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Fiat 500 Manual

Fiat 500 Manual

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  • Page 1 FIAT 500...
  • Page 2 © 2007 - Fiat Group Automobiles S.p.A. All rights reserved. Distribution or reproduction by any means is forbidden. Fiat Auto S.p.A. shall not be liable for any involuntary errors or omissions in the publication. The information provided in this document is subject to continual updating: Fiat Auto S.p.A.

  • Page 3: Table Of Contents

    ..........................253 NSTRUMENT PANEL ........................270 LIMATE CONTROL SYSTEM ............................301 UDIO SYSTEM ............................314 ELEMATICS (AIRBAG)......................338 ASSIVE SAFETY SYSTEM BODY............................355 ............................355 ODY SHELL ..............................364 TICKERS ............................369 ASHBOARD ............................372 NTERIOR TRIM 3/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 4: Briefing

    Realized by the Fiat Styling Center and manufactured in the establishment in Tichy (Poland), the new 500 is a 3-door utility: it is 355 centimeters long, 165 cm wide and 149 cm high, with a wheelbase of 230 centimeters. The car is really fun to drive thanks mainly to its choice of three engines: the 1.3 turbo diesel 16v Multijet and the two petrol versions: the 1.2 8V with 69 HP and the 1.4 16v with 100 HP, all...
  • Page 5 The 500 and the market Fiat has chosen the new 500 to be the driver of its image in the world. The new 500 brings with it all the emotional and social values so closely linked with the old 500; thanks to its new features, the Fiat 500 looks to the market from a broader perspective.

  • Page 6: The Story Of A Legend

    4th of July 1957 “The new 500” “Around halfway through the ‘fifties, Fiat began thinking about a possible successor to the 500 Topolino. It had to be a small, very cheap car to side the newly released 1955 600, and cover the gap in the lower end of the market, but it didn’t have to compete as a direct alternative to the 600, sales of which were...
  • Page 7 The first series The car was presented to the public on the 4th of July 1957 with the name “Nuova 500” to distinguish it from the 500 Topolino, which had reached version “C” and gone out of production a few years earlier. Its maximum speed was 85 kilometers per hour, and its price 490,000 Lira, a little high if compared to the only slightly more expensive 600.
  • Page 8 This car began the 500 boom that was to culminate in the ‘sixties with the version D. The little car became well-liked, sales soared and it became a social phenomenon just like the 600 or even more so. There were those who bought it because they could afford nothing else, and those who bought it precisely because they could afford everything.
  • Page 9 The 500 sport The 500 sport was presented in 1958 to offer a car with a bit more go to enthusiasts and to boost the sales of the other versions thanks to the image return from sporting events, through the 500 championship and participations in important races for its category.
  • Page 10 The air intake was replaced by two column intakes built-in to the rear pillars. The displacement was the same as the 500 sport engine, but a little tamer to adapt to the different use. The engine delivered 17.5 HP and the car could reach 95 kph.
  • Page 11 D. It was derived directly from the 500 sunroof, adopting all the alterations made in 1959 but mounting the 499.5 cc engine from the Sport, slightly toned down to deliver 17.5 CV at 4400 rpm instead of the original 21 HP.
  • Page 12 Training Academy The 500 F The Nuova 500 F, successor to the “D” was presented in 1965, and was destined to become the largest selling of all the versions made. The innovations were above all aesthetic: the most obvious were the front hinged doors.
  • Page 13 Fiat Group Automobiles S.p.A. The 500 L The luxury version to side the 500 F, the Nuova 500 L, was presented in 1968. The differencfes were only aesthetic but nevertheless significant. The most evident is the ercolino consisting of tubular metal elements that supplement the bumpers to limit minor damage to the bodywork when parking.
  • Page 14 The final version, destined to close the long lived and evergreen range 500 range, was presented at the Turin motor show in 1972: the 500 R. It was presented at the same time as the Fiat 126. The letter “R”...
  • Page 15 March 1959 aesth./int./mech sport saloon I° series June 1958 March 1959 sport convertible 1 series aesth./int./mech June 1958 March 1959 America series economic int./mech.. July 1958 March 1959 15/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 16 1959 October 1959 improved series convertible aesth. July 1959 November 1959 America series sunroof America aesth. July 1959 November 1959 series luxus aesth. September 1959 November 1959 (Germany) 16/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 17 1959 October 1960 series convertible 60 aesth. March 1960 November 1960 series convertible aesth./int. November 1959 October 1960 sunroof 60 series convertible aesth. November 1959 October 1960 America 17/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 18 Gennaio 1964 September 1964 series aesth. September 1964 March 1965 aesth./int./mech series March 1965 Aprile 1965 series aesth. Aprile 1965 July 1965 series int. July 1965 November 1965 18/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 19 July 1970 November 1972 aesth./int./mech series Agosto 1968 Febbraio 1970 series aesth. Febbraio 1970 November 1970 series int. November 1970 November 1972 aesth./int./mech November 1972 Agosto 1975 19/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 20: Technical Data

    Maximum power revs 5500 6000 4000 (rpm) Maximum torque (Nm EEC) Maximum torque revs 3000 4250 1500 (rpm) Idle speed 750 ± 50 750 ± 50 830 ± 50 (rpm) 20/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 21 Spark Spontaneous Federal Mogul BAE Coils Champion BAE 940 A 403C Number of coils Spark plugs NGK DCPR7E-N-10 NGK DCPR7E-N-10 Glowplugs Bosch 250.203.002 Firing order 1-3-4-2 1-3-4-2 1-3-4-2 21/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 22: Transmission

    1,345 4th gear ratio 1,121 1,121 0,974 5th gear ratio 0,897 0,921 0,766 6th gear ratio 0,766 RG ratio 3,818 3,818 3,818 Differential final ratio 3,438 4,071 3,438 22/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 23: Braking System

    1.3 Multijet 16V Type Drum Disk (full) Drum Drum diameter (mm) Disk diameter (mm) Rated thickness (mm) Calliper type Bosch BIRIII Cylinder diameter 20,6 20,6 (mm) Brake pad diameter (mm) 23/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 24: Suspension

    260 ±10 277,2 ± 10 315,6 ± 10 with spring length 268,2 ±10 at 189 mm 2 blue 2 pink stripes 2 brown stripes 2 white stipes Color stripes 24/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 25: Battery And Alternator

    Battery capacity (Ah) Alternator (A) 90 - 105 Air-conditioner 1.2 8V 1.4 16V 1.3 Multijet 16V Conditioner circuit 450 ± 40 450 ± 40 450 ± 40 quantity (g) 25/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 26: Fluids And Lubricants

    Oil quantities 1.2 8V 1.4 16V 1.3 Multijet 16V Engine oil (quantity for periodic change, sump and filter, litres) Gearbox / front differential oil (Kg) 1.65 1.65 1.65 26/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 27: Vehicle Specifications

    Rear tyre Front tyre Rear tyre pressures (bar). pressures (bar). pressures (bar). pressures (bar). Size Medium load Medium load Full load Full load 185/55 R15 195/45 R16 27/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 28 Mini spare wheel 1,2 8V 1.4 16V 1.3 Multijet 16V 135/80 R14 Turning circle 1,2 8V 1.4 16V 1.3 Multijet 16V Minimum turning 9285 10680 9285 circle (mm) 28/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 29 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. Vehicle dimensions Vehicle length (cm) Vehicle bredth and height (cm) 29/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 30 Fiat Group Automobiles S.p.A. Training Academy Gauge (mm) Front gauge 1414 mm is with tyre size 195/45 R16; Rear gauge 1408 is for the 1.4 16V version; Wheelbase (cm) 30/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 31: Engines

    ENGINES 1.2 8 V EVO 2 Engine This chapter describes the 1.2 8V EVO 2 engine, derived from the 1.2 8V engine used on the Fiat Panda, with the addition of the timing adjuster and new engine control unit. Technical data sheet...

  • Page 32: Lubrication System

    Module built-in to throttle body EXHAUST SYSTEM Type Exhaust manifold in cast iron with catalytic converter ANTI-EMISSIONS SYSTEMS Idle speed 700 ±50 rpm = 0,1% = 50 ppm 32/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 33 4. Tappets 5. Cotters 6. Upper plate 7. Spring 8. Oil seal 9. Lower plate 10. Intake valve 11. Exhaust valve 12. Valve guide 13. Camshaft with phonic wheel 33/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 34 The oil flow is enabled by a box solenoid valve that opens the oil channels present in the cylinder heads to the advance or retard chambers. 34/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 35 INTAKE CAMSHAFT IN CYLINDER terminals to the battery for a HEAD – S.R. WITH SHAFT REMOVED few sconeds. -Check that there is a significant variation in idle speed. 35/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 36 28. Catalytic converter 13. Timing sensor 29. Lambda probe (post-cat) 14. Body Computer (Fiat CODE signal) 30. Timing adjuster pilot solenoid valve 15. Absolute pressure and temperature sensor. 36/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 37 (specifically electroinjectors, ignition coils and throttle) in order to realize the best possible conditions of engine function. The adoption of Fiat CODE does not permit interchangeability of control units between vehicles Note: The Engine Control Module has a built-in atmospheric pressure sensor (A) Pin - out The diagram below shows the pin-out of the electronic control unit.
  • Page 38 (+ 5 V) . 31. Manifold pressure and temperature sensor 14. Not connected signal. 15. DBW power (+5 V) DBW (motorized throttle) 32. Upstream lambda probe heater command 38/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 39 61. Not connected 47. Not connected 62. Not connected 48. Pinging sensor negative 63. Air temperature signal 49. Cylinder 3 injector command 64. Downstream lambda probe heater command 39/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 40 Turn the ignition OFF and wait 1 minute while the data is permanently saved in the memory. With the diagnosis instrument it is possible to check phonic wheel teach-in correctness, regardless of warning light MI, by checking the error memory. 40/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 41 It follows that the high signal and low signal alternate four times for each engine cycle. This signal, along with the revs and TDC signals, allows the control unit to recognize the cylinders and determine the injection and ignition points. 41/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 42 With engine running, the effect of the vacuum causes a mECManical effect on the sensor membrane, which deforms, varying the resistance value. Since the power supply is maintained strictly at 5V by the control unit, varying resistance varies output voltage. 42/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 43 Engine Control Module and the NTC resistor in the sensor. The Engine Control Module can thus evaluate the variations in sensor resistance through changes in voltage and thereby obtain temperature information. 43/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 44 Temperature and resistance table - 20 15971 1152 - 10 9620 5975 3816 2502 2044 1679 Pin - out Signal Engine temperature sensor ground Engine temperature sensor signal 44/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 45 When the crystal is subjected to pressure or impact (B), the molecules align, the more organized the greater the pressure applied. This alignment produces a voltage at the terminals. 45/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 46 A spring on the shaft offers the right level of resistance to pressure while another spring assures pedal return on release. 46/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 47: Throttle Body

    Pin - out Signal Throttle sensor 1 signal Throttle sensors +5V power supply. Throttle motor command positive. Throttle sensor 2 signal Throttle motor command negative Throttle sensors ground. Electroinjectors 47/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 48 Power supply 12 V Injector command. Fuel intake manifold 1. Fuel manifold 2. Injector 3. Fuel pressure check connector 4. Quick connector 5. Fuel delivery pipe Specifications and function 48/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 49: Ignition Coils

    Pin - out Signal Common +12V power supply Cylinder 1 coil command Cylinder 2 coil command Cylinder 3 coil command Cylinder 4 coil command Common ground 49/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 50 In practice, this is a process that the electronic control unit runs to command timed and sequential aperture of the four injectors, one for each cylinder, for the time strictly necessary for forming the fuel-air mixture as close as possible to the stoichiometric ration. 50/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 51 Via CAN line, the control unit receives fuel level and vehicle speed data. The information concerning the robotic gearbox (where fitted) comes from the injection control unit via C- CAN line 51/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 52 18. Pinging sensor 19. Throttle actuator and position sensor 20. Engine speed and TDC sensor 21. Timing sensor 22. Absolute air pressure and temperature sensor 23. Low oil pressure switch 52/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 53 In these conditions there is a natural leanness of the mixture caused by the poor low-temperature turbulence of the fuel particles, reduced evaporation and greater lubricating oil viscosity which, as is known, at low temperatures increase rolling friction of all mECManical engine components. 53/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 54 After a certain period (3 seconds) with the ignition switch to RUN without starting the engine (timed enable) If the fuel cut-off function is activated (via inertia switch) Injector command Injector command is timed-sequential. 54/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 55 The diagram below gives an example of the phases of a low temperature start, showing the FULL GROUP control of the injectors (INJ1, INJ3, INJ4, INJ2). Whereas the diagram below illustrates starting with temperature 20°C 55/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 56 The Engine Control Module recognizes engine idling condition through the “released” position of the accelerator pedal To control engine idle speed according to the utilities being used aboard the vehicle 56/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 57 Monitors camshaft position. The Engine Control Module commands the adjuster pilot valve through a duty-cycle command. Starter motor control The starter motor is commanded directly from the ignition switch. 57/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 58 Engine Control Unit. In case of slow adjuster, the Engine Control Module commands the solenoid valve to keep the adjuster in maximum advance position (rest position). 58/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 59 E050 INSTRUMENT PANEL I020 REVERSING LIGHTS SWITCH (GEARBOX HARNESS) I030 BRAKE PEDAL SWITCH H001 COMMUTATORE DI ACCENSIONE M001 BODY COMPUTER M010 ENGINE CONTROL MODULE N040 FUEL PUMP AND GAUGE 59/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 60 K017 POST-CAT LAMBDA PROBE K030 ENGINE OIL PRESSURE SENSOR (SWITCH) K055 ACCELERATOR PEDAL POTENTIOMETER K098 TIMING ADJUSTER SOLENOID VALVE L010 FUEL VAPOR RECOVERY VALVE M010 ENGINE CONTROL MODULE N070 INJECTORS 60/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 61 K036 ENGINE COOLANT TEMPERATURE SENSOR/TRANSMITTER K044 INTEGRATED AIR PRESSURE AND TEMPERATURE SENSOR K047 TIMING SENSOR K048 PRESSURE SENSOR K050 KNOCK SENSOR M010 ENGINE CONTROL MODULE N075 THROTTLE ACTUATOR 61/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 62: 1.4 16V Engine

    Fiat Group Automobiles S.p.A. Training Academy 1.4 16V Engine This chapter describes the new 16 V 1.4 engine derived from the engines already used on the Fiat Panda, and equipped with a new engine management system. Technical data sheet ENGINE...
  • Page 63 Intake manifold in plastic material EXHAUST SYSTEM Type Exhaust manifold in cast iron with catalytic converter ANTI-EMISSIONS SYSTEMS Idle speed 750 ±50 rpm = 0,3% = 50 ppm 63/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 64: Engine Management

    Radiator fan relay/s 18. Pinging sensor Radiator fan 19. Throttle actuator and position sensor Compressor activation relay 20. Engine speed and TDC sensor 10. Compressor 21. Timing sensor 64/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 65 The ignition system is static type with coils and spark plugs, with power modules contained in the Engine Control Module. Through the pre-catalyzer Lambda probe the Engine Control Module verifies that combustion is within optimal values. 65/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 66 Vehicle speed state Brake Module parameters state for ESP/ASR control. Robotic Gearbox Module parameters state Sport button pressed state from Body Computer Module Alternator state Fuel level state 66/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 67: Electrical Connections

    (-) . Pin 27 oil level switch not used Pin 53 Downstream Lambda probe signal . Pin 28 Timing sensor ground reference Pin 54 Downstream Lambda probe ground. 67/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 68 Pin 49 5V to accelerator potentiometer power Pin 92 N.C. “POT. 1” Pin 93 N.C. Pin 50 N.C. Pin 94 Engine revs signal not used Pin 51 N.C. 68/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 69 This oscillation induces an electromotive force in the winding (2), alternately generating a positive voltage (tooth facing sensor) and negative voltage (valley facing sensor) at the winding terminals. 69/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 70 The required distance (gap) between the phonic wheel and the sensor to obtain correct signals must be between 0.5 - 1.5 mm. Example of revs signal obtained with the oscilloscope 70/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 71: Timing Sensor

    Location The timing sensor is located on the upper head in a specific housing, and faces toward the camshaft, intake side. 71/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 72 Gap 1 +/- 0,5 mm Fastener torque 8 +/- 1.6 Nm Example of timing signal obtained with the oscilloscope Note: the sensor is powered directly by the Engine Control Module Electrical connections 72/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 73 To provide a signal, the sensor element varies its resistance according to temperature, Location The temperature sensor is mounted on the thermostat cup. Specifications and function 1. NTC element 2. Sensor body 3. Electrical connector 73/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 74 308,6 5975 231,2 3816 175,7 2502 135,2 2044 105,4 1679 83,1 1152 66,2 MBCManical specifications Tightening torque 22 Nm Electrical connections Signal Pin 1 signal Pin 2 ground 74/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 75 This information is used by the BCM to define the quantity of air drawn in by the engine. It is then used to calculate injection time and ignition point. Location The air pressure and temperature sensor is mounted on the intake manifold 75/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 76 With engine running, the effect of the vacuum causes a mBCManical effect on the sensor membrane, which deforms, varying the resistance value. Since the power supply is maintained strictly at 5V by the control unit, varying resistance varies output voltage. 76/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 77: Atmospheric Pressure Sensor

    The information is used by the BCM to correct the quantity of air drawn in by the engine according to altitude. The information is used to calculate injection time and ignition advance. 77/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 78 The resistance at the sensor terminals is circa 4.87 Mohm +/- 20% Mechanical specifications The pinging sensor has to be tightened to a torque of 20 Nm +/- 20% 78/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 79 In case of failure of one of the two potentiometers, the control unit using the remaining track, without limiting torque, and controls plausibility with the brake pedal. In case of total failure of both potentiometers, it disables throttle aperture. 79/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 80 Potentiometer 2 5V power supply Pin B Potentiometer 2 ground Pin C Potentiometer 2 signal Pin D Potentiometer 1 5V power supply Pin E Potentiometer 1 ground Pin F Potentiometer 1 signal 80/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 81 1. Therefore: Lambda = 1 ideal mixture Lambda > 1 lean mixture Lambda < 1 rich mixture Rich mixture (lacking air) Rich mixture (excess of air) 81/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 82 “closed loop” control (Lambda = 1) within 10 seconds of starting the engine. 1. Connector 2. Protective sheath 3. Planar sensor element 4. Ceramic support tube 5. Probe seat 6. Ceramic gasket 7. Protective tube 82/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 83 4. Terminals of probe with potential difference Heater electrical specifications Nominal voltage 12V Maximum voltage 14V Nominal power 7W Resistance 9 Ohm at 20°C Maximum current 2.1° at 13V 83/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 84 Pin 3 Heater command Pin 4 12V power supply Post Catalyzer Probe Signal Pin 1 Signal Pin 2 Signal ground Pin 3 Heater command Pin 4 12V power supply 84/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 85 Location The sensor is positioned on the engine oil filter support Electrical connections Signal Pin 1 Connection with the Engine Control Module 85/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 86 The figure below shows the electrical circuit with brake pedal pressed and the function diagram. Note: on the Fiat 500, only the NO contact is connected to the Engine Control Module. The NC contact is connected instead to the Body Computer Module, which gives state information via C-CAN network Key: A.
  • Page 87 Note: the switch is not present on versions with MTA gearbox. Specifications and function The switch consists of a container with a normally open switch (NO) that closes when the clutch pedal is pressed. 87/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 88 Compressor and fan activation according to pressure variation takes place in this range of pressures. Above and below this range the compressor is disabled as safety to prevent damage to the system. 88/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 89 Pin 1 Ground Pin 2 Power supply Pin 3 Output signal Note: power supply may vary by +/- 10% and sensor operating temperature is between 5°C and 80°C. 89/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 90 In intermediate positions, it cuts fuel to one or more pistons until reaching a maximum speed of 1,200 rpm. Note: Replacement of the throttle body, Injection Control Module or intake manifold requires execution of the teach-in procedure. 90/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 91 Fastened in specific seat in the intake manifold and facing the ducts of the two intake valves. They are connected by a common feed pipe fitted with a bleed valve. 91/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 92: Electrical Specifications

    Tensione di alimentazione 12 V Resistenza 14,5 ± 5% ohm. Collegamenti elettrici Segnale Pin 1 Alimentazione + 12 v Pin 2 Comando a massa da nodo Controllo Motore 92/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 93 Primary circuit resistance 0.5 Ω ± 10% at 23°C Secondary circuit resistance 6300 Ω ± 10% at 23°C Mechanical specifications Coppia di serraggio della vite di fissaggio alla semitesta superiore 8 +/-1 Nm 93/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 94 E’ utilizzata dal Nodo Controllo Motore per pulire il filtro a carboni attivi dell’impianto antievaporativo Ubicazione It is mounted in the lower part of the intake manifold, in a position not visible. 94/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 95: Caratteristiche Meccaniche

    1. CANISTER side socket A arrow toward flow. 2. intake side socket Electrical connections Signal Pin 1 Alimentazione + 12 V Pin 2 Comando a massa da Nodo Controllo Motore 95/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 96 96/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 97 Ignition advance regulation Pinging control Engine maximum speed control Controllo combustione con sonda lambda; Controllo elettroventola raffreddamento motore. Air-conditioning system control Emissions control systems Recovery and self-diagnosis Self-adaptation 97/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 98: Cylinder Position Recognition

    1, otherwise without the two spaces and timing notch (sensor signal low) cylinder 4 is the next in compression. 98/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 99 FULL GROUP, but timed sequential, and to illustrate the signals panel with the engine starting Signal panel with engine starting Note: the firing order of the injectors and coils is 1,3,4,2 99/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 100 Fuel condensation on the inner walls of intake ducts High lubricating oil viscosity. The Engine Control Module recognizes this condition and corrects injection time according to. Engine coolant temperature Intake air temperature Battery voltage Engine revs 100/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 101 Instead, once converted, slow torque will define the throttle aperture angle Estimation of air intake allows the Engine Control Module to calculate the quantity of fuel, and thus the injector aperture time. 101/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 102 The Engine Control Module implements electrical balance strategy on the basis of battery voltage When battery voltage drops at a rate greater than a set threshold, the minimum target is increased (ramp). 102/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 103 Intake air temperature Engine coolant temperature Ignition can be retarded selectively cylinder by cylinder, through the combination of the value recorded by the revs sensor and the “timing” data 103/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 104 80 seconds after engine start, second loop mixture control starts after 450 seconds. Note: the voltage of the downstream probe is approx. 630mV and is constant (if it starts to fluctuate, it means the catalytic converter is worn). 104/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 105 If instead the result is greater than this threshold, and vehicle speed is less than 10 kph, conditioner function is disabled. 105/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 106 On the second and third ramps of the 2nd urban subcycle Practically over the entire EUDC cycle Throughout the cycle, cleaning is disabled in gear changes and cut-offs. 106/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 107 During increase in turbo pressure in acceleration transitions, if the difference (target)-(read) >200mbar the throttle is closed. If there is an error on the accelerator pedal or on the throttle actuator, turbo pressure is limited. 107/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 108 (when mixture control is active). Additive coefficient mixture ratio control (ORA). Corrects for injector losses. Updates at idle. The self-adapting parameters are not deleted when the battery is disconnected. 108/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 109 E050 INSTRUMENT PANEL I020 REVERSING LIGHTS SWITCH (GEARBOX HARNESS) I030 BRAKE PEDAL SWITCH H001 IGNITION SWITCH M001 BODY COMPUTER M010 ENGINE CONTROL MODULE N040 FUEL PUMP AND GAUGE 109/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 110 I031 CLUTCH PEDAL SWITCH K015 PRE-CAT LAMBDA PROBE K017 POST CAT LAMBDA PROBE K055 ACCELERATOR PEDAL POTENTIOMETER L010 FUEL VAPOR RECOVERY VALVE M010 ENGINE CONTROL MODULE N070 INJECTORS 110/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 111 K036 ENGINE COOLANT TEMPERATURE SENSOR/TRANSMITTER K044 INTEGRATED AIR PRESSURE AND TEMPERATURE SENSOR K047 TIMING SENSOR K048 PRESSURE SENSOR K050 KNOCK SENSOR M010 ENGINE CONTROL MODULE N075 THROTTLE ACTUATOR 111/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 112: Mjt Engine

    FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy Motore 1.3 16 V MJT Engine This chapter describes the 1.3 16VMJT engine derived from the engine already used on the Fiat Panda. Technical data sheet ENGINE Engine Common Rail direct Diesel injection...
  • Page 113 ANTI-EMISSIONS SYSTEMS Idle speed 830 ±50 rpm Maximum loadless speed 5200 rpm Anti-emissions system EGR valve Exhaust anti-emissions system UEGO lambda probe, in alternative DPF system, catalytic converter. 113/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 114 Injection pressure closed loop control; Electrical balance control; IMA code injector calibration; Fuel pressure control; Lambda probe control; DPF control (for versions with DPF). Engine oil life control (for versions with DPF). 114/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 115 25. Catalytic converter 11. Compressor 26. Lambda probe (UEGO) 12. Intercooler 27. Pedal board 13. E.G.R. solenoid valve 28. Engine Control Module 14. Water-exhaust gas heat exchanger for E.G.R 115/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 116 13. E.G.R. solenoid valve 28. DPF relative pressure sensor 14. Water-exhaust gas heat exchanger for 29. Pedal board E.G.R 30. Engine Control Module 15. E.G.R. diffuser 31. Turbo pressure regulator actuator 116/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 117 27. Debimeter negative 58. Not connected 28. Not connected 59. Revs sensor negative 29. Engine coolant temperature sensor ground 60. Not connected 30. Waste gate solenoid valve (ver. DPF) 117/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 118 (ver. DPF) 43. Not connected 92. Not connected 93. Not connected 44. Lambda probe signal (VS+) (ver UEGO) 45. Lambda probe signal (IP+) (ver UEGO) 94. Reversing switch 118/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 119 (or phonic wheel). The frequency and amplitude of the voltage delivered to the electronic control unit provides the crankshaft angular velocity and position. 119/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 120 To obtain this change, the sensor is periodically approached by a notch in the inner part of the pulley Pin - out 120/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 121 The sensor is powered directly from the control unit at 5 V and gives an output voltage directly proportional to turbo pressure. Pin - out Signal type Name Power supply 5 V input Ground Ground Sensor output Analogue output 121/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 122 Regulating injection time. The sensor is powered directly by the control unit with 5V. The output voltage varies linearly between 0.5 V (0 bar) and 4.5 V (1500 bar). 122/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 123 Engine Control Unit by the potentiometer connected to the pedal. The accelerator pedal position sensor signal is processed with the information on engine revs to obtain injection times and corresponding pressure. 123/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 124 The functional principle is based on heating of a membrane (sensitive element containing two elements upstream and downstream of the support) with a measuring passage (by-pass) between them for the air drawn in by the engine. 124/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 125 Pin - out 1. Power supply (12 V) 2. Ground 3. Air temperature signal 4. Air mass signal Signal type Power supply 12V Ground Air temperature signal Air temperature signal 125/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 126 The two comparison cells and the heater are built-in to the same planar ceramic element (a sandwich of various ceramic elements) to render the structure compact and assure high response speed and rapid element heating. 126/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 127 Heater max power 7.5 V from control unit Heating element 3.2 ± 0.8 Ω Pin out Name Pumping current (Ip) Virtual ground Heater (-) Heater (+) Calibration current Nerst voltage 127/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 128: Pressure Regulator

    The pressure regulator is mounted on the rail and controlled by the Engine Control Module. It regulates fuel delivery pressure to the electroinjectors. The pressure regulator consists essentially of: A ball shutter (1); A valve (3) command pin (2); 128/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 129 (7). At the same time, the line pressure through the feed passage (12) exercises a force on the feed volume (8) of Fa > Fc causing the needle (2) to rise consequently injecting fuel into the cylinder. 129/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 130 The fuel pressure sensor (3) is mounted on one side of the delivery manifold (1), and the pressure regulator (2) is connected from the other. The hydraulic connections (high pressure) between rail-pump and manifold-electroinjectors are made by steel pipes with ext. diameter 6 mm. 130/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 131 Power supply from Engine Control Module Ground connection (GND) Control start input from Engine Control Module Control start input from Engine Control Module Direct diagnosis output to Engine Control Module 131/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 132 The turbocompressor is also fitted with a WASTE-GATE valve (2) commanded by an pneumatic actuator (4), that regulates the flow of exhaust gas to the turbine, according to the pressure reached at the compressor output. 132/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 133 The turbocompressor is also fitted with a boost control valve commanded by an pneumatic actuator (4), which regulates the flow of exhaust gas to the turbine, according to the power/torque demand from the engine. 133/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 134 The atmospheric pressure signal is used in piloting the E.G.R. valve to recognize altitude conditions, in order to reduce the quantity of recirculated gas to prevent engine smoke. 134/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 135 A - E.G.R. valve body B – Gas input from exhaust manifold C – Gas output to intake manifold Pin - out Name Solenoid positive Solenoid negative 135/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 136 6. Engine cooling fan 16. Air temperature/pressure sensor 7. Glowplug control unit 17. Timing sensor 8. Two-track accelerator pedal potentiometer 18. Revs sensor 9. Brake pedal switch 19. Tachometer 136/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 137 15. Engine coolant temperature sensor 34. Particulate filter clogged warning light 16 Water in Diesel filter sensor 17. Exhaust gas temperature sensor 18. Overpressure sensor 19. Timing sensor 137/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 138 According to the signals received from the sensors, the control unit controls the regularity of torque down to idle speed: It varies the quantity of fuel injected into the individual injectors (injection time). 138/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 139 Cuts-off power to the auxiliary pump if engine is not started within a few seconds. Cylinder position recognition During each engine revolution, the engine control module recognizes which cylinder is in the ignition stroke and commands the injection sequence accordingly. 139/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 140 The oxidation reaction of the CO, HC and particulate is effective at temperatures between 200 and 350°C. Indeed, over 350°C the sulphur contained in Diesel begins to oxidize, producing sulphur monoxide and dioxide. 140/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 141 (up to five injections in the same engine cycle per cylinder) and on air control (E.G.R. and turbo pressure). The regeneration takes only a few minutes and does not have any effect on the torque delivered by the engine with respect to normal function. 141/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 142 1. Particulate filter (DPF) 2. Exhaust gas pressure take-off 3. Exhaust gas temperature sensor 4. Differential pressure sensor 5. Engine Control Module 6. Exhaust pipe with flexible section. 142/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 143 D006 JUNCTION E050 INSTRUMENT PANEL I030 BRAKE PEDAL SWITCH I031 CLUTCH PEDLA SWITCH H001 IGNITION SWITCH M001 BODY COMPUTER M010 ENGINE CONTROL MODULE N040 FUEL PUMP AND GAUGE 143/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 144 I031 CLUTCH PEDLA SWITCH K040 LAMBDA PROBE K055 ACCELERATOR PEDAL POTENTIOMETER K101. FUEL TEMPERATURE AND WATER IN FUEL FILTER SENSOR M010 ENGINE CONTROL MODULE M015 GLOWPLUGS CONTROL UNIT 144/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 145 K046 REVS SENSOR K047 TIMING SENSOR K082 TURBO PRESSURE SENSOR K083 FUEL PRESSURE SENSOR L030 EGR SOLENOID VALVE M010 ENGINE CONTROL MODULE N070 ELECTROINJECTOR N077 FUEL PRESSURE REGULATOR 145/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 146 D006 JUNCTION E050 INSTRUMENT PANEL I030 BRAKE PEDAL SWITCH I031 CLUTCH PEDAL SWITCH H001 IGNITION SWITCH M001 BODY COMPUTER M010 ENGINE CONTROL MODULE N040 FUEL PUMP AND GAUGE 146/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 147 D029 ENGINE HARNESS / ENGINE SERVICE HARNESS JUNCTION I020 REVERSING LIGHTS SWITCH (GEARBOX HARNESS) I031 CLUTCH PEDAL SWITCH K055 ACCELERATOR PEDAL POTENTIOMETER K101. FUEL TEMPERATURE AND WATER IN FUEL FILTER SENSOR M010 ENGINE CONTROL MODULE 147/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 148 K082 TURBO PRESSURE SENSOR K083 FUEL PRESSURE SENSOR L030 EGR SOLENOID VALVE L037 WASTE GATE COMMAND SOLENOID VALVE M010 ENGINE CONTROL MODULE N070 ELECTROINJECTOR N077 FUEL PRESSURE REGULATOR 148/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 149 B001 JUNCTION BOX UNIT C015 GROUND E050 INSTRUMENT PANEL H001 IGNITION SWITCH K187 FAP DIFFERENTIAL PRESSURE SENSOR K190 UPSTREAM PARTICULATE FILTER (DPF) TEMPERATURE SENSOR M001 BODY COMPUTER M010 ENGINE CONTROL MODULE 149/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 150: Gearbox

    An engine to gearbox union box that contains the clutch and related command levers. For the version with electro hydraulic actuator, the box is adapted to support the group selector. 150/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 151 The planets have splines for connecting the two joints connected to the two transfer shafts driving the wheels. The speedometer drive gear is fitted to the outside of the gearbox. 151/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 152 An engine to gearbox union box that contains the clutch, the thrust bearing and related command levers. 152/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 153 A single piece differential box with built-in planet and satellite gears. The differential is carried by two tapered roller bearings. The planets have splines for connecting the two joints connected to the two transfer shafts driving the wheels. 153/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 154: Robotised Transmission ( Dual Logic )

    (Up/Down). • AUTOMATIC MODE (AUTO): The electronic system shifts gears according to two strategies, the first focusing on comfort (NORMAL) and the second on efficient consumption (ECO). 154/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 155 3. Transmission ECU 4. Hydraulic control unit 5. Pump 6. Reservoir 7. Oil pressure sensor 8. Gear and operating mode display 9. Transmission failure warning light 10. Primary speed sensor 155/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 156: System Components

    • a power unit consisting of a hydraulic pump and reservoir. 156/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 157 (electrical motor and geared pump) • an oil reservoir. Key: 1. Pump 2. Fastening bracket 3. Reservoir 4. High pressure delivery tube 5. Low pressure return tube 157/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 158 Mechanical gear pump Key: 1. Engine connection 2. High pressure delivery (threaded connection to HP delivery semi-rigid pipe) 3. Input from reservoir (direct connection to reservoir) 158/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 159 Line pressure sensor (0-80 bars) • Check valve. Key: 1. Accumulator 2. Clutch stroke potentiometer 3. Shift stroke potentiometer 4. Clutch lever strut 5. Low pressure oil relief port 6. Pressure sensor 159/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 160 The control current is from 0 to 2.5 A controlled directly by the C.F.C328F unit. The electrical resistance of the winding is 2.5 ohm ± 6% at 20˚C. 160/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 161 • Selection potentiometer Mechanical unit view Key: 1. S-shaped cam containing port cover 2. Range change cam lock on-off electromagnet 3. Reverse switch 4. Engagement piston connection finger 161/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 162 3. The electromagnetic brake is not active and allows the sliding of the drum (3) which is moved by the spider (6). 4. The bolt (4) does not move and keeps the forks non involved in the gear shift aligned. 162/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 163 4. The bolt (4) slides being drawn by the translating shaft. It is responsible for ending the dog recall of the gear being disengaged to home position and keeping it aligned with the others not involved in the gear shift. 163/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 164: Electronic Control Unit

    C-CAN diagnostic line (500 kbyte) An identification plate is applied onto the upper surface showing fundamental identification data, such as ECU number, part number, SW version and calibration. 164/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 165 Not connected Not connected Not connected Not connected Not connected Not connected ( H ) C-CAN from ECM Not connected Not connected Not connected Not connected Not connected 165/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 166 Not connected Clutch speed sensor signal (negative) Input Gear selection sensor signal Input Clutch position sensor signal Input Not connected Not connected Not connected Not connected Not connected 166/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 167 They are always active. 2. The NCR receives/sends the following signals on the CAN : • Vehicle speed signal (RX) • Engine speed (RX) • Buzzer control (TX) 167/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 168 Two (optional) levers on the steering wheel may be provided for better safety and sportier use in combination with the lever unit. The steering wheel levers are always active for shift up and down requests. 168/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 169 (i.e. simply shift the lever back to the position prior to the request). Then press the brake pedal and repeat the operation: the gear shift request will be accepted by the system in this manner. 169/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 170: Engine Started

    The car will start-off only when the accelerator is pressed. Only 1st, 2nd and R may be engaged when the engine is running. The brake pedal must be pressed to engage the gears. 170/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 171 The system will accept requests made using the lever (TIP+ or TIP-) also is automatic mode without switching to manual (AUTOMATIC GEAR SUGGESTION strategy). 171/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 172 "OPERATION NOT ALLOWED" will appear on the display. The buzzer will sound. NOTE: with the brake pedal pressed, reverse can only be selected if the vehicle is expected to stop within approximately 3 seconds. 172/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 173: Safety Systems

    N will blink for approximately 4 seconds. The buzzer will sound and the vehicle will be parked in neutral (N). 173/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 174 Vehicle misuse (associated to warning messages) • Potential critical system/vehicle situations • System failures • R engagement Note: The system shows the gear actually engaged during automatic operation. 174/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 175 - During this step, if the driver presses the accelerator pedal, the driver returns to controlling the torque transmitted by the clutch. 175/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 176 The shifting method is identical to that in semiautomatic mode using the lever and the same gearbox/engine actuator control parameters are employed. Automatic mode is selected by tipping the lever to the specified position and deselected by repeating the same operation. 176/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 177 Dynamic signal out of range The ECU diagnostic outputs related to: • the three proportioning solenoid valves; • the two on-off solenoid valves; • the two pump and engine ignition relays. 177/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 178 • When the oil pressure is insufficient to manage the clutch (only if the clutch conditions allow when the car is travelling a slow speed, approximately 5 km/h). 178/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 179 When the Cruise Control is on and the transmission system is in automatic mode, gear shift requests made either by the system or by the driver ("gear shift suggestion") will not cause the Cruise Control to be switched off. 179/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 180 (NCR) via the CAN. This signal is used by the robotised transmission system to calculate the (estimated) temperature of the gearbox oil. 180/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 181: Wiring Diagram

    FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. WIRING DIAGRAM 181/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 182 24. Starter motor command (+50). 25. Battery voltage (power) 26. Robotised gearbox front connection (vehicle side) 27. C-CAN - Twisted wires 28. Earth 29. Robotised gearbox hydraulic oil pump 182/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 183: Suspension

    The stanchion is in cast iron. The holes for fastening the heat shield are separated from the ones for fastening the brake caliper. The seat of the union pin with the steering box links is tapered 1:6 The module is in forged steel. 183/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 184: Front Suspension

    Upper shock absorber section with optimized axial rigidity to improve comfort. Wheel stanchion with transverse inclination angle increased to optimize camber angle when turning (wheel perpendicular to road). 184/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 185: Rear Suspension

    Drum brakes for the 1.2 8V petrol and 1.3 Multijet versions Full disk brake for the 1.4 16V petrol version. 1.2 8V petrol / 1.3 Multijet version 1.4 16V petrol version 185/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 186 The limit stop buffers are in cellastio. For this reason, due to the shape, they are fastened to a support welded to the rear spar, the same one that serves as the upper spring support. 186/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 187: Braking System

    A wide diameter (9”) Bosch brake booster is fitted with aluminium master cylinder and extra stroke to ensure good pedal stroke reserve also in extreme overheating conditions caused by intensive use. The pedal is collapsible. 187/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 188: Operation

    Pressure increase step without ABS operation With the brake pedal pressed, the ECU (1): does not power the charging solenoid valve (NO) (2) does not power the relief solenoid valve (NC) (3). 188/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 189 The system is equipped with a check valve (11) mounted in parallel to the charging solenoid valve (2) which allows a rapid pressure reduction on the brake callipers (5) during brake pedal release. 189/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 190 (static or dynamic), running conditions (on straights or bends) and vehicle wear conditions (tyres, brakes and suspensions) actuating a strategy which follows the ideal brake force distribution curve. 190/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 191: Abs System Components

    The brake lines (pipes and hoses) are anchored to the body by means of brackets and/or fastening pegs. 191/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 192 ABS and EBD warning lights • to transmit and receive data via the C-CAN line (where fitted) • to transmit and receive data via the diagnostic socket. 192/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 193 K070 wheel sensor power Vehicle speed signal (not Not connected connected) K line (not connected) Not connected K071 wheel sensor power Not connected K076 wheel sensor power Earth 193/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 194 I030: Brake pedal switch M001: Body Computer M051: ABS ECU K070: Left front wheel sensor K071: Right front wheel sensor K075: Left rear wheel sensor K076: Right rear wheel sensor 194/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 195: Hydraulic Control Unit

    (instead of a minimum speed of 2.5 km/h detectable by a passive sensor) • less weight and compacter dimensions • simplified transmission connections because there is no phonic wheel. 195/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 196 Key: 1 - Magnetised ring 2 - Bearing 3 - Sensor head 4 - Active sensor 5 - Sealed connector 196/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 197 8 - Left-hand rear wheel sensor 9 - ESP warning light 10 - EBD warning light 11 - ABS warning light 12 - Left-hand front wheel sensor 13 - HHC warning light 197/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 198 ABS ECU are larger in diameter (6mm) with respect to the normal lines (4mm) to prevent negative effects on ESP operation at low engine oil temperatures. 198/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 199: Input/Output Signals

    Steering angle/steering wheel rotation sensor integrated in electrical steering Robotised gearbox ECU (in version where fitted, gear engaged status) Vehicle speed signal for VSO speed indicator and odometer (NBC) Brake pressure modulator control Reverse sensor 199/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 200 An oversteering vehicle will tend to slew round (the rear axle will tend to go straight and as a consequence the car will turn in). Given constant lateral acceleration, the slip angle of the rear axle will increase more than that of the front axle. 200/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 201 In the case of sudden deviations from a straight line (e.g. overtaking, slalom, gusts of wind), the ECU can detect the condition and the prevalence of slip on the axles and consequently correct the line by appropriately operating the brakes and the engine. 201/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 202: Hydraulic System Operation

    The ESP system increases driving safety but there are limit situations which cannot be controlled by the ESP. As a consequence, the system must be considered as a device for increasing vehicle safety not as a device for increasing vehicle performance. 202/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 203 2% NQS warning light management pressure holding time equal to 1+15 sec automatically shut-down after acceleration clutch release or brake pedal release timeout. 203/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 204: Warning Light

    (3) According to type of failure: if the relief valves, the speed value and C-CAN communication are available, the function is maintained and the warning light is off. 204/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 205 - stores failure codes and operates the ABS/EBD/ASR/ESP/HHC warning lights on C-CAN - transmits and receives data via the C-CAN (interface with other nodes) - controls the ASR, ESP, HHC activation process. 205/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 206 K070 wheel sensor power Vehicle speed signal (not Not connected connected) K line (not connected) ASR off LED control K071 wheel sensor power Not connected K076 wheel sensor power Earth 206/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 207 M086: Steering angle sensor (inside power steering) M091: Yaw sensor K070: Left front wheel sensor K071: Right front wheel sensor K075: Left rear wheel sensor K076: Right rear wheel sensor 207/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 208 Assembly is univocal and the sensor is provided with six pins, all connected. Yaw sensor pin-out Description Description Power C-CAN High 1 C-CAN Low 1 C-CAN High 2 C-CAN Low 2 Earth 208/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 209: Eps Electric Power Steering

    Power steering settings (Normal / City/Sport ) Components Steering column The electric steering columns have adjustable inclination, with total excursion of 5 degrees. Manual columns are not adjustable, as on the Panda. 209/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 210 4. Engine timing circuit (EBMD) 5. Power electronics (FET) 6. Analogue signal interface. 7. Position and torque sensor 8. Servo mecanism 9. Electric motor (with motor position sensor) 210/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 211 The power steering control unit is fastened to the power steering box itself and interfaces with the harness through two separate connectors: one 10-pin and the other 2-pin. 211/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 212 1 Nm. During the key to STOP / key to RUN cycle, the Body Computer Module maintains the previous setting. Steering is always assisted, and decreases as speed increases. 212/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 213 Through this indication the control module recognizes network) engine running. System error Fault light on via CAN network. Normal/City/Sport selection (included in According to driver command by button, system system) activates corresponding strategy (soft/hard). 213/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 214 In the adjustable steering column version, the angle and axial position of the steering wheel can be adjusted in the vehicle. It is strictly forbidden to dismantle the steering reduction gearbox, as it would NOT be possible to reassemble it as in the factory 214/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...

  • Page 215: Electric Motor

    (Hall-effect sensors), allowing the control unit to power the appropriate phases. To reduce noise and vibration in the steering column, the motor is mounted with three silent blocks for the stator and one for the motor. 215/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 216 The synchronous self-commutating motor always operates are the torque required by the force exerted on the steering wheel, and as torque demand increases, the current in the windings increases proportionally: this value will be around zero when no torque is demanded. 216/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 217 This information serves to make realignment more rapid, by inverting the servo motor to assist the normal geometric effect. 217/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 218 The system manages 5 drive settings. The NGE receives the vehicle information (engine and steering box type) from the Body Computer through the CAN network and selects the correct settings from its memory. 218/373 © 2007 Fiat Group S.p.A. - All rights reserved FIAT 500...
  • Page 219 Legenda A001 BATTERY H090CITY/SPORT BUTTON B001 ENGINE BAY JUNCTION BOX M001 BODY COMPUTER MODULE C015 GROUND M086 ELECTRIC POWER STEERING E050 INSTRUMENT PANEL MODULE MODULE H001 IGNITION SWITCH 219/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 220: Electric System

    Radio receiver module Nodo radioricevitore Diagnostic link connector EOBD Connettore di diagnosi For the Fiat 500, the communications line architecture envisages: A 50 kbit/s B-CAN network, Specifications: Two network cables, B-CANb and B-CANa, Resistance to network faults; 29 bit standard 220/373 ©...
  • Page 221 The module that permits the Gateway function, meaning transit of information between one network and the other and vice-versa, is the BCM (NBC) (Body Computer Module); PROXY Alignment 221/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 222 B-CAN B: +15 slave B-CAN (NSP) AIR BAG B-CAN B: +15 slave B-CAN (NAB) BLU & ME B-CAN B: +30 slave B-CAN (NCV) (C1/C3) C: +15 C-CAN (C3) 222/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 223 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. Network configuration B – CAN network 223/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 224 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy B – CAN with Convergence 224/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 225 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. C – CAN 1 (FULL) C – CAN 2 225/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 226 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy C – CAN 3 C- CAN 4 226/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 227 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. C – CAN 5 BCM (NBC) (NBC) (Body Computer Module) 227/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 228 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy PIN-OUT Inner side 228/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 229 Doors status led command Comando Led stato porte Hazard switch signal Segnale luci d’emergenza VSO Output generation Generazione uscite VSO Hazard led command Comando luci d’emergenza 229/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 230 Segnale interruttore porta guidatore aperta Serial line F for ABS/Doors Lin Lina seriale per ABS doors LIN Roof LIN _ A-bus for Rain sensor Linea A-BUS per sensore pioggia 230/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 231 Front passenger window UP switch signal Segnale interruttore “SU” finestrino passeggero Front passenger window DOWN switch signal Segnale interruttore “GIU” finestrino passeggero LS CAN-A LS CAN-A LS CAN-A LS CAN-A 231/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 232 Comando negativo luci di posizione (DEV) Steering wheel command (right side Comandi 3 volante comandi radio SCAN infotainment commands: scan-; scan+; source; - ; SCAN + ; Source ; TEL tel) 232/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 233 A0 ( mini) Front ceiling, rear, boot and puddle light. 7.5 A Diagnosis socket NRR/Cell/ECC A0 ( mini) (NCL)/EOBD (DLC (Conn. EOBD))) A0 ( mini) Stop lights switch, IPC (NQS) 233/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 234 Lampeggiante laterale SX Night lighting 58d Illuminazione notturna 58d Rear right fog ligth command/reverse gear ligth Comando luce retronebbia destra/comando command luce retromarcia Comfort enable supply Alimentazione comfort enable 234/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 235 Bonnet ajar switch signal (normally open) Segnale interruttore cofano aperto (NA) A/C request signal Segnale richiesta A/C Tachometer sensor signal Segnale sensore techimetrico Front Driver door Limit switch Interruttore limite porta guidatore 235/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 236 Alimentazione per plafoniera sinistra Predisposition (Kl30) Predisposizione (Kl30) Supply for rear wiper Alimentazione per tergicristalli posteriore Front Wiper motor (high speed command) Motore tergicristallo anteriore (comando alta velocità) 236/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 237 Rear Right flasher Lampeggiante posteriore destro Fuel level sensor (signal) Segnale sensore di livello Rear right parking light (FRONT/REAR or Luce posizione posteriore destra (Fronte/retro o LEFT/RIGHT) SX/DX) 237/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 238 (normalmente aperto) Pin not present Pin non presente Pin not present Pin non presente Rear right fog light command/Reverse gear Comando retronebbia destro/comando luce light command retromarcia 238/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 239 Pin non presente Pin not present Pin non presente Left stop light Luce stop sinistra Connector G +30 BCM (NBC) (NBC) from SCM +30 BCM (NBC) (NBC) per SCM 239/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 240 The alternator is connected to the ECM, to which it transmits its status message via C-CAN network, the BCM (NBC) processes this information and renders alternator charge status over both networks, and any fault messages to the electronic control units concerned. Battery voltage acquisition 240/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 241 When commanded, the BCM transmits the corresponding message via B-CAN network to allow the IPC to command the corresponding indications on the panel. The same message is transmitted over the C-CAN network 241/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 242 In case of direction change, shifting the indicator stalk, the BCM commands the direction indicators from the selected side, LH or RH. Lane change function In case of lane change, for example, overtaking on motorway, flicking the stalk (less and 500 ms), the BCM commands three flashes of the selected indicator. Lane change function stop The lane change function can be stopped by flicking the stalk in the opposite direction.
  • Page 243 Ceiling light on Ceiling light on/off by BCM: The BCM (NBC) can command the courtesy light directly in the following conditions: On opening a door (activation time approx 3 minutes) 243/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 244 The ground signal is transmitted to the BCM. The BCM sends a message via B-CAN to the IPC that activates the brake wear warning light. Engine compartment control unit The engine compartment control unit is embedded in the engine bay harness and cannot be singularly replaced. 244/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 245 Engine cooling + 30 low speed Engine cooling + 30/ T07 high speed +30/ T08 Climate control fan + 30 free + 30 Horns 245/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 246 Climate control fan bar 3A (87) + 30 (30) Engine control system (main relay) Free Fuel pump Free Fog lights Free Free Free Demisting Free Start disable with robotic transmission 246/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 247 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. bus-bar 2A (30) Selespeed servo pump + 30 (30), bus- Front power point (with or without cigar bar 3B (87) lighter) 247/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 248 Having received the various commands the BCM commands the door and trunk lock servo motors, activates the hazard lights, and transmits door status over the B-CAN and C-CAN networks. As can be seen in the diagram, the commands are direct. 248/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 249 One click Unlock command Hazard lights flash Double click Unlock command Lock button One click Unlock command Hazards lights flash Trunk button One click Trunk release Hazard lights flash 249/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 250 On connection of the +30 the BCM will not accept commands for at least 2 seconds, moreover the BCM (NBC) does not recognize door status until a centralized key command is given by the remote control, immobillizer remote or FOPS function. 250/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 251 The BCM interrupts the servos when the command is inverted e.g. from raise to lower, or when the upper or lower limit is reached. There is no anti-pinching function. 251/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 252 2.5 (+/-0,5)m/s Note: the lights are commanded with a higher flashing rate than in normal hazard warning conditions 252/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 253: Instrument Panel

    The image below shows the comfort version: Sport version The sports version of the Fiat 500 is fitted with the Sport instrument panel, which has different graphics for the speedometer and rev counter. Available also for COMFORT and DOT-MATRIX versions.
  • Page 254 The Instrument panel is essentially subdivided into four functions zones, and specifically: 1. Warning lights zone 2. Electronic speedometer zone 3. Electronic rev counter zone 4. Central zone reserved for alphanumerical display 254/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 255 Follow me Note: Enabling the “SPORT” function by means of the button on the dashboard sets sports operation for the following systems: Engine control Robotic gearbox Electric power steering 255/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 256 9-segment bar graph fuel gauge Odometer Spanner icon (SERVICE) Clock CITY/SPORT mode Ice warning 14 characters used for messages (pseudo dot-matrix) 8-segment bar graph engine coolant temperature indicator Headlight trim adjuster indication 256/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 257 6. Robotic gearbox indication, SPORT mode (S), CITY and AUTO Ice warning 14 characters used for messages (pseudo dot-matrix) 8-segment bar graph engine coolant temperature indicator Headlight trim adjuster indication 257/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 258 9-segment bar graph fuel gauge External temperature indication Ice warning Spanner icon (SERVICE) Clock Odometer 8. Central dot-matrix area 8-segment bar graph engine coolant temperature indicator Headlight trim adjuster indication 258/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 259 • C – Displayed function title • Information displayed in area A: • Audio repeat • Trip • Menu • Dimming • Feedback • Blue&Me • “Other messages” 259/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 260 Note 2: The name of the phone operator is sent from the phone paired with the Blue&Me system. Not all mobile phones have this function. Display with send operator name function not supported by mobile phone: 260/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 261 For more information, refer to the states-event matrix. The “Sport” version starts a graphic animation of the “500 logo” after approx. 4 seconds of opening or closing the doors with key-off, as illustrated in the sequence below:...

  • Page 262: Warning Lights

    Important: the rheostat adjustment for panel illumination does not affect the warning lights (intensity always at 100%). The dimming value is transmitted to the Instrument Panel over the CAN network. Note: 33.Menu (+); 34. Menu (-); 35. Menu/ESC 262/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 263 RH direction indicator green Handbrake / low brake fluid / EBD fault Brake pads worn amber ABS fault amber ESP cut-in / fault amber Door open warning Immobilizer fault amber 263/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 264 All the modules of the Instrument Panel system (Network, Wakeup, Diagnosis) use only the physical key. The BCM recovery conditions, the instrument panel no longer considers the network key and manages its functions with only the physical key. 264/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 265 + Headlight from NBC (headlight icon activation on display) n.c. TRIP command from combi switch stalk n.c. Note: The signal from pin 7 is a percentage of the power on pin 8. 265/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 266: Menu Function

    Note: pressure longer than 1s on button (3) memorizes the modifications made with the short pulse. If no operation is carried out within 60 s, the standard video page is displayed. Key: 1.Menu (+) ; 2. Menu (-); 3. Menu/ESC 266/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 267 Note: Seat belt beep : the customer cannot disable the seat belt beep, but only restore it if it has been disabled by the authorized service network using the diagnosis instrument. 267/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 268 Tock 2000 Hz 0 ms light on IPC light on IPC Memory Roger 1 beep 2000 Hz 75 ms 0 ms 0 ms 0 ms Beep 268/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 269 - Press and hold the “TRIP” button on the combiswitch stalk until the letter “H” disappears from the odometer display, and the odometer simultaneously zeroes. 269/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 270: Climate Control System

    FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy Climate control system Introduction The new Fiat 500 may fit either a heating system or one of two different types of climate control systems, namely: • Heater • Manual climate control system •...
  • Page 271 Brown 12-pin connector A FUNCTION Earth (GND) Speed 1 Speed 2 Speed 3 Speed 4 Not connected Not connected Not connected Not connected Not connected Not connected Not connected 271/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 272 G045B: Heater control lights H001: Ignition switch H081: Climate control system fan control M001: Body Computer N085: Passenger compartment air fan O030: Passenger compartment air fan control resistor 272/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 273: Manual Climate Control System

    C. Air flow speed control knob (4 positions) and gas compressor control. D. Air temperature mixing control knob (22 positions). E. Compressor state indicator LED (on/off). Note: Press knob (C) to operate the gas compressor. 273/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 274 Brown 12-pin connector A FUNCTION Earth ( GND ) Speed 1 Speed 2 Speed 3 Speed 4 Not connected Not connected Not connected Not connected Not connected Not connected Not connected 274/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 275 Blue 12-pin connector B FUNCTION ? N086 pin 1 Not connected Earth Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected 275/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 276 H001: Ignition switch H080: Climate control system controls M001: Body Computer N085: Passenger compartment air fan N086: Electronic thermostat (frost sensor) O030: Passenger compartment air fan control resistor 276/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 277 The body computer, in turn, sends the compressor activation request on the CAN line. The engine ECU receives the compressor on/off information on the C-CAN and activates the compressor after checking that the operating conditions are within safety parameters. 277/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 278: Automatic Climate Control System

    9. Air flow control button (+) 10. Air flow control button (-) 11. Air distribution button (FRONT) 12. MAX DEF button 13. Air distribution button (FLOOR) 14. Air distribution button (BI-LEVEL) 278/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 279 The set air flow display graphics are shown in the figure below. Rear view (automatic climate control system) The figure shows the back of the unit with the connections to the electrical system. The connector pinout is shown below. 279/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 280 +15 (INT) Electronic earth Not connected Analogue earth Frost sensor Fan feedback Fan control B CAN (B) (High) B Can (A) (Low) Low temperature sensor High temperature sensor 280/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 281 Nota: In seguito alla sostituzione della centralina o di uno degli attuatori è necessario eseguire la procedura di autoapprendimento della posizione portelle utilizzando Examiner. Nota: La richiesta di Attivazione /disattivazione compressore è inviata sulla rete CAN. 281/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 282 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy CIRCUIT DIAGRAM (automatic climate control system) Diagram A Diagram B 282/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 283 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. Compressor control (1.2 engine) Compressor control (1.4 engine) 283/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 284 P061: External right-hand rearview mirror (external air temperature sensor) K086: Frost sensor K087: Low mixed air temperature sensor K088: High mixed air temperature sensor K120: Linear sensor (for climate control system) 284/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 285 This also applies to the OFF function: if the system was off when the engine was stopped, it will be off again when the system is restarted. If MAX DEF was selected at key-off, the system will return to the conditions before MAX DEF was selected at key-on. 285/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 286: Temperature Control

    Maximum cold management is interrupted following one of the following functions which have a higher priority with respect to LO state: • +KEY OFF status management • OFF status management • MAX DEF status management 286/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 287 Hold one of the two buttons (up/down) pressed for longer than 0.8 seconds to activate the "repeat" function which increases/decreases the air flow rate by one step every 0.4 seconds. 287/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 288: Air Distribution Control

    The following occurs when the user switches the compressor off: • The button LED will go out • The AUTO LED will go out (if it was on). 288/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 289 The LEDs corresponding to DEF, compressor, recirculation open and rear window demister will light up. • HI temperature setting is shown on the display. • Ventilation will appear on display. 289/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 290 Only the required main distribution will be implemented when the system is switched on by pressing a distribution button. The conditions prior to switch-off will be restored when the system is off and the OFF button is pressed again. 290/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 291 Radiator - heater Evaporator Condenser Linear sensor Frost sensor Outside air temperature sensor Passenger compartment temperature sensor Mixed air temperature sensor Pollen filter Fan in passenger compartment Dehydrator filter 291/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 292 The efficiency of the climate control system would be severely compromised in these conditions because the evaporator coated with frost would loose its heat exchanging capacity with the air. 292/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 293: Expansion Valve

    It is integrated in the climate control unit and is provided with a fan to avoid stagnation of air and to make the temperature reading and coherent as possible. EXPANSION VALVE The assembly position in the engine compartment is shown in the following figure. 293/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 294: Operation

    Important: The valve regulation screw is calibrated at the factory and must never been tampered with to prevent compromising the efficiency of the A/C system. 294/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 295 Operation of the compressor is enabled and the fan speed is adjusted according to pressure variations in this pressure range. Under or over these values, the compressor is off to prevent possible damage to the system itself. 295/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 296 From here the gas is released through the outlet fitting towards the condenser. 296/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 297 An insufficient heat exchange in the condenser increases the pressure in the system and causes incomplete condensation of the fluid, thus reducing the system efficiency. 297/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 298: Pollen Filter

    A control panel containing the following controls is the heart of the heating and manual climate control system: rear window demister button ASR on/off button passenger compartment air temperature sensor (in the middle). Basic version Top-of-the-range version 298/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 299 The configuration of the gas circuit in the engine compartment is shown, specifically: 1. Connection of the condenser unit 2. Connection to gas compressor 3. Connection to expansion valve/evaporator unit. 1.2. petrol version 299/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 300 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy 1.4 petrol version. 1.3 MJET version. 300/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 301: Audio System

    Connection for hands-free phone (external phone). User-friendly menu for radio settings and external interfaces (CD-Changer, telephone). Remote controls on steering wheel. Possibility of interfacing with external CD-Changer via ASCI-BUS line. 301/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...
  • Page 302 23. Plug fro radio extraction tool hole. 24. Radio on/off button. 25. Mute button. 26. Audio volume decrease button (-). 27. CD-ROM enable button. 28. Plug from radio extraction tool hole. 302/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 303: Radio Display

    5. TPM. 13. TA. 6. CD-IN. 14. FM1, FM2, FM, AM. 7. EQ. 15. Selected memory ( P1…P6 ). 8. LOUD. 16. Stereo station symbol. Example of display 303/373 FIAT 500 © 2007 Fiat Group S.p.A. – All rights reserved...

  • Page 304: Pin Description

    Ground ( GND ) Telephone AF in - n.c. Telephone mute n.c. LS RR + C 10 n.c. D 10 n.c. LS RR - C 11 n.c. 304/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 305: Base Audio System

    2 front woofers, installed in door panel. ( 200 Hz; ≤ 7 ohm; 165mm ). 2 rear full-range, installed in side panels. ( 200 Hz; ≤ 7 ohm; 165mm ). 305/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 306 2 front tweeters, installed on pillars ( 10.000 Hz; 2V rms; ≤ 5 ohm; ). 2 front woofers, installed in door panel ( 500 Hz; 2V rms; ≤ 7 Ohm; 165mm ). 2 rear full-range, installed in side panels ( 500 Hz; 2V rms; ≤ 7 Ohm; 165mm ).

  • Page 307: Audio System Components

    FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. AUDIO SYSTEM COMPONENTS Tweeters Woofers Full-Range 307/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 308 The figure below gives and internal functional outline of the SubWoofer. Sub-Woofer PIN-OUT DESCRIPTION Left audio input + Right audio input + +13.5 Vdc power supply Left audio input - Right audio input ( - ) n.c. Ground 308/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 309 Front right speaker output ( + ) Rear right speaker output ( - ) Rear right speaker output ( + ) Front left speaker output ( - ) 309/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 310 There are two antenna versions according to whether the vehicle has the optional sun roof. Antenna (without sun roof) Antenna stem 36 cm Antenna support, inclined 75° Antenna (with sunroof) Antenna stem 36 cm Antenna support, inclined 60° 310/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 311: Circuit Diagrams

    FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. CIRCUIT DIAGRAMS Base version HI FI version (diagram A) 311/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 312 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy HI FI version( diagram B ) Predisposition 312/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 313 P036: Front right door speaker. P045: Front left tweeter. P046: Front right tweeter. P070: Radio / CD amplifier. P092: Subwoofer. E3570 : Circuit diagram reference. E4090 : Circuit diagram reference. 313/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 314: Telematics

    Telematics Blue&Me This telematics system is Fiat’s answer to the ever-increasing market demand for systems that permit the use of the cell phone in the vehicle, protecting the safety and operation of the user, and offering a range of multi-media services.

  • Page 315: Components And Location

    The Blue&Me control unit is connected to the B-CAN network with the radio node and the Body Computer, in turn connected to the controls on the steering wheel. 315/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 316 Operating voltage range : 6 – 16 Volt. Nominal power supply voltage : 13.5 Volt. Voltage limit for 1 min. : 24 Volt. Current draw Max: 220 mA ( C1V2 ) 500 mA ( C3 ). Current draw in standby: 1.7 mA. CONNECTORS ( Blue&Me control unit) On the control unit there are two 32-pin connectors, which, according to the Blue&Me version, can be...
  • Page 317 Pin 11: SOS, INFO, NAV ( GND ) keys – Voltage splitter. Pin 12: No GSM signal LED command. Pin 28: SOS, INFO, NAV ( Input )keys – Voltage splitter. 317/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 318 Microphone in ceiling light The microphone is mounted on the roof panel near the front ceiling light. 318/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 319: Usb Socket

    The picture below shows the location of the USB socket, on the central tunnel near the parking brake lever. PIN OUT USB Description Signal ( BUS ) Power supply ( + ) Power supply ( - ) Ground ( GND ) 319/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 320: Controls On Steering Wheel

    For both modes to activate steering wheel controls (brief or long pressure) the function is actuated when the key is released 320/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 321 SETTINGS - with this sub-menu you can manage the names in your phone book, record a new device or have access to the identity code of the hands-free system . 321/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 322: Media Player

    Deactivates the function for automatic audio playing when car USB device is inserted. Any – Activates automatic playing of all digital audio pieces present . Multimedia file settings – Activates Media player menu . 322/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 323 Dictate destination – Enable or not voice completion of the destination. Car position – Supplies an indication regarding latitude, longitude and number of GPS satellites Route simulation – Simulates the set route. 323/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 324 Recall – Access to last call. Made – Composes last phone number of last person who was called . Received – Composes phone number of last person who called. 324/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 325 French English German Italian European Spanish Dutch European Portuguese Polish The change of language and any software updating of components is to be carried out by the dealer. 325/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 326 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy Instrument panel display • Bluetooth attivo • Cellulare • Nome operatore • Menù • Radio • Navigazione 326/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 327: Additional Control Panel

    SOS and INFO applications will not function in areas without GSM cover. Rear view of additional control panel PIN OUT of additional control panel Connector A Description Ground ( GND ) Close roof (OPT) Open roof (OPT) Lighting 327/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 328 Keys voltage splitter circuit diagram ( SOS, INFO, NAV ) Resistance values: R1: 4 KΩ ± 1% R2: 261 Ω ± 1% R3: 127 Ω ± 1% R4: 46 Ω ± 1% 328/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 329 In any case the possibility to converse with hands-free is not compromised. 329/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 330 C500, C600 Telit Note: On the official FIAT website (www.fiat.com), selecting the “Blue&Me” window, there is an updated list of cell phones that are compatible with Blue&Me Note: It is pointed out that because of possible different software versions available on the market for different cell phone models, some functions may not correspond exactly to what is described.
  • Page 331 Set the car ignition key on MAR. Note: In compliance with the highway code, some functions, such as, for example, entering a new destination, are only enabled when the vehicle is stationary. 331/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 332: Operating Procedure

    USB device, just by connecting it to the USB port of the car at the base of the central console, next to the current socket/cigar lighter. 332/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 333 (example :-) will be read as “Smile") that are used today i SMS messages Warning : Some cell phones on the market may not support the transmission of linked SMS messages (more than 160 characters). See the cell phone owner’s handbook. 333/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 334 - with the key on STOP , insert the USB pen in the USB port of the control unit, or i the external port at the base of the central console , next to the current socket/cigar lighter. 334/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 335 Possibility, with the same system, to of loading maps of other countries and navigate from country to country without interruption (1 GB contains Western Europe). Additional maps can be purchased from dealers (P&S). 335/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 336 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy Blue & Me circuit diagram ( C1V2 ) Version without navigator. 336/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 337 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. Blue & Me circuit diagram ( C3 ) Version with navigator. 337/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 338: Passive Safety System (Airbag)

    338/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 339 - Passenger air bag disabled indicator on instrument panel; - Seat belt reminder warning on instrument panel; - connection via B-CAN to diagnostics socket for functional checks using EXAMINER. 339/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 340 If the maximum number is not reached, after restoring system operative conditions, it is possible to use the control unit again after carrying out a RESET using the EXAMINER. Once the maximum number is reached, a further reset is not possible. 340/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 341 N.C. Driver air bag 2nd stage + N.C. Driver air bag 2nd stage - N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. 341/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 342 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy N.C. N.C. N.C. Circuit diagram for version without side bags 342/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 343 Switch on buckle passenger side + Switches on buckle driver side and Passenger - Switch on buckle driver side + Passenger present detector + (PPD) Passenger present detector - (PPD) N.C. N.C. 343/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 344 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy Full version circuit diagram. 344/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 345: Spiral Cable

    The figure below illustrates the spiral cable. 1 – Air bag first stage electrical connector 2 – Air bag second stage electrical connector 3 – Steering wheel electrical functions cable 4 – Spiral cable 345/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 346 During operations that require removal of the steering wheel and the device, it is mandatory to: - Always work with the wheels aligned straight; - For safety, lock the two plates together with a clamp before removing the device from the combi switch. 346/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 347: Passenger Side Air Bag Module

    - using the + o – buttons select “YES” (to confirm enable/disable) or “no” (to quit confirmation); - press MENU ESC again to return to the set-up menu. When disabled, the corresponding warning light lights on the instrument panel. 347/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 348 After inflating, the cushion is in an optimal position to protect the occupant. The cushion deflates immediately due to the presence of a vent hole. 348/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 349 When deployed, the cushion is in an optimal position for protecting the occupant. The cushion deflates immediately after inflation due to the porosity of the nylon fabric. 349/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 350: Seat Belt Pretensioners

    One, conventional type, installed in the belt winder and one on the buckle anchored to the floor. The pre-tensioners intervene simultaneously on both ends of the belt permitting uniform distribution of the recovered length with consequent reduced injury to the occupant. 350/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 351 16 belt winder with pyrotechnic pre-tensioner 2 belt 5 belt anchor to pillar 8 belt buckle 9 buckle stop 11 belt fastening to spar 18 re-tensioner on fixed buckle 351/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 352 NOTE: Once triggered, the belt pre-tensioners remain locked and must be replaced. 352/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 353 NOTE: The passenger side air bag may only be disabled with the key OFF or removed, as this operation is recorded as a fault in the control unit). 353/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 354 New warning The warning cycle is only repeated again if the belts are unfastened (transition from belts fastened to unfastened) or in one of the three previously described conditions. 354/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 355: Body

    It is not possible to disable the reminder, which will remain active (on steady) until the belts are fastened. BODY Body shell The body shell of the New Fiat 500 is realized with the greatest attention to passenger safety, thanks to the application of the most advanced design techniques. This has allowed us to obtain the following specifications:...
  • Page 356 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy The lower front of the Fiat 500 body shell is fitted with a pedestrian impact bar that allows the body design to meet the most stringent of pedestrian safety standards hird Load line 356/373 ©...
  • Page 357 This system consists of two longitudinal links under the vehicle spar, referred to as the “third load line” 357/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 358 Electric opening sunroof Fixed sunroof The Fiat 500 can fit a fixed sunroof as shown below. The thickness of the glass is around 4 mm, with 16% light transmission and energy transmission lower than 19% It has a manually operated roller blind.

  • Page 359: Electric Sunroof

    Opening/closing time: 5 ± 2 sec. Peak motor absorption: 30 Amp. max. Motor opening/closing absorption: 12 Amp. Frame group The frame group carries all the mechanical and electrical components of the sunroof. 359/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 360: Control Unit

    VSO – vehicle speed signal from Body Computer + 30 – from engine junction box Ground ( gnd ) Open command (ground - gnd ) Close command (ground - gnd ) 360/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 361 The back of the control panel has the two connectors for connecting to the vehicle wiring harness. Pin-out Connector A – Control panel Description Ground ( gnd ) Sunroof close control Sunroof open control LED ideogram on command 361/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 362: Circuit Diagram

    Pressing the button again moves the sunroof to fully closed. After the first open command, the sunroof can be stopped in any position simply by pressing the button again. 362/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 363: Manual Closing

    Release the button, then press it again within 5 seconds and hold it down for a complete opening/closing cycle. After complete closure, release the button. This completes the initialization cycle. 363/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 364: Stickers

    Training Academy Stickers The Fiat 500 is designed to distinguish itself and certainly not pass unnoticed. For this reason a series of Stickers are available to render the vehicle unique, to apply on purchase or in after market. OPT: 5H0...
  • Page 365 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. OPT: 5H2, 5H3 OPT : 5H4, 5H5, 5H6 365/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 366 FIAT 500 COURSE OUTLINE Fiat Group Automobiles S.p.A. Training Academy OPT: 5H7, 5H8, 5H9 OPT: 5HA, 5HB 366/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 367 FIAT 500 COURSE OUTLINE Training Academy Fiat Group Automobiles S.p.A. OPT: 5HC, 5HD OPT: 5HE 367/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 368 Remove any air bubbles trapped under the sticker by pressing the sticker with the special spatula provided Remove the protective film and run the spatula over the sticker again, increasing pressure applied 368/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...

  • Page 369: Dashboard

    The design and conformation of the linings is aimed toward achieving a high level of acoustic comfort and passive safety, by eliminating all protrusion that could be considered hazardous for the occupants in the event of a collision. 369/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...
  • Page 370 B. Electric steering City button. C. Sport button. Centre button (T2) Key: E. Hazard warning lights Passenger side keys (T3) Key: F. Rear fog warning lights button. H. Front/rear fog lights button. 370/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 371 (hazard lights fitting) +15 – ideogram power supply City / Sport n.c. WINDOW WINDER CONTROLS The right and left window winder controls are located under the air-conditioner or heater group. 371/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

  • Page 372: Interior Trim

    2. Detach and remove the door panel molding. 1. Unscrew the inner door panel screws. - Using a detacher lever (1.878.077.000), remove the inner door panel by separating the corresponding push-fasteners. 372/373 © 2007 Fiat Group S.p.A. – All rights reserved FIAT 500...
  • Page 373 - Fit the door panel, carefully aligning and fastening the corresponding push-fasteners. - Insert and tighten the door panel screws. - Fit the molding on the door handle - Fit the protective cover to the handle. 373/373 FIAT 500 © 2007 Fiat Group S.p.A. - All rights reserved...

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