Fiat Punto 2004 Training Manual

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FIAT PUNTO TRAINING OUTLINE

After Sales Training

Fiat Punto

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FIAT PUNTO

Table of Contents

Summary of Contents for Fiat Punto 2004

Page 2 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to continuous updates: Fiat Auto S.p.A. undertake no responsibility for the consequences resulting from the use of outdated information.
Page 3: Table Of Contents
Type of engine..............................33 2.1.2 Engine data ............................... 34 ................................. 35 IMING ANGLES ..........................37 NGINE CHARACTERISTIC CURVES ................................41 RANSMISSION ..................................41 LUTCH .................................. 42 EARBOX 3 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 4 Connecting rods .............................. 74 3.2.11 Camshaft drive ..............................76 3.2.12 Camshaft drive idlers ............................77 3.2.13 Distributing shafts in the upper head ......................77 3.2.14 Tappets ................................78 4 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 5 Types of configuration ............................137 3.8.4 Operation................................138 3.8.5 Control unit ingoing/outgoing information diagram ..................141 ..............................143 DIAGNOSIS 3.9.1 FAULT SIGNALLING UPON VEHICLE START ....................143 5 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 6 ................................203 OMPONENTS 4.3.1 Electric injectors ..............................203 4.3.2 Ignition coils ..............................208 4.3.3 Petrol vapour recovery solenoid valve (canister) ....................213 4.3.4 Throttled body ..............................216 6 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 7 Air-conditioning system control ........................295 4.5.19 Phase variator control ..........................297 ................................297 ROCEDURES 4.6.1 Camshaft assembling position self-learning procedure..................297 4.6.2 Timing detachment/reattachment camshaft drive ....................300 7 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 8 ................................367 ESCRIPTION ..............................368 RONT SUSPENSIONS 8.2.1 General remarks ..............................368 8.2.2 Characteristic angles ............................370 ..............................373 EAR SUSPENSIONS 8.3.1 General remarks ..............................373 8 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 9 General remarks ..............................460 9.3.1 System functions..............................464 ..........................472 LECTRIC WINDOW REGULATORS 9.4.1 General remarks ..............................472 ............................... 479 XTERNAL LIGHTING ................................ 489 UDIO SYSTEM 9 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 10 Sunroof opening ............................528 11.2.2 Sunroof closing.............................. 529 11.2.3 Window shades.............................. 530 11.3 ........................ 530 UNROOF CLOSING ANTI PINCH FEATURE 11.4 ............................531 MERGENCY ACTUATION 11.5 ............................... 531 NITIALIZATION 10 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 11: Briefing
FIAT’s calling for youth-appealing sportscars. The determined line of new Fiat Punto, tailored by Giugiaro, has a tremendous pull on those who wish to own a car for the young, comfortable and carefully planned to the last detail.
Page 12: Market And Customers
(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 selling car in Italy and the third best seller in West Europe.
Page 13 FIAT PUNTO TRAINING OUTLINE After Sales Training This step will allow the FIAT brand to make a comeback, which has somehow started with Nuova Panda and currently in progress with Idea and Croma. The main goal of Nuova Punto is to win back the young customers thanks to its dynamic and sporting character, through a typically Italian style –...
Page 14: The Vehicle
European car manufacturers. A ‘real’ automobile line, which originally and nicely combines style, sporting character, elegance and beauty while following the modern customer’s tastes. 14 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 15: Dimensions
L104 Front pivot L105 Rear pivot H100 Vehicle height 1490 1480 1442 1436 1467 1418 1525 1516 1534 1465 P: Current Fiat Punto N: Nuova Punto 15 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 16: Body Versions
Height-adjustable steering wheel Rear headrests The ELEGANCE version features the following standard items: DYNAMIC contents Leather-covered steering wheel and gear shift lever cap Car radio/CD player Air conditioner 16 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 17 Front armrest Electric lumbar adjustment Automatic air conditioner Cruise control Rain sensor Parking sensor Tyre pressure sensor (TPMS) Leather upholstery Alloy wheel rims (different designs and dimensions) 17 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 19: Gearbox
DIESEL: Active Dynamic Elegance Sport 1.3 Multijet 16V 75 HP Manual, 5-speed 1.3 Multijet 16V 90 HP Manual, 5/6-speed 120 HP Manual, 6-speed 1.9 Multijet 8V 19 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 20: Active Safety
With Nuova Punto, FIAT has made important progress as far as safety is concerned. Innovative design and construction solutions have been adopted on Nuova Punto, so as to obtain the best results in terms of occupant protection.
Page 21 When designing Nuova Punto, Fiat has paid great attention to the safety of the children on the vehicle and the pedestrians as well.
Page 22: Tyres And Wheels
ALLOY RIM NON-CATENABILE 17" 205/45/R17 tyres 15 flat-surface rungs colour: chrome shadow ALLOY RIM NON-CATENABILE 205/45/R17 tyres 3 dual rungs (spider-type) colour: chrome shadow 22 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 23: Tyre Repair Kit
The Fix&Go kit may also be used to check and restore the tyre pressure, by connecting the special tube equipped with the quick coupling. 23 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 24: Comfort
1.2.12 Interior comfort and room When evaluating a passenger compartment, customers seem to base their assessment of the vehicle interior comfort mainly on the driver’s seat comfort. 24 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 25 Easy access into the vehicle Visibility Luggage compartment Utilization capabilities These functions are related to parameters that measure the vehicle’s capability of meeting with the interior comfort requirements. 25 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 26: Air Conditioning
In addition, the windscreen demisting function comes as a useful tool. The versions equipped with air conditioner feature air ducts in the rear passenger foot zone. Air flow and vent diagram 26 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 27 Fiat Auto S.p.A. BRIEFING FIAT PUNTO TRAINING OUTLINE After Sales Training Heater Air conditioner Automatic, two-zone air conditioner Air conditioning control layout 27 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 28: Sunroof
The sound sources available depending on the versions are a radio tuner and a CD/MP3 player. The sound system found on the vehicle may be of two different kinds: standard; hi-fi sound system. 28 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 29 130 mm) to reproduce the lowest frequencies. This box is fitted into the luggage compartment, on the right wheelbox side; single-channel sound power amplifier, located inside the sub-woofer box and used for sub- woofer drive. 29 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 30: Accessory Line
The accessory designing activity has been supported by the FIAT Style Centre and has been guided by the search for exclusive products consistent with the vehicle identity, integrated into the vehicle’s essential lines and of high practical value.
Page 31: Safety
(loudspeaker) preset is available. All of this means safe, comfortable driving, in compliance with the rules of the Highway Code. 31 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 32 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. 32 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 33: Technical Specifications
Common Rail type, with Fuel feed sequential, sequential, variable- type, with variable- timed) timed) geometry turboblower geometry and intercooler turboblower turboblower and and intercooler intercooler 33 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 34: Engine Data
Max. torque 11.6 20.4 10.4 19.4 28.5 (EC kgm) Max. torque speed 3000 1750 3000 1750 2000 (r.p.m.) Idling speed 750±50 n.d. 750±50 n.d. n.d. (r.p.m.) 34 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 35: Timing Angles
16V (90 HP) 16V (75 HP) 8V (120 HP) Opening before B.D.C. (°) 57° n.d. 51° n.d. n.d. -9° n.d. -3° n.d. n.d. Closing after T.D.C. (°) 35 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 36 NGK ZKR7A- Spark plugs ZKR7A-10 Preheating drive Bitron n.d. n.d. control unit Preheating spark Beru 4L01192 n.d. n.d. plugs Ignition sequence 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 36 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 37: Engine Characteristic Curves
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 Speed [r.p.m.] Engine: 1.4 8V Max. torque: 114 Nm at 3,000 r.p.m. Max. rating: 56 KW at 5,750 r.p.m. 37 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 38 TECHNICAL FIAT PUNTO TRAINING OUTLINE SPECIFICATIONS After Sales Training 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. 38 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 39 FIAT PUNTO TRAINING OUTLINE SPECIFICATIONS 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. 39 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 40 FIAT PUNTO TRAINING OUTLINE SPECIFICATIONS After Sales Training Engine: 1.3 Multijet 16V (90 HP) Max. torque: 200 Nm at 1,750 r.p.m. Max. rating: 66 Kw at 4,000 r.p.m. 40 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 42: Gearbox
Gear ratio (3) 1.480 1.302 1.302 Gear ratio (4) 1.121 0.959 0.959 Gear ratio (5) 0.921 0.744 0.744 Gear ratio (6) 0.614 Gear ratio (REV) 3.818 3.909 3.545 42 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 43: Braking System
Self-ventilated ventilated ventilated Disc diameter (mm) Rated thickness (mm) Type of caliper Bosch ZOH Bosch ZOH Bosch ZOH Bosch ZOH Bosch ZOH Caliper piston diameter (mm) 43 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 44: Rear Brakes
Rack travel Effort on the steering wheel from stationary 2.5 (mod. city) 2.5 (mod. city) 2.5 (mod. city) 2.5 (mod. city) 2.5 (mod. city) position (Nm) 44 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 45: Front Suspensions
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) Pack spring height Spring height under control load (mm) 45 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 46 Front stabilizer bar 1.3 Multijet 16V 1.3 Multijet 1.9 Multijet 1.4 8V 1.2 8V (90 HP) 16V (75 HP) 8V (120 HP) Bar diameter n.d. n.d. n.d. (mm) 46 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 47: Rear Suspensions
Free spring height 291.5 n.d. n.d. n.d. (mm) Spring height under theoretic n.d. n.d. n.d. project load Pack spring n.d. n.d. n.d. height (mm) 47 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 48 1.3 Multijet 1.9 Multijet 8V 1.4 8V 1.2 8V 16V (90 HP) 16V (75 HP) (120 HP) “Soft“ link (mm) “Medium” link (mm) “Hard” link (mm) 48 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 49: Suspension Characteristic Angles And Trim
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. 49 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 52: Rear
1.3 Multijet 16V 90 cv +1,3mm+/-2mm +1,5mm+/-2mm 1.9 Multijet 8V 120 cv +1,3mm+/-2mm +1,5mm+/-2mm 1.4 16V +1,3mm+/-2mm +1,5mm+/-2mm 195/55 R16 87H 1.9 Multijet 8V 120 cv +1,3mm+/-2mm +1,5mm+/-2mm 52 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 53 1.3 Multijet 16V 90 cv -1°+/-20’ -1°+/-20’ -1°+/-20’ -1°+/-20’ 1.9 Multijet 8V 120 cv 1.4 16V -1°+/-20’ -1°+/-20’ 195/55 R16 87H 1.9 Multijet 8V 120 cv -1°+/-20’ -1°+/-20’ 53 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 54: Battery And Alternator
Tutela Top 4 Tutela Top 4 Tutela Top 4 Brake fluid Paraflu up Paraflu up Paraflu up Paraflu up Paraflu up Radiator fluid (50%) (50%) (50%) (50%) (50%) 54 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 55 16V (90 HP) 16V (75 HP) 8V (120 HP) Engine oil (amount for regular replenishment, 4.18 sump and filter) (litres) Gearbox oil/front 2.08 2.08 differential (kg) 55 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 56: Vehicle Features
4,030 2,510 2,510 2,510 2,510 2,510 1,490 1,490 1,490 1,490 1,490 1,473 1,473 1,473 1,473 1,473 1,687 1,687 1,687 1,687 1,687 1,466 1,466 1,466 1,466 1,466 56 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 57: Performance
Fuel tank capacity (l.) (5-7) (5-7) (5-7) (5-7) (5-7) Fuel reserve (l.) Cooling system (l.) 5.27 5.27 6.35 Oil sump and filter (l.) 4.18 Brake circuit (kg) 57 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 58: Consumption
Spare 175/65 R15 84T 185/65 R15 88T 175/65 R15 84T 175/65 R15 84T 185/65 R15 88T wheel 185/65 R15 88T 185/65 R15 88T 185/65 R15 88T 58 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 61: 1.3 Multijet 16V, 75 And 90 Hp Engines
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 Multijet MJD6F3 control unit. 61 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 62 The operation of these systems can be optimized by means of an electronic control system managed by a control unit. Understanding the control unit operation logic allows you to get an overall picture of the entire system. 62 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 63: Components
Moreover, the 90 HP version features one further support for the right-hand axle shaft. 1 Support on the valve gear side 2 Support on the gearbox side 63 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 65: Engine Base
A nozzle (2) is fitted into the lower part of each cylinder, through which oil is sprayed on the piston crown in order to cool the piston and ensure pin lubrication through falling. 65 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 66: Lower Engine Base
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 lower base (2). 66 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 68: Cylinder Head
The combustion chamber design has been modified, by increasing the chamber diameter and, as a result, reducing the compression ratio from 18:1 to 17.6:1. 68 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 70: Base Sump And Covers
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. 70 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 71: Oil Seals On The Drive Shaft
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 3 Phonic wheel for revs number 71 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 72: Drive Shaft
Accurate balancing of the rotating masses is ensured by eight counterweights. A number of channels run through the drive shaft for lubrication of journals and crankpins. 72 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 73: Pistons
Coupling with the pin is carried out by means of two copper-alloy bushings. 1 Piston 2 Electric injector 3 Preheating spark plugs 4 Air inlet 5 Exhaust gas outlet 73 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 74: Connecting Rods
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. 74 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 76: 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 5 Timing chain 76 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 77: Camshaft Drive Idlers
3.2.13 Distributing shafts in the upper head These are two camshafts made of cast iron, with induction-hardened cams. 77 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 80: Turboblower
It is essentially made up of two impellers force-fitted to one single shaft that rotates on floating bearings lubricated through a branch (3) of the engine lubricating circuit. 80 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 81 The 1.3 MJTD, 90 HP engine features a new generation of turboblowers: the VNT (Variable Nozzle Turbines) turboblower. The distributor blades are actuated electro-pneumatically. This technology makes it possible to achieve optimum turboblower with all engine speeds. 81 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 83 (75 & 90 HP) After Sales Training Turboblower view 1. Low engine revs number and small exhaust gas amount 2. High engine revs number and large exhaust gas amount 83 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 84: Inlet Manifold
Special guards reduce heat diffusion toward the body. The various components are supported by means of special supports (5) and snap rings (6) secured to the underbody. 84 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 85: Exhaust Emission Control System
The chemical reaction for CO, HC and particulate oxidation is efficient at temperatures ranging between 200°C and 350°C. Beyond 350°C, the sulphur contained in the diesel fuel starts oxidizing, thus giving rise to sulphur dioxide and sulphur trioxide. 85 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 86: Exhaust Gas Recirculation (E.g.r.) System
(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 temperature. 86 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 87 The atmospheric pressure signal is used when driving the E.G.R. solenoid valve to recognize the high-altitude driving condition, so as to reduce the amount of recirculated gas and avoid engine smokiness. 87 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 89: Engine Base Vapour/Gas Recirculating System
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 89 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 90: Engine Oil Lubricating Circuit
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 Timing chain cover 90 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 91: Heat Exchanger And Oil Filter Assembly
The vacuum is found starting from the gear partition bulkhead (1) up to the oil sump plummet. Conversely, the pressure develops starting from the partition bulkhead (1) in all the engine oil supply ducts (2). 91 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 92 2 Oil supply duct 3 Driven gear 4 Driving gear 5 Low-pressure chamber 6 Relief valve 7 Pressure chamber 8 Connecting duct between high and low pressure 92 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 93: Engine Cooling
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 Water recirculation pipe 93 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 94: Engine Cooling Tank And 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 plastic. 3.4.1 Water pump and thermostat Water pump 94 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 95 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 4 radiator output 95 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 96: Water Temperature Control Devices
The drive shaft pulley (4) incorporates an elastic sector that reduces the torsion vibrations of the drive shaft and the stress on the belt (and, therefore, on the engine’s auxiliary members). 96 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 97 1.3 MULTIJET 16V FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training Alternator Belt stretcher Water pump Drive shaft pulley Engine member drive belt 97 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 98 Fiat Auto S.p.A. 1.3 MULTIJET 16V FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training Versions with air conditioner. 98 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 99: Fuel Feed System
T.D.C., manages according to the revs number and the engine load, which make it possible to distribute the pressure into the combustion chamber more evenly, with lower noise levels. 99 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 100 It is made up of the following items: - auxiliary electric pump immersed into the tank; - fuel filter with inner cartridge; - fuel return manifold pipe; - connecting pipes. 100 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 101 FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training Low pressure line Low pressure circuit (75 HP) Low pressure line Low pressure circuit (90 HP) 101 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 102 - single fuel manifold pipe with built-in pressure regulator and pressure sensor - electric injectors CR1MI2.2 - connecting pipes. High pressure line Injectors (75 HP & 90 HP) = CR1MI2.2 102 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 103 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 15 Fuel heater 103 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 105 The maximum discharge pressure reaches 1,400 bar. The pressure pump is lubricated and cooled by the fuel itself through special channelling. 105 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 106 Fiat Auto S.p.A. 1.3 MULTIJET 16V FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training Pump section View of the three plungers 106 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 107 FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training CP1 pump diagram and section CP1 pump section a: Shut-off valve b: Lubrication hole holeazione 107 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 108: Bosch Cp1H High-Pressure Pump (90 Hp)
Such flow rate adjustment makes it possible to reduce both the high- pressure pump power absorption and the maximum fuel temperature. The feed pressure required for the high-pressure pump is made available by an electrically-operated fuel feed 108 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 111 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. 111 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 112 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 %) 112 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 113: Electric Injectors And Pipes
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. 113 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 114 (3) (such holes amount to 6 in the CR1 MI 2.2 injector; they feature a diameter of 0.121 mm and a flow rate of 280 cm3 / 30 s at 100 bar). 114 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 116 The new spare control units and the ones supplied at the FIAT plant are delivered with a standard default IMA code with a 00 hex value; the vehicles fitted with control units that have...
Page 117 CCM cannot, after the operation has been carried out, be brought back to the virgin state when classification has to be performed. Classification shall ALWAYS be carried out at the FIAT production plant and at the Service Centre every time the CCM control unit/injector needs be replaced.
Page 118 High-pressure ring Core Shim Body Spring Reference dowel Coil Spring Retaining nut Valve ball Valve body Full valve Adapter Connector Guide Washer Bar filter IMA CODE 118 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 119: Single Fuel Manifold Pipe
The difference between the two rails lies with the manufacturing procedure: one is forged (FR), whereas the other is made with laser welds (LWR) that ensure more accurate manufacture and higher resistance to high pressures (1,600 bar). 119 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 120 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. 120 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 121: Fuel Tank And Components
The pumping unit is of the roller type and makes it possible to achieve a flow rate of 160 litres/h. 121 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 122 The advantages compared with the electric pumps operating according to the volumetric principle are as follows: - less weight; - small dimensions. 122 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 124: Inertia Switch
A steel ball (1) fitted into a tapered housing (2) is normally kept secured through the attraction force of an adjacent magnet. 124 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 126: Fuel Filters
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 sensor electric connection 10 Diesel fuel heater 126 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 127: Fuel Temperature Sensor And Heating Device
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. 127 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 128 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) 4 GROUND 128 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 129: Engine Air Feed Circuit
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 7 Air intake (manifold) 129 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 130: Mjd 6F3 Diesel Engine Management Control Unit
(E.G.R.) control; max. torque restraint control; peak r.p.m. restraint control; preheating spark plug control; air-conditioning system actuation control (vehicles equipped with A/C); auxiliary fuel pump control; 130 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 131: Pin-Out
Cylinder 4 injector positive Not connected Not connected Fuel pressure regulator positive Positive from the main relay Fuel pressure sensor negative Not connected Fuel pressure sensor positive 131 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 132 Not connected Engine coolant temperature sensor ground Not connected Cylinder 3 injector negative Not connected Not connected Fuel pressure regulator negative Not connected Not connected Not connected 132 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 133 Connector B Control unit power ground Control unit power ground Control unit power ground Control unit power supply (12 V) Control unit power supply (12 V) 133 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 134 Request for air conditioner actuation from the control button Engine revs number signal for robotized gearbox Not connected Not connected Accelerator potentiometer race 2 negative Not connected Not connected 134 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 135 Not connected Not connected Not connected Not connected Not connected Not connected Fuel temperature sensor signal Not connected Not connected High speed H CAN 1 line 135 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 136 Air conditioner linear sensor signal Diagnosis line K Not connected Diesel fuel filter water presence sensor signal Not connected Brake pedal switch signal (N.A.) Clutch pedal switch 136 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 137: Types Of Configuration
Fiat Auto S.p.A. 1.3 MULTIJET 16V FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training 3.8.3 Types of configuration 75 HP system with CP1 pump 137 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 138: Operation
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. 138 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 139 1 PILOT injection + PRE + MAIN 2 PRE injection + MAIN 3 PILOT injection + PRE + MAIN (with dwell time between PILOT and PRE > 1000 usec.) 4 MAIN injection 139 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 140 - air temperature (from the air flow meter); - sucked air amount; - battery voltage; - diesel fuel pressure; - accelerator pedal position; - diesel fuel temperature. 140 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 141: Control Unit Ingoing/Outgoing Information Diagram
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 14 Cruise Control (where available) 141 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 142 24 Preheating spark plugs 25 Spark plug preheating warning light 26 Injection warning light 27 Max. water temperature warning light 28 Fuel water presence warning light 142 / 532 FIAT PUNTO © 2004 Fiat Auto S.p.A. – All rights reserved.
Page 143: Self-Diagnosis
Warning light OFF after the engine has been started: no fault is found on the components that affect the system safety. Warning light ON when the engine is running: a fault is present. 143 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 144: Fault Signalling During Vehicle Operation
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. Engine control unit Immobilizer FIAT CODE 144 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 145: Checks
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. 145 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 146: Engine Coolant Temperature Check
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. 146 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 147: Injected Fuel Amount Check
“pilot” injection time over the entire revs range; varies the “main” injection time. 147 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 148: Idling Speed Check
(DRV2); it varies the injection time of electric injectors (CR1MI2.2). Within some thresholds, the speed allows for the battery voltage. 148 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 152: Checking The Exhaust Smoke Level During Acceleration
- pressure regulator (DRV2); - the injection time of electric injectors (CR1MI2.2). 152 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 154: Max. Torque Restraint Check
- vehicle speed; - air temperature. The control unit also controls the amount of fuel to be injected (pressure regulator – electric injectors). 154 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 155: Max. R.p.m. Restraint Check
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. 155 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 156: Preheating Spark Plug Check
- post-starting phase, - the control unit manages timed operation of the spark plug preheating control unit (BITRON) depending on the engine temperature. 156 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 157: Air-Conditioning System Actuation Check
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. 157 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 158: Auxiliary Fuel Electric Pump Check
“MAR”; cuts the auxiliary pump power supply off if the engine is not started within a few seconds. 158 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 159: 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. 159 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 161: Injection Pressure Closed Cycle Check
The control unit varies the idling speed depending on the battery voltage: it increases the injection time of electric injectors (CR1MI2.2); it controls the line pressure by means of the pressure regulator (DRV2). 161 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 162: 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. 162 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 163: Cruise Control System Check (Where Available)
The ASR (antispin) function takes priority over the Cruise Control, for safety reasons. 163 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 164 Oxygen sensor control Oxygen sensor control Functions Cylinder balancing control Cylinder balancing control Injection correction control Injection correction control IMA procedure IMA procedure VGT control 164 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 165: Sensors
The injection control unit uses the revs sensor signal to: determine the engine rotation speed; determine the angular position of the drive shaft. The figure illustrates the revs sensor components. 165 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 166 PIN-OUT Name Type of signal Phonic wheel signal Frequency output Phonic wheel signal Frequency output Technical features Winding resistance: 790 Ω ± 20% 166 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 167 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 167 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 169 Input (12 V) In the specific case of the phase sensor, this is powered by the engine management control unit with 5 V. 169 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 170 The sensor is directly powered by the electronic control unit with 5 V and provides the output voltage directly proportional to the boosting pressure. 170 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 171 (75 & 90 HP) After Sales Training Overpressure sensor pin-out Type of Name signal Power supply Input (5 V) Ground Ground Analog Sensor output output 171 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 172 FIAT PUNTO TRAINING OUTLINE (75 & 90 HP) After Sales Training In the 90 HP engine version, the sensor also incorporates the boosting temperature sensor. 172 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 173 After Sales Training Pin-out 1 Pressure signal output 2 Power supply from the control unit (5 V) 3 Temperature signal output 4 Ground 173 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 174 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 Temperature Resistance (KΩ) (C°) 48.80 27.41 15.97 9.62 5.97 174 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 175: Air Flow Meter With Built-In Air Temperature Sensor (Hfm 6)
(new by-pass); turret welded to the air flowing duct; protection grid at the air flowing duct outlet section (with oil vapour condensing function). 175 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 177 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%). 177 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 178 (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). 178 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 180 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). 180 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 181 (DRV2) so as to raise the bottom pressure by 100 bar (from 250 bar to 350 bar). N.B. The engine can be started and operate even if the sensor is faulty. 181 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 182 The accelerator pedal position signal is processed together with the revs number data, to obtain the injection time and pressure. 182 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 183 Resistance at the potentiometer cursor terminals: 1 KΩ ± 0.4 KΩ Race 1 resistance: 0.9 KΩ ± 35% ….1.4 KΩ ± 35% Race 2 resistance: 1.2 KΩ ± 35% ….2.0 KΩ ± 35% 183 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 184: Vgt Solenoid Valve
Electric resistance: 15.4 ± 0.7 Ω at 20°C; TYPE OF CONTROL PWM (V=12V) Oscilloscope or analog instrument (Examiner with MEASURING MEANS SMA) UEGO oxygen sensor 184 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 187: 8-Valve 1.4 Engine
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 to significantly reduce fuel consumption and exhaust emission, especially when driving in the city traffic and out of town.
Page 188 The optimization of the valve gear timing and the introduction of such items as: electronically-controlled, hydraulic continuous phase variator; variable-turbulence combustion chamber; special intake and exhaust ducts; special inlet manifold; 188 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 189 8-valve 1.4 litre engine specifications Engine type 1.4 8v Displacement 1,368 cm³ Bore 72 mm Stroke 84 mm Intake valve diameter N.D. Exhaust valve diameter N.D. 189 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 190 Anti-pollution regulatory standard Euro 4 Torque curve and power curve 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 Speed [r.p.m.] 190 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 191: Iaw 5Sf Injection/ Ignition Control Unit
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 ). 191 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 192 Fuel electric pump Multi-purpose valve Safety valve Fuel delivery pipe Injection-ignition electronic control unit Battery Ignition switch Inertia switch Engine compartment branching-off control unit 192 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 193 Revs counter Catalyst Oxygen sensor (downstream) Atmospheric pressure sensor Phase variator drive solenoid valve Control unit ingoing/outgoing information diagram Control unit ingoing/outgoing information diagram 193 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 194 Body computer (with built-in Fiat CODE control unit) Throttle control actuator and throttle position sensor Electric injectors Fuel vapour solenoid valve Diagnosis connector Spark plugs 194 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 195 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 195 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 196: Main Features
The introduction of the Fiat CODE protection system does not make it possible to exchange control units among different Fiat Punto vehicles of the same engine version.
Page 197 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Control unit pin-out Connector (vehicle side) Connector (engine side) 197 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 198 400 mA @ 13,5 V control switch Not connected D+ signal alternator 24 mA @ 5 V Not connected Not connected Not connected Not connected Not connected 198 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 199 C-Can H Accelerator pedal potentiometer 1 0.01 mA @ 5 V signal Brake pedal switch warning light 10 mA @ 13.5 V Not connected 199 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 200 Not connected Not connected Not connected Phase sensor/air temperature sensor/ +5V (ECU) atmospheric pressure sensor power 100 mA @ 5 V supply Not connected 200 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 201 Sensor 1 throttled body position 0.01 mA @ 16 V Engine water temperature sensor 5 mA @ 5 V Not connected Not connected 201 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 202 Atmospheric pressure sensor Not connected Sucked air temperature 2.5 mA @ 5 V Oxygen sensor downstream the catalyst 1.4 A @ 16 V 202 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 203: Components
The injector control logic is of the “phased, sequential” type, i.e. the four injectors are controlled according to the intake phases of every single cylinder. 203 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 204 ENGINE After Sales Training Electric features Engine management system remote- control switch 1,2,3,4: Electric injectors 5,6: Junction 7:ECM 8:FDU (Engine management remote-control switch) 204 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 205 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Position of injectors on the vehicle Injector housing on the intake pipe 205 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 206 Power supply 3 (junction) 1 (junction) D1 (FDU) from the battery Electric injector Electric injector 49 (ECM 4 (junction) — 3 control connector B) 206 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 207 Power supply 3 (junction) 1 (junction) D1 (FDU) from the battery Electric injector Electric injector 4 33 (ECM 5 (junction) — control connector B) 207 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 208: Ignition Coils
The vicinity of the primary to the magnetic core makes it possible to reduce the magnetic flux loss, thus making the most of the coupling on the secondary. 208 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 209 Otherwise, the module might be broken. Position of components 1,1,2: Tightening order for the ignition module fastening screws 209 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 210 Electric features Primary circuit resistance: 0.5 Ω ± 10% at 23 ± 3°C Secondary circuit resistance: 6.0 kΩ ± 10% at 23 ± 3°C. 210 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 211 Cylinder 3 Cylinder 4 Cylinder 2 Cylinder 1 1: ECM 2: FDU (engine management remote-control switch) 3: Ignition module 4: Junction 5: Engine ground B 211 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 212 Cylinder 3 ignition control 3 (ECM connector B) — Cylinder 4 ignition control 1 (ECM connector B) — Engine ground Engine ground B — 212 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 213: Petrol Vapour Recovery Solenoid Valve (Canister)
4.3.3 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 213 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 214 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Position of components on the vehicle Canister 214 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 215 7 (junction) reaches FDU from the battery until pin D3 Petrol vapour recovery solenoid valve Canister valve 51 (ECM — control connector B) 215 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 216: Throttled Body
The replacement of the throttled body or injection control unit or air intake manifold does not ask for the execution of the self-learning procedure. Position on the vehicle 216 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 217 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Throttle Potentiometers Motor 217 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 218 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features 1: ECM 2: Throttle actuator 218 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 219 50° throttle opening will be set. The dash-pot and mixture ratio/idling speed self-adapting strategies will be blocked. 219 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 220: Hydraulic Valve For Camshaft Phase Control
FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 4.3.5 Hydraulic valve for camshaft phase control Electric features 1: Camshaft phase control valve 2: ECM 220 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 221 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Position on the vehicle Phase control valve 221 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 222 In the event that the variator is slow, the ECM will control the solenoid valve so as to hold the variator in a max. advance position (rest position). 222 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 223: Head
Moreover, this system makes it possible to recirculate a considerable amount (approximately 25%) of the exhaust gas in the combustion chamber. Figure “A” Exhaust gas masking 223 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 224 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Intake whirl Exhaust gas whirl Intake tangent to the opening Variable-turbulence system 224 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 227: Inlet Manifold
Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 4.3.8 Inlet manifold Newer inlet manifold. 227 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 229 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. 229 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 232 Engine oil inlet from the head Check OCV control Oil drain into valve the head Camshaft pulley Rotor Stator Spaces Phase sensor Engine revs sensor 232 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 233 After Sales Training The engine oil flows into the tappet cover at point 1 and then into the channel to the right (2). 233 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 234 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). 234 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 235 The following figures (a, b, c, d) illustrate the section that makes the solenoid valve and the phase variator to communicate with each other. 235 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 238 (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. Spring 238 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 240 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Blades on the rotor Effects of delay timing variation 240 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 242 The engine control unit interprets the wave amplitudes differing from the reference ones as failed ignition; therefore, it will actuate an emergency program. A. Rest position B. Position under pressure 242 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 243 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features • resistance: 532÷588 Ω at 20°C. 1: ECM 2: Knock sensor 243 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 244 Recovery In case of sensor failure, the engine management control unit actuates more conservative ignition advance “maps” in order to protect the engine. 244 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 245: Oxygen Sensor
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. 245 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 246 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Position on the vehicle 1: oxygen sensor upstream the catalyst 2: oxygen sensor downstream the catalyst 246 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 247 Engine management system remote-control switch control switch) 2: ECM 3: Oxygen sensor upstream the catalyst 4: Oxygen sensor downstream the catalyst 5: Junction 247 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 248 It is of the inductive type, i.e. it works through the magnetic field variation generated by the passage of the phonic wheel teeth (60-2 teeth). 248 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 249 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. 249 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 250 The distance (gap), required to obtain correct signals, between the sensor end and the phonic wheel shall be in the range of 0.5 to 1.5 mm. 250 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 251 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 1: Revs sensor Engine pulley 251 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 252: Engine Revs Number Sensor
Receiving item pin connector pin Engine revs signal A 9 (ECM connector B) Engine revs number sensor Engine revs signal B 23 (ECM connector B) 252 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 253: Phase Sensor
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 253 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 254 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 1: Ground 2: Output or signal 3: Supply voltage 254 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 256 Ground from the ECU 7 (ECM connector B) Phase sensor Phase sensor signal 24 (ECM connector B) Power supply from the ECU 13 (ECM connector B) 256 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 257: Engine Coolant Temperature Sensor
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 2: Sensor body 3: Electric connector 257 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 258 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 15971 9620 5975 3816 2502 2044 1679 1152 258 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 259 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features 1: ECM 2: Engine water temperature sensor 259 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 260 ECU will increase it gradually depending on the time since the engine start, until a temperature of 80 °C is reached. The radiator cooling fan is actuated. 260 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 261: Sucked Air Pressure And Temperature Sensor
The sensor is fitted to the inlet manifold. Position on the vehicle Sucked air pressure and temperature sensor 261 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 262 Since the power supply is strictly kept constant (5 V) by the control unit, the resistance value variation causes the output voltage value to vary, too. 262 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 263 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features The figure below illustrates the sensor’s electric features. 263 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 264 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 1: ECM 2: Sucked air pressure and temperature sensor 264 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 265 If the error is found in the other conditions: • the latest valid value is stored, which is updated depending on the coolant temperature. 265 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 266: Accelerator Pedal 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°. 266 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 267 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features 1: ECM 2: Junction 3: Dual accelerator pedal potentiometer 267 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 268 40° over a very long time period; in case of full failure to both potentiometers, it cuts throttle opening out. 268 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 270 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): 270 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 271 The supply voltage may undergo a variation of ± 10%, whereas the sensor’s utilization temperature is included between –5°C and 80°C. 271 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 272 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features 1: Ground 2: Supply voltage 3: Output signal 272 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 273 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 1: FDU 2: ECM 3: A/C linear pressure sensor 273 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 274 Ground from the ECU 15 (ECM connector A) A/C linear Power supply from the 3 (ECM connector A) sensor A/C sensor signal 5 (ECM connector A) 274 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 275 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Atmospheric pressure sensor Atmospheric pressure sensor 275 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 276 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Electric features 1: ECM 2: Atmospheric pressure sensor 276 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 277 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Position on the vehicle Atmospheric pressure sensor position 277 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 278 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. 278 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 279: Operation Logic
The control unit modifies, through the exhaust gas analysis, the basic mapping with respect to the as-new features of the engine. The self-adaptive parameters will not be cleared when the battery is disconnected. 279 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 280: Self-Diagnosis And Recovery
The control unit defines each time the type of recovery depending on the broken components. The recovery parameters are managed by the unbroken components. 280 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 281: Cylinder Position Recognition
To this regard, the purpose of loop 2 adaptivity is to recover both the production dispersions and the slow drift that the pre-catalyst sensor response may exhibit due to ageing and contamination. 281 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 282 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training This control is referred to as loop 2 control (post-catalyst sensor closed loop). 282 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 283: Cold Operation
The electronic control unit recognizes this condition based on the cooling fluid temperature signal, and increases the injection base time. 283 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 284: Fully-Loaded Operation
Under fully-loaded conditions, the injection base time has to be increased in order to obtain the maximum power delivered by the engine. 284 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 285: Operation During Deceleration
The recognition of the accelerator pedal non-released condition and engine speed of less than 1,270 r.p.m. (approximate value varying according to the various models) enables engine feed again. 285 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 286 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). 286 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 287: Operation During Acceleration
(extra pulse) again, to be able to compensate for the ratio as quick as possible; conversely, the following injections will be increased according to the above-mentioned coefficients. 287 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 288: Out-Of-Revs Protection
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. 288 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 289: Fuel Electric Pump Control
• 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. 289 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 290: Electric Injector Control
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. 290 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 291: Knock Control
The strategy is capable of resuming the advance to the threshold value stored in the memory when the conditions that caused reduction to occur are not present any more. 291 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 292: Radiator Electric Fan Control
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 driven by the injection control unit. 292 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 293: Engine Idling Control Management
(duty-cycle) that modulates its opening. Thus, the control unit checks the amount of fuel vapour sent to the intake, thus avoiding significant variations of the mixture ratio. 293 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 294 • 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. 294 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 295: Air-Conditioning System Control
• with engine speed of less than 650 r.p.m. The compressor will be switched on again when the engine speed reaches 750 r.p.m. again. 295 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 296 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. 296 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 297: Phase Variator Control
The procedure must be carried out again in the following cases: phonic wheel actuation/replacement; revs sensor actuation/replacement; 297 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 298 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. 298 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 299 In the event that a vehicle is allowed to travel in the traffic with engine timing out of the permitted tolerances, the engine itself may be broken. 299 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 300: Timing Detachment/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). Moving idler 300 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 301 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Moving idler (1a) Drive shaft pulley (2b) 301 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 302 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Press the clips, then remove the coil air inlet sleeve. Air inlet sleeve 302 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 303 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. 303 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 304 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Air filter fastening screws Air filter 304 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 305 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Engine oil vapour pipe 1. Unscrew the timing belt protection upper cover fastening screws. 305 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 306 Disconnect the electric 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. 306 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 307 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Oxygen sensor upstream the catalyst, with its respective connection 307 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 308 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. 308 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 309 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Ignition coil module Phase variator control electromagnet with its respective connection 309 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 310 After Sales Training Unscrew the screw, then remove the phase sensor. Unscrew the screws, then remove the injection control unit support. Phase sensor 310 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 311 ENGINE After Sales Training 1. Unscrew screws (1a), then remove tappet cover (1b) and timing belt upper cover (1c). Timing belt upper cover 311 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 312 Unscrew the screws, then remove the timing belt lower cover. Disconnect the revs sensor electric connection. Disconnect the minimum oil pressure switch connection. Timing belt lower cover 312 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 313 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). 313 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 314 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Power unit support (valve gear side) Act on belt stretcher (1a) to remove timing belt (1b). 314 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 315 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Moving belt stretcher Fit template (2000004400) onto the distributing shaft rear shank. 315 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 317 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Fit the template securing the pulley to the camshaft. Fit in the timing belt. 317 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 318 Fiat Auto S.p.A. 8-VALVE 1.4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Fit drive shaft timing template (2000004500) onto the driving pulley. 318 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 319 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Proceed as shown in the figure to bring the automatic stretcher reference fork to the abutting end. 319 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 320 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. 320 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 321 ENGINE After Sales Training Position tappet cover (1a) onto the head, then draw fastening screws (1b) closer. Fit tappet cover centring tool (2000004300). 321 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 322 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. 322 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 323 Connect the electric connection of the oxygen sensor upstream the catalyst. Connect the injection control unit ground cable. Connect the injection control unit electric connections. 323 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 324 After Sales Training List of tools Type Item code Function Template 2000004500 Drive shaft timing Template 2000004400 Camshaft timing Tool 2000004300 Tappet cover centring 324 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 325: M20 Gearbox
(Borg-Warner type) and is placed on the countershafts (upper shaft for the 3 gears and the reverse gear; lower shaft for the 1 and 6 gears). 325 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 326: Component
2 gears. 1. Inner synchromesh ring 2. Intermediate ring 3. Outer synchromesh ring 4. Engaging sleeve 5. Synchromesh hub 6. Push dowels 326 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 327 The two-cone synchromesh is used with the 3 and 4 gears. 1. Intermediate ring 2. Synchromesh ring 3. Engaging sleeve 4. Synchromesh hub 327 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 328 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. 328 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 329: Drive
After Sales Training 5.2.2 Drive The M20-6 manual gearbox features a tie-rod drive. Every single gear is selected by means of a central control unit. 329 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 330: Shafts
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 330 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 331 14. Fastening bushing 15. Reverse gear headlamp switch 16. Central disengagement 17. Pressure pipe 18. Clutch housing 19. Gearbox control assembly 20. Magnet 331 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 332 10. Synchromesh hub 11. Spacer bushing 12. Safety ring 13. 3 speed gear (driven) 14. 3 speed gear roller bearing 15. Intermediate ring 332 / 532 gb Fiat Grande Punto OK © 2004 Fiat Auto S.p.A. – All rights reserved...
Page 333 24. 4 speed gear 25. Intermediate ring 26. Synchromesh ring 27. 3 speed engaging fork 28. Gearshift lever pin 29. Reverse gear engaging fork 333 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 334 10. Thrust washer 11. 5 speed gear (driven) 12. 2 speed gear roller bearing 13. Synchromesh ring 14. Push dowel 15. Synchromesh hub 334 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 335 (driven) 31. 1 speed gear roller bearing 32. Safety ring 33. Output shaft roller bearing 34. Output shaft 35. Oil recovery pipe 335 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 336 7. Differential 8. Top gear shaft bearing 9. 6 speed gear (driving) 10. 4 speed gear (driving) 11. Spacer bushing 12. 3 speed gear 336 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 337: 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. 337 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 338 Both the bearing play and preload are obtained, during the manufacture, by using compensating washers under the oblique, tapered-roller bearings in the transmission case. 338 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 339: Speed Gear Arrangement
This 3-shaft gearbox unit is advantageous in that the 3 speed gear on the top gear shaft is also used for the 5 speed. 339 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 340: Kinematic Route Of The Single Gears
M 20 Fiat Auto S.p.A. FIAT PUNTO TRAINING OUTLINE GEARBOX After Sales Training 5.5 Kinematic route of the single gears speed speed 340 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 344: Brakes
(each circuit acts on a front wheel and the diagonally opposing rear wheel) in order to ensure braking and vehicle stability even when one of the circuits is broken. 344 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 345 Fiat Auto S.p.A. BRAKES FIAT PUNTO TRAINING OUTLINE After Sales Training Ventilated front disc Rear drum Rear disc 345 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 346 257 x 22 mm; Bosch ZOH brake calipers with piston diameter of 54 mm; brake pad surface area: 43 cm rear drum diameter: 228 mm. 346 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 347: Power Brake
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. 347 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 348: Pedal Unit
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. In case of disconnection, the pedal shall be replaced. 348 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 349 The pedal unit system is made up of the following components: plastic pedal support; plastic accelerator pedal, with a potentiometer; metal brake pedal; plastic clutch pedal. 349 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 350: Abs System
Therefore, continuous information is essential, even at low speeds, about the road along which the vehicle is driven, to calculate the exact position of the vehicle. 350 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 351: Abs Wiring Diagram
6.4.1 ABS wiring diagram Rear left ABS sensor Rear right ABS sensor Front left ABS sensor Front right ABS sensor Ground BSM (Brake node) 351 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 352 19. Rear right ABS sensor signal 20. Brake lights 21. ASR button input 22. ASR button LED 23. VSO output 24. N.C. 25. C-CAN H1 26. C-CAN H” 352 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 353: Abs Hydraulic Unit
(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). ABS hydraulic unit 353 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 354: E.s.p
1 side acceleration and yaw sensor incorporated into one single device fitted onto the central tunnel; 1 electro-hydraulic unit fitted onto the special support in the engine compartment; 1 switch on the brake pedal; 354 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 356: Esp Wiring Diagram
Fiat Auto S.p.A. BRAKES FIAT PUNTO TRAINING OUTLINE After Sales Training 6.5.1 ESP wiring diagram ASR button on the dashboard BSM (Brake node) Ground 356 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 357: Yrs (Yaw Rate Sensor)
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. 357 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 358: Anti Slip Regulator)
The ASR can be switched off and then on again when the vehicle is running, by pressing the special switch located among the controls on the instrument board. 358 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 359: M.s.r
This function combines the information gained, through special sensors, from the pedal unit, gearbox and engine management control unit, so as to automatically deliver the 359 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 361: Electric Drive
It is made up of a steering column with integrated, electric drive system, and a special management control unit. 361 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 362: Electric Power Steering (Eps)
The driver can choose from two drive programs (City and Normal), which can be selected by means of a button available on the dashboard. 362 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 365: Drive Housing
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. 365 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 366: Steering Column
All of this reduces to a large extent the load suffered by the occupant’s thorax during the collision. 366 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 367: Suspensions
The elastic bushing dimensions have been increased to improve the damping of road roughness and increase the driving comfort. Shock-absorbers with 22 mm stems on all versions, to increase the stability limit conditions when cornering. 367 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 368: Front Suspensions
Punto, to improve comfort (to dampen minor roughness) and, at the same time, ensure optimum road holding and stability when cornering; 368 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 369 The front suspension crossbar is the lowest part of the vehicle, since the body struts have been lowered to improve the vehicle performance during the crash test. Only toe-in can be adjusted on the front suspension. 369 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 370: Characteristic Angles
-26' +/- 20' -28' +/- 20' 1,9 MJet 120 CV 1,9 MJet 120 CV 195/55 R16 87H -19' +/- 20' -21' +/- 20' 370 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 372 Represented by mm (d2 – d1, see figure above). Only toe-in can be adjusted in the traditional way, by acting on the steering connecting rod nuts. 372 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 373: Rear Suspensions
Neither toe-in nor the camber angle can be adjusted: the correct values shall therefore be guaranteed during the assembling phase. 373 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 374: Characteristic Angles
-1°+/- 20’ -1°+/- 20’ 1,2 JTD (90 CV) 1,9 JTD -1°+/- 20’ -1°+/- 20’ 1,9 JTD 195/55 R16 87H -1°+/- 20’ -1°+/- 20’ 374 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 375 (e.g. the centre line between the bolts) have changed: trying to do so would affect the integrity of the wheel-hub components and, above all, the driving safety. 375 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 376: Electric System
9.1 General description of the system The technology used for the electric system of the Nuova Punto is based on the complex architecture called “Famiglia1”, first used on a FIAT model. Modular system To obtain the minimum number of wiring families, each circuit connected to a sectioning joint holds the same position inside the joint, regardless of the trim level;...
Page 377: General Features
Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training 9.1.1 General features 377 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 379 The most complete structure is made up of two CAN communication lines that connect nodes belonging to two different areas (dynamic vehicle control and bodywork function/on-board information) and also an additional “LIN bus” serial line (first used on a FIAT model of this segment).
Page 380: Network Architecture
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 protocol on the CAN network (ISO 14229).
Page 381 R = __________________ = _______________ = _________ = _____ x _____ = 60 ____ ____ _____ + _____ ____...
Page 382 Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training Full optional network architecture 381 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 383 (e.g. rain sensor control unit): in fact, they do not feature any implemented diagnostic protocol, and their errors (if any) are detected through the diagnosis of other control units (e.g. BCM). 382 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 384: Diagnosis Instrument Adapter
After Sales Training 9.1.4 Diagnosis instrument adapter The diagnosis of Fiat Punto, which makes use of a serial network of the CAN HIGH SPEED type, can be performed by means of the new A16HS high-speed cable. Moreover, release 6.30 (or any other subsequent release) shall be installed on the Examiner in order to access all the functions.
Page 385: B-Can Low-Speed Line
Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training 9.1.5 B-CAN low-speed line 384 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 386 Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training FULL B-CAN NETWORK BASE A-CAN NETWORK BASE B-CAN NETWORK 385 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 387: C-Can High-Speed Line
Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training 9.1.6 C-CAN high-speed line BASE C-CAN 386 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 391: Remote-Control Switch/Fuse Holder Unit
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. 390 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 392 (LED), ELC control illumination (LED), SWC control illumination (LED), TPMS, sunroof motor. Luggage compartment door unlock actuator Engine fuel lid and door closing Reserve output 391 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 393 Fuel water sensor, reversing light, flow meter hot film Rear heated window Side mirror defrosting Front right window regulating motor Front left window regulating motor Spare Spare 392 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 394: Wiring
Washing pump Power supply with FDU G005 Rubber G001 Plastic inserts Wiring HVAC (K) G029 Intrument panel wiring (P) G031 G021 393 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 395 Wiring + Battery (B) Alternator wiring (J) Selespeed pump Starting motor Alternator Selespeed pump relay Selespeed In-line connection Front wiring body (L) 394 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 396 Preset G033 Rear bumper wiring (X) G041 Rear fog Reversing light License plate Rear left light Rear right light light light Parking sensor wiring 395 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 397: Electronic Components
AHM (Auxiliary heater node) The derived components differ in the HW/SW implementation from the components used on the reference models (e.g. Nuova Croma). 396 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 398 Information-communication/roof control dashboard on the ceiling light fixture The derived components feature the same interface to the vehicle wiring (wiring diagram/connector) as the reference model. 397 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 399: Description Of Components
The front distribution nodes manages the following functions: headlamp washing; right and left side rear-view mirrors; rear heated window; cigar lighter; horns; engine cooling fans. 398 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 400: 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. 399 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 401: Body Computer Node (Bcm)
(see figure below). Body Computer node (BCM) The Body Computer node is interconnected to the front bodywork cable harness and the dashboard cable harness. 400 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 402 B-CAN and C-CAN networks, and between the LIN and B-CAN. The immobilizer and remote control RF antenna interfaces are provided on the BCM. 401 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 403 Brake light switch signal (normally open) Front driver’s door key cylinder switch (lock/unlock) Front passenger’s door key cylinder switch (lock/unlock) Reserve output Antenna RF (GND) – coaxial cable 402 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 404 Front driver’s door closing switch signal Left door rear glass detection switch External temperature sensor ground External temperature sensor signal Connector LC Description Front right indicator light 403 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 405 Rear window regulator relay control Spare Light switch module Four indicator button LED Central locking button LED Rear window button LED Parking assist deactivation LED 404 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 406 Lock/unlock signal Front wiper adjustment control Cruise Control settings Reference ground Spare Rear fog light control signal Cooling fluid level signal Spare Spare 405 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 407 Bi-directional washing pump control (rear) Rear wiper switch control power supply Wiper high speed control power supply Spare Door locking control power supply 406 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 408 Boot lock power supply Driver’s door unlocking control Front wiper low speed power supply Connector LK Description RF antenna signal RF antenna ground 407 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 409 Display power supply Telephone + 30 Spare Glove compartment chest light power supply Glove compartment light power supply ELC light power supply Spare Spare Spare 408 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 410: Instrument Board Node (Ipc)
Features The design of the 199 instruments has been realized by establishing a “family feeling” with the other FIAT vehicles of its generation, such as Stilo, Punto Face Lifting and Panda, all of which feature orange background 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.
Page 411 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 presettings that can be actuated through the CAN network). 410 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 412 - if the temperature is included between 115° and 124°C (uphill) and between 120° and 115°C (downhill), the pointer will move linearly. 411 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 413 Visible area 64.5 x 27 mm Pixel dimensions 0.7 x 0.94 mm Max. interpixel dimensions 0.03 mm Power supply 4 / 7 V 412 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 414 0.37 x 0.37 mm Max. interpixel dimensions 0.02 mm Position on the vehicle The IPC is located in the driver’s side dashboard. Instrument board pin-in/pin-out 413 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 415 (permanently, until their are remedied) into the IPC memory. If the signal from the SDM in the B-CAN is delayed, the IPC shall make the airbag warning light to come on. 414 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 416 Comfort and Matrix panels, or 3999.9 km (miles) for the Mode panel], or when the driving time reaches 99:59 (99 hours and 59 minutes); every time after the battery is reconnected. 415 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 417 Driving time [hh:mm]: it indicates the time [00:00 to 99:59) elapsed since the start of the mission, with resolution and updating of 1 minute. When the maximum value is reached, the count will be reset automatically. 416 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 418 Clock and time format (12/24 h) setting. Date setting. Audio information repeat actuation/deactivation. Actuation/deactivation of automatic door/boot locking above 20 k.p.h. Setting the units of measurement (distance, consumption, temperature). 417 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 419 Alarm/fault/warning buzzer volume setting. Button pressing buzzer volume setting (roger beep). Seat belt reminder re-actuation. Servicing slip expiry displaying (km/miles). Passenger’s airbag actuation/deactivation. 418 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 420 Consumption unit of represented by the measurement kilometre; m.p.g. if (k.p.l., l/100 km, the speedometer m.p.g.) scale is represented by the mile 419 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 421 Service (km or miles) kilometre; mi if the speedometer scale is represented by the mile Depending on the signals from the Passenger’s airbag actuation/deactivation Confirmation: always 420 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 422 The expiry value can be displayed at request at any time by means of a specific item of the set-up menu. When the limit expiry value (0 km/miles) has been reached, the “Servicing expired” message will be displayed. 421 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 424 When the low-beam headlamps are switched off, both the symbol and the respective number will go out, and the function will be disabled. 423 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 425 The writing will be displayed for about 20 seconds after the latest pulse given, unless the function is deactivated (through the steering column stalk). EXAMPLE (Mode panel) 424 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 426 Telephone displaying through the Convergence module (Comfort panel) The panel displays the Convergence status: - BLUETOOTH status - telephone company name. Telephone company Bluetooth name status 425 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 427 This function can be actuated/deactivated only through the diagnostic network and makes it possible to cut down consumption (current absorbed) so as to prevent the battery from running down. 426 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 428 Comfort panel: on displaying strings, each of them lasts 1.5 seconds max. and occupies 5 rows max (these strings make up a displaying cycle); Matrix panel: on one single screen. 427 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 429 - robotized gearbox request signalling (where the robotized gearbox is available); - parking sensor signalling (where the parking sensor is available); - safety belt reminder signalling; 428 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 430 The “safety belt” warning light informs that the safety belt has not been fastened (both on the driver’s and passenger’s sides) by coming on steadily since the key-ON. 429 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 431 3°C, the Comfort panel display shows the warning message: the blinking external temperature (for the duration of the message); 430 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 432 (if any) during the cranking phase: clock/date; trip computer (A and B); trip odometer (included in the trip computer). 431 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 433 The vehicle panel lighting provides for two different modes: active with the lights ON: indicators, graphic elements, display; active with the key ON (key-ON): display. 432 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 434: Steering Column Stalk Control Module (Csm)
The module may include the Trip function (available on all the body versions) and the Cruise Control function (available as an option). It is interconnected through the dashboard cable harness. 433 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 436 (the former is unstable, the latter is stable); pulling movement towards the driver, with double click (unstable); ring rotation by 3 or 4 clicks. 435 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 437 “Trip” function button: by pressing the unstable button located at the lever end, the “Trip” function will be commanded to the vehicle panel. 436 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 438 (referred to as “direction change”). The “lane change” function is actuated through a smaller angular travel than the one required to actuate the “direction change”. 437 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 439 Intermittent operation: the windscreen wiper is controlled at speed 1, yet with a pause between two subsequent strokes that varies depending on the vehicle speed, in accordance with the diagram below: 438 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 440 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). 439 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 441 When the rain sensor operation is resumed, a windscreen wiper stroke will occur, regardless of the windscreen conditions, to inform the user that the operation has been resumed. 440 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 442 In the event that the windscreen wiper has already been actuated prior to actuating the washing control through the lever, the smart washing logic will only be performed to actuate the same in the intermittent mode. 441 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 443 In the event that the rear window wiper has already been actuated prior to actuating the washing control through the lever, the smart washing logic will only be performed to actuate the same in the intermittent mode. 442 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 445 After the ASR system has stopped operating, the Cruise Control function is automatically resumed to the latest speed value stored in the memory. 444 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 446 “–” sign and subsequently released, thus causing the speed to decrease by steps of equal size. When the lever is released, the system will maintain and memorize the new speed reached by the vehicle. 445 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 447 In any case, the Cruise Control will remain ON, without having to press the resume (“RES”) button to resume the previous conditions once acceleration has ended. 446 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 448: Radio Receiver Node (Rrm)
Interfacing with an external audio amplifier is provided on the radio receiver node (RRM), with a CD changer and an external module for GSM (telephone) and GPS (navigation) management. 447 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 449: Rear Parking Sensor Node (Pam)
IPC instrument board node are provided on the PAM parking sensor node. The parking assist system of FIAT Nuova Punto is made up of the following components: - ultrasound sensors on the rear bumper;...
Page 450 - Acquiring the external temperature signal for the diagnosis strategy (see diagnosis specification). - Parking sensor management. - Transmitting, on the B-CAN line, parking sensor correct operation. 449 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 451 - 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. - Actuating the obstacle detection acoustic signal. 450 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 453 Failure to even one single sensor will disable the operation of the entire system: in this case, the system will cut itself off and send a failure message. 452 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 454: External Audio Amplifier For The Hi-Fi System
(CSM), which ensure connection between the dashboard cable harness, the controls on the steering wheel (SWC) (audio and telephone systems) and the airbag modules. 453 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 455: Rain Sensor Control Unit (Rls)
This switch is located on the brake pedal and is connected to the body-to-front cable harness. Its function is to indicate the brake pedal status in order to report the latter to the control units that request so. 454 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 456: Control Board On The Driver's Side Front Door (Ddc)
The second model incorporates an electronic module for controlling the up and down movement of the driver’s side front electric window regulator only, in automatic mode. 455 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 458: Switch On Clutch Pedal
9.2.14 Central control board (CSS) The central control board (CSS) includes the following buttons: “City” button for actuation/deactivation of the City mode on the electric drive; 457 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 460: Tpms Tyre Pressure Control System
In case of tyre puncture, the panel will also emit an acoustic signal. Moreover, a TPMS failure signal (warning light/icon + message) is available. 459 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 461: Central Locking
The keys are supplied in duplicate together with the vehicle. They are accompanied by the CODE Card. electronic code; 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.
Page 462 1 blink ON steadily for approximately 3 Blinks twice, Deterrent seconds, then then deterrent Deterrent Deterrent Switch-off deterrent blinking blinking blinking Switch-off blinking 461 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 464 The boot can also be opened from the inside (in case of electric system malfunction) by means of a mechanic safety device that can be actuated through a mask located in the upper portion of the luggage board. 463 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 465: System Functions
The boot and door locking/unlocking can be actuated from the central board by means of button C. Button actuates the remote opening of the boot. 464 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 466 (deterrent function). If the boot or one or several doors are not closed correctly, the LED will blink quickly together with the indicator lights. 465 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 467 Fiat Auto S.p.A. ELECTRIC FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training Control dashboard Body Computer node (NBC) 466 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 468 – briefly press the MENU ESC button to go back to the submenu screen, or press the button for a long time to go back to the main menu screen without storing in the memory; 467 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 469 Therefore, the deadlock ensure the best protection against any attempt at theft. It is recommended that the system is actuated every time the vehicle is left parked. 468 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 470 BODY-TO-FRONT CABLE BODY-TO-FRONT CABLE Body Computer node (NBC) Rear left door locking actuator BODY-TO-FRONT CABLE REAR LEFT DOOR Driver’s side front door locking actuator 469 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 473: Electric Window Regulators
The driver’s side window regulator can be operated both manually and automatically. The passenger’s side window can be operated in manual mode only. 472 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 474 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. 473 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 475 The passenger’s side window actuation is managed both by the local and driver’s side control. The rear window actuation is managed both by the local controls (one per window) and the driver’s side controls. 474 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 476 - rear left window opening/closing (where provided for); - rear right window opening/closing (where provided for); - rear door switch control disable (where provided for). 475 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 477 (of the driver’s side front door external handle) and is actuated only upon key-OFF. The window central closing/opening actuation is not simultaneous for the 4 windows: it follows a programmed sequence. 476 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 479 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 front windows: 478 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 480: External Lighting
Every time the key is next OFF, the function will no longer be active: it can be actuated again by repeating the aforesaid actuating operation. 479 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 481 Turning the vehicle off (key-OFF) with the rear fog light ON will cause the latter to be switched on. Upon the following key-ON, the rear fog lights will remain OFF. 480 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 482 The diagnosis will be carried out for every single brake light bulb and the third brake light bulb as well. If an anomaly is found, the failure signalling will be actuated on the instrument board 481 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 484 (the headlamp shall not be taken off the bumper). Fuse replacement: the F31 protection fuse is located inside the engine compartment control unit (FDU). 483 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 485 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. 484 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 486 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). 485 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 487 Two lights with W5W bulbs, housed onto the rear bumper. Optimum homogeneity of light distribution, which allows the license plate to be clearly seen. 486 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 488 2: five persons travelling on the vehicle and luggage compartment loaded; position 3: driver plus maximum permitted load stored in the luggage compartment. 487 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 489 End of function: when the lights ON time expires, the “Follow me home” function will be switched off: therefore, both the dimmers and the low-beam headlights will be switched off. 488 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 490: Audio System
• tweeter loudspeakers (40 W) located on the door opening handle, designed to reproduce the highest frequencies; 489 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 491 The following information is transferred through this interface: • anti-theft code; • ignition control (for switch-off logic); • volume control depending on the vehicle speed; • lighting control; 490 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 492 • provision for selecting the HICUT (High-cut, i.e. dynamic high sound reduction depending on the RF signal) function; • autostore function (automatic memorization of the radio channels with the best signal); 491 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 493 • “Track Repeat” function; • CD naming (8 characters for 30 CDs); • CD display (displaying the name of the disc/track elapsed time); 492 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 494 • balance; • fader; • loudness; • 7-band equalization: Preset (default), Rock, Jazz, Classic, User (provision for customization); • Blaupunkt CD-changer audio input. 493 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 495 The car radio system features remote controls on the steering wheel (see figures below). Actuates MUTE voice/radi Radio volume control +/– Radio sound source se arch List UP/DOWN scrolling 494 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 496: Airbag System
Thanks to the sturdy structural construction and the use of energy-absorption highly-efficient materials, the intrusion levels for this type of test have proved to be very low on 495 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 497 Moreover, a side protection system is available as an optional item, which features two bags on the front seats and two curtain bags in the rails under the roof and two side collision detecting sensors. 496 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 499 Early crash sensor (ECS) Passenger’s side head airbag Passenger’s side collision sensor Driver’s side collision sensor Passenger’s side pretensioner Driver’s side head airbag Driver’s side pretensioner 498 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 500: Smart 2 Airbag System
Driver’s side front airbag: it consists of an instantly inflating cushion held in a special compartment located in the middle of the steering wheel. 499 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 501 (this phase shall therefore be completed before the occupant starts moving forward towards the steering wheel or the dashboard. 500 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 502 They are used to protect the front and rear occupants’ heads in case of side collisions, thanks to the wide deployment surface of the cushions. 501 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 503 FIAT PUNTO TRAINING OUTLINE SYSTEM After Sales Training Connections The airbag node (SDM) is connected to the B-CAN line. B-CAN NETWORK “A” B-CAN NETWORK “B” 502 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 504: Airbag Node (Sdm)
Acquiring data from the various side and front sensors. Actuating the various airbags and pretensioners. 503 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 508 Internal Internal Safety threshold airbag side accelerom. accelerom. function airbag Pretensioner Front protection Side Side limiter protection Rear protection Fuel cut-off 507 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 509 R11 = if the passenger’s airbag deactivation warning light status or switch are not clear (either of them is faulty, or out-of-time message), the warning light will be actuated immediately and the passenger’s airbag will be promptly deactivated. 508 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 511 Warning messages from the airbag (IPC side). The SDM will start its diagnosis activity upon key-ON; thus, it will be able to detect any airbag system trouble. 510 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 512: Fire Protection
In the late 1990s, the introduction of the new European regulations on the crash tests and also of the injection fuel feed system has made FIAT 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.
Page 513 (RDU, wired on the vehicle cable and positioned in the rear left headlamp area). The cable routing is properly arranged, to avoid cable pinching when the trimmings are fitted. 512 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 514: Air Conditioner
Inside the mask are also the buttons for recirculation control, rear heated window actuation and compressor switch-on (versions with air conditioner only). 513 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 515: Air Flows
Fiat Auto S.p.A. AIR CONDITIONER FIAT PUNTO TRAINING OUTLINE After Sales Training 10.1.2 Air flows Air flow and vent diagrams 514 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 516: Components
Temperature sensor 4 signal Temperature sensor 3 signal Spreading sensor signal Temperature sensor 2 signal N.C. N.C. N.C. N.C. Left mixing motor position signal 515 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 517: Actuators And Sensors
DEF SX – dashboard – foot area air distribution actuator; DEF DX – dashboard – foot area air distribution actuator; fan speed actuator; compressor disable actuator; 516 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 518: Compressor
“dumpers” (4) and an inertia ground (5) directly secured to the shaft are also used. Since the motion is always transmitted to the compressor shaft, the compressor switch-on/off function is entrusted to the “ON/OFF” valve (6). 517 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 519 8,500 number of pistons: 5 minimum displacement: 0 cm /rev maximum displacement: 126 cm /rev amount of lubricant: 80 cm 518 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 520 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 the rod-holder plate (2). 519 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 521: Filters And Condenser
The pollen filter features a rectangular shape. It can be replaced by removing the plastic guard located inside the passenger compartment, on the passenger’s side under the glove compartment. 520 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 522: Expansion Valve
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 521 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 523: Fluids
10.3 Operation logic The air conditioner control layout varies according to the body versions (heater, manual conditioner, automatic, two-zone air conditioner). Heater Air conditioner 522 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 524 12) left-hand air distribution selection buttons (three green LEDs); 13) fan speed pivoting button (increase/decrease); 14) right-hand air distribution selection buttons (three green LEDs); 523 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 525: Diagnosis
This operation shall be repeated after at least one actuator has been replaced. The procedure shall be started again in case of interruption. 524 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 526: Sunroof
During the opening phase, the front mobile panel slides out of the roof panel (“spoiler” function). In particular, the sunroof consists of the following: 525 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 527 (C) which acts as an air baffle (it lifts when the roof is opened); two polyester roller-type window shades (front and rear) with manual, two-position control (open/closed). 526 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 528 2. Speed signal from the brake node 3. Power supply (+30) Built-in motor & control unit 4. Ground 5. N.C. 6. N.C. Motor/control unit pin-out 527 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 529: Operation
This function allows the user to position the front panel at intermediate positions with respect to the maximum opening position. 528 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...
Page 530: Sunroof Closing
(still within the time range of 60 to 300 ms), the panel will jolt along until it reaches the maximum closing position. 529 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved.
Page 531: Window Shades
EC Directive 2000/4. Possible pinching from the vehicle interior in the panel side zones is avoided by making use of side guards that prevent the hazard zones from being reached. 530 / 532 gb Fiat Grande Punto OK © 2005 Fiat Auto S.p.A. – All rights reserved...

Fiat Punto 2004 Training Manual

1 Briefing

2 Technical Specifications

3 3 Multijet 16V, 75 and 90 Hp Engines

8 Valve 1.4 Engine

5 M20 Gearbox

6 Brakes

7 Electric Drive

8 Suspensions

9 Electric System

10 Air Conditioner

11 Sunroof

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Summary of Contents for Fiat Punto 2004