Fiat Punto 2004 Training Manual Download Page 328

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M20 GEARBOX

FIAT PUNTO TRAINING OUTLINE

Fiat Auto S.p.A.

After Sales Training

gears

The single-cone synchromesh is used with the 5

and 6

gears.

1. Synchromesh ring Intermediate ring

2. Engaging sleeve

3. Synchromesh hub

Reverse gear

The reverse gear features a single-cone synchromesh, just like the 5

and 6

gears.

gb Fiat Grande Punto OK

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Summary of Contents for Punto 2004

Page 2: ...ans Processing the material below may not involve specific responsibilities for unintentional errors or omissions The information given in this publication are liable to continuous updates Fiat Auto S p A undertake no responsibility for the consequences resulting from the use of outdated information This publication is issued for training purposes only As regards the technical information complete...

Page 3: ...20 1 2 9 Tyres and wheels 22 1 2 10 Tyre repair kit 23 1 2 11 Comfort 24 1 2 12 Interior comfort and room 24 1 2 13 Air conditioning 26 1 2 14 Sunroof 28 1 2 15 Audio system 28 1 3 ACCESSORY LINE 30 1 3 1 Sporting character 30 1 3 2 Comfort utility leisure time 30 1 3 3 Safety 31 2 TECHNICAL SPECIFICATIONS 33 2 1 ENGINE 33 2 1 1 Type of engine 33 2 1 2 Engine data 34 2 2 TIMING ANGLES 35 2 3 ENGIN...

Page 4: ...d filling 57 2 14 4 Consumption 58 2 14 5 Emissions 58 2 14 6 Tyres 58 2 14 7 Inflating pressure bar 59 3 1 3 MULTIJET 16V 75 AND 90 HP ENGINES 61 3 1 GENERAL REMARKS 61 3 2 COMPONENTS 63 3 2 1 Power unit supports 63 3 2 2 Engine base 65 3 2 3 Lower engine base 66 3 2 4 CYLINDER HEAD 68 3 2 5 Base sump and covers 70 3 2 6 Oil seals on the drive shaft 71 3 2 7 Engine flywheel 71 3 2 8 Drive shaft 7...

Page 5: ... thermostat 94 3 4 2 Water temperature control devices 96 3 4 3 96 3 5 SERVICE CONTROL 96 3 6 FUEL FEED SYSTEM 99 3 6 1 Features 99 3 6 2 Bosch CP1 high pressure pump 75 HP 104 3 6 3 Bosch CP1H high pressure pump 90 HP 108 3 6 4 Electric injectors and pipes 113 3 6 5 Single fuel manifold pipe 119 3 6 6 Fuel tank and components 121 3 6 7 Inertia switch 124 3 6 8 Fuel filters 126 3 6 9 Fuel temperat...

Page 6: ...ug check 156 3 10 13 Air conditioning system actuation check 157 3 10 14 Auxiliary fuel electric pump check 158 3 10 15 Cylinder position check 159 3 10 16 Main injection and pilot injection advance check 160 3 10 17 Injection pressure closed cycle check 161 3 10 18 Electric balance check 161 3 10 19 Electric fan check 162 3 10 20 Cruise Control system check where available 163 3 11 SENSORS 165 3 ...

Page 7: ...on recognition 281 4 5 4 Oxygen sensor combustion check 281 4 5 5 Cold operation 283 4 5 6 Fully loaded operation 284 4 5 7 Operation during deceleration 285 4 5 8 Atmospheric correction 285 4 5 9 Operation during acceleration 287 4 5 10 Out of revs protection 288 4 5 11 Fuel electric pump control 289 4 5 12 Electric injector control 290 4 5 13 Knock control 291 4 5 14 Radiator electric fan contro...

Page 8: ...0 6 4 1 ABS wiring diagram 351 6 4 2 ABS hydraulic unit 353 6 5 E S P 354 6 5 1 ESP wiring diagram 356 6 5 2 YRS Yaw Rate Sensor 357 6 5 3 A S R Anti Slip Regulator 358 6 5 4 M S R 359 6 5 5 Hill Holder 359 7 ELECTRIC DRIVE 361 7 1 DESCRIPTION 361 7 2 ELECTRIC POWER STEERING EPS 362 7 3 DRIVE HOUSING 365 7 4 STEERING COLUMN 366 8 SUSPENSIONS 367 8 1 DESCRIPTION 367 8 2 FRONT SUSPENSIONS 368 8 2 1 ...

Page 9: ...omputer node BCM 400 9 2 4 Instrument board node IPC 409 9 2 5 Steering column stalk control module CSM 433 9 2 6 Radio receiver node RRM 447 9 2 7 Rear parking sensor node PAM 448 9 2 8 External audio amplifier for the hi fi system 453 9 2 9 Spiral cable 453 9 2 10 Rain sensor control unit RLS 454 9 2 11 Brake pedal switch 454 9 2 12 Control board on the driver s side front door DDC 455 9 2 13 Sw...

Page 10: ...COMPONENTS 515 10 2 1 ECC Electronic Climate Control control unit 515 10 2 2 Actuators and sensors 516 10 2 3 Compressor 517 10 2 4 Filters and condenser 520 10 2 5 Expansion valve 521 10 2 6 Fluids 522 10 3 OPERATION LOGIC 522 10 4 DIAGNOSIS 524 11 SUNROOF 525 11 1 DESCRIPTION 525 11 2 OPERATION 528 11 2 1 Sunroof opening 528 11 2 2 Sunroof closing 529 11 2 3 Window shades 530 11 3 SUNROOF CLOSIN...

Page 11: ...heart thanks to its trim engine driving pleasure and comfort Nuova Punto stands out from its main competing cars for the following STYLE meant as the capability of coming up to the expectations of the end customer thanks to designs and versions that appeal to the customer and make the latter eager to own a Nuova Punto DRIVING PLEASURE meant as the capability of accommodating all the passengers int...

Page 12: ...unto belongs accounts for 26 of the West European car market that is to say the market core with approximately 3 750 000 units sold annually In Italy this segment accounts for as much as 37 of the market which is made up of petrol engines 56 and diesel engines 44 FIAT has always been a key player in the small average car segment Despite the crisis of the past few years Fiat Punto has been the best...

Page 13: ... 30 who are sensitive and open to the most noticeable expressions of performance related values dynamic open minded people full of energy DYNAMIC for the young to middle aged people between 30 and 45 resourceful people hovering between emotional impulse and rationality youthful enthusiasm and adult control ELEGANCE for mature people who make firm choices and count on high quality outfit and optimu...

Page 14: ...elying on a modern fascinating line launching out to the young world thanks to its nimbleness and versatility that distinguish it from ordinary two box cars 1 2 The vehicle 1 2 1 Style Nuova Punto features a design style and lines that are deeply rooted in the most authentic and renowned tradition of Italian car making with a surprising unexpected shapes that make it go against the current compare...

Page 15: ...o at the top of its market segment see table below Competitor car comparing table P OPEL CORSA 5P PEUGEOT 206 5P FIESTA 02 RENAULT CLIO 98 NISSAN MICRA TOYOTA YARIS 5P CITROEN C3 VW POLO 02 5P L101 Wheelbase 2460 2491 2441 2486 2472 2427 2373 2460 2460 L103 Vehicle length 3835 3816 3837 3917 3772 3717 3607 3849 3897 Width 1660 1645 1650 1680 1640 1660 1660 1670 1650 L104 Front pivot 775 747 787 77...

Page 16: ...els and seats Active Dynamic Elegance Sporting The ACTIVE version features the following standard items ABS Electric power steering Electric window regulators Dual airbag The DYNAMIC version features the following standard items ACTIVE contents Remote control Height adjustable driver s seat Rear split seat 5 door version Height adjustable steering wheel Rear headrests The ELEGANCE version features...

Page 17: ...pecial measuring instrument Sports design front seats greater restraint Car radio CD player Air conditioner Below are other optional items Knee airbag Window bag Side bag Front seat anti whiplash whiplash restraint Rear electric window regulators 5 door versions Front armrest Electric lumbar adjustment Automatic air conditioner Cruise control Rain sensor Parking sensor Tyre pressure sensor TPMS Le...

Page 18: ... system Kit Bluetooth Headlamp washer 6 speed gearshift 1 3 Multijet 16V 90 HP 1 2 4 Engines Below are the engines fitted to the vehicle at the commercial launch PETROL ENGINES 1 2 8V 65 HP 1 4 8V 75 HP DIESEL ENGINES 1 3 Multijet 16V 75 HP 1 3 Multijet 16 V 90 HP 1 9 Multijet 8V 120 HP FIAT PUNTO 18 532 2004 Fiat Auto S p A All rights reserved ...

Page 19: ...514 5 1 2 8V and 1 4 8V C 510 5 1 3 Multijet 16V 75 and 90 HP M20 6 1 3 Multijet 16 V 90 HP option M32 6 1 9 Multijet 8V 120 HP 1 2 6 Range PETROL ENGINES Active Dynamic Elegance Sport 1 2 8V 65 CV Manual 5 speed X X 1 4 8V 77 CV Manual 5 speed X X DIESEL Active Dynamic Elegance Sport 1 3 Multijet 16V 75 HP Manual 5 speed X X 1 3 Multijet 16V 90 HP Manual 5 6 speed X X 1 9 Multijet 8V 120 HP Manua...

Page 20: ...P system comes as a standard item on the Sporting version only The entire range is equipped with ABS system with EBD and ventilated brake discs on the front wheels except for the 1 2 8V engine version which is equipped with non ventilated discs 1 2 8 Passive safety Passive safety is meant as the whole of the technical and product solutions that protect the driver and the passengers in case of acci...

Page 21: ... objects and parts When designing Nuova Punto Fiat has paid great attention to the safety of the children on the vehicle and the pedestrians as well Children safety is ensured by devices that make it possible to achieve the maximum protection that can be obtained at present i e isofix mounts on the rear seats and passenger s airbag disable through the vehicle s trip computer Pedestrian safety has ...

Page 22: ...are concerned Nuova Punto comes with a full range that stands out for style dimensions and paint colours FIAT PUNTO 22 532 2004 Fiat Auto S p A All rights reserved ALLOY RIMS 5 dual rungs colour silver standard ALLOY RIM 10 rungs of which 5 dual rungs colour aluminium ALLOY RIM 195 55 R16 tyres 14 rungs thick thin colour aluminium ALLOY RIM 195 55 R16 tyres 18 triangular section rungs colour alumi...

Page 23: ...r supplying through the cigar lighter socket The kit is even easier to use The procedure to repair a punctured tyre is essentially as follows Connect the electric cable to the cigar lighter socket connect the silicone tube to the tyre valve then switch the compressor on the sealant will be automatically injected into the tyre mixed with air The repair will be completed when the tyre pressure reach...

Page 24: ... driver s body even in the most dynamic driving situations In order to make Nuova Punto a landmark car within its own category great care has been specially devoted to the following passenger compartment soundproofing interior noise rolling noise and vibration filtering acoustic sensitivity to the excitation transmitted through solid pathways vehicle compactness on rough road surfaces dynamic syst...

Page 25: ...t which features a minimum holding capacity of 263 litres with the standard running trim Feeling good on board means having a lot of space available and such space should be available just where it is needed for Nuova Punto features living space volume cubic volume values at the top of its category The passenger compartment profile makes it possible to easily accommodate two passengers on the rear...

Page 26: ...itioner with provision for obtaining different air temperatures and distribution patterns both for the driver and the passenger These systems make it possible to choke and direct the air flow in many ways so as to create the desired effect which is always homogeneous in the entire passenger compartment In addition the windscreen demisting function comes as a useful tool The versions equipped with ...

Page 27: ...IAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Heater Air conditioner Automatic two zone air conditioner Air conditioning control layout FIAT PUNTO 27 532 2004 Fiat Auto S p A All rights reserved ...

Page 28: ...slides out of the roof panel spoiler position The wide roof glass surface lets a lot of sunshine into the vehicle interior This helps increasing the feeling of much interior space available to the occupants The Skydome sunroof is equipped with sliding curtains that allow less sunshine into the passenger compartment 1 2 15 Audio system The sound sources available depending on the versions are a rad...

Page 29: ...kers and a sub woofer box containing a single channel power amplifier Below are the main features of the components mid woofer loudspeakers 40 W diameter 160 mm located on the front doors designed to best reproduce the low middle frequencies the water resistant technology is used with these components tweeter loudspeakers 40 W located on the door opening handle designed to reproduce the highest fr...

Page 30: ...vailable which include a 16 and a 17 alloy wheel rims to be used with 195 55R16 and 205 45R17 tyres respectively The tailored sporting accessories also include leather steering wheel and gearshift lever knob and aluminium pedal covers with rubber inserts for safer comfortable driving 1 3 2 Comfort utility leisure time Optimum driving comfort is ensured by a range of accessories such as modern anti...

Page 31: ...tion The ACCESSORY LINE module matched with the traditional anti theft system allows you to always keep your vehicle under control by clearly identifying its position and also receive any break in message The ultrasound parking sensor is actuated when the reverse gear is engaged and gives out an acoustic signal to warn you of the obstacles that cannot be seen by means of the rear view mirrors FIAT...

Page 32: ...E child seat is available with the vehicles equipped with specific mounts for children weighing 9 to 18 kg The range is made complete by traditional seats such as CRADLE for children weighing up to 10 kg KIDDY LIFE seat for children weighing 9 to 36 kg FIAT PUNTO 32 532 2004 Fiat Auto S p A All rights reserved ...

Page 33: ...ers In line In line In line In line In line No of valves per cylinder 2 4 2 4 2 Cycle Otto Diesel Otto Diesel Diesel 1ACT with phase variator 2ACT 1ACT 2ACT 1ACT Timing With mechanic tappets Finger rocker arm with hydraulic tappet With mechanic tappets Finger rocker arm with hydraulic tappet With mechanic tappets Fuel Petrol Diesel Petrol Diesel Diesel Fuel feed MPI electronic sequential timed Mul...

Page 34: ... 90 4 Total displacement cm 1368 1248 1242 1248 1910 Compression ratio 11 1 17 6 1 11 1 17 6 1 18 1 Max rating EC HP 77 90 65 75 120 Max rating EC KW 56 66 48 55 88 Max power speed r p m 5750 4000 5500 4000 4000 Max torque EC Nm 114 200 102 2 190 280 Max torque EC kgm 11 6 20 4 10 4 19 4 28 5 Max torque speed r p m 3000 1750 3000 1750 2000 Idling speed r p m 750 50 n d 750 50 n d n d FIAT PUNTO 34...

Page 35: ... 3 n d Cold operation valve play Exhaust mm 0 4 0 4 n d Intake 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Opening before T D C 7 n d 1 n d n d Closing after B D C 41 n d 47 n d n d Exhaust 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Opening before B D C 57 n d 51 n d n d Closing after T D C 9 n d 3 n d n d FIAT PUNTO 35...

Page 36: ...16C9 Injection sequence 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 Ignition 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Coils F M BAE 940A F M BAE 940A No of coils 4 4 Spark plugs NGK ZKR7A 10 NGK ZKR7A 10 Preheating drive control unit Bitron n d n d Preheating spark plugs Beru 4L01192 n d n d Ignition sequence 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 FIAT PUNTO ...

Page 37: ...es 0 5 10 15 20 25 30 35 40 45 50 55 60 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 Speed r p m Rating kW 75 80 85 90 95 100 105 110 115 120 125 130 135 Torque Nm Engine 1 4 8V Max torque 114 Nm at 3 000 r p m FIAT PUNTO 37 532 2004 Fiat Auto S p A All rights reserved Max rating 56 KW at 5 750 r p m ...

Page 38: ...FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Rating kW Torque Nm Engine 1 2 8V Max torque 102 2 Nm at 3 000 r p m Max rating 49 5 KW at 5 500 r p m FIAT PUNTO 38 532 2004 Fiat Auto S p A All rights reserved ...

Page 39: ...ONS FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Engine 1 9 Multijet 8V 120 HP Max torque 280 Nm at 2 000 r p m Max rating 88 Kw at 4 000 r p m FIAT PUNTO 39 532 2004 Fiat Auto S p A All rights reserved ...

Page 40: ...ONS FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Engine 1 3 Multijet 16V 90 HP Max torque 200 Nm at 1 750 r p m FIAT PUNTO 40 532 2004 Fiat Auto S p A All rights reserved Max rating 66 Kw at 4 000 r p m ...

Page 41: ... 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Drive Push type Push type Push type Push type Push type Control Hydraulic with external actuator Hydraulic with external actuator Hydraulic with external actuator Hydraulic with external actuator Hydraulic with external actuator and SAC Disc spring load daN n d n d n d n d n d Supplier Valeo Luk AP Valeo Luk play r...

Page 42: ...length from the engine flywheel mm 372 75 382 5 on main axle 332 Weight kg 33 dry 34 5 with oil 35 5 dry 37 3 with oil 45 dry 46 5 with oil 47 dry 48 5 with oil Synchronizers 1 2 3 4 5 R 1 2 3 4 5 R 1 2 3 4 5 6 R Gears HCR High Contact Ratio toothing HCR High Contact Ratio toothing HCR High Contact Ratio toothing Gear ratio 1 3 909 3 818 3 818 Gear ratio 2 2 158 2 053 2 053 Gear ratio 3 1 480 1 30...

Page 43: ...e cylinder diameter 10 10 10 10 10 Anti lock system Bosch 8 0 Bosch 8 0 Bosch 8 0 Bosch 8 0 Bosch 8 0 2 7 1 Front brakes 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Type of disc Self ventilated Self ventilated Non ventilated Self ventilated Self ventilated Disc diameter mm 257 284 257 257 284 Rated thickness mm 22 22 12 22 22 Type of caliper Bosch ZOH Bosch Z...

Page 44: ... 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Type Electric EPS Electric EPS Electric EPS Electric EPS Electric EPS Steering diameter m 10 1 10 76 10 1 10 1 11 No of steering wheel turns for full steering 2 8 2 8 2 8 2 8 2 8 Steering box ratio mm turn 51 60 44 51 60 44 60 44 Steering wheel angle wheel angle ratio 15 7 13 4 15 7 13 4 13 4 Rack travel Effort on the ste...

Page 45: ...t 16V 75 HP 1 9 Multijet 8V 120 HP Edge diameter mm 11 2 11 5 11 2 11 5 11 8 No of active coils 4 32 4 82 4 32 4 82 5 32 Helix direction Rightward Rightward Rightward Rightward Rightward Free spring height mm 353 377 353 377 402 Pack spring height 60 67 60 67 75 Spring height under control load mm 178 178 178 178 178 FIAT PUNTO 45 532 2004 Fiat Auto S p A All rights reserved ...

Page 46: ... x 46 5 diameters stem piston ext tube Traditional mechanic stop Dual tube size 22 x 32 x 46 5 diameters stem piston ext tube Traditional mechanic stop Dual tube size 22 x 32 x 46 5 diameters stem piston ext tube Traditional mechanic stop Open length start of plugging mm 527 527 527 527 527 Close length at abutting end mm 351 351 351 351 351 Travel mm 176 176 176 176 176 different calibration Fron...

Page 47: ...ultijet 16V 75 HP 1 9 Multijet 8V 120 HP Edge diameter mm 10 5 10 5 n d n d n d No of active coils 4 2 4 2 n d n d n d Helix direction Rightward Rightward n d n d n d Free spring height mm 291 5 279 n d n d n d Spring height under theoretic project load 155 155 n d n d n d Pack spring height mm 58 58 n d n d n d FIAT PUNTO 47 532 2004 Fiat Auto S p A All rights reserved ...

Page 48: ...be size 14 2 x 27 x 38 diameters stem piston ext tube Traditional mechanic stop Dual tube size 14 2 x 27 x 38 diameters stem piston ext tube Traditional mechanic stop Open length start of plugging mm 651 0 651 0 651 0 651 0 651 0 Close length at abutting end mm 388 0 388 0 388 0 388 0 388 0 Travel mm 263 263 263 263 263 The stabilizer bar is not available and has been replaced by a twisting link o...

Page 49: ...d Medium link mm 5 9 5 9 n d n d n d Hard link mm 7 1 7 1 n d n d n d 2 11 Suspension characteristic angles and trim Standard A vehicle unloaded incl spare wheel tools accessories fuel and fluid filling Standard 0 vehicle unloaded incl spare wheel tools accessories fluid filling with 5 litres fuel N B Only front wheel toe in can be adjusted at a workshop FIAT PUNTO 49 532 2004 Fiat Auto S p A All ...

Page 50: ...mm 1 mm 1 88 mm 1mm 1 4 8V 175 65 R15 84T 2 mm 1 mm 1 88 mm 1mm 1 4 16V 2 mm 1 mm 1 88 mm 1mm 1 3 Multijet 16V 90 cv 2 mm 1 mm 1 88 mm 1mm 1 4 16V 2 mm 1 mm 1 88 mm 1mm 1 3 Multijet 16V 90 cv 2 mm 1 mm 1 88 mm 1mm 1 9 Multijet 8V 120 cv 185 65 R15 88T 2 mm 1 mm 1 88 mm 1mm 1 4 16V 2 mm 1 mm 1 87 mm 1mm 1 9 Multijet 8V 120 cv 195 55 R16 87H 2 mm 1 mm 1 87 mm 1mm FIAT PUNTO 50 532 2004 Fiat Auto S p...

Page 51: ... 20 1 4 8V 22 20 27 20 1 2 8V 22 20 27 20 1 4 8V 175 65 R15 84T 22 20 27 20 1 4 16V 26 20 28 20 1 3 Multijet 16V 90 cv 26 20 28 20 1 4 16V 26 20 28 20 1 3 Multijet 16V 90 cv 26 20 28 20 1 9 Multijet 8V 120 cv 185 65 R15 88T 26 20 28 20 1 4 16V 19 20 21 20 1 9 Multijet 8V 120 cv 195 55 R16 87H 19 20 21 20 FIAT PUNTO 51 532 2004 Fiat Auto S p A All rights reserved ...

Page 52: ... 1 4 8V 175 65 R15 84T 1 3mm 2mm 1 5mm 2mm 1 4 16V Toe in 1 4 8V 1 3mm 2mm 1 3mm 2mm 1 5mm 2mm 1 3 Multijet 16V 90 cv 1 3mm 2mm 1 5mm 2mm 1 4 16V 1 3mm 2mm 1 5mm 2mm 1 3 Multijet 16V 90 cv 1 3mm 2mm 1 5mm 2mm 1 9 Multijet 8V 120 cv 185 65 R15 88T 1 3mm 2mm 1 5mm 2mm 1 4 16V 1 3mm 2mm 1 5mm 2mm 1 9 Multijet 8V 120 cv 195 55 R16 87H 1 3mm 2mm 1 5mm 2mm FIAT PUNTO 52 532 2004 Fiat Auto S p A All righ...

Page 53: ...8V 1 20 1 20 1 4 8V 1 20 1 20 1 2 8V 1 20 1 20 1 4 8V 175 65 R15 84T 1 20 1 20 1 4 16V 1 20 1 20 1 3 Multijet 16V 90 cv 1 20 1 20 1 4 16V 1 20 1 20 1 3 Multijet 16V 90 cv 1 20 1 20 1 9 Multijet 8V 120 cv 185 65 R15 88T 1 20 1 20 1 4 16V 1 20 1 20 1 9 Multijet 8V 120 cv 195 55 R16 87H 1 20 1 20 FIAT PUNTO 53 532 2004 Fiat Auto S p A All rights reserved ...

Page 54: ...attery capacity Ah 50 50 50 50 60 Alternator A 70 90 70 90 120 2 13 Fluids and lubricants Oils and fluids Recommended product features 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Engine oil Selenia K Selenia WR Selenia K Selenia WR Selenia WR Gearbox front differential oil Tutela car Technyx Tutela car Matryx Tutela car Technyx Tutela car Technyx Tutela car M...

Page 55: ...tar 500 Tutela Star 500 Tutela Star 500 Tutela Star 500 Tutela Star 500 Wheel hubs steering rods various members n d n d n d n d n d Underbody member protection lubrication n d n d n d n d n d Brake circuit component lubrication n d n d n d n d n d Steering box and rack n d n d n d n d n d Lubricant capacity Oil amounts 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 12...

Page 56: ... 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP A 4 030 4 030 4 030 4 030 4 030 B 875 875 875 875 875 C 2 510 2 510 2 510 2 510 2 510 D 645 645 645 645 645 E 1 490 1 490 1 490 1 490 1 490 F 1 473 1 473 1 473 1 473 1 473 G 1 687 1 687 1 687 1 687 1 687 H 1 466 1 466 1 466 1 466 1 466 FIAT PUNTO 56 532 2004 Fiat Auto S p A All rights reserved ...

Page 57: ...ation sec 0 to 100 k p h 2 persons 20 kg 12 12 14 3 14 5 9 sporting body version 2 14 3 Fuelling and filling 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Fuel tank capacity l 45 45 45 45 45 Fuel reserve l 5 7 5 7 5 7 5 7 5 7 Cooling system l 5 27 7 4 5 27 7 3 6 35 Oil sump and filter l 2 6 3 2 2 6 3 2 4 18 Brake circuit kg 0 5 0 5 0 5 0 5 0 5 FIAT PUNTO 57 532...

Page 58: ...n All engines complying with the Euro 4 emission level requirements 2 14 6 Tyres 1 4 8V 1 3 Multijet 16V 90 HP 1 2 8V 1 3 Multijet 16V 75 HP 1 9 Multijet 8V 120 HP Standard items 175 65 R15 84T 185 65 R15 88T 185 65 R15 88T 195 55 R16 87H 205 45 R17 88V 175 65 R15 84T 185 65 R15 88T 175 65 R15 84T 185 65 R15 88T 185 65 R15 88T 195 55 R16 87H 205 45 R17 88V Snow tyres 175 65 R15 84T 185 65 R15 88T ...

Page 59: ...load Inflating pressure with full rear load 175 65 R 15 84T 2 2 2 1 2 2 2 2 185 65 R 15 88T 2 2 2 0 2 2 2 2 Version 1 3 Multijet 16V 90 HP Size Inflating pressure with average front load Inflating pressure with average rear load Inflating pressure with full front load Inflating pressure with full rear load 185 65 R 15 88T 2 3 2 1 2 3 2 3 195 55 R 16 87H 2 3 2 1 2 4 2 4 205 45 R 17 88V 2 4 2 2 2 5 ...

Page 60: ...lating pressure with average front load Inflating pressure with average rear load Inflating pressure with full front load Inflating pressure with full rear load 175 65 R 15 84T 2 4 2 1 2 5 2 2 185 65 R 15 88T 2 3 2 1 2 3 2 3 Version 1 9 Multijet 8V 120 HP Size Inflating pressure with average front load Inflating pressure with average rear load Inflating pressure with full front load Inflating pres...

Page 61: ... cylinder with hydraulic tappets two overhead camshafts with motion gear drive air boosting by means of a turboblower and an intercooler no load weight 137 kg 75 HP and 139 kg 90 HP Magneti Marelli MJD 6F3 Common Rail electronic injection system These engines make use of a Magneti Marelli Common Rail high pressure electronic injection system for fast diesel engines which is fully controlled by a M...

Page 62: ... system UEGO oxygen sensor temperature sensors for DPF available as options for 90 HP versions only new DRV 2 pressure regulator new RDS 4 air pressure sensor The unit consists of a system made up of the engine and all the systems required for its operation fuel feed system air boosting system engine cooling system exhaust system with catalytic converter oil vapour recirculation system exhaust gas...

Page 63: ...eater weight and torque values 200 Nm Each support features a metal rubber dowel used to dampen the vibrations generated by the engine thus reducing to a significant extent the vibrations transmitted to the body The power unit support is of the barycentre type it is made up of two dowels and a reaction link which acts as a tie rod where the new supports are aligned to an axis passing through the e...

Page 65: ... dimensional classes plus one oversize class Class A Class B Class C FIAT PUNTO 65 532 2004 Fiat Auto S p A All rights reserved Plus one oversize The drive shaft is rested by means of five main bearings 1 Special channels obtained in the base walls allow the cooling fluid and the lubricating oil to flow through A nozzle 2 is fitted into the lower part of each cylinder through which oil is sprayed ...

Page 66: ...e cast aluminium alloy with cast iron main caps The main bearing and cap finishing operations are carried out by joining with the upper engine base Joining with the upper base is carried out by means of screws and dowel bolts that ensure assembling accuracy A bead of sealant is put between the two engine bases to avoid engine oil leaks The figure below illustrates the upper engine base 1 and the l...

Page 68: ...ling by means of a special boring machine Compared with the cylinder heads with precombustion chamber the entire combustion process takes place in the combustion chamber obtained on the piston The gasket between the cylinder head and the engine base is made of metal moreover the cylinder head shall not be retightened during the entire engine life On the versions fitted with the 90 HP engine the co...

Page 70: ...ting oil It is made of stamped sheet metal and includes the threaded hole with cap for engine oil drain Sealing with the engine base is achieved by means of a bead of silicone sealant A bulkhead is put between the engine base and the oil sump which prevents the engine oil from being shaken off due to the vehicle and drive shaft motion and also ensures that the level remains constant FIAT PUNTO 70 ...

Page 71: ...by means of an oil seal fitted directly into the housing obtained between the engine base and the underbase 3 2 7 Engine flywheel The engine flywheel is made of cast iron with set steel ring gear The flywheel is secured to the drive shaft through a flange with bolts a phonic wheel for the revs sensor is secured toward the engine side 1 Engine flywheel 2 Set ring gear FIAT PUNTO 71 532 2004 Fiat Au...

Page 72: ...allow the engine to idle without coming to a halt and overcoming the friction work developed by the same during no load operation 3 2 8 Drive shaft It is made of forged steel and rests on five main bearings Its axial play is controlled by two half rings housed in the central main bearing Accurate balancing of the rotating masses is ensured by eight counterweights A number of channels run through t...

Page 73: ... nd 90 HP Class C 69 540 69 550 75 HP nd 90 HP The OMEGA combustion chamber is obtained on the piston crown to improve combustion efficiency see Cylinder head A channel is obtained inside the pin through which the oil sent to the nozzles flows thus ensuring better piston cooling Coupling with the pin is carried out by means of two copper alloy bushings 1 Piston 2 Electric injector 3 Preheating spa...

Page 74: ...oupling with piston pin 2 The pins of the float type are retained by two expansion snap rings 3 found in the special slots obtained within the pin housing Coupling between the connecting rod and the cap through machined surfaces To withstand specific pressure values in the 90 HP engine the upper bronze bushings have been modified Refer to the diagram FIAT PUNTO 74 532 2004 Fiat Auto S p A All righ...

Page 76: ...Auto S p A After Sales Training 3 2 11 Camshaft drive The camshaft drive is of the direct type and takes place by means of a chain 1 Driven gear 2 Driving gear 3 Moving shoe 4 Fixed shoe FIAT PUNTO 76 532 2004 Fiat Auto S p A All rights reserved 5 Timing chain ...

Page 77: ...ched by an automatic oil pressure operated stretching device which minimizes maintenance operations fitted inside the valve gear on the block which acts on the moving shoe 3 2 13 Distributing shafts in the upper head These are two camshafts made of cast iron with induction hardened cams FIAT PUNTO 77 532 2004 Fiat Auto S p A All rights reserved ...

Page 78: ...the intake side drives the vacuum pump 3 2 14 Tappets A hydraulic tappet is used for every single valve which is actuated by a rocker arm that is in turn driven by the cam axle The rocker arms are made in such a way as to avoid serious damage to the other engine members in case of timing chain breaking or stepping In fact they are able thanks to a pre established fracture section to get deformed s...

Page 79: ...gine preheating phase The control unit includes a protection device against high current and overvoltage and also features an electronic self resetting logic Considering the thermal and weather resistance features the device can be fitted directly to the engine compartment The control unit is protected against any possible electric connections with battery polarity reversal on all of its terminals...

Page 80: ... start from the engine control unit K Input for control start from the engine control unit DI Output for direct diagnosis toward the engine control unit 3 2 16 Turboblower FIAT PUNTO 80 532 2004 Fiat Auto S p A All rights reserved The turboblower 1 is connected to the exhaust manifold it is used to enhance the engine s volumetric efficiency It is essentially made up of two impellers force fitted t...

Page 81: ... controlled by a pneumatic actuator 4 which makes it possible to choke the exhaust gas flow to the turbine depending on the pressure reached at the compressor outlet BORG WARNER VNT 90 HP turboblower FIAT PUNTO 81 532 2004 Fiat Auto S p A All rights reserved The 1 3 MJTD 90 HP engine features a new generation of turboblowers the VNT Variable Nozzle Turbines turboblower The distributor blades are a...

Page 82: ... way that the exhaust gas flow hits the outer edge of the turbine blades This causes the exhaust gas flow to be restricted and involves increasing exhaust gas flow speed and boosting pressure According to the principle of the lever all of this involves a higher torque at low speeds If the engine revs number increases the exhaust gas inlet section will be increased by displacing the distributor bla...

Page 83: ...TRAINING OUTLINE Fiat Auto S p A After Sales Training Turboblower view 1 Low engine revs number and small exhaust gas amount FIAT PUNTO 83 532 2004 Fiat Auto S p A All rights reserved 2 High engine revs number and large exhaust gas amount ...

Page 84: ...from the E G R valve and flowing toward the cylinders 3 2 18 Exhaust pipes and silencer The engine s exhaust gas flows through the manifold to the turboblower and next to the oxidizing catalytic converter 1 A flexible element 2 is found in the front part of the exhaust pipe which is used to reduce the transmission of vibrations The rear exhaust section is made up of a intermediate pipe 3 and a rea...

Page 85: ...honeycomb monolith 1 the cells of which are soaked with platinum 2 a catalyzing substance of oxidation reactions Operation FIAT PUNTO 85 532 2004 Fiat Auto S p A All rights reserved The exhaust gas flowing through the cells heats the catalyst thus triggering the conversion of polluting substances into inert compounds The chemical reaction for CO HC and particulate oxidation is efficient at tempera...

Page 86: ...temperature peak is lowered in the combustion chamber thus reducing the formation of nitric oxides NOx The function of the E G R solenoid valve 1 controlled by the injection control unit 2 is to let a portion of the exhaust gas drawn by exhaust manifold 4 again into the engine intake A heat exchanger 3 makes it possible to partially cool the exhaust gas by further lowering the combustion chamber t...

Page 87: ...bustion temperature is lowered due to the presence of inert gas thus reducing the formation of NOx nitric oxides The injection control unit is constantly informed about the amount of recirculated gas by the data from the air flow meter In fact if a certain amount of air Qam is to be sucked with a given engine speed and the value provided by the air flow meter Qar is smaller the difference Qgr will...

Page 88: ... depending on the control of the injection control unit Modulation takes place by means of the inner solenoid PWM controlled by the control unit which actuates the control rod of the inner valve that conveys after it has opened the gas into the inlet manifold E G R valve body Gas inlet from the exhaust manifold Gas outlet to the inlet manifold Solenoid positive FIAT PUNTO 88 532 2004 Fiat Auto S p...

Page 89: ... collects the vapour from the engine base and the valve gear cover through pipe 2 Condensed vapour returns to the sump through pipe 3 whereas non condensed vapour is conveyed through pipe 4 to the turboblower air inlet sleeve 1 Oil separator 2 Oil vapour outlet from the cover 3 Condensed vapour return to the sump 4 Pipe for sending the vapour to the intake FIAT PUNTO 89 532 2004 Fiat Auto S p A Al...

Page 90: ...tem Plummet with filter strainer Oil pump Oil filter with replacement cartridge Engine oil cooling water oil heat exchanger Nozzle timing chain lubrication Engine oil pressure warning light switch Turboblower lubrication pipes Engine oil level dipstick Engine oil level maintaining and scraper ring bulkhead FIAT PUNTO 90 532 2004 Fiat Auto S p A All rights reserved Timing chain cover ...

Page 91: ...ling cap 2 Filter element cover 3 Water oil heat exchanger 3 3 5 Engine oil pump FIAT PUNTO 91 532 2004 Fiat Auto S p A All rights reserved The engine oil is sucked by the sump through the vacuum generated by the rotation of the gears force fitted onto the drive shaft The vacuum is found starting from the gear partition bulkhead 1 up to the oil sump plummet Conversely the pressure develops startin...

Page 92: ...ction of the spring underneath and moves the valve until the connecting duct 8 between pressure chamber 7 and low pressure chamber 5 is opened 1 Partition bulkhead 2 Oil supply duct 3 Driven gear 4 Driving gear 5 Low pressure chamber 6 Relief valve 7 Pressure chamber FIAT PUNTO 92 532 2004 Fiat Auto S p A All rights reserved 8 Connecting duct between high and low pressure ...

Page 93: ...ngine cooling Engine cooling system Water pump Engine coolant temperature sensor Thermostat Radiator Electric fan Feed tank Engine oil heat exchanger Vehicle interior heating radiator E G R exhaust gas heat exchanger FIAT PUNTO 93 532 2004 Fiat Auto S p A All rights reserved Water recirculation pipe ...

Page 94: ...ated valve included in the pressurized cap the following will be obtained air flows out of the circuit which is collected by the pipe from the thermostat air flows in when the circuit is in vacuum condition due to engine cooling Engine cooling radiator It is made up of a core and two side trays for coolant inlet and outlet The core pipes and fins are made of aluminium whereas the tanks are made of...

Page 95: ...entrifugal vane type with pump body and impeller made of phenol resin and arbor made of steel It is secured to the engine base and driven directly through the service belt Thermostat 1 EGR valve output 2 temperature sensor 3 oil filter output FIAT PUNTO 95 532 2004 Fiat Auto S p A All rights reserved 4 radiator output ...

Page 96: ...ic fans The 2 speed electric cooling fans make it possible to increase the heat discharge capacity of the radiator and or air conditioning system condenser They are controlled directly by the injection control unit according to a specific operating logic 3 4 3 3 5 Service control Construction FIAT PUNTO 96 532 2004 Fiat Auto S p A All rights reserved The single engine member drive belt 5 is of the...

Page 97: ...6V 75 90 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Alternator Belt stretcher Water pump Drive shaft pulley FIAT PUNTO 97 532 2004 Fiat Auto S p A All rights reserved Engine member drive belt ...

Page 99: ...by quick combustion thus ensuring smoother operation and also allows emissions to be further reduced The injection pressure can be controlled thanks to the construction features of the system which is equipped with a pressure pump pressure regulator pressure sensor and separate electric injectors all of which are managed by a control unit Thus the injection pressure is independent from the engine ...

Page 100: ... Construction The fuel feed system is divided into a low pressure circuit and a high pressure circuit Low pressure circuit It is made up of the following items auxiliary electric pump immersed into the tank fuel filter with inner cartridge fuel return manifold pipe FIAT PUNTO 100 532 2004 Fiat Auto S p A All rights reserved connecting pipes ...

Page 101: ... 90 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Low pressure line Low pressure circuit 75 HP Low pressure line FIAT PUNTO 101 532 2004 Fiat Auto S p A All rights reserved Low pressure circuit 90 HP ...

Page 102: ...cuit It is made up of the following items pressure pump CP1 75 HP CP1H 90 HP single fuel manifold pipe with built in pressure regulator and pressure sensor electric injectors CR1MI2 2 connecting pipes High pressure line FIAT PUNTO 102 532 2004 Fiat Auto S p A All rights reserved Injectors 75 HP 90 HP CR1MI2 2 ...

Page 103: ...uel filter water sensor 6 Pressure pump 7 High pressure pipes 8 Single fuel manifold pipe rail 9 Electric injectors CR1MI2 2 10 Pipe from electric injectors to fuel return manifold pipe 11 Fuel return manifold pipe 12 Pressure regulator DRV 2 13 Fuel pressure sensor RDS 4 14 Fuel temperature sensor FIAT PUNTO 103 532 2004 Fiat Auto S p A All rights reserved 15 Fuel heater ...

Page 104: ... latter feeds the pump with a fuel amount that is always larger than the engine needs so as to make the fuel circulate back to the tank by doing so pump lubrication and cooling will be achieved the former taking priority over the latter Piston motion is obtained through a cam integral to the pump shaft the latter actuates a polygonal ring that acts on the piston foot Each pumping unit is equipped ...

Page 105: ...ing unit is made up of the following items three pistons 5 actuated by a cam 2 integral to the pump shaft 6 one gate intake valve for each piston 3 one ball delivery valve for each piston 4 The pressure pump must be fed with a pressure of at least 0 7 bar therefore the fuel feed system is equipped with an auxiliary electric pump immersed into the tank The maximum discharge pressure reaches 1 400 b...

Page 106: ...1 3 MULTIJET 16V 75 90 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Pump section View of the three plungers FIAT PUNTO 106 532 2004 Fiat Auto S p A All rights reserved ...

Page 107: ...0 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training CP1 pump diagram and section FIAT PUNTO 107 532 2004 Fiat Auto S p A All rights reserved a Shut off valve b Lubrication hole holeazione CP1 pump section ...

Page 108: ...ve units and measures taken to increase the body sturdiness To ensure a sufficient amount of fuel the high pressure pump has been set to reach a total flow rate of 160 l h The required flow rate is adjusted continuously by means of the M PROP solenoid valve found on the high pressure pump This valve adjusts the fuel amount let into the rail to the system requirement Such flow rate adjustment makes...

Page 109: ...pressure pump and is recovered through the KUEV valve approximately 50 corresponds to the excess fuel recovered through the pressure accumulator and the injectors KUEV valve The purpose of this mechanic valve is to keep the pressure inside the pump constant it discharges any overpressure to prevent pressure peaks from damaging the pump and also control the fuel flow needed to cool and lubricate th...

Page 110: ...ctronically controlled valve is used to modulate the feed rate from the low pressure circuit to the high pressure pump by rotating a flap inside the valve directly controlled by the ECM I 0 amp max flow rate even if disconnected I 2 5 amp zero flow rate FIAT PUNTO 110 532 2004 Fiat Auto S p A All rights reserved ...

Page 111: ... Auto S p A After Sales Training DRV 2 pressure regulator FIAT PUNTO 111 532 2004 Fiat Auto S p A All rights reserved It is fitted onto the rail and controlled by the injection control unit It is used to control the fuel feed pressure to the electric injectors ...

Page 112: ...ng The pressure regulator is essentially made up of the following items 1 Round shutter 2 Pin 3 Valve 4 Preload spring max sealing pressure 50 bar 5 Coil 6 Body 7 Anchorage 8 Filter Current graph depending on the DRIVING DUTY PWM FIAT PUNTO 112 532 2004 Fiat Auto S p A All rights reserved ...

Page 113: ...e speed rail pressure 1 400 bar 90 HP Idling engine rail pressure 250 bar Max engine speed rail pressure 1 600 bar 3 6 4 Electric injectors and pipes CR1 MI 2 2 electric injectors The electric injectors are fitted onto the cylinder head and controlled by the injection control unit The electric injector can be divided into two parts 1 actuator nozzle 2 control solenoid valve FIAT PUNTO 113 532 2004...

Page 114: ...that acts on feed volume 8 START OF INJECTION coil 4 is energized and causes shutter 6 to be raised The control volume fuel 9 flows out toward return manifold 10 thus causing a pressure drop on control area 7 At the same time the line pressure through feed duct 12 exerts a force Fa Fc in feed volume 8 thus causing pin 2 to be lifted with resulting fuel flow into the cylinders through holes 3 such ...

Page 115: ...sion levels by properly matching the construction features of every single injector with the software control strategies within the engine management control unit Thus the production tolerances can be recovered each injector is tested at 7 characteristic operation points associated with special control time and fuel pressure conditions which reproduce the engine s typical operation points idling f...

Page 116: ...RAIN engine have to receive and interpret the IMA codes for every single electric injector reading by means of a camera in order to match the same with the corresponding cylinder to which the injector is fitted and also produce a label that is put onto the timing belt cover The FIAT bodywork plants match the engine management control units with the respective software control strategies by means o...

Page 117: ...ittent until Key OFF To cause the DTC to be automatically cleared off the error memory a key OFF key ON operation shall be carried out complete with power latch after classifying the four injectors The DTC can no longer appear over the entire control unit life cycle after it has been cleared off the error memory the CCM cannot after the operation has been carried out be brought back to the virgin ...

Page 118: ...drawing Shim Anchor guide Anchor spring Ball Full valve Valve ball Coil Spring Connector Bar filter Guide Pin High pressure ring Washer Adapter Anchor Ring Shell Reference dowel Retaining nut Core Cap Anchor pin Spring Body Shim Rod Valve body Co moulding FIAT PUNTO 118 532 2004 Fiat Auto S p A All rights reserved IMA CODE ...

Page 119: ...ail FR for the 75 HP engine version one standard laser welded rail LWR for the 90 HP engine versions fitted to the cylinder head on the intake side With a volume of approximately 20 cm it dampens the fuel pressure oscillations due to the pressure pump operation the opening of the electric injectors The difference between the two rails lies with the manufacturing procedure one is forged FR whereas ...

Page 120: ...o the other side The hydraulic high pressure connections between the pump manifold and the electric injectors manifold are made by means of steel pipes with inner diameter of 2 mm and outer diameter of 6 mm With regard to these pipes special wrenches shall be used for disassembling and assembling and a torque wrench shall be used when tightening to less than 20 Nm FIAT PUNTO 120 532 2004 Fiat Auto...

Page 121: ...laced as individual items The function of the fuel electric pump is to feed the high pressure pump It is fully immersed into the fuel inside the tank The pump unit is realized so as to obtain the maximum fuel level in the suction area This function is implemented by means of a Venturi pipe placed on the suction return pipe with respect to the one of the tank The pumping unit is of the roller type ...

Page 122: ...trols the pump impeller 2 and an end support cover 3 that contains the electric and hydraulic connections The electric pump stage is of the single peripheral flow type with high performance in low voltage and temperature conditions The advantages compared with the electric pumps operating according to the volumetric principle are as follows less weight FIAT PUNTO 122 532 2004 Fiat Auto S p A All r...

Page 123: ...75 90 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Power supply 13 V Current absorption 4 6 A Pressure 2 to 4 bar FIAT PUNTO 123 532 2004 Fiat Auto S p A All rights reserved Flow rate 160 litres h ...

Page 124: ...e dashboard on the passenger side In case of vehicle collision the switch cuts off the ground connection of the fuel electric pump and as a result the fuel supply to the injection system FIAT PUNTO 124 532 2004 Fiat Auto S p A All rights reserved A steel ball 1 fitted into a tapered housing 2 is normally kept secured through the attraction force of an adjacent magnet ...

Page 125: ...n when it is hit by the ball from N C circuit to normally open N A circuit thus cutting off the fuel electric pump ground circuit The switch can be restored by pushing a button protected by a flexible cover 4 FIAT PUNTO 125 532 2004 Fiat Auto S p A All rights reserved NOTE Following any collision even a slight one the switch shall not be actuated again if fuel smell is smelt or leaks are found fro...

Page 126: ...hetic material which is highly efficient in terms of performance service life and water separation 1 Diesel fuel inlet 2 Filtering cartridge sealing O ring supplied 3 Temperature sensor 4 Diesel fuel outlet from the injection system 5 Diesel fuel outlet from the control valve toward the tank 6 Regulating valve inside the outlet 7 Water drain actuating screw 8 Water escape zone 9 Water presence sen...

Page 127: ...fuel filter is equipped with a fuel preheating device and a fuel temperature sensor through a NTC thermistor fitted inside the cover The heater is controlled by the injection control unit depending on the signal of the fuel temperature sensor Refer to the fuel temperature sensor for specifications FIAT PUNTO 127 532 2004 Fiat Auto S p A All rights reserved ...

Page 128: ...to S p A After Sales Training HEATER WIRING DIAGRAM NTC WIRING DIAGRAM Batteries Relays PIN OUT 1 SENSOR GROUND 2 TEMPERATURE SIGNAL analog output toward the ECM 3 POWER SUPPLY 12 V from the ECM FIAT PUNTO 128 532 2004 Fiat Auto S p A All rights reserved 4 GROUND ...

Page 129: ...lter complete with resonator 2 Digital air flow meter 3 Sleeve for connection with the turboblower 4 Turboblower with waste gate 75 HP VNT with VGT valve 90 HP 5 Air air heat exchanger intercooler 6 Intercooler air inlet manifold connecting sleeve FIAT PUNTO 129 532 2004 Fiat Auto S p A All rights reserved 7 Air intake manifold ...

Page 130: ...conditions injection control accuracy advance and injection duration less consumption lower emission levels The main functions of the system are essentially as follows fuel temperature control engine coolant temperature control injected fuel amount control idling speed control fuel cut off during the release phase cut off idling cylinder balancing control engine jerk prevent check acceleration exh...

Page 131: ...ine compartment The control unit is of the flash e p r o m type i e it can be re programmed from outside without acting on the hardware The injection control unit incorporates the absolute pressure sensor 3 8 2 PIN OUT CONNECTOR A Cylinder 4 injector positive Not connected Not connected Fuel pressure regulator positive Positive from the main relay Fuel pressure sensor negative Not connected FIAT P...

Page 132: ...or positive Not connected Not connected Not connected Phase sensor negative Not connected Sucked air temperature and boosting pressure sensor positive Sucked air temperature and boosting sensor negative Phase sensor positive Not connected Air flow meter negative Not connected Engine coolant temperature sensor ground Not connected Cylinder 3 injector negative Not connected Not connected Fuel pressu...

Page 133: ...der 1 injector negative Cylinder 3 injector negative Cylinder 2 injector negative Not connected Not connected Not connected Not connected Engine coolant temperature sensor signal Not connected Phase sensor signal Not connected Not connected Revs sensor negative Not connected Connector B Control unit power ground Control unit power ground Control unit power ground Control unit power supply 12 V FIA...

Page 134: ...ace 2 positive on the accelerator pedal potentiometer Not connected Not connected Not connected Not connected Not connected Not connected Not connected Key controlled power supply Not connected Not connected Not connected Not connected Request for air conditioner actuation from the control button Engine revs number signal for robotized gearbox Not connected Not connected Accelerator potentiometer ...

Page 135: ...otentiometer race 2 signal Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Direct power supply from the battery Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Fuel temperature sensor signal Not connected Not connected FIAT PUNTO 135 532 2004 F...

Page 136: ...ntrol Fuel pump relay control Fuel heater relay control Not connected Injection system failure warning light MIL Air conditioning compressor control Main relay control Not connected Not connected Accelerator potentiometer race 1 power supply Not connected Not connected Not connected Air conditioner linear sensor signal Diagnosis line K Not connected Diesel fuel filter water presence sensor signal ...

Page 137: ...3 MULTIJET 16V 75 90 HP FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 3 8 3 Types of configuration 75 HP system with CP1 pump FIAT PUNTO 137 532 2004 Fiat Auto S p A All rights reserved ...

Page 138: ...ntity control valve downstream the CP1 H pump 3 8 4 Operation Operation logic FIAT PUNTO 138 532 2004 Fiat Auto S p A All rights reserved The MARELLI MJD6F3 Euro 4 engine control system with EOBD features multiple injection control from which the term Multijet is derived Below is a short description of the system ...

Page 139: ...ly Multiple injections make it possible to reduce the pollutants to a significant extent while ensuring optimum engine performance The engine management control unit can perform up to 5 injections per engine cycle which are referred to as follows PILOT injection PRE injection MAIN injection AFTER injection POST injection Injection Combustion factor T D C Four work areas can be identified in this a...

Page 140: ...tion processed by the control unit to control the amount of fuel to be injected engine revs cooling fluid temperature boosting pressure air temperature from the air flow meter sucked air amount battery voltage diesel fuel pressure accelerator pedal position FIAT PUNTO 140 532 2004 Fiat Auto S p A All rights reserved diesel fuel temperature ...

Page 141: ...onditioner compressor where available 4 E G R solenoid valve 5 Revs counter 6 Electric fans 7 Spark plug preheating control unit 8 Dual trace accelerator pedal potentiometer 9 Dual brake pedal switch clutch pedal switch 10 Fuel pressure sensor 11 Air flow meter 12 Cooling fluid temperature sensor 13 Fuel temperature sensor FIAT PUNTO 141 532 2004 Fiat Auto S p A All rights reserved 14 Cruise Contr...

Page 142: ...18 Speedometer 19 Battery 20 FIAT CODE body computer 21 Diagnosis connector 22 Pressure regulator 23 Electric injectors 24 Preheating spark plugs 25 Spark plug preheating warning light 26 Injection warning light 27 Max water temperature warning light FIAT PUNTO 142 532 2004 Fiat Auto S p A All rights reserved 28 Fuel water presence warning light ...

Page 143: ...res them with the permitted limit data 3 9 1 FAULT SIGNALLING UPON VEHICLE START Warning light ON until the engine has been started test phase Warning light OFF after the engine has been started no fault is found on the components that affect the system safety gb Fiat Grande Punto OK 143 532 2004 Fiat Auto S p A All rights reserved Warning light ON when the engine is running a fault is present ...

Page 144: ...e control unit defines each time the type of recovery depending on the broken components The recovery parameters are managed by the components in good working order 3 9 3 FIAT CODE recognition The control unit exchanges at the instant when it receives the key turned to MAR signal data with the body computer through the CODE function to obtain start enable gb Fiat Grande Punto OK 144 532 2004 Fiat ...

Page 145: ...perature check When the fuel temperature is 80 C as measured by the sensor in the diesel fuel filter the ECM controls the pressure regulator in order to reduce the line pressure if this is not enough it will also reduce the amount of injected fuel gb Fiat Grande Punto OK 145 532 2004 Fiat Auto S p A All rights reserved ...

Page 146: ...emperature check When the engine coolant temperature is higher than 105 C the ECM reduces the amount of injected fuel i e reduces the engine power controls the cooling electric fans causes the cooling fluid temperature warning light to come on gb Fiat Grande Punto OK 146 532 2004 Fiat Auto S p A All rights reserved ...

Page 147: ...heck The control unit carries out the following operations depending on the signals from the sensors and on the measured values controls the pressure regulator varies the pilot injection time over the entire revs range varies the main injection time gb Fiat Grande Punto OK 147 532 2004 Fiat Auto S p A All rights reserved ...

Page 148: ...gnals from the various sensors engine revs engine temperature vehicle speed and adjusts the amount of injected fuel it controls the pressure regulator DRV2 it varies the injection time of electric injectors CR1MI2 2 Within some thresholds the speed allows for the battery voltage gb Fiat Grande Punto OK 148 532 2004 Fiat Auto S p A All rights reserved ...

Page 149: ...e cut off The control unit performs during the accelerator pedal release phase the following logics it sets the injection time to zero it partially varies the electric injector injection time before the idling speed is reached controls the fuel pressure regulator gb Fiat Grande Punto OK 149 532 2004 Fiat Auto S p A All rights reserved ...

Page 150: ...l unit checks depending on the signals from the various sensors engine revs vehicle speed phase sensor that the torque is correct until the idling speed is reached it varies the amount of injected fuel in every single electric injector i e it varies the injection time gb Fiat Grande Punto OK 150 532 2004 Fiat Auto S p A All rights reserved ...

Page 151: ...ensors engine revs vehicle speed engine temperature accelerator pedal potentiometer brake and clutch switches and corrects the amount of fuel to be injected in order to improve driveability by reducing the running jerks through the opening time of electric injectors CR1MI2 2 and the amount control valve DRV2 gb Fiat Grande Punto OK 151 532 2004 Fiat Auto S p A All rights reserved ...

Page 152: ...to reduce the smoke during quick transients the control unit reduces depending on the signals from the accelerator pedal potentiometer the air flow meter and the engine revs the amount of fuel to be injected through pressure regulator DRV2 the injection time of electric injectors CR1MI2 2 gb Fiat Grande Punto OK 152 532 2004 Fiat Auto S p A All rights reserved ...

Page 153: ... EURO 3 4 anti pollution regulatory standard the control unit reduces depending on the engine load and the signal from the accelerator pedal potentiometer the amount of sucked fresh air by partially sucking the exhaust gas through the adjustment of the electric E G R valve opening gb Fiat Grande Punto OK 153 532 2004 Fiat Auto S p A All rights reserved ...

Page 154: ...ues on preset maps the limit torque the permitted smoke limit level It compares these minimum values and corrects the same by means of other parameters cooling fluid temperature engine revs number vehicle speed air temperature The control unit also controls the amount of fuel to be injected pressure regulator electric injectors gb Fiat Grande Punto OK 154 532 2004 Fiat Auto S p A All rights reserv...

Page 155: ...Auto S p A After Sales Training 3 10 11 Max r p m restraint check When the engine reaches 5 200 r p m the control unit cuts off injector drive as a result the feed pressure will be reduced gb Fiat Grande Punto OK 155 532 2004 Fiat Auto S p A All rights reserved ...

Page 156: ...3 10 12 Preheating spark plug check During the phases below starting phase post starting phase the control unit manages timed operation of the spark plug preheating control unit BITRON depending on the engine temperature gb Fiat Grande Punto OK 156 532 2004 Fiat Auto S p A All rights reserved ...

Page 157: ...em actuation check The control unit drives the air conditioner compressor by turning it ON OFF when the respective switch is pressed by turning it off temporarily i e a few seconds in case of heavy acceleration or when the maximum power is requested gb Fiat Grande Punto OK 157 532 2004 Fiat Auto S p A All rights reserved ...

Page 158: ...uxiliary fuel electric pump check Regardless of the revs number the control unit powers the auxiliary fuel pump with the key turned to MAR cuts the auxiliary pump power supply off if the engine is not started within a few seconds gb Fiat Grande Punto OK 158 532 2004 Fiat Auto S p A All rights reserved ...

Page 159: ...ning 3 10 15 Cylinder position check The control unit recognizes during every single engine rev the cylinder in the bursting stroke through the phase sensor and controls the injection sequence to the proper cylinder gb Fiat Grande Punto OK 159 532 2004 Fiat Auto S p A All rights reserved ...

Page 160: ...nsors engine temperature engine revs camshaft sensor air mass meter including the absolute pressure sensor built into the control unit itself the control unit determines according to internal mapping the optimum injection point based on the driving comfort and also the emission limits laid down by the EURO 3 4 standards gb Fiat Grande Punto OK 160 532 2004 Fiat Auto S p A All rights reserved ...

Page 161: ...ngine temperature RDS4 rail pressure sensor fuel temperature the control unit drives the regulator in order to obtain optimum line pressure 3 10 18 Electric balance check The control unit varies the idling speed depending on the battery voltage it increases the injection time of electric injectors CR1MI2 2 gb Fiat Grande Punto OK 161 532 2004 Fiat Auto S p A All rights reserved it controls the lin...

Page 162: ...ing 3 10 19 Electric fan check Depending on the engine water temperature and the coolant pressure in the air conditioning system the control unit drives the actuation of the electric fans to the first or second speed gb Fiat Grande Punto OK 162 532 2004 Fiat Auto S p A All rights reserved ...

Page 163: ...ashboard indicates the system s operation or deactivation state The Cruise Control is temporarily disabled by pressing the brake pedal by pressing the clutch pedal the speed stored in the memory will be resumed by pressing the Resume button The Cruise Control will not be disabled in case heavy acceleration is requested e g when overtaking and will resume the vehicle s set speed as soon as the acce...

Page 164: ...uator NO X Max rail pressure 1400 1600 Injectors CRI2 MI uSAC KS 6 x280 CRI2 MI uSAC KS 6 x280 Control system DRV2 on the rail MPROP in CP1 H DRV2 on the rail Functions Multiple injection EGR control DPF control Oxygen sensor control Cylinder balancing control Injection correction control IMA procedure Multiple injection EGR control DPF control Oxygen sensor control Cylinder balancing control Inje...

Page 165: ...l It is of the induction type i e it operates through the variation of the magnetic field generated by the passage of the phonic wheel teeth 60 2 teeth The injection control unit uses the revs sensor signal to determine the engine rotation speed determine the angular position of the drive shaft gb Fiat Grande Punto OK 165 532 2004 Fiat Auto S p A All rights reserved The figure illustrates the revs...

Page 166: ...sor body 4 Coil winding 5 Polar core 6 Ring gear or phonic wheel 7 Coaxial two wire cable or electric connection PIN OUT Pin Name Type of signal 1 Phonic wheel signal A Frequency output 2 Phonic wheel signal B Frequency output Technical features gb Fiat Grande Punto OK 166 532 2004 Fiat Auto S p A All rights reserved Winding resistance 790 Ω 20 ...

Page 167: ... range of 0 8 to 1 5 mm This distance cannot be adjusted therefore if an out of tolerance gap value is found verify that the sensor and the phonic wheel are intact The diagram shows the sensor output signal in connection with the horizontal development of the phonic wheel 1 Toothed wheel contour 2 Revs sensor signal 3 Reference tooth 4 Measuring point for T D C recognition gb Fiat Grande Punto OK ...

Page 168: ...ontrol unit provide the latter with the measurement of the drive shaft angular speed Cam or phase angle sensor This is a Hall effect sensor fitted to the overhead just next to the distributing shaft on the exhaust side A tooth is obtained on the overhead which allows the phase sensor to signal the engine timing position The injection control unit uses the phase sensor signal to know the top dead c...

Page 169: ...eld intensity Therefore it is enough for the magnetic field intensity to vary periodically in order to obtain a modulated electric signal the frequency of which is proportional to the speed by which the magnetic field changes To obtain this change the sensor is periodically moved near by a tooth obtained on the inner side of the pulley PIN OUT Pin Name Type of signal 1 Ground Ground 2 Phase signal...

Page 170: ... emergency mapping which will allow the engine to be started in any case Boosting pressure sensor The boosting pressure sensor is fitted to the inlet manifold and makes it possible to measure a suction pressure up to 1 5 bar corresponding with 2 5 absolute bar The sensitive element consists of a piezoresistive element the signal of which is amplified by an electronic circuit built into the sensor ...

Page 171: ...ING OUTLINE Fiat Auto S p A After Sales Training Overpressure sensor pin out Pin Name Type of signal 1 Power supply Input 5 V 2 Ground Ground 3 Sensor output Analog output gb Fiat Grande Punto OK 171 532 2004 Fiat Auto S p A All rights reserved ...

Page 172: ... FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training In the 90 HP engine version the sensor also incorporates the boosting temperature sensor gb Fiat Grande Punto OK 172 532 2004 Fiat Auto S p A All rights reserved ...

Page 173: ... TRAINING OUTLINE Fiat Auto S p A After Sales Training Pin out 1 Pressure signal output 2 Power supply from the control unit 5 V 3 Temperature signal output gb Fiat Grande Punto OK 173 532 2004 Fiat Auto S p A All rights reserved 4 Ground ...

Page 174: ...re sensor It is fitted to the thermostat and measures the water temperature by means of a NTC with negative resistance coefficient Engine water temperature sensor features gb Fiat Grande Punto OK 174 532 2004 Fiat Auto S p A All rights reserved Temperature C Resistance KΩ 40 48 80 30 27 41 20 15 97 10 9 62 0 5 97 ...

Page 175: ...into the sensor against the air impurities particles water oil vapour etc greater measurement accuracy Below are the differences between the HFM6 air flow meter and the earlier versions air flow rate and temperature digital signals 4 wire electric connection different channelling of the air flow which hits against the sensitive measuring element new by pass turret welded to the air flowing duct pr...

Page 176: ...cts the measuring sensor sensitive element against the blow by vapour that might flow back during the engine switch off phase In the digital air flow meter the turret 2 is welded to the sensor housing duct and cannot therefore be separated from it In the analog air flow meter the turret is secured to the duct by means of two screws 1 gb Fiat Grande Punto OK 176 532 2004 Fiat Auto S p A All rights ...

Page 177: ...erator 2 data memory 3 A D converter DIGITAL AIR FLOW METER OPERATION Temperature signal trend In the digital air flow meter the temperature value sent to the engine management control unit is a signal of the PWM duty cycle type fixed frequency The working voltage is 5 V whereas the measuring interval ranges between 50 ºC and 150 ºC with a resulting duty cycle value in the range of 10 to 90 gb Fia...

Page 178: ... value variation is converted from analog into logic thanks to a digital analog converter 3 The data item obtained is stored in a data memory 2 Data are sent to the engine management control unit through a function generator 1 gb Fiat Grande Punto OK 178 532 2004 Fiat Auto S p A All rights reserved 1 2 3 ...

Page 179: ...ncy of the output signal from the meter and as a result a decrease in the period value Air flow rate Frequency output Digital air flow meter AIR FLOW RATE signal To measure and check the signal amplitude voltage 5 V a graphic voltmeter is needed To measure the frequency value you will just need to use a multimeter with selection of the frequency measurement and the respective prods connected as fo...

Page 180: ...e and is used to provide the injection control unit with a feedback signal in order to adjust the injection pressure adjust the injection time The sensor is powered directly by the engine management control unit with 5 V The output voltage varies in a linear fashion between 0 5 V 0 bar and 4 5 V 1 500 bar gb Fiat Grande Punto OK 180 532 2004 Fiat Auto S p A All rights reserved ...

Page 181: ...or output Analog output 3 Power supply Input 5 V If the sensor is faulty the control unit drives through emergency mapping the quantity control valve DRV2 so as to raise the bottom pressure by 100 bar from 250 bar to 350 bar gb Fiat Grande Punto OK 181 532 2004 Fiat Auto S p A All rights reserved N B The engine can be started and operate even if the sensor is faulty ...

Page 182: ...eas one further spring ensures the return when releasing Redundant signal reading makes it possible to continuously monitor the plausibility of measured values so as to ensure full driving safety even in case of failure Operation gb Fiat Grande Punto OK 182 532 2004 Fiat Auto S p A All rights reserved The accelerator pedal position is converted into an electric voltage signal and sent to the injec...

Page 183: ...alog output Technical features of the Bosch sensor Supply voltage 5 V 0 3 V Resistance at the potentiometer cursor terminals 1 KΩ 0 4 KΩ Race 1 resistance 1 2 KΩ 0 4 KΩ Race 2 resistance 1 7 KΩ 0 8 KΩ Technical features of the hella sensor Supply voltage 5 V 0 3 V Resistance at the potentiometer cursor terminals 1 KΩ 0 4 KΩ Race 1 resistance 0 9 KΩ 35 1 4 KΩ 35 gb Fiat Grande Punto OK 183 532 2004...

Page 184: ...noid valve Rated voltage 12 V Operating voltage range 10 16 V Control signal PWM modulated square wave Modulation frequency 500 Hz Electric resistance 15 4 0 7 Ω at 20 C TYPE OF CONTROL PWM V 12V MEASURING MEANS Oscilloscope or analog instrument Examiner with SMA UEGO oxygen sensor gb Fiat Grande Punto OK 184 532 2004 Fiat Auto S p A All rights reserved ...

Page 187: ...engines which helped cutting down fuel consumption by 4 The power and above all the low speed torque of this engine enhance the elasticity features of Fiat Punto ensuring smooth driving and quick pick up without having to shift down with very good consumption levels The introduction of the continuous phase variator and a new concept of variable turbulence combustion chamber have made it possible t...

Page 188: ... fitted onto the engine gear pump for forced lubrication optimized rod piston crank mechanism for reduction of the alternate mass which is the main cause of engine vibration excitation single block coils with ignition elimination of lost sparks and knock control on a cylinder by cylinder basis Magneti Marelli engine control unit of the torque based type resistant to the engine s mechanic and therm...

Page 189: ...ficant amount of the exhaust gas approximately 25 thus reducing to a considerable extent fuel consumption and exhaust emission when the vehicle is being driven with a partial load 8 valve 1 4 litre engine specifications Engine type 1 4 8v Displacement 1 368 cm Bore 72 mm Stroke 84 mm Intake valve diameter N D gb Fiat Grande Punto OK 189 532 2004 Fiat Auto S p A All rights reserved Exhaust valve di...

Page 190: ...000 r p m Compression ratio 11 1 Engine management control unit Marelli 5SF3 Anti pollution regulatory standard Euro 4 Torque curve and power curve 0 5 10 15 20 25 30 35 40 45 50 55 60 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 75 80 85 90 95 100 105 110 115 120 125 130 135 Rating kW Torque Nm Speed r p m gb Fiat Grande Punto OK 190 532 2004 Fiat Auto S p A All rights reserve...

Page 191: ...F injection ignition control unit 4 2 1 Injection system architecture The Marelli IAW 5SF systems falls into the category of the integrated systems for digital electronic ignition with inductive discharge static distribution electronic injection of the phased sequential type 1 3 4 2 gb Fiat Grande Punto OK 191 532 2004 Fiat Auto S p A All rights reserved ...

Page 192: ...an overall view of the system Fuel tank Fuel electric pump Multi purpose valve Safety valve Fuel delivery pipe Injection ignition electronic control unit Battery Ignition switch Inertia switch gb Fiat Grande Punto OK 192 532 2004 Fiat Auto S p A All rights reserved Engine compartment branching off control unit ...

Page 193: ...Coolant temperature sensor Electric injectors Throttle control actuator and throttle position sensor Accelerator pedal potentiometer Fuel feed manifold Air filter Ignition coils Oxygen sensor upstream System failure optical indicator Revs counter Catalyst Oxygen sensor downstream Atmospheric pressure sensor Phase variator drive solenoid valve Control unit ingoing outgoing information diagram Contr...

Page 194: ...rol unit Phase variator drive solenoid valve Body computer with built in Fiat CODE control unit Throttle control actuator and throttle position sensor Electric injectors Fuel vapour solenoid valve Diagnosis connector gb Fiat Grande Punto OK 194 532 2004 Fiat Auto S p A All rights reserved Spark plugs ...

Page 195: ...ensor Sucked air temperature and pressure sensor Accelerator pedal sensor Knock sensor T D C and revs sensor Ignition switch Oxygen sensor pre catalyst Fuel electric pump Radiator electric fan high low speed control remote control switches Speedometer odometer Oxygen sensor post catalyst Injection phase sensor Fuel level sensor Atmospheric pressure sensor gb Fiat Grande Punto OK 195 532 2004 Fiat ...

Page 196: ...o maintenance requirements The function of the electronic control unit is to process the signals from the various sensors by applying software algorithms and also drive the actuators in particular the electric injectors ignition coils and the power driven throttle in order to achieve optimum engine operation The introduction of the Fiat CODE protection system does not make it possible to exchange ...

Page 197: ...4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Control unit pin out Connector vehicle side Connector engine side gb Fiat Grande Punto OK 197 532 2004 Fiat Auto S p A All rights reserved ...

Page 198: ...ressure sensor AC 0 01 mA 5 V 6 Not connected 7 Not connected 8 I Engine oil level switch not used 10 mA 12 V 9 Not connected 10 Not connected 11 Not connected 12 Not connected 13 Not connected 14 Not connected 15 S sig_GND ECU Linear pressure sensor AC and accelerator pedal potentiometer 2 ground 16 I Remote control switch key 5 mA 16 V 17 O Engine management system remote control switch 400 mA 1...

Page 199: ...or pedal potentiometer 2 signal 0 01 mA 5 V 39 I Oil temperature sensor 5 mA 5 V 40 O Starting motor remote control switch 500 mA 13 5 V 41 Not connected 42 Not connected 43 Not connected 44 Not connected 45 S Sig_GND ECU Accelerator pedal potentiometer 1 ground 46 Not connected 47 S Main relay Engine management system remote control switch 6 4 A 13 5V 48 S Main relay Engine management system remo...

Page 200: ...ction Max content 63 O Engine cooling electric fan 1 remote control switch 200 mA 13 5 V 64 O Malfunction warning light 200 mA 13 5 V Connector B engine side Tyco 2 284272 9 Pin I O S Supply source Function Max content 1 O Coil 4 control 9 A 16 V 2 O VVT solenoid valve 3 O Coil 3 control 9 A 16 V 4 S Power supply from the main relay for VVT solenoid valve 5 S Pow_GND Engine ground A 6 S Pow_GND En...

Page 201: ...source Function Max content 28 Not connected 29 Not connected 30 I Sensor 2 throttled body position 0 01 mA 16 V 31 I Intake pipe pressure 0 1 mA 5 V 32 O Oxygen sensor upstream the catalyst 1 4 A 16 V 33 O Cylinder 4 injector 1 2 A 16 V 34 O Cylinder 2 injector 1 2 A 16 V 35 S sig_GND ECU Throttled body sensor ground 36 S sig_GND ECU Engine water temperature sensor ground 37 Not connected 38 Not ...

Page 202: ...nnected 55 Not connected 56 Not connected 57 O Throttled body actuator positive 6 A 16 V Pin I O S Supply source Function Max content 58 S sig_GND ECU Ground for oxygen sensor downstream the catalyst 0 01 mA 5 V 59 Not connected 60 S sig_GND ECU Ground for oxygen sensor upstream the catalyst 0 01 mA 5 V 61 I Atmospheric pressure sensor 62 Not connected 63 I Sucked air temperature 2 5 mA 5 V 64 O O...

Page 203: ...as the fluoridated rubber O rings 1 and 2 ensure the sealing on the intake manifold and the fuel manifold Fuel is fed from the upper part 3 of the electric injector the body of which includes the winding 4 connected to the terminals 5 of electric connector 6 The fuel jet comes at the absolute pressure of 3 5 bar out of the injector and is immediately atomized Operation The injector control logic i...

Page 204: ...After Sales Training Electric features Engine management system remote control switch 4 3 2 5 6 7 8 gb Fiat Grande Punto OK 204 532 2004 Fiat Auto S p A All rights reserved 1 2 3 4 Electric injectors 5 6 Junction 7 ECM 8 FDU Engine management remote control switch ...

Page 205: ... FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Position of injectors on the vehicle 1 2 3 4 Injector housing on the intake pipe gb Fiat Grande Punto OK 205 532 2004 Fiat Auto S p A All rights reserved ...

Page 206: ...nent connector pin I O S Function Receiving item pin Receiving item pin Receiving item pin 1 S Power supply from the battery 3 junction 1 junction D1 FDU Electric injector 2 2 I Electric injector 2 control 2 junction 34 ECM connector B gb Fiat Grande Punto OK 206 532 2004 Fiat Auto S p A All rights reserved Component Component connector pin I O S Function Receiving item pin Receiving item pin Rece...

Page 207: ...o OK 207 532 2004 Fiat Auto S p A All rights reserved Component Component connector pin I O S Function Receiving item pin Receiving item pin Receiving item pin 1 S Power supply from the battery 3 junction 1 junction D1 FDU Electric injector 4 2 I Electric injector 4 control 5 junction 33 ECM connector B ...

Page 208: ...all gap carries both windings Operation The windings are covered by a stamped plastic container and insulated by being immersed into a epoxy resin and quartz compound that gives them outstanding dielectric mechanic and thermal properties since they are able to withstand very high temperatures too The vicinity of the primary to the magnetic core makes it possible to reduce the magnetic flux loss th...

Page 209: ...assembled first tighten the two screws located outside and then tighten the central screws to the specified torque value Otherwise the module might be broken Position of components 2 1 1 gb Fiat Grande Punto OK 209 532 2004 Fiat Auto S p A All rights reserved 1 1 2 Tightening order for the ignition module fastening screws ...

Page 210: ...t Auto S p A After Sales Training 1 4 3 1 2 3 4 Spark plug outlets Electric features Primary circuit resistance 0 5 Ω 10 at 23 3 C Secondary circuit resistance 6 0 kΩ 10 at 23 3 C gb Fiat Grande Punto OK 210 532 2004 Fiat Auto S p A All rights reserved ...

Page 211: ...to S p A After Sales Training Cylinder 3 Cylinder 4 Cylinder 2 Cylinder 1 5 1 2 3 4 1 ECM 2 FDU engine management remote control switch 3 Ignition module 4 Junction 5 Engine ground B gb Fiat Grande Punto OK 211 532 2004 Fiat Auto S p A All rights reserved ...

Page 212: ...ly from the main relay 1 JUNCTION The wires reaches FDU until pin D1 2 I Cylinder 1 ignition control 17 ECM connector B 3 I Cylinder 2 ignition control 19 ECM connector B 4 I Cylinder 3 ignition control 3 ECM connector B 5 I Cylinder 4 ignition control 1 ECM connector B Coils 6 S Engine ground Engine ground B gb Fiat Grande Punto OK 212 532 2004 Fiat Auto S p A All rights reserved ...

Page 213: ... 3 3 Petrol vapour recovery solenoid valve canister Electric features Engine management system remote control switch 1 ECM 2 FDU engine management remote control switch 3 Junction 4 Canister solenoid valve 1 2 3 4 gb Fiat Grande Punto OK 213 532 2004 Fiat Auto S p A All rights reserved ...

Page 214: ... VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Position of components on the vehicle gb Fiat Grande Punto OK 214 532 2004 Fiat Auto S p A All rights reserved Canister ...

Page 215: ... Component connector pin I O S Function Receiving item pin Remarks 1 S Power supply from the battery 7 junction The wire reaches FDU until pin D3 Petrol vapour recovery solenoid valve 2 I Canister valve control 51 ECM connector B gb Fiat Grande Punto OK 215 532 2004 Fiat Auto S p A All rights reserved ...

Page 216: ...cluding the idling speed control The throttled body is equipped with two integrated potentiometers so that the injection control unit knows when either of them is broken In the event that both potentiometers are broken or if the power supply is missing the control unit will depending on the accelerator pedal position perform a recovery strategy with resulting degraded operation which will be perce...

Page 217: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 217 532 2004 Fiat Auto S p A All rights reserved Throttle Motor Potentiometers ...

Page 218: ... VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features 1 ECM 2 Throttle actuator 2 1 gb Fiat Grande Punto OK 218 532 2004 Fiat Auto S p A All rights reserved ...

Page 219: ...Potentiometer 2 position 30 ECM connector B I Throttle motor negative 52 ECM connector B Throttled body 6 S Ground from the ECU 35 ECM connector B 5 Recovery In case of failure a value is set which is calculated starting from the values read by the absolute pressure sensor if the latter is broken a fixed value equal to 50 throttle opening will be set The dash pot and mixture ratio idling speed sel...

Page 220: ...RAINING OUTLINE Fiat Auto S p A After Sales Training 4 3 5 Hydraulic valve for camshaft phase control Electric features 1 2 1 Camshaft phase control valve 2 ECM gb Fiat Grande Punto OK 220 532 2004 Fiat Auto S p A All rights reserved ...

Page 221: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Position on the vehicle gb Fiat Grande Punto OK 221 532 2004 Fiat Auto S p A All rights reserved Phase control valve ...

Page 222: ...ent that the phase variator has got stuck in a position max advance max delay or an intermediate position due to a mechanic fault to the variator or short circuit to the variator drive solenoid valve the solenoid valve will not be controlled by the ECM any longer gb Fiat Grande Punto OK 222 532 2004 Fiat Auto S p A All rights reserved In the event that the variator is slow the ECM will control the...

Page 223: ...e combustion chamber This feature combined with the new intake and exhaust pipes and optimized valve gear timing ensure bright performance low fuel consumption and emission levels Moreover this system makes it possible to recirculate a considerable amount approximately 25 of the exhaust gas in the combustion chamber gb Fiat Grande Punto OK 223 532 2004 Fiat Auto S p A All rights reserved Figure A ...

Page 224: ...AT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Variable turbulence system Intake tangent to the opening Intake whirl Exhaust gas whirl gb Fiat Grande Punto OK 224 532 2004 Fiat Auto S p A All rights reserved ...

Page 227: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 4 3 8 Inlet manifold Newer inlet manifold gb Fiat Grande Punto OK 227 532 2004 Fiat Auto S p A All rights reserved ...

Page 228: ...e opening and the exhaust valve closing a portion of the intake stroke the greater the phase variator stepping the greater such portion will take place with the intake valve closed and the exhaust valve still open whereby a portion of the burnt gas will be sucked by the exhaust EGR Such gas will take the place of a portion of the cylinder volume less displacement In order to let the same amount of...

Page 229: ...ift Valve lift mm Description The CVCP is fully managed by the engine management control unit ECM which Identifies the camshaft position through the phase sensor modifies this position based on the engine operation point according to a calibrated map keeps the camshaft position under control gb Fiat Grande Punto OK 229 532 2004 Fiat Auto S p A All rights reserved ...

Page 230: ...Auto S p A After Sales Training The CVCP is made up of a rotor integral to the camshaft that can rotate with respect to the pulley stator set moving by the drive shaft gb Fiat Grande Punto OK 230 532 2004 Fiat Auto S p A All rights reserved Stator Rotor ...

Page 231: ...Sales Training a box solenoid valve that allows oil to flow into the openings by making the advance or delay openings to be connected with the oil channels in the engine head Position on the vehicle gb Fiat Grande Punto OK 231 532 2004 Fiat Auto S p A All rights reserved ...

Page 232: ... p A After Sales Training Operation ECU Check OCV control valve Engine revs sensor Phase sensor Oil drain into the head gb Fiat Grande Punto OK 232 532 2004 Fiat Auto S p A All rights reserved Engine oil inlet from the head Camshaft pulley Rotor Stator Spaces ...

Page 233: ...TO TRAINING OUTLINE Fiat Auto S p A After Sales Training The engine oil flows into the tappet cover at point 1 and then into the channel to the right 2 gb Fiat Grande Punto OK 233 532 2004 Fiat Auto S p A All rights reserved 1 2 ...

Page 234: ...t Auto S p A After Sales Training The engine oil reaches the box valve seat through a hole flywheel side in the tappet cover 1 The oil flows into the valve through a filter 2 gb Fiat Grande Punto OK 234 532 2004 Fiat Auto S p A All rights reserved 2 1 ...

Page 235: ...ade to communicate with the drain 3 by the solenoid valve Therefore each of holes 1 and 2 1 2 will always act an in inlet in the direction of the variator and an outlet in the direction of the head respectively depending on whether the phase is to be delayed or advanced by the engine control unit The following figures a b c d illustrate the section that makes the solenoid valve and the phase varia...

Page 237: ...o openings advance and delay openings are obtained at the sides of each of the blades the engine oil may flow into either opening The pressure of the oil flowing into an opening pushes the blade on one side whereas the oil found in the other opening is drained into the engine head through the solenoid valve as we have said above one of the holes on the solenoid valve is made to communicate with th...

Page 238: ...continuously for an equal time period dynamic pressure balance will be achieved at the two rotor sides as a result the rotor will be stationary The advance position corresponds to the rest position in fact the spring that acts as a flexible coupling i e prevents the camshaft play from occurring especially when the vehicle is started due to poor oil pressure is loaded to the advance position gb Fia...

Page 240: ...LVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Blades on the rotor Effects of delay timing variation gb Fiat Grande Punto OK 240 532 2004 Fiat Auto S p A All rights reserved ...

Page 241: ...caused by the knock in the combustion chamber The knocks generate a mechanic rebound on a piezoelectric crystal that sends a signal to the control unit the engine control unit will based on this signal reduce the ignition advance until the phenomenon disappears Next the advance is gradually restored to the base values Position on the vehicle 1 1 phase sensor gb Fiat Grande Punto OK 241 532 2004 Fi...

Page 242: ... quartz characteristic the more pronounced the molecule orientation Such orientation generates a voltage at the crystal ends Therefore such voltage is the result of the vibrations generated by the burst in the various cylinders The reference wave amplitudes are mapped in the engine control unit with correct engine operation The engine control unit interprets the wave amplitudes differing from the ...

Page 243: ...NGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features resistance 532 588 Ω at 20 C 1 1 ECM 2 Knock sensor 2 gb Fiat Grande Punto OK 243 532 2004 Fiat Auto S p A All rights reserved ...

Page 244: ... Receiving item pin 1 O Knock sensor signal 41 ECM connector B Knock sensor 2 S Ground from the ECU 48 ECM connector B Recovery In case of sensor failure the engine management control unit actuates more conservative ignition advance maps in order to protect the engine gb Fiat Grande Punto OK 244 532 2004 Fiat Auto S p A All rights reserved ...

Page 245: ...k the combustion result The control unit analyzes its signal and corrects the stoichiometric ratio so as to always keep combustion within the limits necessary for emissions The oxygen sensor downstream the catalyst is used to check the actual efficiency of the catalyst the control unit analyzes its signal and informs you of catalyst deterioration through the MIL warning light gb Fiat Grande Punto ...

Page 246: ...TRAINING OUTLINE Fiat Auto S p A After Sales Training Position on the vehicle gb Fiat Grande Punto OK 246 532 2004 Fiat Auto S p A All rights reserved 1 2 1 oxygen sensor upstream the catalyst 2 oxygen sensor downstream the catalyst ...

Page 247: ...lectric features Engine management system remote control switch 1 FDU engine management remote control switch 2 ECM 3 Oxygen sensor upstream the catalyst 4 Oxygen sensor downstream the catalyst 5 Junction 2 1 4 3 5 gb Fiat Grande Punto OK 247 532 2004 Fiat Auto S p A All rights reserved ...

Page 248: ...n I O S Function Receiving item pin Remarks 1 O Oxygen sensor signal 42 ECM connector B 2 S Ground from the ECU 58 ECM connector B 3 I Oxygen sensor heating control 64 ECM connector B Oxygen sensor downstream the catalyst 4 S Power supply from the battery 7 Junction The wire reaches FDU until pin D3 4 4 3 Engine revs number sensor Description It is fitted to the engine base and overlooks the phoni...

Page 249: ...g 1 which incorporates a permanent magnet 3 and an electric winding 2 The magnetic flux created by the magnet 3 undergoes due to the passage of the phonic wheel teeth oscillations resulting from the gap variation These oscillations induce an electromotive force in the winding 2 an alternately positive tooth facing the sensor and negative slot facing the sensor voltage is found at the winding ends ...

Page 250: ...wo of these teeth are removed so as to make a reference the wheelbase will therefore correspond to an angle of 6 360 divided by 60 teeth The synchronism point is recognized at the end of the first tooth following the space of two missing teeth when the latter passes below sensor the engine s piston pair 1 4 will be found at 114 before the T D C resistance 1134 1386 Ω at 20 C gb Fiat Grande Punto O...

Page 251: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 251 532 2004 Fiat Auto S p A All rights reserved 2 1 Engine pulley 1 Revs sensor ...

Page 252: ...r pin I O S Function Receiving item pin 1 O Engine revs signal A 9 ECM connector B Engine revs number sensor 2 O Engine revs signal B 23 ECM connector B gb Fiat Grande Punto OK 252 532 2004 Fiat Auto S p A All rights reserved The engine revs sensor seat has no adjustments therefore the sensor assembling poses no problem ...

Page 253: ...sor Description The sensor is of the Hall effect type A semiconductor layer through which current flows immersed into a standard magnetic field generates a potential difference known as Hall voltage at its ends 1 Phase sensor gb Fiat Grande Punto OK 253 532 2004 Fiat Auto S p A All rights reserved 1 ...

Page 254: ...ction Conversely when these projections are not found the sensor will generate a higher voltage signal It follows that the high signal alternates with the low signal four times every single engine cycle This signal together with the T D C and revs signal allows the control unit to recognize the cylinders and determine the injection and ignition point Electric features gb Fiat Grande Punto OK 254 5...

Page 255: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 1 2 gb Fiat Grande Punto OK 255 532 2004 Fiat Auto S p A All rights reserved 1 ECM 2 Phase sensor ...

Page 256: ...ut Component Component connector pin I O S Function Receiving item pin 1 S Ground from the ECU 7 ECM connector B 2 O Phase sensor signal 24 ECM connector B Phase sensor 3 S Power supply from the ECU 13 ECM connector B gb Fiat Grande Punto OK 256 532 2004 Fiat Auto S p A All rights reserved ...

Page 257: ...iption It is fitted to the thermostatic unit and measures the water temperature by means of a NTC sensor with negative resistance coefficient Construction The figure below illustrates the sensor construction 1 NTC resistor gb Fiat Grande Punto OK 257 532 2004 Fiat Auto S p A All rights reserved 2 Sensor body 3 Electric connector ...

Page 258: ...uch voltage is distributed between a resistor available in the control unit and the sensor s NTC resistor It follows that the control unit is capable of evaluating the sensor resistance variations through the voltage variations and thus obtaining the temperature piece of information C Ω 20 15971 10 9620 10 3816 20 2502 25 2044 30 1679 40 1152 50 807 60 576 70 418 80 90 231 100 176 gb Fiat Grande P...

Page 259: ...1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features 2 gb Fiat Grande Punto OK 259 532 2004 Fiat Auto S p A All rights reserved 1 1 ECM 2 Engine water temperature sensor ...

Page 260: ...CM connector B It sets the latest measured temperature value in the event that it does not correspond with the running speed one the ECU will increase it gradually depending on the time since the engine start until a temperature of 80 C is reached Recovery Coolant temperature sensor In case of failure the ECU cuts out the idling mixture ratio self adaptation The radiator cooling fan is actuated gb...

Page 261: ...ture of the air inside the inlet manifold Both of the above pieces of information are used by the injection control unit to define the amount of air sucked by the engine the latter piece of information is subsequently used to calculate the injection time and the ignition point The sensor is fitted to the inlet manifold Position on the vehicle Sucked air pressure and temperature sensor gb Fiat Gran...

Page 262: ...mbrane the vacuum found in the inlet manifold acts on the opposite face The signal of a piezoresistive nature resulting from the distortion suffered by the membrane is amplified by an electronic circuit contained in the support that houses the ceramic membrane and is then conveyed to the engine management control unit The diaphragm bends with the engine off depending on the atmospheric pressure va...

Page 263: ...NE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features The figure below illustrates the sensor s electric features gb Fiat Grande Punto OK 263 532 2004 Fiat Auto S p A All rights reserved ...

Page 264: ...VE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 1 2 gb Fiat Grande Punto OK 264 532 2004 Fiat Auto S p A All rights reserved 1 ECM 2 Sucked air pressure and temperature sensor ...

Page 265: ...wer supply from the ECU 13 ECM connector B Sucked air pressure temperature sensor 4 O Pressure sensor signal 31 ECM connector B Recovery If the error is found upon vehicle starting a value of 50 C is assumed the mixture ratio self adaptivity is cut out If the error is found in the other conditions the latest valid value is stored which is updated depending on the coolant temperature gb Fiat Grande...

Page 266: ...er Operation The sensor is made up of a frame secured to the accelerator pedal support which incorporates a shaft placed in an axial position and connected to the dual race potentiometer A helical spring fitted onto the shaft ensures proper compressive strength whereas one further spring ensures the return when releasing Operating range 0 to 70 mechanic stop at 88 gb Fiat Grande Punto OK 266 532 2...

Page 267: ...E FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features 3 1 ECM 2 Junction 3 Dual accelerator pedal potentiometer 1 2 gb Fiat Grande Punto OK 267 532 2004 Fiat Auto S p A All rights reserved ...

Page 268: ...tiometer 1 ground from the ECU 14 Junction 45 ECM connector A 5 S Potentiometer 2 ground from the ECU 15 Junction 15 ECM connector A Accelerator potentiometer 6 O Potentiometer 2 signal 9 Junction 38 ECM connector A Recovery The injection control unit implements the following recovery strategies under the conditions below in case of failure to either potentiometer it allows the throttle to open up...

Page 269: ...y the quadrinary pressure switch The sensor continuously analyzes the air conditioning system circuit pressure and provides the engine control unit with real time data of pressure variations thus making the actuation threshold management more flexible Position on the vehicle 1 A C linear pressure sensor placed on the high pressure duct gb Fiat Grande Punto OK 269 532 2004 Fiat Auto S p A All right...

Page 270: ... by the engine control unit to actuate the electric fan speeds and turn the compressor off if the pressure goes above or below the permitted limits safety function The linear sensor operating range goes from 3 018 bar to 29 508 bar according to the following characteristic curve for pressure bar output voltage percentage Vcc gb Fiat Grande Punto OK 270 532 2004 Fiat Auto S p A All rights reserved ...

Page 271: ...ure variation take place within this pressure range Below and above these values the compressor will be turned off as a safety condition to avoid damaging the system itself The supply voltage may undergo a variation of 10 whereas the sensor s utilization temperature is included between 5 C and 80 C gb Fiat Grande Punto OK 271 532 2004 Fiat Auto S p A All rights reserved ...

Page 272: ... 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features gb Fiat Grande Punto OK 272 532 2004 Fiat Auto S p A All rights reserved 1 Ground 2 Supply voltage 3 Output signal ...

Page 273: ... VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 1 2 3 1 FDU 2 ECM 3 A C linear pressure sensor gb Fiat Grande Punto OK 273 532 2004 Fiat Auto S p A All rights reserved ...

Page 274: ...t Component Component connector pin I O S Function Receiving item pin 1 S Ground from the ECU 15 ECM connector A 2 S Power supply from the ECU 3 ECM connector A A C linear sensor 3 O A C sensor signal 5 ECM connector A gb Fiat Grande Punto OK 274 532 2004 Fiat Auto S p A All rights reserved ...

Page 275: ...VE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Atmospheric pressure sensor gb Fiat Grande Punto OK 275 532 2004 Fiat Auto S p A All rights reserved Atmospheric pressure sensor ...

Page 276: ...E 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Electric features 1 2 1 ECM 2 Atmospheric pressure sensor gb Fiat Grande Punto OK 276 532 2004 Fiat Auto S p A All rights reserved ...

Page 277: ...1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Position on the vehicle gb Fiat Grande Punto OK 277 532 2004 Fiat Auto S p A All rights reserved Atmospheric pressure sensor position ...

Page 278: ...onnector B 2 S Ground from the ECU 7 ECM connector B Atmospheric pressure sensor 3 O Atmospheric pressure sensor signal 61 ECM connector B Recovery In case of sensor failure the value found in the inlet manifold upon key ON or in fully loaded conditions throttle fully open will be considered as the atmospheric pressure value gb Fiat Grande Punto OK 278 532 2004 Fiat Auto S p A All rights reserved ...

Page 279: ...ions their purpose is to adapt the system operation to the progressive engine and component alterations compared with as new features This self adapting feature also makes it possible to compensate for the unavoidable differences due to production tolerances of replaced components if any The control unit modifies through the exhaust gas analysis the basic mapping with respect to the as new feature...

Page 280: ...ns ON until the engine has been started the control unit self diagnosis system checks the signals from the sensors and compares them with the permitted limit data Fault signalling upon engine starting the warning light s failure to go out after the engine has been started indicates the presence of an error stored in the control unit Fault signalling during operation the blinking warning light come...

Page 281: ...stion check In EOBD systems two oxygen sensors which are of the same type but cannot be exchanged with one another are available one before the catalyst system pre catalyst and one after the same post catalyst The pre catalyst sensor determines the loop 1 mixture ratio control pre catalyst sensor closed loop The post catalyst sensor is used to diagnose the catalyst and finely modulate the loop 1 c...

Page 282: ...E FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training This control is referred to as loop 2 control post catalyst sensor closed loop gb Fiat Grande Punto OK 282 532 2004 Fiat Auto S p A All rights reserved ...

Page 283: ...y condensation on the inlet manifold inner walls All of this is enhanced by the greater viscosity of the lubricating oil which as everyone knows increases at low temperatures the rolling resistance of the engine s mechanic members The electronic control unit recognizes this condition based on the cooling fluid temperature signal and increases the injection base time gb Fiat Grande Punto OK 283 532...

Page 284: ...ndition is detected by the control unit by means of the values provided by the throttle position and absolute pressure sensors Under fully loaded conditions the injection base time has to be increased in order to obtain the maximum power delivered by the engine gb Fiat Grande Punto OK 284 532 2004 Fiat Auto S p A All rights reserved ...

Page 285: ...rection will depend on the altitude variation and will be automatically updated by the electronic control unit every time the engine is switched off and also under certain throttle position and revs number conditions typically with low engine speed and throttle opened to a large extent dynamic atmospheric correction adjustment Cut off operation The cut off fuel cut off strategy is implemented when...

Page 286: ...ining In case of very high engine speeds the cut off strategy is implemented also when the throttle valve is not fully closed but when the pressure in the inlet manifold is significantly low partial cut off gb Fiat Grande Punto OK 286 532 2004 Fiat Auto S p A All rights reserved ...

Page 287: ...ction time is multiplied by a coefficient depending on the engine coolant temperature the accelerator throttle opening rate and the pressure increase in the inlet manifold If the sudden change of the injection time is calculated when the injector is already closed the control unit will open the injector extra pulse again to be able to compensate for the ratio as quick as possible conversely the fo...

Page 288: ...t by the manufacturer the engine itself will be operating in critical conditions When the electronic control unit recognizes that the aforesaid speed has been exceeded it will disable electric injector driving When the revs number falls again into a non critical value 6 500 r p m the driving will be restored gb Fiat Grande Punto OK 288 532 2004 Fiat Auto S p A All rights reserved ...

Page 289: ...nit by means of a remote control switch The pump is stopped if the engine speed falls below approximately 40 r p m after some time approximately 6 seconds when the ignition switch has been set to the MAR position and the starting operation is not carried out timed enable if the inertia switch has come into action gb Fiat Grande Punto OK 289 532 2004 Fiat Auto S p A All rights reserved ...

Page 290: ...e intake phases of every single cylinder However the electric injectors will during the starting phase be first driven in parallel full group The electric injector control timing varies depending engine speed and the sucked air pressure in order to improve cylinder filling with advantages in terms of consumption driveability and pollution prevention gb Fiat Grande Punto OK 290 532 2004 Fiat Auto S...

Page 291: ... the phenomenon occurs again In particular the advance increases are implemented in a gradual way whereas the decreases are implemented immediately During acceleration the strategy will make use of a higher threshold to allow for increased engine noise under this condition Moreover this strategy features a self adapting function that memorizes in a non permanent fashion the advance reductions that...

Page 292: ...f when the temperature exceeds 95 C 1st speed or 105 C 2nd speed The switch off takes place with hysteresis 3 C lower than the actuation threshold approximate values varying according to the various models and based on experimental tests The high and low speed functions are managed by the actuation of special remote control switches placed in the air conditioning system management control unit and...

Page 293: ...nd the brake clutch pedal signals the power driven throttle position The idling speed envisaged for hot operation is 750 50 r p m 4 5 16 Optimization of thermal operating conditions The revs number is corrected above all depending on the engine coolant temperature This strategy controls the vapour cut off solenoid valve position as follows during the starting phase the solenoid valve remains close...

Page 294: ...nhibited by keeping the same closing position under the operating conditions listed below throttle valve in the closing position engine speed of less than 1500 r p m intake manifold pressure lower than a limit value calculated by the control unit depending on the revs number gb Fiat Grande Punto OK 294 532 2004 Fiat Auto S p A All rights reserved ...

Page 295: ...re switch condition and implements the respective actions radiator electric fan control If the engine runs at idling speed the control unit will increase the throttle opening and therefore the air flow rate in advance compared with the compressor actuation and conversely will resume the normal throttle position behind time compared with the compressor switch off The control unit will automatically...

Page 296: ... p A After Sales Training The control unit temporarily controls the compressor switch off for a few seconds when very high engine power is requested heavy acceleration upon engine pick up gb Fiat Grande Punto OK 296 532 2004 Fiat Auto S p A All rights reserved ...

Page 297: ...on of the advance which corresponds to the rest position or the delay openings the variator will move in the direction of the delay or into the advance and delay openings alternately and continuously the variator remains in the controlled position The control unit drives the variator driving solenoid valve through a duty cycle command 4 6 Procedures 4 6 1 Camshaft assembling position self learning...

Page 298: ...hall exceed i 20 C During the starting phase the accelerator pedal needs be fully released i e the engine rotation speed should be in the range of 650 to 1 300 r p m After 30 seconds have elapsed from starting switch the key contact to the OFF position then wait for data item recording in the permanent memory Which tools should be used Operations required to carry out the procedure The self learni...

Page 299: ...is required Possible problem Solution DTC P 0016 76 Engine timing does not fall within the permitted tolerances DTC P 0016 76 The enable conditions are not met upon execution of the procedure Repeat the procedure Engine timing falls within the permitted tolerances None No DTC The enable conditions are not met upon execution of the procedure In the event that a vehicle is allowed to travel in the t...

Page 300: ...chment reattachment camshaft drive Act on the moving idler 1a with a wrench in the counterclockwise direction then remove the single engine member drive belt 1b Unscrew screws 2a then remove the drive shaft pulley 2b gb Fiat Grande Punto OK 300 532 2004 Fiat Auto S p A All rights reserved Moving idler ...

Page 301: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 301 532 2004 Fiat Auto S p A All rights reserved Drive shaft pulley 2b Moving idler 1a ...

Page 302: ...NGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Press the clips then remove the coil air inlet sleeve gb Fiat Grande Punto OK 302 532 2004 Fiat Auto S p A All rights reserved Air inlet sleeve ...

Page 303: ...to S p A After Sales Training Unscrew the air filter fastening screws Lift the air filter Loosen the strap then disconnect the engine oil vapour pipe from the air filter and remove it gb Fiat Grande Punto OK 303 532 2004 Fiat Auto S p A All rights reserved ...

Page 304: ...8 VALVE 1 4 ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 304 532 2004 Fiat Auto S p A All rights reserved Air filter fastening screws Air filter ...

Page 305: ...T PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 1 Unscrew the timing belt protection upper cover fastening screws gb Fiat Grande Punto OK 305 532 2004 Fiat Auto S p A All rights reserved Engine oil vapour pipe ...

Page 306: ...ctric connections from the injection control unit Disconnect the ground cable Disconnect the electric connection of the oxygen sensor upstream the catalyst Disconnect the front engine junction gb Fiat Grande Punto OK 306 532 2004 Fiat Auto S p A All rights reserved Timing belt upper and lower protection ...

Page 307: ... ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 307 532 2004 Fiat Auto S p A All rights reserved Oxygen sensor upstream the catalyst with its respective connection ...

Page 308: ...ase variator control electromagnet electric connection Disconnect the electric connection from the ignition coil module Unscrew screws 3a then remove the ignition coil module 3b Remove the electric connection from the phase sensor gb Fiat Grande Punto OK 308 532 2004 Fiat Auto S p A All rights reserved ...

Page 309: ...T PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Phase variator control electromagnet with its respective connection Ignition coil module gb Fiat Grande Punto OK 309 532 2004 Fiat Auto S p A All rights reserved ...

Page 310: ...UTLINE Fiat Auto S p A After Sales Training Unscrew the screw then remove the phase sensor Unscrew the screws then remove the injection control unit support gb Fiat Grande Punto OK 310 532 2004 Fiat Auto S p A All rights reserved Phase sensor ...

Page 311: ... TRAINING OUTLINE Fiat Auto S p A After Sales Training 1 Unscrew screws 1a then remove tappet cover 1b and timing belt upper cover 1c gb Fiat Grande Punto OK 311 532 2004 Fiat Auto S p A All rights reserved Timing belt upper cover ...

Page 312: ...Sales Training Unscrew the screws then remove the timing belt lower cover Disconnect the revs sensor electric connection Disconnect the minimum oil pressure switch connection gb Fiat Grande Punto OK 312 532 2004 Fiat Auto S p A All rights reserved Timing belt lower cover ...

Page 313: ...Training Disconnect the intermediate junction of the degassing pipe Position an arm lifting device below the engine oil sump Unscrew fasteners 2a then remove the power unit cover on the valve gear side 2b gb Fiat Grande Punto OK 313 532 2004 Fiat Auto S p A All rights reserved ...

Page 314: ...IAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Act on belt stretcher 1a to remove timing belt 1b gb Fiat Grande Punto OK 314 532 2004 Fiat Auto S p A All rights reserved Power unit support valve gear side ...

Page 315: ...IAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Fit template 2000004400 onto the distributing shaft rear shank gb Fiat Grande Punto OK 315 532 2004 Fiat Auto S p A All rights reserved Moving belt stretcher ...

Page 317: ...INE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Fit the template securing the pulley to the camshaft Fit in the timing belt gb Fiat Grande Punto OK 317 532 2004 Fiat Auto S p A All rights reserved ...

Page 318: ... ENGINE FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Fit drive shaft timing template 2000004500 onto the driving pulley gb Fiat Grande Punto OK 318 532 2004 Fiat Auto S p A All rights reserved ...

Page 319: ...TO TRAINING OUTLINE Fiat Auto S p A After Sales Training Proceed as shown in the figure to bring the automatic stretcher reference fork to the abutting end gb Fiat Grande Punto OK 319 532 2004 Fiat Auto S p A All rights reserved ...

Page 320: ...ettle the engine timing belt Loosen the belt stretcher fastening nut then act on the front fork until the latter coincides with the rear fork Tighten the belt stretcher fastening nut to the specified torque 2 5 3 0 daNm Fit the templates previously removed in order to check engine timing gb Fiat Grande Punto OK 320 532 2004 Fiat Auto S p A All rights reserved ...

Page 321: ...NG OUTLINE Fiat Auto S p A After Sales Training Position tappet cover 1a onto the head then draw fastening screws 1b closer Fit tappet cover centring tool 2000004300 gb Fiat Grande Punto OK 321 532 2004 Fiat Auto S p A All rights reserved ...

Page 322: ...g Tighten the tappet cover screws previously drawn nearer to the specified torque 0 8 1 0 daNm Remove the tappet cover centring tool previously fitted Fit the phase sensor Fit the injection control unit support gb Fiat Grande Punto OK 322 532 2004 Fiat Auto S p A All rights reserved ...

Page 323: ...n secure it by means of its respective screws Fit the drive shaft pulley then tighten the screws to the specified torque 2 2 2 7 daNm Act on the belt stretcher to fit the auxiliary member belt Fit the timing belt upper cover Fit the ignition coil module then tighten the respective screws to the specified torque 0 8 1 0 daNM Connect the ignition coil module electric connection Connect the phase sen...

Page 324: ...uto S p A After Sales Training List of tools gb Fiat Grande Punto OK 324 532 2004 Fiat Auto S p A All rights reserved Type Item code Function Template 2000004500 Drive shaft timing Template 2000004400 Camshaft timing Tool 2000004300 Tappet cover centring ...

Page 325: ...nsions The gearbox configuration is of the transverse type with 3 shafts and a differential HCR High Contact Ratio toothing is provided for all the gears Precision finishing after the thermal treatment is provided for all the gears and the final reduction in order to ensure total toothing accuracy and therefore noiseless operation Both the wheelcase and the clutch housing have been optimized for l...

Page 326: ...ths through holes on the cases and shafts This ensures better torque transmission performance and higher efficiency in terms of wear and manoeuvrability even at low temperatures thanks to the use of multigrade oil 5 2 Component 5 2 1 Synchromesh The M32 6 gearbox features the upgraded synchromesh unit previously fitted to the F40 manual gearbox The synchronization springs and pins used so far have...

Page 327: ...o S p A After Sales Training 3rd 4th gears The two cone synchromesh is used with the 3rd and 4th gears 1 Intermediate ring 2 Synchromesh ring 3 Engaging sleeve 4 Synchromesh hub gb Fiat Grande Punto OK 327 532 2004 Fiat Auto S p A All rights reserved ...

Page 328: ...ngle cone synchromesh is used with the 5th and 6th gears 1 Synchromesh ring Intermediate ring 2 Engaging sleeve 3 Synchromesh hub Reverse gear The reverse gear features a single cone synchromesh just like the 5th and 6th gears gb Fiat Grande Punto OK 328 532 2004 Fiat Auto S p A All rights reserved ...

Page 329: ...NE Fiat Auto S p A After Sales Training 5 2 2 Drive gb Fiat Grande Punto OK 329 532 2004 Fiat Auto S p A All rights reserved The M20 6 manual gearbox features a tie rod drive Every single gear is selected by means of a central control unit ...

Page 330: ...awing 1 Axle shaft seal 2 Differential case guide bushing 3 Differential case 4 Axle shaft seal ring sealing flange 5 Axle shaft seal ring sealing flange 6 Axle shaft sealing 7 Differential 8 Differential unit 9 Transmission case gb Fiat Grande Punto OK 330 532 2004 Fiat Auto S p A All rights reserved ...

Page 331: ...t assembly 11 Top gear shaft assembly 12 Lower output shaft assembly 13 Clutch vent coupling 14 Fastening bushing 15 Reverse gear headlamp switch 16 Central disengagement 17 Pressure pipe 18 Clutch housing 19 Gearbox control assembly 20 Magnet gb Fiat Grande Punto OK 331 532 2004 Fiat Auto S p A All rights reserved ...

Page 332: ...put shaft roller bearing 4 Safety ring 5 Reverse gear roller bearing 6 Reverse speed gear driven 7 Reverse gear engaging sleeve 8 Reverse gear synchromesh ring 9 Push dowel 10 Synchromesh hub 11 Spacer bushing 12 Safety ring 13 3rd speed gear driven 14 3rd speed gear roller bearing 15 Intermediate ring gb Fiat Grande Punto OK 332 532 2004 Fiat Auto S p A All rights reserved ...

Page 333: ...h dowel 19 Synchromesh hub 20 Safety ring 21 Differential 22 Output shaft roller bearing 23 4th speed gear roller bearing 24 4th speed gear 25 Intermediate ring 26 Synchromesh ring 27 3rd 4th speed engaging fork 28 Gearshift lever pin gb Fiat Grande Punto OK 333 532 2005 Fiat Auto S p A All rights reserved 29 Reverse gear engaging fork ...

Page 334: ...speed engaging sleeve 4 Outer synchromesh ring 5 Outer synchromesh ring 6 Inner synchromesh ring 7 2nd speed gear driven 8 2nd gear roller bearing 9 Closing ring 10 Thrust washer 11 5th speed gear driven 12 2nd speed gear roller bearing 13 Synchromesh ring 14 Push dowel 15 Synchromesh hub gb Fiat Grande Punto OK 334 532 2005 Fiat Auto S p A All rights reserved ...

Page 335: ...ler bearing 22 Differential 23 5th 6th speed engaging fork 24 Gearshift lever pin 25 1st 2nd speed engaging fork 26 Synchromesh hub 27 Outer synchromesh ring 28 Intermediate ring 29 Inner synchromesh ring 30 1st speed gear driven 31 1st speed gear roller bearing 32 Safety ring 33 Output shaft roller bearing 34 Output shaft gb Fiat Grande Punto OK 335 532 2005 Fiat Auto S p A All rights reserved 35...

Page 336: ...ar shaft seal ring 2 Roller bearing 3 Top gear shaft 4 1st speed gear driving 5 2nd speed gear driving 6 Top gear shaft screw 7 Differential 8 Top gear shaft bearing 9 6th speed gear driving 10 4th speed gear driving 11 Spacer bushing 12 3rd 5th speed gear gb Fiat Grande Punto OK 336 532 2005 Fiat Auto S p A All rights reserved ...

Page 337: ...r Sales Training 5 3 Configuration Transverse with 3 shafts supported on ball bearings 6 forward gears reverse gear Transmissible torque 230 Nm Total length from the engine flywheel 332 mm gb Fiat Grande Punto OK 337 532 2005 Fiat Auto S p A All rights reserved ...

Page 338: ...haft 3 Lower output shaft 2 Top gear shaft 4 Differential gb Fiat Grande Punto OK 338 532 2005 Fiat Auto S p A All rights reserved Oblique tapered roller bearings are used with all the shafts in this gearbox unit These bearings require some bearing play as well as a bearing pre load Both the bearing play and preload are obtained during the manufacture by using compensating washers under the obliqu...

Page 339: ...speed gear 2 2nd speed gear 3 5th speed gear 4 6th speed gear 5 3rd 5th speed gear 6 6th speed gear 7 4th speed gear 8 4th speed gear 9 Reverse speed gear 10 3rd speed gear gb Fiat Grande Punto OK 339 532 2005 Fiat Auto S p A All rights reserved This 3 shaft gearbox unit is advantageous in that the 3rd speed gear on the top gear shaft is also used for the 5th speed ...

Page 340: ... GEARBOX FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 5 5 Kinematic route of the single gears gb Fiat Grande Punto OK 340 532 2005 Fiat Auto S p A All rights reserved 1st speed 2nd speed ...

Page 344: ...eel antilock function in case of excessive exhaust braking Hill holder with ESP a device that allows the driver to park and start the vehicle again along steep roads without using the handbrake HBA emergency braking assist device gb Fiat Grande Punto OK 344 532 2005 Fiat Auto S p A All rights reserved The braking system is of the hydraulic power assisted type and is made up of 2 self contained cro...

Page 345: ...BRAKES FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Ventilated front disc Rear drum Rear disc gb Fiat Grande Punto OK 345 532 2005 Fiat Auto S p A All rights reserved ...

Page 346: ...ersion front solid disc diameter 257 x 12 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 43 cm2 rear drum diameter 203 mm 1 4 8V 1 3jtd 70 HP engine version ventilated front disc diameter 257 x 22 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 43 cm2 gb Fiat Grande Punto OK 346 532 2005 Fiat Auto S p A All rights reserved rear dru...

Page 347: ...d surface area 52 cm2 rear drum diameter 228 mm 1 9 jtd 120 HP engine version ventilated front disc diameter 284 x 22 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 52 cm2 Bosch BIR II brake caliper solid disc 264 x 11 mm 6 2 Power brake Nuova Punto features a 10 power brake with 15 16 pump and tank gb Fiat Grande Punto OK 347 532 2005 Fiat Auto S p A All rights r...

Page 348: ...ccelerator pedals The accelerator and clutch pedals are made of plastic The pedal unit features a device that allows the brake pedal to collapse in case of collision thus minimizing its penetration into the passenger compartment and therefore lower limb injury gb Fiat Grande Punto OK 348 532 2005 Fiat Auto S p A All rights reserved In case of disconnection the pedal shall be replaced ...

Page 349: ... Sales Training The pedal unit system is made up of the following components plastic pedal support plastic accelerator pedal with a potentiometer metal brake pedal gb Fiat Grande Punto OK 349 532 2005 Fiat Auto S p A All rights reserved plastic clutch pedal ...

Page 350: ...th the road grip conditions available it ensures full vehicle control under extreme conditions when the wheels are about to get locked it ensures prompt control response it is capable of adjusting itself automatically to a wide range of operating conditions the control unit is lightweight The function of the active sensors is to measure the wheel speed The main peculiarity of active sensors is tha...

Page 351: ...o S p A After Sales Training 6 4 1 ABS wiring diagram gb Fiat Grande Punto OK 351 532 2005 Fiat Auto S p A All rights reserved BSM Brake node BCM Front left ABS sensor Rear left ABS sensor Rear right ABS sensor Front right ABS sensor CVM Ground ...

Page 352: ... 6 Rear left ABS sensor power supply 7 N C 8 Rear right ABS sensor power 9 Front right ABS sensor power supply 10 Front right ABS sensor signal 11 K line 12 N C 13 N C 14 C CAN L1 in 15 C CAN L1 out 16 Front left ABS sensor power supply 17 Rear left ABS sensor signal 18 Body Computer node 19 Rear right ABS sensor signal 20 Brake lights 21 ASR button input 22 ASR button LED 23 VSO output 24 N C 25 ...

Page 353: ...pipes and makes up together with the electronic control unit 2 the electro hydraulic driving unit This unit is fitted in a vertical position and incorporates 4 couplings 3 on its side two front pipe couplings and two rear pipe couplings Moreover two pipes from the master cylinder are found on the upper part 4 2 4 1 ABS hydraulic unit gb Fiat Grande Punto OK 353 532 2005 Fiat Auto S p A All rights ...

Page 354: ...g torque control and applies a proper braking torque distributed to each of the four wheels Direction is controlled by taking advantage from the tyre s longitudinal grip the different braking action between the two vehicle sides generates a rectifying yawing torque that stabilizes the vehicle The ESP function is managed by the ABS control unit which monitors by processing the values of the quantit...

Page 355: ...ne ABS data exchange with the engine control unit automatic transmission control unit power assembly specific brake pump power driven throttled body petrol versions data exchange with the ASR instrument board warning lights of the active type steering angle sensor fitted to the steering column yaw sensor located on the central floor in the central cabinet area to detect the vehicle s side accelera...

Page 356: ...UNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 6 5 1 ESP wiring diagram gb Fiat Grande Punto OK 356 532 2005 Fiat Auto S p A All rights reserved BSM Brake node ASR button on the dashboard BCM YRS Ground ...

Page 357: ...n the sheet facing the direction of running and the connector facing the vehicle rear part 1 Power supply 2 C Can L1 3 C Can L2 4 C Can H1 5 C Can H1 6 Ground This node incorporates the yaw longitudinal acceleration and transverse acceleration sensors into one single component gb Fiat Grande Punto OK 357 532 2005 Fiat Auto S p A All rights reserved ...

Page 358: ...ation by automatically braking the slipping wheel The ASR system is very useful especially if the following conditions occur inner wheel slip when cornering due to dynamic load variations or excessive acceleration excessive power transmitted to the wheels even depending on the road surface conditions vehicle acceleration on slippery snow covered or icy road surfaces loss of grip on wet roads A S R...

Page 359: ...scribed type make and dimensions 6 5 4 M S R This function is an integral part to the ASR and comes into operation in case of a sudden shift down by delivering torque to the engine again Thus excessive driving wheel drag is avoided which may cause the vehicle s loss of grip especially in poor grip conditions 6 5 5 Hill Holder The Hill holder function combined with the ESP system assists the driver...

Page 360: ...er Sales Training gb Fiat Grande Punto OK 360 532 2005 Fiat Auto S p A All rights reserved braking torque required to keep the vehicle stationary until when the driver releases the clutch pedal and the deflecting torque is enough to set the vehicle moving ...

Page 361: ...d driving 2 8 steering wheel turns are required for full stop to stop steering and the kerb to kerb steering diameter is 10 1 m vehicles equipped with long travel rack and 175 tyres or 10 76 m vehicles equipped with short travel rack and any other type of tyre The electric power steering is actuated by an electric motor that is more compact and lightweight compared with the previous systems gb Fia...

Page 362: ... delivered at the input by the driver is detected by a sliding contact potentiometer sensor The electric steering column fitted to the Nuova Punto incorporates the steering angle sensor too this signal is also used by the ESP control unit if available In case of service procedures the steering angle sensor shall be reset by means of a suitable diagnosis instrument gb Fiat Grande Punto OK 362 532 2...

Page 363: ...euvres while ensuring a gradual optimum effort on the steering wheel even at low speeds especially in poor road grip conditions In any case both programs provide varying interlocking depending on the vehicle speed gradual power assistance therefore with no compromise between the performance during the parking manoeuvres and the steering control quality when the vehicle is running A special calibra...

Page 364: ...stem to ensure correct operation of the latter The alternator and vehicle speed values are read on the C CAN line The position and torque signals from the sensors represent the base values by means of which the microprocessor processes the output data in terms of current delivered to the engine The drive interlocking management control unit is secured onto the electric drive body 1 Power supply fr...

Page 365: ... wheel degrees steering wheel turns 2 8 with kerb to kerb steering diameter of 10 1 m Technical features for diesel engines reduction ratio 60 44 mm rev steering wheel angle wheel angle ratio 13 4 steering wheel degrees wheel degrees in the middle and 18 2 steering wheel degrees wheel degrees at the end of travel steering wheel turns 2 8 with kerb to kerb steering diameter of 10 76 m gb Fiat Grand...

Page 366: ...sion and pivoting to allow for vertical adjustment when requested or previously provided for by the body version The steering column is borne by a support which is in turn bound to a bracket both of these items are made of steel These components contribute to a significant extent thanks to their very high rigidity to reduce the steering wheel vibrations All of this makes it possible to achieve imp...

Page 367: ...Torsional axle rear suspension designed in order to increase both structural rigidity and loaded suspension flexibility obtained by optimizing the bushing that connects the rear axle with the body The development of the new suspension has also concerned the plugging configuration in order to improve the dynamic response when cornering Great attention has been devoted during the component design ph...

Page 368: ...he rear on average 8 2 Front suspensions 8 2 1 General remarks The front suspensions feature an independent wheel configuration of the Mc Pherson type In particular the main components of this structural layout are as follows two shell swinging arms made of stamped sheet metal instead of cast iron as with the current Punto with a significant weight reduction gb Fiat Grande Punto OK 368 532 2005 Fi...

Page 369: ...e when cornering offset helical springs for thrust axis optimization in order to reduce the tangential forces on the shock absorber stem and therefore the internal friction with resulting better damping of minor road roughness Hydraulic telescopic dual effect shock absorbers with stem diameter of 22 mm on all the versions for very high side rigidity to improve road holding when cornering Moreover ...

Page 370: ...STD A 1 2 8V 22 20 27 20 1 4 8V LE 22 20 27 20 1 3 MJet 70 CV 22 20 27 20 1 2 8V 22 20 27 20 1 3 MJet 70 CV 22 20 27 20 1 4 8V 175 65 R15 84T 22 20 27 20 1 3 MJet 90 CV 26 20 28 20 1 3 MJet 90 CV 26 20 28 20 1 9 MJet 120 CV 185 65 R15 88T 26 20 28 20 1 9 MJet 120 CV 195 55 R16 87H 19 20 21 20 gb Fiat Grande Punto OK 370 532 2005 Fiat Auto S p A All rights reserved ...

Page 372: ... 88 mm 1mm 1 4 8V 175 65 R15 84T 2 mm 1 mm 1 88 mm 1mm 1 3 MJet 90 CV 2 mm 1 mm 1 88 mm 1mm 1 3 MJet 90 CV 2 mm 1 mm 1 88 mm 1mm 1 9 MJet 185 65 R15 88T 2 mm 1 mm 1 88 mm 1mm 1 9 MJet 195 55 R16 87h 2 mm 1 mm 1 87 mm 1mm 1 3 MJet 70 CV 2 mm 1 mm Only toe in can be adjusted in the traditional way by acting on the steering connecting rod nuts Represented by mm d2 d1 see figure above gb Fiat Grande P...

Page 373: ...ional contour with different thicknesses depending on the versions has made it possible to obtain optimum roll stabilizing rigidity even if an antiroll bar has not been added therefore the antiroll bar shall not fitted to any of the Nuova Punto models The vertical arrangement of the shock absorbers with the body attachment inside the wheelbox has made it possible to dampen the road surface roughne...

Page 374: ...RSIONS TYRES STD O STD A 1 2 8V 1 20 1 20 1 4 8V LE 1 20 1 20 1 3 MJet 70 CV 1 20 1 20 1 2 8V 1 20 1 20 1 3 MJet 70 CV 1 20 1 20 1 4 8V 175 65 R15 84T 1 20 1 20 1 2 JTD 90 CV 1 20 1 20 1 2 JTD 90 CV 1 20 1 20 1 9 JTD 185 65 R15 88T 1 20 1 20 1 9 JTD 195 55 R16 87H 1 20 1 20 gb Fiat Grande Punto OK 374 532 2005 Fiat Auto S p A All rights reserved ...

Page 375: ... mm 2mm 1 3 MJet 90 CV 1 3 mm 2 mm 1 5 mm 2mm 1 9 MJet 185 65 R15 88T 1 3 mm 2 mm 1 5 mm 2mm 1 9 MJet 195 55 R16 87h 1 3 mm 2 mm 1 5 mm 2mm 1 3 MJet 70 CV 1 3 MJet 70 CV 1 5 mm 2mm 1 3 MJet 90 CV N B The wheels of the previous Punto models cannot be fitted to the Nuova Punto since the dimensions e g the centre line between the bolts have changed trying to do so would affect the integrity of the wh...

Page 376: ...of wiring families each circuit connected to a sectioning joint holds the same position inside the joint regardless of the trim level also the position and type of the joint on the vehicle does not depend on the body version level gb Fiat Grande Punto OK 376 532 2005 Fiat Auto S p A All rights reserved To safeguard the modular arrangement of the cable harnesses the inputs outputs of each control u...

Page 378: ...Connector Diagnosis connector RDU Rear Distribution Unit Luggage compartment node Front Distribution Unit Engine compartment node BDU Battery Distribution Unit Battery fuse control unit WLM Window Lift Module Window regulator module SDM FDU 9 1 2 Serial lines and networks The Famiglia 1 architecture especially designed for the Nuova Punto controls the vehicle s electric system As regards the syste...

Page 379: ...d on a FIAT model of this segment The developed architecture is compatible with various user interfacing solutions control arrangement information display modes and assignment The electric protections fuses and the remote control switches are grouped in the power distribution control units positioned in the engine compartment and in the dashboard These control units also act as interconnections fo...

Page 380: ... in the Body Computer node A LIN serial communication line is also available between the Body Computer control unit and the control unit on the rain sensor in this case the Body Computer node performs the gateway function between the LIN serial line and the CAN networks The node diagnosis in the B CAN and C CAN is performed for the first time on a FIAT model through the CAN line by using a protoco...

Page 381: ...1 1 1 1 120 R __________________ _______________ _________ _____ x _____ 60 1 1 1 1 2 1 2 ____ ____ _____ _____ ____ R1 R2 120 120 120 ...

Page 382: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Full optional network architecture gb Fiat Grande Punto OK 381 532 2005 Fiat Auto S p A All rights reserved ...

Page 383: ... CAN Air conditioner node B CAN YES B CAN Convergence node B CAN B C CAN YES B CAN B C CAN Instrument board node B CAN YES B CAN Radio receiver node B CAN NO Parking sensor node B CAN YES B CAN Auxiliary heater node B CAN YES B CAN Engine control node C CAN YES C CAN Robotized gearbox node C CAN YES C CAN Braking node C CAN YES C CAN Electric drive node C CAN YES C CAN Yaw sensor node C CAN NO Som...

Page 384: ...N A16HS high speed interface between the vehicle s diagnosis connector and the Examiner extension cord After making the connection the take off LED will blink then it will blink steadily in a green colour After actuating communication with the control unit on the CAN line the LED will be ON steadily yet it will turn yellow The continuous blinking of the yellow LED indicates that a communication er...

Page 385: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 9 1 5 B CAN low speed line gb Fiat Grande Punto OK 384 532 2005 Fiat Auto S p A All rights reserved ...

Page 386: ...TRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training FULL B CAN NETWORK gb Fiat Grande Punto OK 385 532 2005 Fiat Auto S p A All rights reserved BASE A CAN NETWORK BASE B CAN NETWORK ...

Page 387: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 9 1 6 C CAN high speed line gb Fiat Grande Punto OK 386 532 2005 Fiat Auto S p A All rights reserved BASE C CAN ...

Page 388: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 387 532 2005 Fiat Auto S p A All rights reserved C CAN with MTA without ESP ...

Page 389: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 388 532 2005 Fiat Auto S p A All rights reserved C CAN with ESP without MTA ...

Page 391: ...logies power PCB sheared circuit wired with sheared circuit In particular Body Computer node control unit BCM Body Computer Module realized with Power PCB Engine compartment control unit FDU Front Distribution Unit realized by means of a sheared circuit Fuse control unit on the battery positive pole BDU Battery Distribution Unit realized by means of a sheared circuit gb Fiat Grande Punto OK 390 53...

Page 392: ... YRS ASR deactivation switch F42 20 Bidirectional window washing pump F44 ESL F45 10 IPC diagnosis connector DLC display DAB F51 15 ITM or radio CTM or mobile phone connector F53 10 Front dome light rear dome light glove compartment light sun visor light front door mudguard light boot light F58 10 Airbag module SDM weight sensor F61 7 5 Rain twilight sensor parking assist module CTM or mobile phon...

Page 393: ...HM 34 F27 Oxygen sensor heater heating EGR canister etc secondary loads F28 Ignition coils injectors or ECM 2 nd power supply primary loads 33 F29 Power supply ECM 51 F30 Fuel pump 25 F31 Fog lights 27 F32 Headlamp washing pump 37 F33 Horn 42 F34 A C compressor 49 F35 Starter relay 29 F36 Valves Bi power 29 F36 Fuel filter heater 04 F37 Robotized gearbox pump 54 F38 30 A C control panel ECC 36 F39...

Page 394: ...ont wiring R Front bodywork wiring L Intrument panel wiring P Engine cooling fans Left headlamp Right headlamp Wiring HVAC K ECC G005 G029 G031 G001 Rear washing pipe Washing pump B D A C pressure sensor Power supply with FDU G009 B001 Plastic inserts Rubber G021 gb Fiat Grande Punto OK 393 532 2005 Fiat Auto S p A All rights reserved ...

Page 395: ...32 2005 Fiat Auto S p A All rights reserved ECM I n t e r m e d i a t e w i r i Alternator Starting motor Engine wiring E G012 Wiring Battery M Front wiring body L Engine sensors G002 G006 B D L 5 0 3 0 Wiring Battery B 30 Alternator wiring J A C compressor Reversing switch Selespeed pump Selespeed pump relay Selespeed In line connection B001 ...

Page 396: ...BCM Rear left light Door wiring S Door wiring T Rear right light Door wiring F Door wiring D Front bodywork wiring L Table 3 Bodywork G041 PAM Rear bumper wiring X Parking sensor wiring RDU G036 EPS Pedal switch channel channel SDM Front seat G024 YRS DLC Preset G033 Front seat Cockpit wiring P MTA C514 Reversing light Rear fog light License plate light ...

Page 397: ... Alfa 939 RLS Rain sensor control unit New SRM Sunroof control unit Derived from Ypsilon SDM Airbag node New MTA Robotized gearbox node for petrol version 1 4 Fire New MTA Robotized gearbox node for diesel version 1 3 jtd 90 HP New Derived from Ypsilon ECM Engine control node New Derived for engine versions BSM Braking system node New YRS Yaw sensor New EPS Electric drive node New AHM Auxiliary he...

Page 398: ...el CSM Steering column stalk control module Derived from Ypsilon Switch on the clutch Common component derived from Opel Control dashboard on the driver s side front door New CSS Central control dashboard New ELC Left control dashboard New New Steering wheel controls for the horn and the audio telephone systems New Information communication roof control dashboard on the ceiling light fixture New G...

Page 399: ... left headlamp area which holds fuses and remote control switches and protects the electric loads The FDU node is interconnected to the front bodywork cable harness the front cable harness and the engine service pre wired cable harness Functions The front distribution nodes manages the following functions headlamp washing right and left side rear view mirrors rear heated window cigar lighter horns...

Page 400: ...ing 9 2 2 Luggage compartment node This node is located in the left bottom part of the luggage compartment next to the rear headlamp It also houses some fuses used to protect the systems managed by the node gb Fiat Grande Punto OK 399 532 2005 Fiat Auto S p A All rights reserved ...

Page 401: ...trument board in the bottom left part under the left control dashboard It can be easily located since it houses the instrument board fuses see figure below Body Computer node BCM The Body Computer node is interconnected to the front bodywork cable harness and the dashboard cable harness gb Fiat Grande Punto OK 400 532 2005 Fiat Auto S p A All rights reserved ...

Page 402: ... manage the vehicle s serial lines as well as the functions below passenger compartment interior lighting external lighting sidelights brake lights low high beam headlamps indicator lights reversing lights wiper operation rear heated window door and boot lock unlock fuel level fuel pump key status management and acquisition gateway between the B CAN and C CAN networks and between the LIN and B CAN...

Page 403: ...nected 15 Not connected 16 Low beam headlamp relay control 17 Boot opening switch signal 18 Four indicator switch signal 19 Light switch signal normally closed 20 Rear defrosting switch signal 21 Brake oil level signal 22 Front wiper parking contact signal 23 Reserve input Front wiper contact signal 25 Clutch switch signal 26 After sales anti theft system signal 27 Front brake pad wear sensor sign...

Page 404: ... 45 Fuel level sensor signal 46 Rear window defrosting relay control 47 Antenna RF Signal coaxial cable 48 Quick signal 2 lock 49 A C request signal gb Fiat Grande Punto OK 403 532 2005 Fiat Auto S p A All rights reserved 50 Serial line ASM 51 Front HS CAN H to ACC LHL 52 HS Powertrain Chassis CAN H to the a diagnosis connector 53 HS Powertrain Chassis CAN H on wiring L 54 LS CAN B on wiring L 55 ...

Page 405: ...l brake light 14 License plate light 15 Right brake light 16 Left brake light 17 Rear right dimmer 18 Rear left dimmer 19 Left side indicator light 20 Rear left indicator light 4 Connector PD Pin Description 1 Immobilizer antenna 2 Spare 3 Spare 4 Bus LIN 5 B CAN B 6 C CAN H Rear window regulator relay control 8 Spare 9 Light switch module 10 Four indicator button LED 11 Central locking button LED...

Page 406: ...n actuation control 26 Spare 27 Spare 28 City button control 29 Windscreen wiper control 30 Fog light control 31 Acc signal 32 15 signal 33 Spare 34 Reference ground 35 C CAN L 36 Spare 37 Blinking control 38 Light self actuation control 39 Lock unlock signal 40 Front wiper adjustment control 41 Cruise Control settings 42 Reference ground Spare 44 Rear fog light control signal 45 Cooling fluid lev...

Page 407: ...ndow washing fluid level signal Connector LE Pin Description 1 Central door deadlock control power supply 2 Cigar lighter socket light 3 Bi directional washing pump control 4 Right dome light control 5 Rear dome light control 6 Pam Tpms roof power supply 7 Rain sensor power supply 8 Brake switch normally open 9 Clutch switch 10 Spare Spare 12 Spare 13 Bi directional washing pump control rear 15 Re...

Page 408: ...ly 24 EPS power supply 25 Front ceiling light fixture power supply 26 Rear ceiling light fixture power supply 27 Front mudguard light power supply 28 Luggage compartment light power supply 29 EOBD connector power supply 30 Boot lock power supply 31 Driver s door unlocking control 32 Front wiper low speed power supply Connector LK Pin Description RF antenna signal 2 RF antenna ground gb Fiat Grande...

Page 409: ...e IPC 15 6 EPS 15 7 SDM 15 8 EOBD connector power supply 9 Spare 10 Ground BCM 11 30 esl 12 Display power supply 13 Telephone 30 14 Spare 15 Glove compartment chest light power supply 16 Glove compartment light power supply 17 ELC light power supply 18 Spare 19 Spare 20 Spare 5 gb Fiat Grande Punto OK 408 532 2005 Fiat Auto S p A All rights reserved ...

Page 410: ...round illumination The instrument board node IPC is an electronic component connected to the B CAN network and the dashboard cable harness it acquires some user controls and manages the vehicle menu and the headlamp trim control The connector provides for discrete interfacing with other vehicle systems engine control and is available in two versions with three type of display Version with black gr...

Page 411: ...indicators The electronic architecture of the indicators is realized by means of a microprocessor and stepping motors ensuring accuracy and continuity no tripping or crawling over the entire reading scale under the operating limit conditions It is equipped with a maximum of 30 28 and 23 LED light up warning lights Mode Comfort and Matrix respectively with negative contrast 2 warning light presetti...

Page 412: ...orresponding to the start of the fuel reserve is red and the relevant warning light is made of an amber LED positioned among the indicator s graphic elements The indicator calibration ensures greatest accuracy at the start of the red sector Engine coolant temperature indicator Two seconds after the key ON the indicator displays the engine coolant temperature information The indication correspondin...

Page 413: ...124 C the max engine coolant temperature warning light will come on at the same time the pointer will position itself at the bottom of the scale MODE panel COMFORT panel gb Fiat Grande Punto OK 412 532 2005 Fiat Auto S p A All rights reserved Dimensions 52 x 36 6 mm2 Visible area 44 x 24 6 mm2 Power supply 5 V Dimensions 73 5 x 54 mm2 Visible area 64 5 x 27 mm2 Pixel dimensions 0 7 x 0 94 mm2 Max ...

Page 414: ... Position on the vehicle The IPC is located in the driver s side dashboard Instrument board pin in pin out gb Fiat Grande Punto OK 413 532 2005 Fiat Auto S p A All rights reserved Dimensions 80 x 48 mm2 Visible area 67 x 35 mm2 Pixel dimensions 0 37 x 0 37 mm2 Max interpixel dimensions 0 02 mm ...

Page 415: ...e airbag status signal ON OFF Flash from the SDM Transmitting on the B CAN line through the airbag warning light signal the airbag warning light status ON OFF Fail Diagnosing the airbag warning light and the front passenger s airbag deactivation warning light and storing possible faults permanently until their are remedied into the IPC memory gb Fiat Grande Punto OK 414 532 2005 Fiat Auto S p A Al...

Page 416: ...ist below TRIP A TRIP B Distance covered Fuel distance Distance covered Average consumption Average consumption Average speed Average speed Driving time Driving time Instant consumption Fuel distance The values shown can be represented by means of the decimal system km k p h k p l l 100 km or the British system miles m p h m p g depending on the driver s choice see the set up menu The trip compute...

Page 417: ...n is consistent with the value shown on the odometer The display is updated every 100 metres Average consumption k p l or l 100 km or m p g it indicates the average consumption from the start of the mission The unit of measurement k p l cannot be selected in the Mode panel Instant consumption k p l or l 100 km or m p g it indicates the fuel consumption constantly updated It helps the driver be awa...

Page 418: ... clock with a range of 30 to 250 k p h 20 155 m p h and a step equal to 5 k p h 5 m p h Clock setting the Hour writing appears in place of the odometer Buzzer setting one single setting for the alarms faults warnings button pressing 0 mute to 7 max volume with the Buzz writing in place of the odometer Setting the unit of measurement distance Unit writing in place of the odometer Comfort and Matrix...

Page 419: ...n Portuguese Spanish French Dutch Polish Alarm fault warning buzzer volume setting Button pressing buzzer volume setting roger beep Seat belt reminder re actuation Servicing slip expiry displaying km miles gb Fiat Grande Punto OK 418 532 2005 Fiat Auto S p A All rights reserved Passenger s airbag actuation deactivation ...

Page 420: ...N NO Clock setting hh mm YES 0 00 YES 0 00 Time format 12 24 h YES 24 h NO Date setting dd mm yyyy YES 01 01 aaaa yyyy year of release SW NO Audio information repeat ON OFF YES ON NO Door boot locking with speed 20 k p h ON OFF YES OFF NO Distance unit of measurement km miles YES km if the speedometer scale is represented by the kilometre mi if the speedometer scale is represented by the mile YES ...

Page 421: ...alian English German Portuguese Spanish French Dutch Polish YES Italian NO Buzzer volume 0 7 YES 4 Button volume 0 7 YES 4 YES unified 4 SBR re actuation YES NO Service km or miles YES km if the speedometer scale is represented by the kilometre mi if the speedometer scale is represented by the mile NO Passenger s airbag actuation deactivation YES Depending on the signals from the SDM Confirmation ...

Page 422: ...s carried out not later than 30 000 km or 18 000 miles from the preceding one Automatic displaying The first expiry message will be automatically displayed only once upon key ON if the kilometres or miles left before the vehicle is to be serviced are equal to or less than 2 000 km 1 240 miles Next the message will be displayed only once upon key ON with the following threshold values 1 800 1 600 1...

Page 423: ...ng slip operation shall be stored in the memory therefore the latest slip carried out shall be traceable through such indications as the date of servicing number of the slip and the total distance covered kilometres These stored data are kept even if the battery is disconnected from the vehicle Vehicle panel replacement In case of vehicle panel replacement the following operations shall be carried...

Page 424: ...F light beam raising and CAF light beam lowering buttons an electric motor connected inside the headlamp causes the reflectors to be rotated automatically The current headlamp position is signalled on the vehicle panel by the headlamp inclination icon and the corresponding number 0 to 3 The C A F buttons are active only when the key is ON and the low beam headlamps have been switched on Upon key O...

Page 425: ...as been completed and or when the vehicle speed falls below 5 k p h or the equivalent m p h value with respect to the set limit value Follow me home function This function makes it possible to obtained timed illumination outside the vehicle e g low beam headlamps even after the vehicle has been stopped for safety reasons safe homecoming etc The vehicle panel display will show the F XXX or Follow m...

Page 426: ...all the robotized gearbox displaying functions The gearbox information is always made available under any operating condition Telephone displaying through the Convergence module Comfort panel The panel displays the Convergence status BLUETOOTH status telephone company name gb Fiat Grande Punto OK 425 532 2005 Fiat Auto S p A All rights reserved Bluetooth status Telephone company name ...

Page 427: ...lephone displaying The Convergence status and the information sent by the Convergence module will be displayed on one single screen Navigator displaying The following information is displayed Navigation pictograph Distance to the next turn Unit of measurement Name of the street or road Logistic mode gb Fiat Grande Punto OK 426 532 2005 Fiat Auto S p A All rights reserved This function can be actua...

Page 428: ... are accompanied by an acoustic signal simultaneous with the message displaying All the information contained in the display section reserved for message displaying will be replaced by the information on the anomaly The messages are displayed upon very key ON until the malfunction is identified and remedied In any case the displaying can be interrupted by the driver by pressing the Menu Esc button...

Page 429: ...e panel On the Mode panel the anomalies are signalled by the lighting of their respective warning lights Moreover the messages below are displayed speed limit exceeded for 10 seconds inertia switch actuation the respective message is displayed in place of the odometer the message will remain ON until such the inertia switch is being actuated Speed limit exceeded Inertia switch actuation Acoustic b...

Page 430: ...osis is provided for the warning lights listed below the vehicle panels memorize and transmit through the CAN network the warning light status ON OFF and the presence of possible failure handbrake ON low brake fluid level EBD failure ABS system failure ESP system actuation failure AIRBAG system failure passenger s AIRBAG deactivation safety belts not fastened SBR electric drive failure Signalling ...

Page 431: ...warning cycle is actuated again upon every key ON with the temporary switch off mode Warning cycle re actuation mode the driver may actuate the warning cycle again it the latter has been switched off permanently by either asking for the assistance of the Technical Service personnel Mode panel or through a special item of the set up menu Comfort and Matrix panels This item will disappear when the w...

Page 432: ...and Matrix panels The TPMS system monitors two tyre pressure control thresholds corresponding to the low pressure and tyre puncture conditions In the event that each of these thresholds is exceeded the respective signalling warning light icon will be actuated and the respective message will be shown on the display In case of tyre puncture the panel will also generate an acoustic signal Moreover a ...

Page 433: ...iven by the panel and continues for the warning lights driven by a signal in a discrete fashion indicators zeroing is permitted in order to carry out total recovery Checking upon key ON it starts over Automatic service messages they are displayed again Checking upon key ON Upon every key ON the check phase will start for all the electronic control units fitted to the vehicle and some warning light...

Page 434: ...ng controls on the light lever located on the left and the window rear window wiping and washing controls on the wiper lever located on the right The module may include the Trip function available on all the body versions and the Cruise Control function available as an option gb Fiat Grande Punto OK 433 532 2005 Fiat Auto S p A All rights reserved It is interconnected through the dashboard cable h...

Page 435: ...iat Auto S p A After Sales Training B CAN FOR ORIGINAL SYSTEM RADIO Convergence node NCV Radio receiver node NRR Airbag node Instrument board node NQS Body Computer node NBC gb Fiat Grande Punto OK 434 532 2005 Fiat Auto S p A All rights reserved ...

Page 436: ...tch indicator and lane change lights The controls are actuated by acting on the levers as follows movement on the steering wheel plane in both directions with double click the former is unstable the latter is stable pulling movement towards the driver with double click unstable ring rotation by 3 or 4 clicks gb Fiat Grande Punto OK 435 532 2005 Fiat Auto S p A All rights reserved LIGHT LEVER WIPER...

Page 437: ...ed by pulling the lever towards the steering wheel crown This actuation is unstable therefore the lever shall return to its rest position when it is released thus opening the contact again Rear window wiper control the rear window wiper is controlled by turning a ring with 2 stable positions located in the middle of the lever Rear window washing control the bi directional pump for rear window wash...

Page 438: ... control in this case however the lever shall be allowed to travel a longer stroke up to the second click high beam headlamps contact Here too the actuation is UNSTABLE the lever shall return to its rest position thus opening the high beam headlamp and flashing light contacts The high beam headlamps can be turned off by pulling the lever again up to the high beam headlamp position the same way as ...

Page 439: ...teering column stalk lever located on the driver s right to any of the three position below intermittent operation continuous speed 1 continuous speed 2 the windscreen wiper motor will be actuated as described below gb Fiat Grande Punto OK 438 532 2005 Fiat Auto S p A All rights reserved Intermittent operation the windscreen wiper is controlled at speed 1 yet with a pause between two subsequent st...

Page 440: ...1s 40 k p h 90 k p h 110 k p h Vehicle speed Continuous speed 1 the windscreen wiper is driven at speed 1 45 strokes per minute Continuous speed 2 the windscreen wiper is driven at speed 2 65 strokes per minute gb Fiat Grande Punto OK 439 532 2005 Fiat Auto S p A All rights reserved Pause time ...

Page 441: ... switch on The user may vary the rain sensor sensitivity by means of the vehicle set up menu on the instrument panel If the vehicle is switched off and the lever ring is left in the intermittent automatic operation position no wiping cycle will be carried out when the vehicle is next started even if is rains this will avoid unintentional actuation To restore the system s automatic operation the us...

Page 442: ...the user either selects other speeds continuous speed 1 or 2 or turns the windscreen wiper operation off ring position OFF In the event that any of the above mentioned actions is carried out any further resumption of the intermittent automatic position will make the windscreen wiper to operate in the intermittent mode regardless of whether rain is found on the windscreen In any case the instrument...

Page 443: ...with the reverse gear engaged Smart rear washing by moving the steering column stalk right hand lever rear washing will be actuated By keeping the lever pushed for more than 0 5 seconds the rear window wiper will be automatically actuated at continuous speed When the control is released the washing will be turned off and three further rear window wiping strokes will occur followed by one further w...

Page 444: ...nal pump FRONT CABL BODY TO FRONT CABLE Rear left headlamp area ground Windscreen wiper motor Rear window wiper motor Front left engine compartment ground Engine compartment control unit CVM Body Computer node NBC Rain twilight sensor CSP Tunnel ground Left side dashboard area ground Steering column stalk Front right engine compartment ground Headlamp washing pump ...

Page 445: ...m may function over the entire range of revs permitted by the engine and may manage vehicles equipped both with manual and robotized gearbox units However the system control does not come into action in the following cases neutral reverse gear 1st speed mechanic gearbox vehicle speed lower than 40 k p h The Cruise Control can be deactivated by simply actuating either the brake or the clutch pressi...

Page 446: ... causing the speed to increase by steps of equal size When the lever is released the system will maintain and memorize the new speed reached by the vehicle Decelerate function this function makes it possible to decrease the vehicle speed previously set in the Cruise Control so as to generate as long as the lever is kept operating in the direction a steady slope deceleration ramp When the lever is ...

Page 447: ...andbrake the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button action on the clutch the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button request for gear shift through the lever with the Dualogic gearbox unit in the manual mode the latest set speed will remain stored in the memory it can be r...

Page 448: ...ain switch ON OFF during switch off and switch on and then starting over with the desired speed setting operations In the event that a fault is found in the Cruise Control or the engine control system the Cruise Control will be disabled until key OFF In this case the Technical Service centre shall be contacted CSM Steering column stalk BCM Body Computer node 9 2 6 Radio receiver node RRM The radio...

Page 449: ...bining the visual information with the acoustic information generated by the system the driver will be able to avoid collisions The parking sensor node PAM is an electronic component connected to the B CAN network and the body to front cable harness which assists driving during the manoeuvres with the reverse gear engaged thus recognizing any obstacle at the rear The interfaces for the sensors on ...

Page 450: ...nd in the ray path thus the transducer receives an echo that is converted into a digital signal and sent to the electronic control unit The acoustic device is located inside the instrument board moreover it signals the system actuation when the reverse gear is engaged and the fault if any System coverage area PAM parking node functions Acquiring the signals from the rear ultrasound sensors Acquiri...

Page 451: ...ate the obstacle detection acoustic signal Acquiring on the B CAN line the request for obstacle presence acoustic signal actuation Acquiring on the B CAN line the parking sensor correct operation System failure indication gb Fiat Grande Punto OK 450 532 2005 Fiat Auto S p A All rights reserved Actuating the obstacle detection acoustic signal ...

Page 452: ...em actuation and deactivation When the vehicle is started ignition key turned to MAR a self diagnosis test is carried out by the control unit and the sensors the system will be actuated when the reverse gear is engaged and will be deactivated when the reverse gear is disengaged gb Fiat Grande Punto OK 451 532 2005 Fiat Auto S p A All rights reserved The acoustic signal emitted by the system warns ...

Page 453: ...covers the vehicle s rear side and median areas If the obstacle is positioned in the median rear area the obstacle will be detected at a distance of less than 1 50 m If the obstacle is positioned in a side area the obstacle will be detected at a distance of less than 0 6 m Work conditions Work conditions Functionality Remarks Ignition OFF 30 Ignition ON 15 Parking assist management The system is a...

Page 454: ...front cable harness The audio amplifier receives the signals from the audio outputs of the radio receiver node RRM Moreover it receives the consent to actuation from the radio receiver node itself RRM 9 2 9 Spiral cable The spiral cable is an interconnecting component supplied with the steering column stalk control module CSM which ensure connection between the dashboard cable harness the controls...

Page 455: ...al bridle located on the internal rear view mirror which is connected to the front body wiring harness It is made up of a infrared LED sensor fitted to the vehicle s front window and is capable of detecting the presence of rain and as a result managing the wiping operation depending on the amount of water found on the glass 9 2 11 Brake pedal switch gb Fiat Grande Punto OK 454 532 2005 Fiat Auto S...

Page 456: ... feature the following controls depending on the body version level front electric window regulator control rear electric window regulator if available controls rear electric window regulator where available cut off controls with respective LED electric side mirror selector electric side mirror control joystick Three window regulator control module models are available depending on the vehicle s b...

Page 457: ... on the rear doors complete with its respective signalling LED Window regulator control on the passenger s side front door CDC The window regulator control on the passenger s side front door is connected through the passenger s side front door cable harness to provide the respective window regulator motor with the control It receives the power supply for ideograph lighting and correct operation of...

Page 458: ...trol receives the power supply for ideograph lighting and correct operation of the control itself from the disable control placed on the control board on the driver s side front door 9 2 13 Switch on clutch pedal The clutch pedal signalling switch is fitted to the clutch pedal and is connected through the body to front cable harness It informs the engine management control unit about the pedal sta...

Page 459: ...button to select the Economy mode versions equipped with robotized gearbox 9 2 15 Left control board ELC The left control board ELC consists of a module that incorporates the controls on the steering wheel outer side and is interfaced to the Body Computer node BCM and the instrument panel node IPC through the dashboard cable harness The left control board ELC receives the power supply for ideograp...

Page 460: ... body cable harness 9 2 16 TPMS tyre pressure control system gb Fiat Grande Punto OK 459 532 2005 Fiat Auto S p A All rights reserved The TPMS tyre management system monitors two tyre pressure control thresholds corresponding to the low tyre pressure and tyre puncture conditions If any of these thresholds is exceeded the respective warning light signalling icon available with the Comfort panel onl...

Page 461: ...h the vehicle A electronic code B mechanic code of the key to be notified to the FIAT Dealership if a key duplicate is requested It is recommended that you always bring the electronic code with yourself WARNING To ensure optimum efficiency of the electronic devices fitted inside the key the latter should not be exposed to the sunshine gb Fiat Grande Punto OK 460 532 2005 Fiat Auto S p A All rights...

Page 462: ... Key equipped with remote control Button pressed briefly Button pressed briefly Button pressed twice Button pressed Button pressed fir a long time Button pressed for a long time Indicator light blinking only with key equipped with remote control 2 blinks 1 blink 3 blinks 2 blinks 2 blinks 1 blink Deterrent LED Switch off ON steadily for approximately 3 seconds then deterrent blinking Blinks twice ...

Page 463: ...f the mechanic key whereas the latch on the passenger s door fitted onto the handle allows you to unlock the single passenger s door The key s metal part A is fixed Key equipped with remote control This key consists of a fold away metal insert A and a handle enclosing the same The metal insert can be removed by pressing the special button B on the handle and can be fitted back into place by keepin...

Page 464: ...ecial control In the event that the battery does not deliver enough power for the electric door lock handle function the boot can in any case be unlocked and opened by actuating a special lever that can be reached by removing a mask located on the luggage board No latch is found on the boot The boot can also be opened from the inside in case of electric system malfunction by means of a mechanic sa...

Page 465: ... fully closed In this case a light signal informs you that the doors have not been locked In the event that the boot is open the doors can be locked yet an acoustic signal will inform you that an anomaly is found If the vehicle is locked from the outside the door s central locking unlocking buttons will be disabled and will be enabled again the next time the doors are unlocked Locking unlocking ac...

Page 466: ...locked the LED will light up for approximately 3 seconds and then will start blinking deterrent function If the boot or one or several doors are not closed correctly the LED will blink quickly together with the indicator lights gb Fiat Grande Punto OK 465 532 2005 Fiat Auto S p A All rights reserved ...

Page 467: ...ELECTRIC SYSTEM FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training gb Fiat Grande Punto OK 466 532 2005 Fiat Auto S p A All rights reserved Control dashboard Body Computer node NBC ...

Page 468: ...ted ON or deactivated OFF as follows briefly press the MENU ESC button the display will show a submenu briefly press the MENU ESC button the display will show ON or OFF in the blinking mode depending on what has been previously set select by pressing the or button gb Fiat Grande Punto OK 467 532 2005 Fiat Auto S p A All rights reserved briefly press the MENU ESC button to go back to the submenu sc...

Page 469: ...s the operation of the following items inner handles locking unlocking button gb Fiat Grande Punto OK 468 532 2005 Fiat Auto S p A All rights reserved thus preventing the doors from being opened from inside the passenger compartment in the event that an attempt at breaking into the vehicle has been made e g glass breaking Therefore the deadlock ensure the best protection against any attempt at the...

Page 470: ...Auto S p A All rights reserved Passenger s side front door locking actuator Rear right door locking actuator PASSENGER S SIDE FRONT DOOR REAR RIGHT DOOR Body Computer node NBC Rear left door locking actuator Driver s side front door locking actuator BODY TO FRONT CABLE REAR LEFT DOOR BODY TO FRONT CABLE BODY TO FRONT CABLE ...

Page 471: ...he button placed between the controls on the dashboard The device cannot be switched on if one or several doors are not closed correctly this prevents anybody from getting on the vehicle through the open door and then getting stuck inside the passenger compartment after the door has been closed The device will be automatically deactivated on all the doors when the mechanic starting key is turned t...

Page 472: ...urn the device from position 2 to position 1 then close the leaf After the device has been switched on the rear doors can be opened by acting on the vehicle s inner handles Child safety device 5 door versions This device prevents the rear doors from being opened from the inside and comes useful especially when children are carried on the vehicle The device can be actuated only when the doors are o...

Page 473: ...ocking emergency device simultaneously with the child safety device 9 4 Electric window regulators 9 4 1 General remarks The electric window regulator controls for both the front doors all the range versions and the rear doors where available are managed on the driver s side front door Controls and operation front window regulators only Versions not equipped with the automatic device Following the...

Page 474: ...e actuated on both sides right left only when the key is inserted Following the key OFF the front windows can only be actuated manually over a period of 3 minutes After this time has elapsed the system will not be acquiring new commands any more gb Fiat Grande Punto OK 473 532 2005 Fiat Auto S p A All rights reserved ...

Page 475: ...e actuated on all the windows only when the key is inserted except for window central closing opening by means of the remote control and during the timed period during which the key is not inserted as described below Following the key OFF the front windows can only be actuated manually over a period of 3 minutes After this time has elapsed the system will not be acquiring new commands any more In ...

Page 476: ... switches that allow you to carry out with the starting key turned to position the following operations front left window opening closing front right window opening closing rear left window opening closing where provided for rear right window opening closing where provided for gb Fiat Grande Punto OK 475 532 2005 Fiat Auto S p A All rights reserved rear door switch control disable where provided f...

Page 477: ...by one single operation The central locking function can be implemented through the remote control or the door lock latch of the driver s side front door external handle and is actuated only upon key OFF gb Fiat Grande Punto OK 476 532 2005 Fiat Auto S p A All rights reserved The window central closing opening actuation is not simultaneous for the 4 windows it follows a programmed sequence ...

Page 479: ... inversion zone corresponds to the space included between 200 mm from the upper edge and the latter If on the contrary an obstacle is detected in the non inversion zone during the window upward movement the system will interrupt the upward movement In the event that the battery is disconnected and re connected the following procedure shall be carried out in order to resume correct operation of the...

Page 480: ...control will disable the low beam headlights Subsequent deactivation of the high beam headlight control still with the low beam headlight control ON will involve switching the low beam headlights on again Parking lights This function makes it possible to switch both the dimmers and the license plate lights on with the vehicle key OFF in order to signal the presence of the vehicle when the latter i...

Page 481: ...agnosis is also carried out for every single license plate light with the actuating control ON followed by the license plate light failure indication if any on the instrument board with the key ON When the rear fog light is switched on the respective indication will appear on the panel Rear fog lights The rear fog light can be switched on by pressing the rear fog light button only if either the lo...

Page 482: ...and right moreover the LED will light up on the emergency button and an acoustic signal will be generated inside the passenger compartment If the emergency button is pressed with indicator lights the lights indications previously ON will keep on operating intermittently with no interruption or delay If an anomaly is found on any of the front or rear indicator light bulbs on the vehicle side select...

Page 483: ...mer bulbs can be replaced by removing the rubber cap A force fitted at the light cluster rear Release H4 bulb B and take it out As regards dimmer W5W bulbs C take it out of seat B without taking the light cluster off the vehicle The light indicator bulbs can be removed by steering the front right or left wheels outwards to gain access to the lid on the wheelbox which will be released by turning th...

Page 484: ...headlight fuse F16 right high beam headlight fuse F17 Fog headlamps The are built where available into the bumper and are equipped with a H1 bulb Bulb replacement to replace the lamp unscrew the cap release the retaining clip and take the bulb out the headlamp shall not be taken off the bumper Fuse replacement the F31 protection fuse is located inside the engine compartment control unit FDU gb Fia...

Page 485: ...lip B then take the unit off Rotate connector C then take bulb D off Fixed rear headlamps These rear headlamps are fitted to the red rear pillar with function distribution dual position with R5W bulbs C brake light dimmer P21 5W bulb D and indicator light P21W bulb B arranged vertically Screws A are used to remove the headlamps from the pillar and replace the bulbs gb Fiat Grande Punto OK 484 532 ...

Page 486: ... removed from the pillar undo screw E to release the bulb holder Third brake lamp This lamp located outside and positioned above the rear heated window incorporates the wiping function detergent outlet nozzle and the lighting function by means of 8 bulbs gb Fiat Grande Punto OK 485 532 2005 Fiat Auto S p A All rights reserved ...

Page 487: ...ghts These lights are housed onto the rear bumper Left hand rear fog light P21W bulb A right hand reversing light P21W bulb A for left hand drive versions Reverse arrangement for right hand drive versions Built in reflector Bulb replacement disconnect from under the bumper the connector then take the bulb holder off The lights shall not be removed from the bumper License plate lights gb Fiat Grand...

Page 488: ...ates with the starting key turned to MAR and the low beam headlights ON The vehicle slopes backwards when it is loaded thus causing the light beam to be raised In this case the headlamps shall be orientated correctly again The trim can be controlled by pressing the buttons indicated by the arrows and located on the control mask The instrument board display provides a visual indication of the contr...

Page 489: ...w me home function has been last actuated and is still ON Function deactivation keeping the flashing light control for more than 2 seconds causes both dimmers and the low beam headlights to be switched off the lights ON time to be reset and the counter for the 7 valid commands to be reset N B The deactivation control shall not necessarily provided within 2 minutes after key OFF nor shall any of th...

Page 490: ...ter loudspeakers 30 W located on the door opening handle designed to reproduce the highest frequencies full range loudspeakers 40 W diameter 130 mm located on the rear side frames which can reproduce the entire range of the sound frequencies These components feature the water resistant technology General features of the hi fi sound system This system consists of 6 loudspeakers and a sub woofer box...

Page 491: ... power amplifier located inside the sub woofer box and used for sub woofer drive CAR RADIO The Radio Receiver node RRM is held in a DIN compartment whereas the front radio mask on the dashboard occupies one and a half compartment Two versions are available radio CD player and radio CD MP3 player All the versions are set for connection with the low speed CAN interface on the B CAN line in order to ...

Page 492: ...ding on the vehicle speed can be selected through the menu car radio switch off timing control immediate switch off or 20 minutes after key OFF antenna power supply remote control form the steering wheel provision for interfacing with external Blaupuntk CD changer through a private BUS line provision for connection with a mobile phone hand free set active control of the hi fi system where availabl...

Page 493: ...gh the Autostore function 6 MW stations 6 LW stations 6 stations for PTY types of programs FM only Scan mode listening to a station for a short time and shifting to the next station automatically scanning on the used frequency band scanning on the stored channels CD features power driven eject loading pause selection of the next previous track FF F REW TPM Track Program Memory function for 30 CDs ...

Page 494: ... random playing of the tracks included in a folder or the entire disc Repeat function repetition of one single track or single folder MP3 display folder ID3 TAG information track elapsed time file name printed audio or data CD CD R and CD RW playing Sound features bass treble balance fader loudness 7 band equalization Preset default Rock Jazz Classic User provision for customization Blaupunkt CD c...

Page 495: ...gram Memory function CD Naming 8 characters for 30 CDs Telephone section features telephone mute ON OFF function telephone volume function telephone volume control through the volume knob Steering wheel radio controls The car radio system features remote controls on the steering wheel see figures below gb Fiat Grande Punto OK 494 532 2005 Fiat Auto S p A All rights reserved List UP DOWN scrolling ...

Page 496: ...ision at a speed of 56 k p h against a fixed rigid barrier typical of a collision against a fixed rigid obstacle Nuova Punto is capable in case of head on collision of retaining the load located in the luggage compartment which may hit the passengers seriously if not properly secured Side collision gb Fiat Grande Punto OK 495 532 2005 Fiat Auto S p A All rights reserved Nuova Punto ensures front a...

Page 497: ... at present Below are the main child safety devices isofix mounts on the rear seats for correct installation of child seats passenger airbag deactivation directly through the trip computer to protect the fitted child seat Description The occupant protection system fitted to Nuova Punto consists of the following components Driver s and passenger s front airbags with dual actuation stage front seat ...

Page 498: ...t Grande Punto OK 497 532 2005 Fiat Auto S p A All rights reserved Moreover Nuova Punto features front seat headrests with heightwise control and lowering lock combined with the new bio mechanic antiwhiplash system optional item This system comes into operation in case of a collision following the heavy load transfer caused by the occupant s body pushing against the seat back after the crash and a...

Page 499: ...p A All rights reserved Driver s side knee bag Passenger s side front airbag Spiral cable CVS Airbag control unit ground Airbag node Passenger s side collision sensor Driver s side collision sensor Early crash sensor ECS Passenger s side head airbag Driver s side head airbag Driver s side pretensioner Passenger s side pretensioner ...

Page 500: ...l head on collisions For this reason airbags with dual actuation stage have been designed When a medium seriousness collision takes place the electronic control unit will only drive the first airbag actuation stage avoiding the development of unnecessary energy for the occupant s protection Conversely in case of very serious collisions the control unit will drive both stages so as to absorb the oc...

Page 501: ...hat reduce the force transmitted by the belts to the thorax The load limiters combine in the front seats with the airbags to better restrain the occupants Passenger detecting sensor This sensor makes it possible to detect the presence of a passenger and if necessary warn the driver that the safety belts have to be fastened by emitting a visual and sound signal through the vehicle panel Auxiliary c...

Page 502: ...ase of medium to high seriousness side collision Curtain airbags they are actuated together with the side airbags where available and interpose themselves between the occupant and the vehicle exterior thus preventing the occupant s head from hitting highly intruding objects The curtain airbags protect both the front and rear passengers since they range from the front pillar to the luggage compartm...

Page 503: ...NTO TRAINING OUTLINE Fiat Auto S p A After Sales Training Connections The airbag node SDM is connected to the B CAN line gb Fiat Grande Punto OK 502 532 2005 Fiat Auto S p A All rights reserved B CAN NETWORK A B CAN NETWORK B ...

Page 504: ...s is in the operators and experts jargon referred to as Crash Severity Algorithm since it can tell whether a collision is serious so as to properly actuate the dual stage airbags SDM functions System fault acquisition Transmitting the airbag status signal ON OFF Flash on the B CAN line Acquiring the airbag warning light status ON OFF Fail from the B CAN line through the warning light itself Perfor...

Page 505: ...tivate the passenger s side airbags without deactivating the side head protection airbag window bag where available Proceed as follows press the MENU ESC button then after displaying the BAG P OFF or Bag Pass OFF message to deactivate or the BAG P ON or Bag Pass ON message to actuate on the display by pressing the or buttons press the MENU ESC button once again the confirmation request message wil...

Page 507: ...on key ON the warning message will be shown for 20 seconds if the light is still ON after the typical time tAB 15 s since the key ON if after the typical time tAB 15 s the signal comes from the SDM while the message is being displayed then the message will further remain ON for a maximum of 5 seconds gb Fiat Grande Punto OK 506 532 2005 Fiat Auto S p A All rights reserved Work conditions Function ...

Page 508: ... the B CAN line a proper collision signal STATUS SDM CrashOutputSts this signal will inform the network about the type of collision and the time when it occurred The airbag node will perform its functions as shown in the table below Functions Driver s side airbag Passen ger s side airbag Front airbag X Internal accelerom Y Internal accelerom X Safety function Actuation threshold Front protection X...

Page 509: ...he CAN communication will stop for 1 second The passenger s airbag will be switched off during this time R9 actuation available It may be cleared off the event memory when all of the following conditions apply R8 relative to side and head airbag disable The opposed side and head airbags will be ensured The front airbags and pretensioners will be ensured one airbag and pretensioner is not actuated ...

Page 511: ...vation indication Airbag warning light IPC side Upon key ON the airbag warning light will if the AIRBAG and passenger s AIRBAG deactivation warning lights are ON be kept ON by the IPC It will illuminate upon key ON for a preset time regardless of the signals form the SDM After this check time the warning light control will be based again on the signals received from the SDM Warning messages from t...

Page 512: ...AT AUTO aware of the need to define from the start the bodywork construction design principles and the layout of the various systems fitted to motorcars For this reason the whole of Fiat Punto from the body to every single component has been designed so as to comply with the strictest latest FIAT in house fire prevention regulations Fire Prevention System FPS All the petrol and diesel engine versi...

Page 513: ...bing The electric insulation of the battery starting motor power cable is made of a material which features high resistance against the abrasions and cuts Moreover the cable routing has been optimized and special fasteners have been used Electric system inside the passenger compartment All the cables are protected by fuses located in the interconnecting control units located in the engine compartm...

Page 514: ...ir conditioner controls feature the same layout characterized by 3 knobs the left knob allows the user to control the temperature of the air let into the passenger compartment the central knob makes it possible to control the fan speed four different speeds can be selected the right knob allows the user to control air distribution five positions shown in the area around the knob During the designi...

Page 515: ...AIR CONDITIONER FIAT PUNTO TRAINING OUTLINE Fiat Auto S p A After Sales Training 10 1 2 Air flows gb Fiat Grande Punto OK 514 532 2005 Fiat Auto S p A All rights reserved Air flow and vent diagrams ...

Page 516: ... O Description 1 CAN L 2 CAN H 3 N C N C 4 N C 5 O PWM output 6 N C 7 O Spreading sensor power supply 8 N C N C I Temperature sensor 1 signal 10 I Spreading sensor signal 11 O Sensor ground 12 O 13 N C N C 14 N C N C 15 N C N C 16 N C 17 I Temperature sensor 4 signal 18 I Temperature sensor 3 signal 19 I Spreading sensor signal 20 I Temperature sensor 2 signal 21 N C 22 O 23 N C N C 24 O 25 I Left...

Page 517: ...sors The air conditioning system is made up of the following items A controls knobs buttons and displays B sensors passenger compartment temperature sensor external temperature sensor left right dashboard mixed air temperature sensor left right foot area temperature sensor solar sensor C actuators left right mixing actuator recirculation actuator DEF SX dashboard foot area air distribution actuato...

Page 518: ...ual conditions low pressure means that the load imposed to the air conditioner is such that it does not require very high fluid flow rate high pressure means that a very high load is imposed to the air conditioner and the required amount of cooling fluid is great Operation The pulley motion is transmitted continuously to the compressor shaft by means of jumpers referred to as limiters 3 which are ...

Page 519: ...om the system as well as changing external temperature and or humidity conditions and sudden engine load changes Below are the main technical features of the compressor direction of rotation clockwise max number of continuous revs 8 500 number of pistons 5 minimum displacement 0 cm3 rev maximum displacement 126 cm3 rev gb Fiat Grande Punto OK 518 532 2005 Fiat Auto S p A All rights reserved amount...

Page 520: ...ody and are set moving by the plate oscillations The plate motion is generated by the rotation of the propeller shaft 3 gb Fiat Grande Punto OK 519 532 2005 Fiat Auto S p A All rights reserved The latter is made to rotate by the pulley connected to the engine by means of the auxiliary member belt The coolant flow rate is controlled by varying the compressor displacement and also the inclination of...

Page 521: ... flow is generated by the engine radiator fan Insufficient thermal exchange in the condenser will cause the pressure to increase in the system and the coolant to be condensed only in part thus reducing the system s efficiency The right side of the condenser incorporates the seat for the cylindrical fully integrated dehydrating filter 1 This arrangement makes it possible to optimize the system layo...

Page 522: ...nts of the same 1 Evaporator outgoing fluid pipe 2 Thermo sensitive element 3 To the compressor intake coupling 4 Pressure fluid 5 Contrast spring 6 Calibrated hole and ball 7 Expanded fluid to the evaporator inlet coupling 8 Valve body 9 Rod C To the compressor F To the dehydrating filter Ei Inlet evaporator Eu Outlet evaporator gb Fiat Grande Punto OK 521 532 2005 Fiat Auto S p A All rights rese...

Page 523: ...0 g for all the engine versions The points for connection with the recharge apparatus are different depending on the models in any case they can be easily located 10 3 Operation logic The air conditioner control layout varies according to the body versions heater manual conditioner automatic two zone air conditioner gb Fiat Grande Punto OK 522 532 2005 Fiat Auto S p A All rights reserved Heater Ai...

Page 524: ... display 6 system deactivation control OFF button yellow LED 7 MAX DEF function control button yellow LED 8 rear heated window yellow LED 9 passenger compartment temperature sensor protection grid 10 AUTO SX button for automatic control of left hand temperature left hand air distribution fan compressor and air recirculation 11 driver s side temperature selection knob 12 left hand air distribution ...

Page 525: ... in the passenger compartment as requested by the passenger can be adapted to the one requested by the driver The operation logic is based on the equivalent temperature 10 4 Diagnosis Control unit proxy procedure The control unit is capable by means of special sensor control logic and setting logic with actuator self learning to record and store in the memory a number of anomalies and faults that ...

Page 526: ...takes the place of over 70 of the sheet metal roof panel surface The glass allows when closed the external light to be let into the vehicle while allowing the occupants inside the passenger compartment to have a very good vision of the outside The glass allows when opened the roof compartment to be opened to approximately half its surface area During the opening phase the front mobile panel slides...

Page 527: ...chassis a sheet metal frame on which the other components are secured D a system right and left of mechanisms secured to the chassis for front glass panel handling which are driven by an electric motor by means of a metal spiral cable E a front fin C which acts as an air baffle it lifts when the roof is opened gb Fiat Grande Punto OK 526 532 2005 Fiat Auto S p A All rights reserved two polyester r...

Page 528: ...f the components below control push button panel electric motor and sunroof control unit built in 1 Key ON 15 2 Speed signal from the brake node 3 Power supply 30 4 Ground 5 N C Built in motor control unit Motor control unit pin out 6 N C gb Fiat Grande Punto OK 527 532 2005 Fiat Auto S p A All rights reserved ...

Page 529: ...el fully closed will open to the spoiler opening position so as to ensure very low drag noise By pressing the button again on the same side the front glass panel will reach the maximum opening position Following the initial opening control the glass panel may be stopped at intermediate positions by pressing the button again Manual opening by pressing the button briefly for 60 to 300 ms the front g...

Page 530: ... the panel will reach the closing position Following the initial opening control the glass panel may be stopped at intermediate positions by pressing the button again gb Fiat Grande Punto OK 529 532 2005 Fiat Auto S p A All rights reserved Manual opening by pressing the button briefly for 60 to 300 ms the front glass panel fully opened will move to close proportionally to the time T during which t...

Page 531: ...anel when an obstacle e g finger hand etc is found as far as the horizontal closing motion is concerned the system is active over the entire travel if the glass is opened for more than 4 mm when an obstacle is found on the front side of the glass panel it reverses the glass motion over a distance of 100 mm from the point where the motion has been reversed as far as the vertical closing motion is c...

Page 532: ...wrench supplied with the tool kit located in the luggage compartment put the wrench into seat A then rotate it clockwise to open the sunroof counterclockwise to close it 11 5 Initialization In case of battery disconnection or manual emergency glass handling the sunroof shall be initialized Follow the procedure below keep button A depressed in the closing position keep the button depressed so that ...

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