1. Loasen bolts retaining front wheels.

2. Raise vehicle and remove front wheels.
Unscrew bolts retaining passenger end
wheel-arch protection and remove from
vehicle.
3. Remove left-hand half-axle by unscrew-
ing bolts indicated by white arrows (fas-
tening axle to differential flange) and re-
lease left-hand stub axle from damper af-
ter unscrewing bolts indicated by black
arrows, which join the two parts.
4. Position left-hand half-axle as shown in
figure and tie in place in order to facilitate
removal of the power unit from the engine
bay.
5. Remove passenger side constant velocity
joint and wheel hub from damper.
P3W09AX03
P3W09AX04 P3W09AX05

10.
P3W10AX01 P3W10AX02
3 1. Open collar indicated from the catalytic

converter end in order to release the pow-
er steering pipe.
2. Unscrew bolts indicated from gearbox.
3. Position profiled bracket of tool
1860859000 on power unit using bolts
removed previously (although note that
reaction bracket bolt must be replaced).
----
4. Raise hydraulic jack (to an appropriate
height) with tool 1860860000 installed to
bring bracket on jack and bracket on pow-
----
-~-
er unit into contact, then fasten with the
aid of the bolts supplied.
5. Position U-bracket on tool 1860860000
as shown in the figure to allow correct in-
stallation to passenger end engine mount.
P3W10AX03
P3W10AX04 P3W10AX05

10.
1. Unscrew central power unit reaction

bracket and loasen the others.
P3W11AX01
2. Loasen nut retaining bracket to flexible
power unit mount (driver's end). Carry out
the same operation for the passenger's
end.
3. Unscrew bolts retaining driver's end flexi-
ble power unit mount to the body. Carry
out the same operation for the passenger
end.
4. Lower hydraulic jack slowly until passen-
ger end half-axle can be removed in arder
to secure to damper, as for driver's end.
Withdraw electrical wiring from inside ve-
hicle. Wiring must be installed by inserting
into access hole to passenger compart-
ment (figure 1 page 2) when wire is long
enough. This operation is impossible with
the power unit fitted.
P3W11AX02
P3W11AX03 P3W11AX04

10.
1
P3W12AX01 P3W12AX02
1. Lower hydraulic jack slowly until power

unit is fully outside engine bay.
2. Hook sling onto power unit and put links
under tension.
3. Unscrew bolts indicated retaining profiled
bracket to tool 1860859000.
4. Raise the power unit and remove profiled
bracket.
5. Before placing power unit on platform,
unscrew lower bolt joining gearbox to en-
gine.
P3W12AX03
----
----
-~-
P3W10AX03 P3W12AX04

10.
P3W13AX01 P3W13AX02
m
m
SEPARATING ENGINE AND GEARBOX
1. After postioning power unit on platform,
remove intermediate drive shaft by un-
screwing the three bolts indicated.
2. Disconnect mileometer pulse generator
connector and release wiring on bracket
located on butterfly valve case.
3. Remove protective boots located on
starter motor electrical connections.
4. Remove starter motor electrical connec-
tions.
5. Unscrew bolts located on starter motor
flange.
P3W13AX03
P3W13AX04 P3W13AX05

10.
P3W14AX01 P3W14AX02
1. Unscrew retaining bolts on profiled brack-
3
m et and remove starter motor from power
unit.
2. Remove bracket located on butterfly valve
m case.
3. Unscrew nuts and bolts joining bell hous-
ing to engine and take both parts apart.
4. Remove engine clutch by unscrewing
bolts indicated.
5. Use tool 1870443000 to locate clutch
when refitting.
NOTE Reverse removal instructions to refit.
Disconnect flexible mounts from

power unit and position on body
without tightening retaining bolts in
P3W14AX03
arder to facilitate refitting on vehi-
cle.
P3W14AX04 P3W14AX05

Cooling system
10.
PJW15AX01 PJW15AX02
REMOVING-REFITTING RADIATOR
1. Remove resonator by unscrewing bolts

indicated in figure.
2. Remove air shroud by undoing collar and
fastenings shown in figure.
3. Remove nuts securing ECU/car alarm
siren, then place on one side of the engine
bay without disconnecting electrical con-
nectors.
4. Remove bracket securing battery to hold-
er, then remove battery from engine bay.
5. Disconnect battery holder by undoing fas-
teners shown in figure.
PJW15AX03
PJW15AX04 P3W15AX05

Cooling system
10.
P3W16AX01 P3W16AX02
g 1 . Remove air intake duct by undoing fastenings

shown in figure.
2. Remove air cleaner assembly mount bracket re-
m
taining bolts and nut retaining pipe connecting
compressor to evaporator.
3. Raise lift and work on lower part of engine bay.
Loosen bolt (1) retaining radiator unit support
l beam to lower beam slightly so that air cleaner as-

sembly may be removed after releasing electric
leads from unit.
4. Remove both bolts retaining pipe connecting
compressor to evaporator from radiator support
beam.
5. Remove lower fan retaining bolts, disconnect
~ electrical connector, and loasen collar (1) on

lower coolant sleeve.
P3W16AX03
P3W16AX04 P3W16AX05

Cooling system
10.
111
g
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.
P3W17AX01
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.
Reverse removal operations to refit.
P3W17AX02
P3W17AX03 P3W17AX04

Replacing auxiliary belt
10.
REMOVING-REFITTING AUXILIARV 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.
P3W09AX01
mi
Check tension and condition of aux-
iliary unit drive belt and in particular
far cracks, tears, surface wear (which
looks smooth and shiny) and dry or
hardened parts that could lead to loss
of grip. lf one of the abo ve defects is
found, replace the belt.
P3W09AX02
3. View of auxiliary drive belt fitted to vehi-

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
A void the belt coming into contact

with oil or solvent that could impair
the flexibility of the rubber with a
consequent loss of grip
P3W18AX01
18 Publication no. 506.586/01

Fiat barchetta Engine
Replacing timing belt
10.
P3W19AX01 P3W19AX02
1. Slacken belt tension by turning central au-

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

order to fit a new belt. The preloaded
automatic tensioner spring wi/1 en-
sure belt tension is correct after turn-
ing the crankshaft a f ew times.
P3W19AX03
REMOVING-REFITTING TIMING BELT
B Befare removing the timing belt, first

=1 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.
P3W19AX04

10.
P3W20AX01 P3W20AX02
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.
P3W20AX03
P3W20AX04 P3W20AX05

10.
P3W21AX01 P3W21AX02
1. Remove the spark plugs using an appro-

priate wrench.
2. Position the guage against cylinder no. 1,
then use tool 1895879000 to turn the
crankshaft to t.d.c.
3. Remove the 2nd intake end camshaft cap
and the 3rd exhaust end camshaft cap as
shown in the figure.
Mark camshaft caps after remova/ to

ensure they are refitted in the correct
position. Otherwise camshafts may
operate inefficiently.
P3W21AX03
4. Position and retain pair of tools

1860847000 on caps removed previously.
=
- Too/ pair 1860847000 must fol/ow
camshaft cam profile exact/y.
P3W21AX04

10.
P3W22AX01 P3W22AX02
1 . Remove the protective cover on the bell

housing shown in the figure, then position
flywheel retainer 18 .........
2. Remove auxiliary drive pulley on the
crankshaft.
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.
P3W22AX03
P3W22AX04 P3W22AX05
22 Pub/ication no. 506.586/01

10.
Refitting timing belt
1. To facilitate t1m1ng belt pos1t1oning,

loosen intake end camshaft pulley bolt by
applying leverage with tool 1860831000.
This pulley is slotted to permit correct
belt-pulley coupling.
P3W23AX01
2
m
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.
P3W23AX02

10.
P3W24AX01 P3W24AX02
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
then tighten nut retaining tensioner to
mount.
2. Tighten bolt retaining intake end camshaft
pulley to a torque of 11.8 daNm. Apply
leverage using tool 1860831000.
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.
P3W24AX03
Loasen belt tensioner retaining nut and use tool 1860845000 to align mobile belt tensioner pointer (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.

Removing-refitting cylinder head
10.
P3W06AX04
REMOVING-REFITTING CVLINDER HEAD
D
~
- Disconnect battery negative lead, re-
move auxiliary drive belt and timing
g 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.
P3W02AX02
P3W06AX04 P3W07AX01

10.
P3W15AX03 P3W16AX04
1. Remove car alarm ECU/siren reta1nmg

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
P3W16AX01 shown.
P3W26AX01 P3W03AX05
26 Publícation no. 506.586/01

10.
2
P3W05AX01 P3W05AX02
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.
P3W05AX03
P3W27AX01 P3W27AX02

10.
1. Disconnect electrical connections from

the following parts:
- lnjectors and timing variator (1 );
- coolant temperature sensor on thermo-
stat (2);
- coolant temperature sensor on head (3);
gearbox end 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).
P3W28AX01
2. Lindo 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.
P3W28AX02
P3W06AX02 P3W28AX03
28 Publícatíon no. 506.586/01

10.
P3W29AX01 P3W07AX06
1. Unscrew both screws retaining thermostat

assembly to cylinder head and move the
assembly out of the way, taking care not
to damage connected 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 head to-
gether with intake manifold and remove
using a lift sling.
5. Place the assembly onto a service bench
and separate the intake manifold by undo-
ing the retaining bolts.
P3W29AX02
P3W29AX03 P3W29AX04

10.
P3W30AX02
Refitting
1. Position cylinder head gasket with the
wording "ALTO" facing the operator.
The cylinder head gasket is AS-
TADUR type. This type of gasket is
made from a special material which
undergoes a process of polymerisa-
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 befare
fitting;
- do not oíl the gasket or contami-
nate with oíl. Ensure cylinder head
and crankcase surfaces are thor-
oughly clean.
2. Position the cylinder head, then tighten
retaining screws to torque. Note that the
P3W30AX03 tightening pattern is as shown in the fig-
ure far each tightening stage.
3. Oil the screws and washers and leave to
drain far 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 270º in
three different stages (90º + 90º + 90º)
using wrench 1852154000 and
1895897000.
Refit parts removed previously by re-

versing disassembly instructions. Fit
timing and auxiliary belts and tension
as described in the previous para-
graphs.
P3W30AX04

10.
P3W23AX01 P3W31AX01
g REMOVING-REFITTING COOLANT PUMP
l\'--...:::=:~~~~~~~~~:=_=_==_==_~=i~~~~
1111
11'--=:----:::::1
g g Befare removing the coolant pump,
rlJ remove the auxiliary and timing belts
"""u""__..-- as described in previous sections.
1. Remove the inlet end camshaft by exert-
ing leverage using tool 1860831000.
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 pul ley retaining bolts to
a torque of 11.8 daNm, exerting leverage
using tool 1860831000. Position timing
and auxiliary belts and tension as de-
P3W31AX02 scribed in previous sections.
P3W24AX02

10 (1) .1 Engine Fiat

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Fíat barchetta Engine

Copyright Fíat Auto

Copyright Fiat Auto

1. Push rubber gasket on body aside in arder

2 Publication no. 506.586

1. Remove air sleeve connecting debimeter

Copyright Fíat Auto 3

1. Raise vehicle and loasen bolt indicated by

4 Publication no. 506.586

1. Unscrew bolts on first exhaust pipe sec-

Copyright Fiat Auto 5

1. Disconnect both pipes from compressor

6 Publication no. 506.586

1. Remove top coolant sleeve by taking off

Copyright Fíat Auto 7

111 1. Remove coolant delivery and return lines

8 Publication no. 506.586

1. Loasen bolts retaining front wheels.

Copyright Fiat Auto 9

3 1. Open collar indicated from the catalytic

10 Publication no. 506.586

1. Unscrew central power unit reaction

Copyright Fíat Auto 11

1. Lower hydraulic jack slowly until power

12 Publication no. 506.586

Copyright Fíat Auto 13

Disconnect flexible mounts from

14 Publication no. 506.586

1. Remove resonator by unscrewing bolts

Copyright Fiat Auto 15

g 1 . Remove air intake duct by undoing fastenings

l beam to lower beam slightly so that air cleaner as-

~ electrical connector, and loasen collar (1) on

16 Publication no. 506.586

1. Lower vehicle and drain coolant. Loosen

2. Remove lower bolts retaining condenser

Reverse removal operations to refit.

Copyright Fiat Auto 17

Position the vehicle on a lift, disconnect bat-

1. Loosen nuts retaining right front wheel.

2. Raise vehicle and remove right front

3. View of auxiliary drive belt fitted to vehi-

A void the belt coming into contact

18 Publication no. 506.586/01

1. Slacken belt tension by turning central au-

Reverse disassembly instructions in

REMOVING-REFITTING TIMING BELT

B Befare removing the timing belt, first

Copyright Fíat Auto 19

1. Unscrew top timing belt cover retaining

20 Publication no. 506.586/01

1. Remove the spark plugs using an appro-

Mark camshaft caps after remova/ to

4. Position and retain pair of tools

Copyright Fiat Auto 21

1 . Remove the protective cover on the bell

4-5. Slacken drive belt tension by undoing

22 Pub/ication no. 506.586/01

1. To facilitate t1m1ng belt pos1t1oning,

2. Fit the belt, observing the following fitting

NOTE Take care not to kink the belt when

Fit the belt so that the arrow on the

Copyright Fíat Auto 23