Workshop Manuals Factory service & repair Fiat

Fiat common faults and how to fix them

Faults that are well known on Fiat models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Fiat 124 Spider Turbo: too much oil reaching the turbocharger

Symptoms

Excess oil in the turbocharger can show up as blue smoke from the exhaust, especially after idling, oil in the intake pipework and higher than normal oil consumption.

Cause

Fiat service letter 103-9 (May 1984) covers all Turbo Spiders converted by Legend Industries. Too much oil was entering the turbocharger's bearing chamber because the union connecting the oil supply line to the turbocharger had an oversized orifice.

Fix

Disconnect the oil inlet hose at the union and measure the orifice: it should be 0.080 in (2 mm), plus or minus 0.015 in. If it isn't, fit the correct union with a new gasket. Fiat asked dealers to mark checked unions with a spot of paint on one of the flats, so look for that mark on a Fiat 124 Spider Turbo before taking the union off. If the turbo has already been running with too much oil, check its seals and shaft play as well, as the bulletin addresses only the cause.

Repair instructions on this site

Sources: Fiat service letter S.L. 103-9 (May 1984).

Fiat Spider fuel injection: uneven idle from a bent air flow sensor stop

Symptoms

An uneven idle on fuel-injected 2.0 Spider and Brava models.

Cause

Fiat service letter 102A-20 (September 1983) covers Brava and Spider models whose air flow sensor has a reinforced sensor flap; this can be seen by looking into the outlet end of the sensor. On these cars, the stop that limits the sensor flap's travel can bend, which upsets the air flow signal the fuel injection relies on and causes the uneven idle.

Fix

Replace the stop for the sensor flap using the kit listed in the bulletin; on cars with the reinforced flap, Fiat specified replacing the stop rather than the whole air flow sensor. After fitting the new stop, adjust the idle speed and the CO level to the manual's figures. The Fiat Spider fuel injection bulletin shows how to identify the reinforced flap.

Repair instructions on this site

Sources: Fiat service letter S.L. 102A-20 (September 1983).

Fiat 124 clutch won't release after fitting a heavy-duty disc (2.0)

Symptoms

After a new clutch has been fitted, it doesn't release properly: gears are hard to select or grate, and the car may creep with the pedal pressed down.

Cause

Fiat service letter 118-1 (September 1985) covers 124 and 131 models with the 2000cc engine. The original clutch assembly and disc part numbers were superseded by a heavy-duty clutch disc. With the new disc, the clutch plate fingers can bottom out on the shoulder of the splined hub in the clutch disc, so the clutch can't release fully.

Fix

Fiat's correction is to lengthen the clutch cable adjustment until the clutch works properly. Adjust the cable gradually and check that the clutch releases fully with the pedal down and still has free play at the top of the pedal travel, so it doesn't slip. The Fiat 124 Spider clutch bulletin lists the part numbers affected. If adjustment doesn't cure it, check the release bearing and fork.

Repair instructions on this site

Sources: Fiat service letter S.L. 118-1 (September 1985).

Fiat X1/9 ignition timing: the crankshaft pulley pointer can shift

Symptoms

Poor running, pinking or a lack of power after the ignition timing has been set, because the timing has been set to the wrong mark.

Cause

Fiat service letter 551-4C (August 1979) covers the 1979 X1/9 and Strada. The ignition timing pointer at the crankshaft pulley can shift, so timing set using only that pointer may be wrong.

Fix

Check the timing marks in both places: at the crankshaft pulley and at the flywheel, through the bell housing. If they don't agree, find out why before setting the timing. The bulletin's timing specification is 5° at 800–850 rpm with a manual gearbox, or at 700–750 rpm with an automatic. Set the idle speed before checking the timing, and use a strobe timing light with the vacuum advance disconnected if the manual calls for it. The Fiat X1/9 ignition timing bulletin gives the details.

Repair instructions on this site

Sources: Fiat service letter S.L. 551-4C (August 1979).