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file:///D|/Volume%202/Vol2.htm08/07/2006 16:19:34
Bravo-Brava
Summary
S E R V I C E MANUAL COMPOSITION
A t p r e s e n t , September 1 9 9 8 , the B r a v o - B r a v a 2 n d v o l u m e m a n u a l is c o m p o s e d of the f o l l o w i n g b o o k l e t s ; Print N Sections 50 506.670/01 W i t h binder
(V/1995)
Comments Heater - Air c o n d i t i o n i n g Electrical equipment W i r i n g diagrams R e m o v i n g & refitting - Replacing b o d y panels U p d a t e : alarm Pre-heating W i r i n g diagrams C o n n e c t o r blocks Electrical equipment fault diagnosis
55 1 -s- 5 5 70 1 145 16 4
506.670/02
(V/1995)
55
1 H- 1 0 3 105-161 1-117
506.670/05
(11/1996)
55
11
U p d a t e : 4 D 1 8 2 L radio
32 20 506.670/06
(IV/1996)
55
1 3 1
506.670/10
(1/1997)
55
W i r i n g diagrams update
506.670/11
(Vl/1997)
55
W i r i n g diagrams
50
1 2
506.670/12
(VII/1997)
55
23 6
70
Summary
Bravo-Btava
P r i n t N
Sections 55
Comments
506.670/14
(111/1998)
55 55
Japanese version
506.670/15
(V/1998)
70
Update: Seats
506.670/16
(IX/1998)
55
43-44
Update: W i r i n g diagrams
f
I
Print no.
506.670/76
Bravo-Brava
Summary
55
11
Updated radio 4 D 1 8 2 L
Updated radio A D 182H Updated alarm system Updated code Updated w i r i n g diagrams Updated connections
55
Updated w i r i n g diagrams
55
W i r i n g diagrams
50
1 2
506.670/12 (VI1/1997)
55
23 6
70
Summary
Bravo-Brava
P u b l i c a t i o n no.
Sections 55
Page numbers 6 26 1-6 19-24 24/1 -24/4 Alarm Air bag Japanese version
Notes
Bravo-Brava
Summary
S E R V I C E MANUAL COMPOSITION
A t present, January 1 9 9 7 , the B r a v o - B r a v a 2nd volume manual is c o m p o s e d of the f o l l o w i n g b o o k l e t s : Print No. Sections 50 506.670/01 W i t h binder
(V/1995)
Page Nos. 1 43
Comments Heater - Air conditioning Electrical equipment W i r i n g diagrams Removing and refitting - Replacing body panels Alarm update Pre-heating
1-154 55 1 70 55
1-145 16 4
506.670/02
(V/1995)
55
1 -
103
105-161 1 506.670/05
(11/1996)
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55
11
4 D 1 8 2 L radio update
32 20 506.670/06
(IV/1996)
55
1 3 1
506.670/10
(1/1997)
55
W i r i n g diagrams update
Bravo-Brava
Summary
Notes Heater - Air conditioner Electrical equipment W i r i n g diagrams Removal-refitting - Replacing b o d y panels Updated alarm system Preheating W i r i n g diagrams Connector blocks Electrical equipment diagnosis
55 1 - 55 70 1-145 16 4
506.670/02
(V/1995)
55
506.670/05
(11/1996)
55
11
32 20 506.670/06
(IV/1996)
Updated radio A D 182H Updated alarm system Updated code system Updated w i r i n g diagrams Updated connections
55
1 3 1
506.670/10
(1/1997)
55
Updated w i r i n g diagrams
506.670/11
(VI/1997)
55
W i r i n g diagrams
50
1 2
506.670/12
(VII/1997)
55
23 6
70
Summary
Bravo-Brava
4A03SV
P u b l i c a t i o n no.
Sections 55
Notes
506.670/14 (1/98 1 11 9 ) 55
Bravo-Brava
Summary
S E R V I C E MANUAL COMPOSITION
A t present, April 1 9 9 6 , t h e B r a v o - B r a v a 2nd volume manual is c o m p o s e d of t h e f o l l o w i n g b o o k l e t s : Print No. Sections 50 506.670/01 W i t h binder
(V/1995)
Page Nos. 1 43
Comments Heater - Air conditioning Electrical equipment Wiring diagrams Removing & refitting - Replacing b o d y panels Alarm update Pre-heating Wiring diagrams Connector blocks Electrical equip, fault diagnosis
1-154 55 1 70 55
1-145 16 4
506.670/02
(V/1995)
55
506.670/05
(11/1996)
55
11
4 D 1 8 2 L radio update
32 20 506.670/06
(IV/1996)
A D 1 8 2 H radio update Alarm update Code update W i r i n g diagrams update Connections update
55
1 3 1
Bravo-Brava
Summary
S E R V I C E MANUAL COMPOSITION
A t present, J u n e 1 9 9 5 , t h e B r a v o - B r a v a 2 n d v o l u m e manual is c o m p o s e d of the f o l l o w i n g b o o k l e t s : Print No. Sections 50 506.670/01 W i t h binder
(V/1995)
Page Nos. 1 43
Comments Heater - Air c o n d i t i o n i n g Electrical equipment W i r i n g diagrams Removing & refitting - Replacing b o d y panels
1-154 55 1 70 55
1-145
Bravo-Brava
Preface
T h i s m a n u a l c o n t a i n s t h e m a i n i n s t r u c t i o n s for repairing a n d m a i n t a i n i n g t h e F i a t B r a v o a n d F i a t B r a v a . T h e m a n u a l is d i v i d e d into sections d i s t i n g u i s h e d by t w o d i g i t n u m b e r s w h i c h appear in t h e parts m i c r o f i c h e s a n d t h e flat rate m a n u a l . T h e s e c t i o n I N T R O D U C T I O N A N D T E C H N I C A L D A T A (00.) has a d u a l f u n c t i o n of i n t r o d u c i n g t h e m o d e l a n d s u p p o r t i n g the r e m a i n i n g part of t h e m a n u a l . T h i s s e c t i o n i n c l u d e s t h e tables o f t e c h n i c a l d a ta a n d specific i n f o r m a t i o n relating t o t h e s e c t i o n s in t h e r e m a i n i n g part of t h e m a n . T h e remaining s e c t i o n s (10. - 1 8 . e t c . ) i n c l u d e d e s c r i p t i o n s of t h e repair operations. T h i s m a n u a l c o n t a i n s g r a p h i c representations a n d s y m b o l s in place of d e s c r i p t i o n s for m e c h a n i c a l c o m p o n e n t s , o p e r a t i o n s a n d repair m e t h o d s . Small e n d diameter For example: Big e n d b e a r i n g h o u s i n g
E
engines
Tighten to torque
ENGINES
Section 10 contains iffusttations of the operations of removing-refitting operations on vehicle and the various fuel, lubrication and cooling The procedures for overhauling which have the following print Engine 1370 12V 1581 16V 174716V 1998 20V 1929 D 1910 T D The first 4 booklets whilst the last ones are inserted are inserted the individual nos.: Print No. 504.589/19 504.589/20 504.589/18 504.589/22 504.593/11 504.593/13 in the Overhauling in the Overhauling Petrol Engines Diesel Engines are described
units, booklets
P a r t No. 604.89.774 604.89.781 604.89.192 604.89.788 604.89.841 604.44.220 Manual Manual 3rd 2nd volume, volume.
G E A R B O X E S ? c f / o / 7 21-27 contains illustiations of the operations of removing and refitting the vaiious gearboxes The procedures for overhauling the various manual geaiboxes at the bench are published in separate booklets which have the following print nos.: 505.023 08 505.023'03 505.023-' 18 Inserted Inserted Inserted in the Overhauling in the Overhauling in the Oveihau/ing yearboxes gearboxes gearboxes manual manual manual 2nd
volume
When using chemical products stick closely to the instructions in the safety supplier must give to the consumer (for Italy in accordance with DM. no.
the
Foreword
Bravo-Brava
The F i a t B r a v o is a 2 b o x , 3 d o o r v e h i c l e w i t h a l o a d carrying s t r u c t u r e , transversely m o u n t e d e n g i n e and f r o n t w h e e l drive It is p r o d u c e d w i t h 6 d i f f e r e n t e n g i n e t y p e s . The e n g i n e s have 4 or 5 c y l i n d e r s in line w i t h c l o c k w i s e r o t a t i o n a n d are m o u n t e d transversely at t h e front. A c c o r d i n g t o t h e trim level, t h e f o l l o w i n g engines are f i t t e d : 1370 c c f o u r c y l i n d e r s in line, 1 2 v a l v e s r u n n i n g o n u n l e a d e d p e t r o l a n d d e v e l o p i n g a p o w e r o u t p u t o f 5 9 k W ( 8 0 C V ) at 6 0 0 0 r p m . f o u r cylinders in line, 16 v a l v e s r u n n i n g o n u n l e a d e d petrol a n d d e v e l o p i n g a p o w e r o u t p u t o f 7 6 k W ( 1 0 3 C V ) at 5 7 0 0 r p m . f o u r cylinders in line, 16 v a l v e s r u n n i n g o n u n l e a d e d petrol a n d d e v e l o p i n g a p o w e r o u t p u t o f 8 3 k W ( 1 1 3 C V ) at 5 8 0 0 r p m . f i v e cylinders in line, 2 0 v a l v e s r u n n i n g o n u n l e a d e d petrol a n d d e v e l o p i n g a p o w e r o u t p u t o f 1 0 8 k W ( 1 4 7 C V ) at 6 1 0 0 r p m . four cylinders in line, 8 v a l v e s , indirect injection r u n n i n g o n diesel f u e l and d e v e l o p i n g a p o w e r o u t p u t of 4 8 k W ( 6 5 CV) at 4 6 0 0 r p m . four c y l i n d e r s in line, 8 valves, i n d i r e c t i n j e c t i o n r u n n i n g o n diesel f u e l and d e v e l o p i n g a p o w e r o u t p u t of 7 4 k W ( 1 0 0 CV) at 4 2 0 0 r p m .
1581 c c
1747 c c
1998 c c
1929 D e c
1910 T D c c
The F i a t B r a v a is a t h r e e b o x v e h i c l e , w i t h 5 d o o r s , a load c a r r y i n g s t r u c t u r e , transversely m o u n t e d e n gine a n d f r o n t w h e e l d r i v e It is p r o d u c e d w i t h 5 d i f f e r e n t e n g i n e t y p e s . The e n g i n e s are the same as t h o s e f i t t e d o n the F i a t B r a v o w i t h t h e e x c e p t i o n of the 1 9 9 8 cc.
Print no.
506.670/06
Bravo-Brava
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Inlet
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Bravo-Brava
Electrical system
Contents
55.
page ALARM - L o c a t i o n of c o m p o n e n t s of alarm system Introduction Receiver Remote control Emergency key s w i t c h Operation Programming Simplified programming Closing the memory Programming w i t h closed memory Opening memory and memorizing a new remote control - R e p l a c i n g alarm c o n t r o l unit
1 2 2 2 3 3 3 4 5 6 6 6
For aspects not discussed, the previous Section 55 system - Alarm, on pages following.
Copyright
Fiat Auto
X I I - 9 7 - Update
Bravo-Brava
Electrical system
Alarm
55.
LOCATION OF COMPONENTS OF ALARM S Y S T E M
P4A01DL01
X I I - 9 7 - Update
Electrical system
Alarm
Bravo-Brava
55.
INTRODUCTION The n e w V . A . S . (Vehicle A l a r m S y s t e m ) r a d i o f r e q u e n c y alarm system offers v o l u m e t r i c a n d perimetral p r o t e c t i o n ; it m o n i t o r s t h e state of t h e b o n n e t , b o o t , fuel flap a n d d o o r s and t h e presence of a m o v i n g object in t h e interior c o m p a r t m e n t . This alarm system has t h e f o l l o w i n g differences c o m p a r e d w i t h t h e m o d e l f i t t e d previously: - n e w r a d i o f r e q u e n c y receiver, i n c o r p o r a t e d in t h e f r o n t central c o u r t e s y light, w i t h green w a r n i n g l i g h t ( L E D ) ( t h e LED w a s previously r e d ) ; - r a d i o f r e q u e n c y remote c o n t r o l , i n t e g r a t e d in t h e d i f f e r e n t l y - s h a p e d i g n i t i o n key; - n e w a l a r m c o n t r o l u n i t integrated in a s e l f - s u p p l i e d siren, w h i c h is located in t h e f r o n t left w h e e l a r c h ; - n e w m e t h o d of p r o g r a m m i n g the r e m o t e c o n t r o l s . RECEIVER The receiver, built i n t o t h e f r o n t central c o u r t e s y l i g h t , is an e l e c t r o n i c device w h i c h captures t h e rad i o f r e q u e n c y signal e m i t t e d by the r e m o t e c o n t r o l a n d carries o u t t h e f u n c t i o n s of o p e n i n g a n d c l o s i n g the d o o r s a n d a c t i v a t i n g t h e alarm c o n t r o l unit. The receiver has a green w a r n i n g l i g h t ( L E D ) ( 1 ) w h i c h c o m e s o n w h e n it receives t h e signal, w h i l e the b u t t o n ( 2 ) a l l o w s t h e c o d e t o be m e m o r i z e d (see " P R O G R A M M I N G " ) . Detail of r e c e i v e r on f r o n t c o u r t e s y light 1 . Green w a r n i n g light ( L E D ) 2. m e m o r i z a t i o n b u t t o n 3. V o l u m e t r i c sensors Receiver connector 1. 2. 3. 4. 5. 6. 7. 8. Not connected Serial line to alarm control unit Battery positive ( + 3 0 ) Earth Door unlock Door lock Ignition-dependent positive ( + 15) Not connected
REMOTE CONTROL T h e alarm system remote c o n t r o l , built i n t o t h e i g n i t i o n key ( f i g u r e o p p o s i t e ) , is an electronic d e v i c e w h i c h sends a signal t o t h e receiver for c o n t r o l l i n g t h e o p e n i n g / c l o s u r e of t h e d o o r s a n d a c t i v a t i o n / d e a c t i v a t i o n of the alarm system. W h e n e v e r t h e b u t t o n ( 1 ) o n t h e remote c o n t r o l is pressed, t h e r e m o t e c o n t r o l issues a r a d i o c o d e w h i c h has a radius of a c t i o n of a b o u t 1 0 metres. 1. 2. 3. 4. Control button Repeater w a r n i n g light ( L E D ) Access c o d e ( p a s s w o r d ) t a g T r a n s p o n d e r (for Fiat C O D E - not v i s i b l e ) If the control unit, receiver and/or remote controls are replaced, components from the same type of system must be used.
NOTE 3
X I I - 9 7 - Update
Bravo-Brava
Electrical system
Alarm
55.
EMERGENCY KEY SWITCH T h e e m e r g e n c y circuit key s w i t c h a l l o w s t h e alarm system t o be e x c l u d e d , if necessary. It is l o c a t e d o n the side under t h e d a s h b o a r d a n d is o n l y accessible after r e m o v i n g t h e b o t t o m left t r i m f r o m t h e d a s h b o a r d (see f i g u r e ) .
T h e e m e r g e n c y key s w i t c h can assume t w o p o s i t i o n s , namely: OFF (key f u l l y rotated in t h e a n t i - c l o c k w i s e direction), corresponding to deactivation of t h e alarm c i r c u i t (key f u l l y rotated in t h e c l o c k w i s e d i r e c t i o n ) , c o r r e s p o n d i n g t o a c t i v a t i o n of t h e s u p p l y t o t h e alarm s y s t e m .
ON
P4A16AL01
OPERATION S w i t c h i n g off t h e a l a r m If t h e remote c o n t r o l ' s batteries b e c o m e d i s c h a r g e d or t h e alarm system is f a u l t y , it can be d e a c t i v a t e d by t u r n i n g t h e e m e r g e n c y key s w i t c h t o t h e OFF p o s i t i o n . This key s h o u l d be rotated t o t h e OFF p o s i t i o n if t h e car is t o be left u n u s e d for l o n g p e r i o d s ( o v e r three weeks). T o reactivate t h e system, t u r n t h e e m e r g e n c y key s w i t c h O N again a n d c h e c k t h a t it is in t h i s p o s i t i o n b e fore delivery of t h e car t o t h e customer. For cars i n t e n d e d for t h e British market w h i c h have n o e m e r g e n c y key s w i t c h , in t h e a b o v e - m e n t i o n e d case in w h i c h t h e remote c o n t r o l ' s batteries are d i s c h a r g e d and t h e alarm c a n n o t be t u r n e d off, w a i t for t h e latter t o be d e a c t i v a t e d (i.e. after t h e cycles of siren c o m i n g o n a n d d i r e c t i o n i n d i c a t o r s f l a s h i n g ) .
As regards "Switching alarm on/off", excluded" and "Discharged batteries ous Section 55. PROGRAMMING
"Surveillance", "Alarm state", "Switching on with indicator", refer to pages 134/1 and 134/2 of the
siren previ-
T h e m e t h o d s of i n d i c a t i n g t h e alarm m a y vary d e p e n d i n g o n the l a w s in force in the c o u n t r y o f registrat i o n ; it is therefore necessary t o p r o g r a m m e t h e system b y e n t e r i n g t h e " c o u n t r y c o d e " , as d e s c r i b e d o n t h e next page. T h e system " r e c o g n i z e s " t h e c o d e of t h e r e m o t e c o n t r o l s w i t h n o l i m i t as t o q u a n t i t y , b u t o n l y t h e last 8 remain stored in m e m o r y ( w h e n the n i n t h remote c o n t r o l is entered, t h e first is d e l e t e d f r o m m e m o r y ) . There are t w o p r o g r a m m i n g m e t h o d s (see t h e d e s c r i p t i o n o n t h e f o l l o w i n g p a g e s ) : - before entering the access code (password): S I M P L I F I E D P R O G R A M M I N G - after closing the memory: P R O T E C T E D P R O G R A M M I N G
In view of the importance of carrying out the programming procedure quickly and precisely, it is advisable, at least initially, for two people to carry out the operation: one to read the instructions in sequence and the other to carry them out closely.
X I I - 9 7 - Update
Electrical system
Alarm
Bravo-Brava
55.
SIMPLIFIED PROGRAMMING The m e m o r i z a t i o n of a r e m o t e c o n t r o l must a l w a y s take place w i t h : - alarm off (dissuasion LED o f f ) - i g n i t i o n key r e m o v e d or at t h e S T O P or P A R K positions - e m e r g e n c y key s w i t c h (except for versions f o r t h e British market w h i c h d o n o t have it) at t h e ON position W i t h t h i s p r o g r a m m i n g system, all t h e c o d e s o f the r e m o t e c o n t r o l s , w i t h n o limit as t o q u a n t i t y , are " r e c o g n i z e d " , b u t o n l y t h e last 8 r e m a i n stored in t h e alarm system's m e m o r y as f o l l o w s : 1. press a n d h o l d d o w n t h e b u t t o n ( 5 ) o n t h e receiver, b u i l t i n t o t h e f r o n t central c o u r t e s y light; t h e a d j a c e n t w a r n i n g l i g h t ( L E D ) ( 4 ) s h o u l d flash; 1. Remote control w a r n i n g light (LED) 2. still h o l d i n g d o w n t h e b u t t o n ( 5 ) , press t h e 2. 4 - d i g i t access code (password) b u t t o n (3) on the remote control; 3. Remote control b u t t o n on ignition key 3. t h e n release t h e b u t t o n ( 3 ) o n t h e r e m o t e c o n t r o l w h e n t h e LED ( 4 ) o n t h e receiver 4. W a r n i n g light (LED) on front central courstays o n p e r m a n e n t l y ; tesy light 4. release t h e b u t t o n ( 5 ) o n t h e c o u r t e s y l i g h t t o 5. Programming b u t t o n c o n c l u d e the p r o c e d u r e . If t h e LED (4) o n t h e receiver s t o p s f l a s h i n g a n d goes o u t w h e n t h e r e m o t e c o n t r o l b u t t o n ( 3 ) is pressed, t h i s means t h a t the receiver's m e m o r y is c l o s e d , s o " P R O T E C T E D " p r o g r a m m i n g s h o u l d be To memorize the subsequent remote controls, repeat the above-mentioned operations.
Programming country code P r o c e d u r e a) After m e m o r i z i n g t h e remote c o n t r o l s as d e s c r i b e d above, w i t h i n 1 5 s e c o n d s of releasing t h e b u t t o n ( 5 ) of t h e receiver o n t h e courtesy l i g h t , t h e c o d e of t h e c o u n t r y w h e r e the alarm system has t o operate m u s t be m e m o r i z e d . The c o u n t r y c o d e is p r o g r a m m e d b y pressing t h e b u t t o n ( 5 ) of t h e receiver in rapid s u c c e s s i o n n t i m e s (see t a b l e b e l o w ) . T h e LED ( 4 ) w i l l flash at each press of t h e b u t t o n . If the b u t t o n ( 5 ) is n o t pressed, t h e system sets itself t o the c o u n t r y c o d e p r e v i o u s l y m e m o r i z e d ; if t h e r e is n o n e (1st p r o g r a m m i n g ) , t h e system sets itself a u t o m a t i c a l l y t o the o p e r a t i n g m o d e f o r " I T A L Y " . NOTE The 75 seconds are reduced to 3 from the second memorization onwards. COUNTRY OF OPERATION UNITED KINGDOM BELGIUM HOLLAND EEC
// the procedure has been carried out correctly, the warning light (LED) (5) on the receiver will flash n times (where n is the selected country code number), confirming that the code has been memorized by both the receiver and the control unit; if not, the LED (5) comes on and stays on for S seconds; at this point it will be necessary to repeat all the programming operations starting from point 1. For cars intended for the British market, if the LED does not come on again, this means that the control unit is not connected to the receiver or is not supplied. NOTE To programme and the other the country diagnostic code, you can use the procedure systems. with the FIAT/LANCIA Tester
X l l - 9 7 - Update
Bravo-Brava
Electrical system
Alarm
55.
Procedure b) A l t e r n a t i v e l y , t h e c o u n t r y c o d e c a n be p r o g r a m m e d b y means of t h e f o l l o w i n g p r o c e d u r e : - open the bonnet; - t u r n t h e i g n i t i o n f r o m o n t o off ( S T O P p o s i t i o n ) , t h e n b e f o r e 1 5 s e c o n d s elapse, press 7 t i m e s in rapid s u c c e s s i o n (in less t h a n 1 0 s e c o n d s ) t h e switch ( A ) (bonnet open sensor); 5 beeps w i l l i n dicate e n t r y i n t o M A N U A L D I A G N O S I S (see page 1 5 0 of previous S e c t i o n 5 5 ) . D u r i n g t h i s stage ( 5 b e e p s ) press a n d h o l d d o w n t h e s w i t c h ( A ) . A f i n a l l o n g beep w i l l indicate a c c e p t a n c e of this action; - hold d o w n the switch (A) throughout the durat i o n of t h e l o n g beep. This l o n g b e e p c o n f i r m s start of " c o u n t r y c o d e p r o g r a m m i n g " , a n d s o t h e p o s s i b i l i t y of s u b s e q u e n t l y e n t e r i n g t h e " c o u n t r y code";
P4A05DL01
release t h e s w i t c h ( A ) a n d w i t h i n 1 0 s e c o n d s press t h e same s w i t c h n times (see t a b l e o n p r e c e d i n g p a g e ) , t o select the o p e r a t i n g m o d e for t h e desired c o u n t r y ( e a c h press w i l l be a c c o m p a n i e d b y a c o n firming beep). The simplified programming the stages prior to delivery CLOSING THE MEMORY T o a v o i d t h e entry of u n a u t h o r i z e d r e m o t e c o n t r o l s , t h e m e m o r y m u s t be p r o t e c t e d ( c l o s e d ) ; t h i s o p e r a t i o n takes place a u t o m a t i c a l l y after t h e alarm system has s w i t c h e d o n / o f f 1 2 8 times. T h e m e m o r y c a n a l so be c l o s e d m a n u a l l y b y e n t e r i n g t h e access c o d e ( P a s s w o r d ) ( 4 - d i g i t n u m b e r stated o n t h e t a g a t t a c h e d t o the i g n i t i o n key w i t h r e m o t e c o n t r o l illustrated o n p a g e 2 ) , for e x a m p l e o n a n e w car b e f o r e delivery, after all t h e c o d e s of t h e r e m o t e c o n t r o l s g i v e n t o t h e C u s t o m e r have been e n t e r e d . The p r o c e d u r e for e n t e r i n g the P a s s w o r d is as f o l l o w s : 1 . Take o n e of t h e t a g s of t h e r e m o t e c o n t r o l s m e m o r i z e d in t h e receiver, t h e n press for 1 s e c o n d t h e b u t t o n o n t h e receiver: t h e LED flashes for as l o n g as t h e b u t t o n is held d o w n . 2. T h e n release the b u t t o n : after a b o u t 3 s e c o n d s , t h e LED flashes briefly, t o i n d i c a t e t h a t t h e first d i g i t of t h e Password c a n be entered. 3. Press t h e receiver b u t t o n as m a n y t i m e s as i n d i c a t e d by t h e first d i g i t of t h e P a s s w o r d ( e . g . if t h e Password is 5.2.0.3.: press 5 t i m e s ) . N o t e t h a t w h e n e v e r t h e b u t t o n is pressed, t h e L E D c o m e s o n briefly t o give visual c o n f i r m a t i o n . 4 . A b o u t 3 seconds after t h e last press of t h e b u t t o n ( t h e f i f t h in t h e e x a m p l e ) , the LED e m i t s a n o t h e r flash t o request t h e e n t r y of t h e n e x t d i g i t . 5. Proceed as described in p o i n t 3 t o enter all t h e s u b s e q u e n t d i g i t s . NOTE When the password wait for the request (see example) contains a "0", do not press the button to enter a new digit, indicated by the next flash. on the receiver, but procedure permanently deletes of the car to the Customer. the UNIVERSAL code, used during
After t h e 4 digits of t h e P a s s w o r d have been e n t e r e d , t h e LED o n t h e receiver may: - f l a s h f o r a b o u t 1 0 s e c o n d s ; t o i n d i c a t e t h a t t h e P a s s w o r d has been entered c o r r e c t l y ; - c o m e o n a n d s t a y o n f o r a b o u t 1 0 s e c o n d s ; t o i n d i c a t e t h a t t h e P a s s w o r d has n o t b e e n e n t e r e d c o r r e c t l y , so after t h e LED has g o n e o u t , t h e P a s s w o r d s h o u l d be r e - e n t e r e d c o r r e c t l y s t a r t ing from point 1. The correct entry of t h e access c o d e ( P a s s w o r d ) " c l o s e s " ( p r o t e c t s ) t h e m e m o e r y , t o p r e v e n t t h e m e m o rization of u n a u t h o r i z e d r e m o t e c o n t r o l s . In fact it is impossible t o memorize a n e w remote c o n t r o l , because after t r a n s m i t t i n g its c o d e , t h e w a r n i n g light ( L E D ) on the receiver w i l l s t o p f l a s h i n g t o indicate t h a t the o p e r a t i o n has failed; in this case t h e m e m ory has t o be " o p e n e d " , p r o c e e d i n g as described o n t h e next page.
X I I - 9 7 - Update
Electrical system
Alarm
Bravo-Brava
55.
PROGRAMMING WITH CLOSED MEMORY If t h e m e m o r y is " c l o s e d " ( p r o t e c t e d ) , f u r t h e r rem o t e c o n t r o l c o d e s c a n o n l y be entered after t h e m e m o r y has been " o p e n e d " w i t h o n e of t h e c o d e s of t h e keys m e m o r i z e d in t h e receiver. O P E N I N G M E M O R Y AND M E M O R I Z A T I O N A NEW REMOTE CONTROL O p e n i n g the m e m o r y T o o p e n t h e m e m o r y , carry o u t t h e o p e r a t i o n s listed b e l o w in q u i c k s u c c e s s i o n : 1. press t h e b u t t o n ( 5 ) o n t h e receiver for a b o u t 2 s e c o n d s ; the L E D ( 4 ) w i l l flash f o r as l o n g as t h e b u t t o n is pressed; 2. release the b u t t o n ; after a b o u t 2 s e c o n d s , t h e LED emits a brief f l a s h t o i n d i c a t e t h a t t h e first d i g i t of t h e P a s s w o r d can be e n t e r e d ; 3. press t h e receiver b u t t o n ( 5 ) as m a n y t i m e s as i n d i c a t e d b y t h e first d i g i t of t h e P a s s w o r d ( e . g . if t h e P a s s w o r d is 5.2.0.3., press 5 t i m e s ) . N o t e t h a t w h e n e v e r t h e b u t t o n is pressed, the LED ( 4 ) c o m e s o n briefly t o give visual c o n f i r m a t i o n ; OF
P4A04DL01
1. 2. 3. 4. 5.
4. after a b o u t 2 s e c o n d s f r o m t h e last press o f t h e b u t t o n ( t h e f i f t h in t h e e x a m p l e ) , t h e LED emits a n o t h e r flash t o request t h e entry of t h e n e x t d i g i t ; 5. p r o c e e d f r o m p o i n t 3 t o enter all f o u r d i g i t s (if t h e d i g i t is " 0 " , d o n o t press the b u t t o n , b u t w a i t f o r t h e next request); 6. if t h e P a s s w o r d has been entered c o r r e c t l y ( m e m o r y o p e n e d ) , t h e L E D starts t o flash (for a b o u t 1 0 s e c o n d s ) ; if instead it c o m e s o n a n d stays o n (for a b o u t 1 0 s e c o n d s ) , t h e p r o c e d u r e w i l l have t o be repeated f r o m p o i n t 1 , as t h e p a s s w o r d has n o t been r e c o g n i z e d . M e m o r i z i n g a n e w remote c o n t r o l 7. W h i l e the LED ( 4 ) is f l a s h i n g , press a n d h o l d d o w n t h e b u t t o n ( 5 ) ; t h e LED ( 4 ) w i l l c o n t i n u e t o f l a s h ; 8. press the b u t t o n ( 3 ) o n t h e n e w r e m o t e c o n t r o l u n t i l t h e g r e e n / r e d L E D ( 4 ) o n t h e c o u r t e s y l i g h t stays o n p e r m a n e n t l y ; 9. t h e n release t h e b u t t o n ( 3 ) of t h e t r a n s m i t t e r w h e n t h e LED ( 4 ) o n t h e c o u r t e s y l i g h t stays o n p e r m a nently; 10. release t h e b u t t o n ( 5 ) o n t h e c o u r t e s y l i g h t t o c o n c l u d e t h e p r o g r a m m i n g p r o c e d u r e . If the procedure has been carried out correctly, the LED on the receiver will flash n times (where n is the selected country code number), confirming that the code has been memorized by both the receiver and the control unit; otherwise the LED comes on and stays on for 5 seconds; all the operations will thus have to be repeated starting from point 1 of the programming procedure. After the new remote control has been memorized, the memory returns to the "closed" state.
REPLACING ALARM CONTROL UNIT If o n l y t h e alarm c o n t r o l u n i t has t o be r e p l a c e d , t h e n e w part must be a c t i v a t e d b y m e m o r i z i n g at least o n e o f t h e r e m o t e c o n t r o l s p r o v i d e d , b y f o l l o w i n g t h e p r o c e d u r e d e s c r i b e d in t h e " S I M P L I F I E D P R O G R A M M I N G " s u b - s e c t i o n o n page 4 or in t h e " P R O G R A M M I N G W I T H C L O S E D M E M O R Y " s u b - s e c t i o n at t h e t o p o f this page.
Publication no.
506.670/14
Bravo-Brava
Section 55 D
Analytical charts
Electrical equipment fault diagnosis
4AS21N
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Chart No. Functions involved
C h a r t (page 1)
C h a r t (page 19)
T r i m level: S - S X Electric f r o n t w i n d o w s
T r i m level: E L - E L X C h a r t (page 35) Version without alarm: S - S X - G T C h a r t (page 4 5 ) 5 Central l o c k i n g 4 Electric rear w i n d o w s
Version: E L - E L X - H G T C h a r t (page 57) 6 Central d o o r l o c k i n g a n d car d o o r s n o t s h u t w a r n i n g s y s tem T r i m level: E L - E L X - H G T C h a r t (page 7 3 ) 7 D i r e c t i o n i n d i c a t o r s a n d w a r n i n g l i g h t - Hazard w a r n i n g lights a n d w a r n i n g l i g h t - B r a k i n g lights - R e v e r s i n g lights
C h a r t (page 97)
V e h i c l e interior l i g h t s - I d e o g r a m l i g h t s
C h a r t (page 107)
Fuel level g a u g e a n d reserve w a r n i n g light - H a n d b r a k e a p p l i e d / i n s u f f i c i e n t brake f l u i d level w a r n i n g l i g h t S p e e d o m e t e r - M i l o m e t e r / t r i p meter d i s p l a y a n d z e r o i n g button - Water temperature gauge - Insufficient engine oil pressure w a r n i n g l i g h t - Front brake p a d w e a r w a r n i n g l i g h t - Rev c o u n t e r
Bravo-Brava
Fault diagnosis
Wiring diagrams
5 5 D.
Parking lights and warning lamp - Dipped beam headlamps - Main beam headlamps and warning light - Parking lights Number plate lights - (See key at end of wiring diagrams)
* 6 0 A fuse f o r D S versions
Fault diagnosis
Location of components
Bravo-Brava
55D.
Parking lights and warning lamp Number plate lights Components key
Dipped beam headlamps - Main beam headlamps and warning light - Parking lights
1 Left front light cluster 2 Right front light cluster 3 Power fuse box: A 30A protective fuse for injection system (60A for DS versions) B 40A protective fuse for ignition system C 60A protective fuse for optional extras D 80A protective fuse for junction unit 4 Junction unit 5 Dipped headlamps relay feed 6 Instrument panel: E Side lights warning light G Main beam headlamps warning light 7 Steering column switch unit: D Flasher control E Switch for dipped/main beam headlamps F Switch for side lights 8 Left front earth 9 Right front earth 10 Earth for battery on bodyshell 11 Battery 12 Ignition switch
13 14 15 16 17 18 19 22 N.D.
Front right/left cables connection Left no. plate light Right no. plate light Left rear light cluster Right rear light cluster Left rear earth Right rear earth Left dashboard earth Ultrasound welding taped in cable loom
4A402N
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The outside lights are not working
Not OK
OK
Not OK
The side lights and the number plate lights are not working
C h e c k t h e c o n d i t i o n o f fuses 2 a n d 3 in t h e j u n c t i o n unit 4
Not OK
OK
C h e c k f o r v o l t a g e at t h e G c o l o u r e d cable, at c o n n e c t o r G p i n 5 of t h e j u n c t i o n u n i t 4
OK
Not OK
OK
Restore t h e c o n t i n u i t y f o r the G coloured cable between the ignition switch 12 and the j u n c t i o n unit 4
Not OK
4A403N
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
Bridge A G & G V c o l o u r e d cables at c o n . B for steering c o l u m n s w i t c h unit 7 OK C h e c k t h e c o n d i t i o n of t h e steering c o l u m n s w i t c h u n i t , o v e r h a u l it or replace it
Not O K
OK
Not O K
OK
Not O K
OK
Not O K
Check t h e c o n d i t i o n of t h e ignition s w i t c h 12
Not OK
O v e r h a u l or switch 12
replace
the
The left front and right real side lights and the left no. plate light are not working Check t h e c o n d i t i o n o f t h e fuse 3 in t h e j u n c t i o n u n i t Not OK C h e c k f o r a short c i r c u i t in the s y s t e m a n d replace t h e fuse 3
OK
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
C h e c k t h e c o n d i t i o n of t h e junction unit 4 Not OK Overhaul or replace junction unit 4 the
The right front and left rear side lights and right no. plate light are not working
C h e c k t h e c o n d i t i o n of t h e f u s e 2 in t h e j u n c t i o n u n i t 4
Not OK
OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
C h e c k t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
Not OK
Replace t h e b u l b h o l d e r
OK
OK
4A406N
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
4
Not O K
OK
Not O K
Not OK
O v e r h a u l or replace j u n c t i o n unit 4
the
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
Check t h e c o n d i t i o n of t h e bulb h o l d e r
Not OK
Replace t h e b u l b h o l d e r
OK
OK
Not O K
4
6
Print no. 506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
C h e c k f o r v o l t a g e at t h e GR coloured cable connector D p i n 1 3 of t h e j u n c t i o n u n i t 4 OK Restore t h e c o n t i n u i t y o f t h e GR c o l o u r e d c a b l e b e t w e e n the junction unit 4 a n d t h e light cluster 2
Not OK
C h e c k t h e c o n d i t i o n of t h e junction unit 4
Not OK
the
C h e c k t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
Not OK
OK
OK
Not OK
C h e c k for v o l t a g e at t h e G N c o l o u r e d cable c o n n e c t o r G p i n 1 of t h e j u n c t i o n u n i t 4
OK
Restore t h e c o n t i n u i t y f o r the GN coloured cable b e tween the junction unit 4 a n d t h e left rear l i g h t c l u s t e r 16
4A407N
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
Not O K
N o t OK
O v e r h a u l or replace j u n c t i o n unit 4
the
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
Check t h e c o n d i t i o n o f t h e bulb h o l d e r
N o t OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not O K
OK
Not O K
Not OK
O v e r h a u l or replace j u n c t i o n unit 4
the
Print no,
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
The side lights warning light is not working
Not OK
O v e r h a u l or r e p l a c e junction unit 4
the
OK
Not OK
OK
Check t h e c o n d i t i o n o f t h e w a r n i n g l i g h t E in t h e i n s t r u m e n t panel 6
N o t OK
Replace t h e w a r n i n g l i g h t E in t h e i n s t r u m e n t p a n e l 6
OK
Check t h e c o n d i t i o n o f t h e i n s t r u m e n t panel 6
Not OK
O v e r h a u l or replace t h e i n s t r u m e n t panel 6
Not OK
the
Check t h e c o n d i t i o n o f t h e bulb
Not OK
Replace t h e b u l b
4A409N
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
OK
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
Ok
Not OK
OK
Not OK
Check t h e c o n d i t i o n o f t h e j u n c t i o n unit 4 The right no. plate light is not working Check t h e c o n d i t i o n o f t h e bulb
Not OK
O v e r h a u l or replace j u n c t i o n unit 4
the
Not OK
Replace t h e b u l b
OK
10
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Check t h e condition of the bulb holder N o t OK O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
OK
Not OK
OK
Not OK
Not OK
O v e r h a u l or r e p l a c e junction unit 4
the
Both the dipped headlamps are not working Check t h e c o n d i t i o n o f fuses 4 a n d 5 in t h e j u n c t i o n u n i t 4 Not OK C h e c k for a s h o r t c i r c u i t in t h e system a n d r e p l a c e t h e fuses 4 a n d 5
OK
Check t h e c o n d i t i o n o f t h e j u n c t i o n unit 4
Not OK
O v e r h a u l or r e p l a c e junction unit 4
the
11
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
Both the (lipped headlamps are not working when operaled by the steering column switch unit
OK
Not OK
Not OK
OK
Not OK
the
Both the dipped headlamps are not working with the main beam headlamps on
OK
O v e r h a u l or replace t h e relay 5
Not O K
OK
O v e r h a u l o r replace t h e relay 5
Not OK
OK
12
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
C h e c k f o r v o l t a g e at t h e R c o l o u r e d cable at t h e relay 5
Not OK
OK
C h e c k f o r v o l t a g e at t h e LR c o l o u r e d cable f o r relay 5
Not OK
OK
C h e c k f o r v o l t a g e at t h e HR c o l o u r e d cable, c o n n e c t o r F pin 2 o f t h e j u n c t i o n u n i t 4
Not OK
OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
the
Not OK
OK
C h e c k t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
13
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
OK
Check t h e c o n d i t i o n of t h e b u l b holder
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
OK
Not OK
Not OK
the
Check t h e c o n d i t i o n of t h e fuse 6 in t h e j u n c t i o n u n i t 4
Not OK
OK
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
14
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
Not OK
OK
C h e c k f o r v o l t a g e at t h e H c o l o u r e d cable f o r t h e r i g h t f r o n t l i g h t cluster 2
OK
Not OK
C h e c k f o r v o l t a g e at t h e H c o l o u r e d cable, c o n n e c t o r C p i n 4 of t h e j u n c t i o n unit 4
OK
Not OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
the
The left dipped headlamp and the warning light are not working
C h e c k t h e c o n d i t i o n of t h e f u s e 7 in the j u n c t i o n unit 4
Not OK
OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
the
4A415N
15
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
The left main beam headlamp is not working
Check t h e c o n d i t i o n o f t h e bulb
Not OK
Replace t h e b u l b
OK
Check t h e c o n d i t i o n of t h e bulb h o l d e r
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not O K
OK
Not O K
Not OK
the
Check t h e c o n d i t i o n o f t h e fuse 6 in t h e j u n c t i o n u n i t 4
Not OK
4
16
Print no. 506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
Not OK
OK
OK
Not OK
C h e c k for v o l t a g e at t h e V c o l o u r e d cable c o n n e c t o r C p i n 7 of t h e j u n c t i o n u n i t 4
OK
Restore t h e c o n t i n u i t y f o r the V coloured cable between the junction unit 4 and the right front light c l u ster 2
Not OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
the
4A417N
17
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
The main beam headlamps warning light is not working Check f o r v o l t a g e at t h e V N c o l o u r e d cable c o n n e c t o r J pin 6 o f t h e j u n c t i o n u n i t 4 Not OK O v e r h a u l or replace j u n c t i o n unit 4 the
OK
Not OK
OK
Not OK
Replace t h e w a r n i n g l i g h t G or o v e r h a u l t h e i n s t r u m e n t panel 6
4A418N
18
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Wiring diagrams
55D.
Trim Level: S - SX Electric front windows - (See key at end of wiring diagrams)
' llllll
11
30A40A 60A80A " L
91
LH]
RN
72
N.D.
2 1 R R R - - R
4 3 2 1
N.D.
N.D.
RN CB
[ a ] 76
Beze-
35 l s 75
- R R R - * R R BR-RU-RU-RU-
36
77\m\
-ZB
N.D.
-RU-
74 [ a ]
N.D.
^-BGR ij-ZGII
RZB' -RU-BR-
-CB-CB-
| N.D.
CB
12
22
* 6 0 A fuse f o r D S v e r s i o n s
P4A037N02
19
Fault diagnosis
Location of components
Bravo-Brava
55D.
P4A039N02
Trim Level: S - SX Electric front windows Components key 3 Power fuse box: A 30A protective fuse for injection system (60A for DS versions) B 40A protective fuse for ignition system C 60A protective fuse for optional extras D 80A protective fuse for junction unit 4 Junction unit 10 Earth for battery on bodyshell 11 Battery 12 Ignition switch 22 Left dashboard earth 35 Dashboard/left front door cables connection 36 Dashboard/right front door cables connection 72 30A protective fuse for electric front windos 73 Left front electric window control panel 74 Right electric front window control panel 75 Right front electric window control panel on left front door 76 Left front electric window motor 77 Right front electric window motor 91 Power relay N.D. Ultrasound welding taped in cable loom
20
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The electric front windows are not working
C h e c k t h e c o n d i t i o n of t h e f u s e 7 2 p r o t e c t i n g t h e electric w i n d o w s
Not OK
OK
OK
N o t OK
OK
Not OK
OK
N o t OK
Not OK
OK
Not OK
Restore the continuity for the RN coloured cable between the electric w i n d o w s relay 91 and the junction unit 4 or overhaul the control unit 4
21
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
OK
Not OK
OK
Not OK
Restore t h e c o n t i n u i t y of t h e R coloured cable between t h e fuse 7 2 a n d t h e u l t r a sound welding towards the connectors 35 and 36
OK
OK
The left front electric window is not working Bridge t h e R / B G a n d Z G / N c o l o u r e d cables at t h e left electric w i n d o w s control panel 7 3 ( w i t h t h e c o n n e c tor f o r t h e c o n t r o l panel d i s c o n n e c t e d f r o m its h o u s i n g ) OK O v e r h a u l or replace t h e left electric window control panel 7 3
Not OK
Bridge t h e R/ZG a n d B G / N c o l o u r e d cables at t h e left electric window control panel 7 3 ( w i t h t h e c o n n e c tor f o r t h e c o n t r o l panel d i s c o n n e c t e d f r o m its h o u s i n g )
OK
Not OK
22
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
Restore t h e c o n t i n u i t y of t h e R coloured cable between t h e left electric window c o n t r o l panel 7 3 a n d t h e u l trasound welding
OK
OK
Restore t h e c o n t i n u i t y of t h e N coloured cable between t h e left electric window c o n t r o l panel 7 3 a n d t h e u l trasound welding
Not OK
Bridge t h e BG coloured cable b e t w e e n t h e left electric w i n d o w control panel 73 and t h e left electric w i n d o w motor 7 6 (without disconnecting the connector)
OK
Restore t h e c o n t i n u i t y f o r the BG coloured cable bet w e e n t h e left electric w i n d o w control panel 7 3 a n d t h e left electric w i n d o w m o tor 7 6
Not O K
B r i d g e t h e ZG c o l o u r e d c a ble b e t w e e n t h e left electric w i n d o w control panel 73 and t h e left electric w i n d o w motor 7 6 ( w i t h o u t disconnecting the connector)
OK
Restore t h e c o n t i n u i t y f o r the Z G coloured cable bet w e e n t h e left electric w i n d o w control panel 7 3 a n d t h e left electric w i n d o w m o tor 7 6
Not O K
Not OK
electric
23
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
The right front electric window is not working when operated by the driver's side control panel Check f o r v o l t a g e at t h e R coloured cable for the right electric window control panel 7 5 Not OK Restore t h e c o n t i n u i t y o f t h e R c o l o u r e d cable b e t w e e n the r i g h t electric w i n d o w control panel 7 5 and t h e u l trasound w e l d i n g
OK
Not OK
The right front electric window is not working opeiated by the passenger side control panel Check f o r v o l t a g e at t h e R c o l o u r e d c a b l e of c o n n e c t o r 36 Not OK Restore t h e c o n t i n u i t y o f t h e R c o l o u r e d cable b e t w e e n the c o n n e c t o r 3 6 a n d t h e u l trasound welding
OK
Not OK
OK
Not OK
The right front electric window is not working Bridge t h e N c o l o u r e d c a b l e at t h e electric w i n d o w c o n trol panel 7 5 w i t h an earth OK Restore t h e c o n t i n u i t y o f t h e N c o l o u r e d cable b e t w e e n t h e electric w i n d o w c o n t r o l panel 7 5 a n d t h e u l t r a s o u n d welding
4A424N
24
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
Not OK
Extract t h e c o n n e c t o r s for t h e electric w i n d o w c o n t r o l panels 7 5 a n d 7 4 f r o m their housings, bridge t h e R V a n d C c o l o u r e d cables at t h e connector for t h e control panel 7 4 a n d insert an o h m meter at t h e RV a n d C cables for t h e c o n t r o l panel 7 5 connector
N o t OK
OK
OK
Not OK
OK
Not OK
Extract t h e c o n n e c t o r f o r t h e electric window control panel 7 5 f r o m its h o u s i n g , bridge both the R/RV and C / N coloured cables
OK
Not OK
25
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
OK
Not O K
OK
Not OK
OK
Not OK
Check c o n d i t i o n of r i g h t electric w i n d o w m o t o r 7 7
Not OK
O v e r h a u l or replace t h e electric w i n d o w m o t o r 7 7
4A426N
26
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Wiring diagrams
55D.
Trim Level. EL - ELX - GT - HGT Electric front windows - (See key at end of wiring diagrams)
' 1111II
11
30A40A ] n 60A80A E
L
72
xi
N.D.
-13- R
4 3 2 1
N.D.
CBI
BG-
ZG-
35 L]75
- R -RUN -RU R RU-
N.D.
35
77^]
- BR-ZB-
I_:.
R0---RU
N.D.
T-
L] 73
N.D.
ehCB1
74 [ ]
- R BG -ZG CBCNCB -CN BGZGZ B
R -CN-
c - c
RU-BR-fe-
N.D.
-CB-CB-
N.D.
N -- N N CB ZG C I RN I CN I BG I N P
n
3 0 5 0
CB
M
+4-
15
30 87 31
mmm va
5EO
12
(e)
22 71
27
Fault diagnosis
Location of components
Bravo-Brava
55D
Components key 3 Power fuse box: A 30A protective fuse for injection system (60A for DS versions) B 40A protective fuse for ignition system C 60A protective fuse for optional extras D 80A protective fuse for junction unit 4 Junction unit 10 Earth for battery on bodyshell 11 Battery 12 Ignition switch 22 Left dashboard earth 35 Dashboard/left front door cables connection 36 Dashboard/right front door cables connection 71 Electric front windows control unit 72 30A protective fuse for electric front windos 73 Left front electric window control panel 74 Right electric front window control panel 75 Right front electric window control panel on left front door 76 Left front electric window motor 77 Right front electric window motor N.D. Ultrasound welding taped in cable loom
4A428N
28
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The electric front windows are not working
C h e c k t h e c o n d i t i o n of t h e f u s e 7 2 p r o t e c t i n g t h e electric w i n d o w s
Not OK
OK
OK
N o t OK
C h e c k f o r v o l t a g e at o n e of t h e R c o l o u r e d cables f o r fuse 7 2
Not OK
OK
C h e c k f o r v o l t a g e at t h e R c o l o u r e d cable f o r t h e e l e c tric w i n d o w s c o n t r o l u n i t 71
Not OK
Restore t h e c o n t i n u i t y o f t h e R coloured cable between t h e electric w i n d o w s c o n t r o l u n i t 71 a n d t h e f u s e 7 2 o r check the condition of t h e fuse holder
OK
C h e c k f o r v o l t a g e at t h e C c o l o u r e d cable f o r t h e e l e c tric w i n d o w s c o n t r o l u n i t 71
Not OK
Restore t h e c o n t i n u i t y f o r the C coloured cable b e t w e e n t h e electric w i n d o w s control unit 71 a n d t h e junction unit 4 connector I p i n 3, or c h e c k t h e c o n d i t i o n of t h e j u n c t i o n u n i t 4
OK
29
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
Check f o r v o l t a g e at t h e R N c o l o u r e d cable at t h e c o n t r o l unit 7 1 Not OK O v e r h a u l or replace t h e c o n trol unit 71
OK
Not OK
OK
Not OK
OK
Bridge t h e N c o l o u r e d c a b l e at c o n n e c t o r 3 5 w i t h a n earth
Not OK
Restore t h e c o n t i n u i t y of t h e N coloured cable between the connector 3 5 and the u l trasound welding
OK
Not OK
N o t OK
OK
4A430N
30
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
Bridge t h e N coloured cable for t h e c o n t r o l panel 7 3 w i t h an earth 7 1 OK Restore t h e c o n t i n u i t y o f t h e N coloured cable b e t w e e n t h e c o n t r o l panel 7 3 a n d t h e ultrasound w e l d i n g
Not OK
OK
Not OK
OK
Not OK
Extract t h e c o n n e c t o r s f o r t h e c o n t r o l panel 7 3 a n d f o r t h e electric w i n d o w c o n t r o l panel 7 1 f r o m their h o u s i n g , bridge C N / C B coloured c a bles at c o n t r o l unit 71 a n d insert an o h m m e t e r b e t w e e n C N / C B c o l o u r e d cables at c o n t r o l panel 7 3 c o n n e c t o r
Not OK
Restore t h e c o n t i n u i t y f o r the C N / C B coloured cables between the control panel 73 a n d the control unit 71
OK
Extract c o n s , f o r electric w i n d o w motor 76 & control u n i t 71 f r o m their h o u s i n g , bridge B G / Z G coloured c a bles at c o n . u n i t 71 & insert ohmmeter btwn BG/ZG c o l o u r e d cables at c o n n e c tor f o r e l . w i n d o w m o t o r 7 6
Not OK
31
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
OK
Check t h e c o n d i t i o n of t h e electric w i n d o w m o t o r 7 6
Not OK
O v e r h a u l or replace t h e electric w i n d o w m o t o r 7 6
OK
Check t h e c o n d i t i o n of t h e electric w i n d o w c o n t r o l u n i t 71
Not OK
Replace t h e electric d o w s c o n t r o l u n i t 71
win-
The right front electric window is not working operated by the drivel's control panel Check f o r v o l t a g e at t h e R c o l o u r e d cable f o r t h e right electric window control panel 7 5 Not OK Restore t h e c o n t i n u i t y o f t h e R c o l o u r e d cable b e t w e e n t h e right electric w i n d o w c o n t r o l panel 7 5 a n d t h e u l trasound w e l d i n g
OK
Not OK
The right front electric window is not working operated by the passenger control panel Check f o r v o l t a g e at t h e R c o l o u r e d cable f o r c o n n e c tor 3 6 Not OK Restore c o n t i n u i t y o f R c o l o u r e d cable b t w n c o n nector 3 6 & ultrasound welding
OK
Not OK
4A432N
32
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
N o t OK
The right front electric window is not working Bridge t h e N coloured cable at t h e electric w i n d o w c o n trol panel 7 5 w i t h a n earth OK Restore t h e c o n t i n u i t y o f t h e N coloured cable b e t w e e n t h e electric w i n d o w c o n t r o l panel 7 5 a n d t h e u l t r a s o u n d welding
Not OK
Extract t h e c o n n e c t o r s f o r t h e electric w i n d o w c o n t r o l panels 7 5 & 7 4 f r o m their h o u s i n g s , b r i d g e t h e RV a n d C c o l o u r e d cables at t h e c o n n e c t o r f o r panel 7 4 a n d insert an o h m m e t e r at t h e RV a n d C cables at t h e c o n trol panel 7 5 c o n n e c t o r
Not OK
OK
OK
Not OK
OK
33
Fault diagnosis
Analytical charts
Bravo-Brava
55D.
Not OK
Extract t h e c o n n e c t o r f o r t h e electric window control panel 7 5 f r o m its h o u s i n g , bridge both t h e R/RV & C / N c o l o u r e d cables
OK
Not OK
Extract t h e c o n n e c t o r for t h e electric window control panel 7 5 f r o m its h o u s i n g , bridge the R/C & R V / N c o l o u r e d cables
OK
Not OK
Extract t h e c o n n e c t o r for t h e electric window control panel 7 4 f r o m its h o u s i n g , bridge the RV/ZB & C / B R c o l o u r e d cables
OK
Not OK
OK
Not OK
Not OK
O v e r h a u l or replace t h e electric w i n d o w m o t o r 7 7
34
Bravo-Brava
Fault diagnosis
Wiring diagrams
5 5 D.
Trim Level: EL - ELX Electric rear windows - (See key at end of wiring diagrams)
'oh-mm11
3
R *
91
30A40A
L
81
{Ml
60A80A E[
;a
ti
ff=F
RN
R R
4 E E
321
ll
N.D.
R - - R
CB RN
[ ] 78
^ANRNABCB
35
L] 79
GNRNGU-
RN RNRN AN-
RN AB
AB CB
-AN-
H 30|l5/HS0
CB
at' mifti
12
-ZG BU-
r[ira
^ . R eRN-
22
tl
RN
RN-
85 [ S ]
AB GN GU RN RN AN l AN RN GU--GU R N - RN -GNGN-
IBR-
ZB-
fal 82
ZG AN RN BuAB1
86
-AB---AB-RN---RNAN---AN-
GU RN |AB GN
....If
83
- 7P FE L BR-GN-* -RN-fe
[m_
87
35
Location of components
Fault diagnosis
Bravo-Brava
55D.
Trim Level: EL - ELX Electric rear windows Components key 3 Power fuse box: A 30A protective fuse for injection system (60A for DS versions) B 40A protective fuse for ignition system C 60A protective fuse for optional extras D 80A protective fuse for junction unit 4 Junction unit 10 Earth for battery on bodyshell 11 Battery 12 Ignition switch 22 Left dashboard earth 28A Dashboard/longitudinal cables connection 35 Dashboard/left front door cables connection 78 Left rear electric window control on left front door 79 Right rear electric window control on left front door 80 Electric rear windows inhibitor switch 81 30A protective fuse for electric rear windows 82 Left rear electric window control panel on left rear door 83 Right rear electric window control panel on right rear door 84 Left rear electric window motor 85 Right rear electric window motor 86 Longitudinal/left rear door cables connection 87 Longitudinal/right rear door cables connection 91 Power relay N.D. Ultrasound welding taped in cable loom
4A436N
36
Print no.
506.670/02
Brava
Fault diagnosis
Analytical charts
55D.
The electric rear windows are not working
Not OK
C h e c k f o r a s h o r t c i r c u i t in t h e system a n d replace t h e f u s e 81
OK
Not OK
OK
C h e c k f o r v o l t a g e at t h e M c o l o u r e d cable f o r c o n n e c tor 3 5
Not OK
OK
Not OK
OK
Extract t h e c o n n e c t o r for t h e i n h i b i t o r b u t t o n 8 0 f r o m its housing, bridge the M c o l o u r e d cable w i t h all t h e RN coloured cables
OK
O v e r h a u l or replace t h e b u t ton 80
4A437N
37
Analytical charts
Fault diagnosis
Brava
55D.
Not O K
4
Bridge t h e N c o l o u r e d c a bles at t h e electric w i n d o w s control panels 7 8 & 7 9 w i t h an earth Not OK O v e r h a u l o r replace panels 78 & 7 9
4
OK
Bridge t h e N c o l o u r e d c a b l e at c o n n e c t o r 3 5 w i t h a n earth
Not OK
4
OK
4
Check condition of N c o l o u r e d cable b t w n c o n . 3 5 & e a r t h o n dash 2 2 Not OK Restore t h e c o n t i n u i t y of t h e N c o l o u r e d cables
The left rear electric window is not working when operated by the left front panel
Not OK
4
OK
N o t OK
O v e r h a u l or replace t h e p a n el 7 8
4A438N
38
Brava
Fault diagnosis
Analytical charts
55D.
The left rear electric window is not working when operated by the left rear panel
Not OK
OK
Not OK
OK
C h e c k f o r v o l t a g e at t h e R N c o l o u r e d cable f o r c o n n e c tor 8 6
Not OK
OK
Not OK
OK
Not OK
O v e r h a u l or replace t h e c o n t r o l panel 8 2
4A439N
39
Analytical charts
Fault diagnosis
Brava
55D.
The right rear electric window is not working when operted by the left front panel
N o t OK
OK
N o t OK
O v e r h a u l or replace t h e p a n el 7 9
The right rear electric window is not working when operated by the right rear panel
N o t OK
OK
N o t OK
OK
N o t OK
OK
40
Brava
Fault diagnosis
Analytical charts
55D.
Not OK
OK
Not OK
O v e r h a u l or replace t h e p a n el 8 3
OK
Not OK
OK
O v e r h a u l or replace t h e p a n el 7 8
Not OK
OK
O v e r h a u l or replace t h e p a n el 7 8
Not OK
41
Analytical charts
Fault diagnosis
Brava
55D.
Extract t h e c o n n e c t o r f o r t h e panel 8 2 f r o m its h o u s i n g , bridge the RN/ZG and B V / A B c o l o u r e d cables OK O v e r h a u l or replace t h e p a n el 8 2
Not O K
OK
O v e r h a u l or replace t h e p a n el 8 2
Not O K
Extract c o n n e c t o r s f o r p a n els 7 8 & 8 2 f r o m their h o u s ings, b r i d g e A N & A B c o l o u r e d cables at c o n n e c tor f o r panel 8 2 & insert an ohmmeter btwn A N & A B c o l o u r e d cables f o r c o n n e c tor f o r panel 7 8
Not OK
OK
Extract t h e c o n n e c t o r s f o r panel 8 2 a n d m o t o r 8 4 f r o m their h o u s i n g s , b r i d g e Z G & BV c o l o u r e d cables at c o n nector f o r m o t o r 8 4 a n d i n sert a n o h m m e t e r b t w n Z G & B V c o l o u r e d cables at c o n n e c t o r for panel 8 2
Not OK
OK
Check t h e c o n d i t i o n o f t h e electric w i n d o w m o t o r 8 4
Not OK
O v e r h a u l or replace t h e m o tor 8 4
42
Print no.
506.670/02
Brava
Fault diagnosis
Analytical charts
55D.
The right rear electric window is not working
OK
Not OK
OK
O v e r h a u l or replace t h e p a n el 7 9
Not OK
OK
O v e r h a u l or replace t h e p a n el 7 9
Not OK
OK
O v e r h a u l or replace t h e p a n el 8 3
Not OK
OK
O v e r h a u l or replace t h e p a n el 8 3
43
Analytical charts
Fault diagnosis
Brava
55D.
Not OK
Extract c o n n e c t o r s f o r c o n trol panels 7 9 & 8 3 , b r i d g e G N & G V c o l o u r e d cables at c o n n e c t o r for c o n t r o l panel 8 3 & insert an o h m m e t e r b e tween G N & GV coloured cables at c o n n e c t o r f o r p a n el 7 9
Not OK
OK
Extract c o n n e c t o r s f o r panel 8 3 & m o t o r 8 5 f r o m their h o u s i n g s , b r i d g e BR & Z B c o l o u r e d cables at c o n n e c tor for m o t o r 8 5 & insert an o h m m e t e r b t w n BR & Z B c o l o u r e d cables at c o n n e c tor f o r panel 8 3
Not OK
OK
Check t h e c o n d i t i o n of t h e electric w i n d o w m o t o r 8 5
Not OK
O v e r h a u l or replace t h e m o tor 8 5
4A444N
44
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Wiring diagrams
55D.
Version without alarm: S - SX - GT Central locking - (See key at end of wiring diagrams)
10
fllllll
11 30A40A
Tt~tl
60A80A
[
28 N.D.
R - R
E
G G
H
110
36
in
ii
N 7 ^ - f N.D.
G I N
N.D. T
N H-
N.D.I"
r,
H
UHG
N.D. 108* 35
a
G G G H
1
N.D.
N N
1
109*
G H
- : - H - T
ID 86 LT 22 113
- zn in 3 2
(e)
87
42 112
45
Location of components
Fault diagnosis
Bravo-Brava
55D.
Version without alarm: S - SX - GT Central locking Components key 3 Power fuse box: A 30A protective fuse for injection system (60A for DS versions) B 40A protective fuse for ignition system C 60A protective fuse for optional extras D 80A protective fuse for junction unit 4 Junction unit 10 Earth for battery on bodyshell 11 Battery 22 Left dashboard earth 28 Dashboard/longitudinal cables connection 35 Dashboard/left front door cables connection 36 Dashboard/right front door cables connection 42 Right dashboard earth 86 Longitudinal/left rear door cables connection 87 Longitudinal/right rear door cables connection 108 Left rear central locking/alarm switch 109 Right rear central locking/alarm on switch 110 111 112 113 N.D. Left front central locking/alarm on switch Right front central locking/alarm on switch Central door locking control unit 20A protective fuse for central locking system Ultrasound welding taped in cable loom
46
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The central locking is not working
Not OK
OK
Not OK
OK
C h e c k f o r v o l t a g e at t h e R c o l o u r e d cable f o r t h e c e n tral l o c k i n g c o n t r o l u n i t 1 1 2
Not OK
OK
OK
Not OK
Extract c o n n e c t o r s 3 5 & 1 1 2 from their housings, bridge H / G c o l o u r e d cables at t h e c o n t r o l unit 1 1 2 & insert an o h m m e t e r at H / G c o l o u r e d cables f o r t h e c o n n e c t o r 3 5
Not OK
Restore t h e c o n t i n u i t y f o r the H/G coloured cables b e t w e e n the control unit 1 1 2 and the ultrasound w e l d i n g
47
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
OK
Not OK
O v e r h a u l or replace t h e c o n t r o l unit 1 1 2
OK
Not O K
Not OK
The cential locking does not lock the doors controlled by the left front lock
OK
Not OK
Extract c o n n e c t o r s 1 1 2 & 3 5 f r o m their h o u s i n g s , b r i d g e A / B c o l o u r e d cables at c o n trol unit c o n n e c t o r 1 1 2 & insert an o h m m e t e r b e t w e e n A / B c o l o u r e d cables f o r connector 3 5
Not OK
48
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
Extract c o n n e c t o r s 1 1 2 & 1 1 0 f r o m their h o u s i n g s , b r i d g e A / B c o l o u r e d cables at t h e c o n t r o l u n i t c o n n e c t o r 1 1 2 & insert a n o h m m e t e r between the A / B coloured c a b l e s of t h e l o c k assy 1 1 0
Not OK
OK
OK
O v e r h a u l or replace t h e l o c k assembly 1 1 0
Not OK
4
Check the condition of the left f r o n t lock a s s e m b l y 1 1 0 Not OK O v e r h a u l or replace t h e l o c k assembly 1 1 0
The central locking does not lock the doors operated by the right front lock
OK
4
Not OK
49
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Extract c o n n e c t o r s 1 1 2 & 3 6 f r o m their h o u s i n g s , b r i d g e A / B c o l o u r e d cables at c o n trol unit c o n n e c t o r 1 1 2 & insert an o h m m e t e r b e t w e e n A / B c o l o u r e d cables f o r connector 3 6
Not OK
OK
Extract c o n n e c t o r s 1 1 2 & 111 f r o m their h o u s i n g s , bridge A / B c o l o u r e d c a b l e s at the c o n t r o l u n i t c o n n e c t o r 112 & insert an o h m m e t e r between A / B coloured c a bles of l o c k assy 111
Not OK
OK
OK
O v e r h a u l or replace t h e l o c k assembly 1 1 1
N o t OK
Not OK
O v e r h a u l or replace t h e l o c k assembly 1 1 1
OK
50
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
Not OK
The central locking does not unlock the doors controlled by the left front lock
OK
Not OK
Extract c o n n e c t o r s 1 1 2 & 3 5 f r o m their h o u s i n g s , b r i d g e A / B c o l o u r e d cables at c o n trol unit connector 112 & insert an o h m m e t e r b e t w e e n A / B c o l o u r e d cables f o r connector 35
Not OK
OK
Extract c o n n e c t o r s 1 1 2 a n d 1 1 0 from their housings, b r i d g e t h e A / B cables at t h e c o n t r o l unit c o n n e c t o r 1 1 2 a n d insert a n o h m m e t e r b e t w e e n the A / B coloured cables o f t h e l o c k assy 1 1 0
Not OK
OK
51
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Bridge t h e B / N c o l o u r e d c a bles at t h e left f r o n t l o c k a s sembly 1 1 0 OK O v e r h a u l or replace t h e l o c k assembly 1 1 0
Not O K
Not OK
O v e r h a u l or replace t h e l o c k assembly 1 1 0
The central locking does not unlock the doors operated by the right front lock
OK
Not O K
Extract c o n n e c t o r s 1 1 2 & 3 6 from their housings, bridge A / B c o l o u r e d cables at t h e control u n i t c o n n e c t o r 1 1 2 & insert an o h m m e t e r b e tween A / B coloured cables for c o n n e c t o r 3 6
Not OK
OK
Extract c o n n e c t o r s 1 1 2 a n d 111 f r o m their h o u s i n g s , bridge t h e A / B cables at t h e control unit connector 1 1 2 and insert an o h m m e t e r b e tween the A / B coloured cables of t h e lock assy 1 1 1
Not OK
52
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
OK
N o t OK
Not OK
O v e r h a u l or replace t h e l o c k assembly 1 1 1
Extract c o n n e c t o r s 1 1 2 a n d 35 from their housings, bridge the H / G coloured cables at t h e central l o c k i n g control unit connector 1 1 2 a n d insert a n o h m m e t e r b e tween the H/G coloured cables of c o n n e c t o r 3 5
Not OK
Restore t h e c o n t i n u i t y f o r the H/G coloured cables b e tween the ultrasound w e l d ing and t h e connector 3 5
OK
Extract c o n n e c t o r s 3 5 a n d 1 1 0 from their housings, bridge the H / G coloured cables at c o n n e c t o r 3 5 a n d i n sert an o h m m e t e r b e t w e e n t h e H / G c o l o u r e d cables at t h e lock assy c o n n e c t o r 1 1 0
Not OK
Restore t h e c o n t i n u i t y f o r the H/G coloured cables b e tween the connector 3 5 and t h e lock assembly 1 1 0
OK
Not OK
O v e r h a u l or replace t h e c e n tral l o c k i n g m o t o r 1 1 0
53
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The right front central locking motor is not working
Extract c o n n e c t o r s 1 1 2 a n d 3 6 f r o m their housings, bridge t h e H / G c o l o u r e d c a bles at t h e central l o c k i n g control unit connector 1 1 2 and insert an o h m m e t e r b e tween the H/G coloured cables o f c o n n e c t o r 3 6
N o t OK
Restore t h e c o n t i n u i t y f o r the H / G coloured cables b e tween the ultrasound w e l d ing and the connector 3 6
OK
N o t OK
OK
N o t OK
O v e r h a u l or replace t h e c e n tral l o c k i n g m o t o r 1 1 1
The left rear central locking motor is not working (Non existent for the Bravo versions)
Extract c o n n e c t o r s 1 1 2 a n d 86 f r o m their housings, bridge t h e H / G c o l o u r e d c a bles at t h e central l o c k i n g control unit connector 1 1 2 and insert an o h m m e t e r b e tween the H/G coloured cables o f c o n n e c t o r 8 6
Not OK
Restore t h e c o n t i n u i t y f o r the H / G coloured cables between the ultrasound w e l d ing and the connector 8 6
OK
4B464N
54
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Extract c o n n e c t o r s 8 6 a n d 1 0 8 f r o m their h o u s i n g s , bridge t h e H/G coloured cables at c o n n e c t o r 8 6 a n d i n sert an o h m m e t e r b e t w e e n t h e H / G c o l o u r e d cables at t h e lock assy c o n n e c t o r 1 0 8 Not OK Restore t h e c o n t i n u i t y f o r the H/G coloured cables between the connector 8 6 and the lock a s s e m b l y 1 0 8
OK
Not OK
The right rear central locking motor is not working (IMon existent for the Bravo versions)
Extract c o n n e c t o r s 1 1 2 a n d 8 7 f r o m their housings, bridge the H / G coloured cables at t h e central l o c k i n g control unit connector 112 a n d insert a n o h m m e t e r b e tween the H/G coloured cables of c o n n e c t o r 8 7
Not OK
OK
Extract c o n n e c t o r s 8 7 a n d 1 0 9 f r o m their h o u s i n g s , bridge the H / G coloured c a bles at c o n n e c t o r 8 7 a n d i n sert an o h m m e t e r b e t w e e n t h e H / G c o l o u r e d cables at t h e lock assy c o n n e c t o r 1 0 9
Not OK
Restore t h e c o n t i n u i t y f o r the H/G coloured cables between the connector 8 7 and t h e lock a s s e m b l y 1 0 9
OK
Not OK
O v e r h a u l or replace t h e c e n tral l o c k i n g m o t o r 1 0 9
55
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The central locking is not working
Not OK
OK
C h e c k f o r v o l t a g e at o n e o f t h e R c o l o u r e d cables f o r fuse 1 1 3
N o t OK
OK
Not OK
OK
OK
Not OK
N o t OK
Restore t h e c o n t i n u i t y f o r the H/G coloured cables b e tween the control unit 1 1 2 and the ultrasound w e l d i n g
59
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
OK
N o t OK
Not OK
OK
N o t OK
OK
Not OK
OK
OK
Not O K
60
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
C h e c k t h e c o n d i t i o n of t h e central locking receiver 437A Not OK Overhaul or replace t h e r e ceiver 1 0 7 A
OK
Not OK
The central lacking does not lock the doors operated by the receiver
B r i d g e t h e A c o l o u r e d cable at c o n n e c t o r 2 8 w i t h a n earth
Not OK
OK
Not OK
OK
Not OK
O v e r h a u l or replace t h e r e ceiver 1 0 7 A
The central locking does not unlock the dorrs operated by the receiver
B r i d g e t h e B c o l o u r e d cable at c o n n e c t o r 2 8 w i t h a n earth
Not OK
OK
61
Analytical charts
Fault diagnosis
4
Bridge t h e B c o l o u r e d c a b l e at t h e receiver 1 0 7 A w i t h an earth Not OK
Bravo-Brava
55D.
Restore t h e c o n t i n u i t y o f t h e B c o l o u r e d cable b e t w e e n t h e receiver 1 0 7 A a n d t h e
OK
4
Check t h e c o n d i t i o n o f t h e receiver 1 0 7 A Not OK O v e r h a u l or replace t h e receiver 1 0 7 A
The central locking is not working operated by the alarm device control unit
OK
Not O K
OK
N o t OK
Check t h e c o n d i t i o n o f t h e receiver 1 0 7 A
Not OK
O v e r h a u l or replace t h e receiver 1 0 7 A
OK
Check t h e c o n d i t i o n o f t h e alarm c o n t r o l u n i t 1 0 0
Not OK
4A463N
62
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
The doors ajar warning light is not working (For the versions with an alarm)
OK
Not OK
OK
Restore t h e c o n t i n u i t y f o r the VB coloured cable between the instrument panel 6 and the connector 7 0
N o t OK
Not OK
Replace t h e w a r n i n g l i g h t U
OK
Not OK
O v e r h a u l or replace t h e p a n el 6
The doors ajar warning light is not working (For versions without alarm)
OK
Restore t h e c o n t i n u i t y f o r the VB coloured cable between the instrument panel 6 and the connector 7 0
N o t OK
4A464N
63
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check t h e c o n d i t i o n of t h e w a r n i n g l i g h t U in t h e i n s t r u m e n t panel 6
Not OK
Replace t h e w a r n i n g l i g h t U
OK
Check t h e c o n d i t i o n o f t h e i n s t r u m e n t panel 6
Not OK
O v e r h a u l or replace t h e p a n el 6
OK
Not O K
Not OK
O v e r h a u l or replace t h e c o n trol u n i t 1 1 2
The central locking does not lock the doors operated by the left front lock
OK
Not O K
4A465N
64
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Extract c o n n e c t o r s 1 1 2 & 3 5 f r o m their h o u s i n g s , b r i d g e A / B c o l o u r e d cables at t h e control unit connector 1 1 2 & insert an o h m m e t e r b e t w e e n A / B c o l o u r e d cables for c o n n e c t o r 3 5 Not OK Restore c o n t i n u i t y o f A c o l oured cable b e t w e e n c o n trol unit 1 1 2 & c o n n e c t o r 3 5
OK
Extract c o n n e c t o r s 1 1 2 & 1 1 0 f r o m their h o u s i n g s , bridge A / B c o l o u r e d cables at c o n t r o l u n i t c o n n e c t o r 1 1 2 & insert an o h m m e t e r between the A / B coloured cables o f t h e lock assy 1 1 0
Not OK
OK
OK
Not OK
Not OK
The central locking does not lock the doors operated by the right front lock
OK
Not OK
65
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Extract c o n n e c t o r s 1 1 2 & 3 6 from t h e i r h o u s i n g s , b r i d g e A / B c o l o u r e d cables at c o n trol u n i t c o n n e c t o r 1 1 2 & insert a n o h m m e t e r b e t w e e n A / B c o l o u r e d cables for connector 36
N o t OK
OK
Extract c o n n e c t o r s 1 1 2 & 111 f r o m their h o u s i n g s , bridge A / B c o l o u r e d cables at t h e c o n t r o l u n i t c o n n e c t o r 112 a n d insert an o h m m e t e r between the A / B coloured cables o f t h e lock assy 1 1 1
N o t OK
Restore t h e c o n t i n u i t y of t h e A coloured cable between the connector 36 and the lock assembly 111
OK
OK
Not O K
N o t OK
OK
Restore t h e c o n t i n u i t y of t h e B coloured cable between the control unit 1 1 2 and the ultrasound welding
66
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
Not OK
O v e r h a u l or replace t h e c o n t r o l unit 1 1 2
The central locking does not unlock the doors operated by the left front lock
OK
Not OK
Not OK
OK
Extract c o n n e c t o r s 1 1 2 a n d 1 1 0 f r o m their h o u s i n g s , b r i d g e t h e A / B c a b l e s at t h e c o n t r o l unit c o n n e c t o r 1 1 2 a n d insert an o h m m e t e r b e tween the A / B coloured cables o f t h e lock assy 1 1 0
Not OK
OK
67
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Bridge t h e B / N c o l o u r e d c a bles at t h e left f r o n t lock a s sembly 1 1 0 OK O v e r h a u l or replace t h e l o c k assembly 1 1 0
Not OK
Not OK
O v e r h a u l or replace t h e l o c k assembly 1 1 0
The central locking does not unlock the doors operated by the right front lock
OK
Not OK
Not OK
OK
Extract c o n n e c t o r s 1 1 2 a n d 111 f r o m their h o u s i n g s , b r i d g e t h e A / B cables at t h e control unit connector 1 1 2 a n d insert an o h m m e t e r b e tween the A / B coloured cables o f t h e l o c k assy 111
Not OK
68
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
OK
Not OK
C h e c k t h e c o n d i t i o n of t h e r i g h t f r o n t l o c k assembly 111
Not OK
Extract c o n n e c t o r s 1 1 2 a n d 3 5 f r o m their housings, bridge the H/G coloured cables at t h e c e n t r a l l o c k i n g c o n t r o l unit c o n n e c t o r 1 1 2 a n d insert an o h m m e t e r b e tween the H/G coloured cables o f c o n n e c t o r 3 5
Not OK
OK
Not OK
OK
Not OK
69
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The right front central locking motor is not working
Extract c o n n e c t o r s 1 1 2 a n d 3 6 f r o m their housings, bridge t h e H / G c o l o u r e d c a bles at t h e central l o c k i n g control unit connector 1 1 2 and insert a n o h m m e t e r b e tween the H / G coloured cables f o r c o n n e c t o r 3 6
Not OK
OK
Not OK
Restore t h e c o n t i n u i t y f o r the H / G coloured cables between the connector 3 6 and the lock 111
OK
Not OK
O v e r h a u l or replace t h e c e n tral l o c k i n g m o t o r 1 1 1
The left rear central locking motor is not working (Non existent for the Bravo versions)
Extract c o n n e c t o r s 1 1 2 a n d 86 from their housings, bridge t h e H / G c o l o u r e d c a bles at t h e central l o c k i n g control unit connector 1 1 2 and insert a n o h m m e t e r b e tween the H / G coloured c a bles at c o n n e c t o r 8 6
Not OK
OK
4A471N
70
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Extract c o n n e c t o r s 8 6 & 1 0 8 f r o m their h o u s i n g s , b r i d g e t h e H / G c o l o u r e d cables at c o n n e c t o r 8 6 a n d insert a n ohmmeter between the H/G c o l o u r e d cables at t h e c o n n e c t o r for t h e l o c k 1 0 8 Not OK Restore t h e c o n t i n u i t y f o r the H/G c o l o u r e d cables between the connector 86 and t h e lock a s s e m b l y 1 0 8
OK
Not OK
The righ rear central locking motor is not working (Non existent for the Bravo versions)
Not OK
OK
Extract c o n n e c t o r s 8 7 & 1 0 9 f r o m their h o u s i n g s , b r i d g e t h e H / G c o l o u r e d cables at c o n n e c t o r 8 7 & insert a n ohmmeter b t w n the H / G c o l o u r e d cables at t h e c o n n e c t o r for t h e l o c k assy 1 0 9
Not OK
OK
Not OK
71
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The direction indicators/hazard warning lights are not woiking
OK
O v e r h a u l or r e p l a c e t h e hazard w a r n i n g l i g h t s s w i t c h 2 3
Not OK
OK
Not OK
OK
OK
Not OK
OK
O v e r h a u l or r e p l a c e t h e hazard w a r n i n g l i g h t s s w i t c h 2 3
Not OK
75
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check f o r v o l t a g e at t h e A R cable at c o n n e c t o r A f o r t h e hazard w a r n i n g l i g h t s c o n trol s w i t c h 2 3 OK O v e r h a u l or replace t h e h a z ard w a r n i n g l i g h t s s w i t c h 2 3
Not OK
4
Check for v o l t a g e at t h e A R c o l o u r e d cable c o n n e c t o r I pin 1 3 of t h e j u n c t i o n unit 4 Not OK O v e r h a u l or replace junction unit 4 the
OK
O v e r h a u l or replace t h e hazard w a r n i n g l i g h t s s w i t c h 2 3
Not OK
Not OK
OK
OK
O v e r h a u l o r replace t h e steering c o l . s w i t c h u n i t 7
Not OK
76
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Bridge the A B / L R coloured c a b l e s at t h e hazard w a r n i n g lights switch 2 3 OK Restore c o n t . o f LR c o l o u r e d cable b t w n s w i t c h 2 3 & st/ col. s w i t c h unit 7
Not OK
OK
O v e r h a u l or r e p l a c e t h e h a z ard w a r n i n g l i g h t s s w i t c h 2 3
The left branch of the diiection indicators-hazard warning lights is not working operated by the steering column switch unit Bridge the L R / A N coloured c a b l e s at c o n n e c t o r C o f steering c o l . s w i t c h unit 7 OK Overhaul or replace s w i t c h H controlling direction indicators, or o v e r h a u l o r r e place s t / c o l . s w i t c h u n i t 7
Not OK
OK
The right branch of the direction indicators hazard warning lights is not working operated by the steering column switch unit Bridge L R / A coloured cables at c o n n e c t o r C of steering c o l . switch unit 7 OK O v e r h a u l or r e p l a c e s w i t c h H controlling direction indicators or o v e r h a u l or r e p l a c e st/col. switch unit 7
Not OK
OK
77
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The left branch of the direction indicators/hazard warning lights is not working operated by the hazard w/lights switch
OK
O v e r h a u l or replace t h e hazard w a r n i n g l i g h t s s w i t c h 2 3
Not O K
OK
The right branch of the direction indicators/hazard warning lights is not working operated by the hazard w/lights switch
OK
O v e r h a u l or replace t h e hazard w a r n i n g l i g h t s s w i t c h 2 3
Not O K
OK
The left front and side direction indicators are not working
Not OK
OK
78
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
C h e c k f o r v o l t a g e at t h e A N c o l o u r e d cable of t h e left f r o n t l i g h t cluster 1 N o t OK Restore t h e c o n t i n u i t y o f t h e A N coloured cable between the j u n c t i o n u n i t 4 , c o n n e c tor I & t h e u l t r a s o u n d w e l d ing
The right front and side direction indicators ate not working
Not OK
Overhaul t h e j u n c t i o n u n i t 4
OK
C h e c k f o r v o l t a g e at t h e A c o l o u r e d cable, c o n n e c t o r 13
Not OK
OK
Not OK
Not OK
Replace t h e b u l b
OK
79
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check t h e c o n d i t i o n o f t h e bulb holder Not OK O v e r h a u l or replace t h e b u l b holder
OK
4
Bridge t h e N c o l o u r e d cable at t h e left f r o n t l i g h t cluster 1 w i t h a n earth OK Restore t h e c o n t i n u i t y o f t h e N coloured cable between t h e left f r o n t l i g h t cluster 1 &
t h e loft f m n t aarth Q
Not O K
4
Check f o r v o l t a g e at t h e A N c o l o u r e d cable o f t h e left front l i g h t cluster 1 Not OK Restore t h e c o n t i n u i t y of t h e A N coloured cable between t h e l i g h t cluster 1 & t h e u l trasound welding
Check t h e c o n d i t i o n o f t h e bulb
Not OK
Replace t h e b u l b
OK
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
80
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
C h e c k f o r v o l t a g e at t h e A c o l o u r e d cable of t h e r i g h t f r o n t l i g h t cluster 2
N o t OK
Check t h e c o n d i t i o n o f t h e bulb
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e bulb holder
N o t OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
N o t OK
Check t h e c o n d i t i o n o f t h e bulb
Not OK
Replace t h e b u l b
4A482N
81
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
OK
Check t h e c o n d i t i o n of t h e b u l b holder
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
Not OK
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
Check t h e c o n d i t i o n of t h e b u l b holder
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
O v e r h a u l o r replace t h e l i g h t cluster 1 6
82
Bravo-Brava
4
Not OK
Fault diagnosis
Analytical charts
55D.
OK
Not OK
N o t OK
O v e r h a u l or r e p l a c e t h e u n i t 4
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
N o t OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
O v e r h a u l or replace t h e l i g h t cluster 17
Not OK
4A484M
83
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check for v o l t a g e at t h e A c o l o u r e d cable c o n n e c t o r G pin 5 o f t h e j u n c t i o n u n i t 4 OK Restore t h e c o n t i n u i t y o f t h e A coloured cable between the j u n c t i o n unit 4 connect o r G & t h e l i g h t cluster 1 7
Not O K
Not OK
the
OK
Not O K
OK
Not OK
Not OK
Check f o r v o l t a g e at t h e A c o l o u r e d c a b l e at c o n n e c t o r B p i n 11 o f t h e i n s t r u m e n t panel 6
OK
4A485N
84
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Not OK
C h e c k f o r v o l t a g e at t h e A c o l o u r e d cable f o r c o n n e c t o r H p i n 1 of t h e j u n c t i o n unit 4
OK
Not OK
C h e c k t h e c o n d i t i o n of t h e j u n c t i o n unit 4
Not OK
Overhaul t h e j u n c t i o n u n i t 4
OK
Not OK
Not OK
Replace t h e w a r n i n g l i g h t A
Not OK
C h e c k t h e c o n d i t i o n of t h e hazard w / l i g h t s s w i t c h 2 3
Not OK
Overhaul or switch 23
replace
the
85
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Both the reveising lights are not working
Bridge t h e A R / B N c o l o u r e d cables at c o n n e c t o r 5 5
OK
Not O K
OK
Not OK
Not OK
OK
OK
The left reversing light is not working (Non existent for the Bravo versions)
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
4A467N
86
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Check t h e condition of t h e b u l b holder Not OK Overhaul or replace t h e b u l b holder
OK
OK
Not OK
C h e c k for v o l t a g e at t h e B c o l o u r e d cable c o n n e c t o r G p i n 6 of t h e j u n c t i o n u n i t 4
OK
Not OK
C h e c k t h e c o n d i t i o n of t h e junction unit 4
Not OK
Overhaul t h e j u n c t i o n u n i t 4
C h e c k t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
C h e c k t h e c o n d i t i o n of t h e b u l b holder
Not OK
4A488N
87
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
OK
OK
O v e r h a u l or replace t h e l i g h t cluster 1 7
Not O K
OK
Restore t h e c o n t i n u i t y of t h e B coloured cable between the junction unit 4 connect o r G & t h e l i g h t cluster 17
Not O K
N o t OK
O v e r h a u l t h e j u n c t i o n unit 4
OK
O v e r h a u l or switch 40
replace
the
Not O K
OK
Not O K
88
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Check f o r v o l t a g e at t h e A R cable c o n n e c t o r D p i n 5 o f the j u n c t i o n unit 4 N o t OK Overhaul t h e j u n c t i o n unit 4
OK
U s i n g a cable bridge p i n 1 8 connector A & pin 14 (12,13) connector E of the junction unit 4
OK
Overhaul t h e j u n c t i o n unit 4
The left brake light is not working (Valid for S SX GT versions) Check t h e c o n d i t i o n o f t h e bulb Not OK Replace t h e b u l b
OK
Check t h e c o n d i t i o n o f t h e b u l b holder
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
O v e r h a u l or replace t h e l i g h t cluster 1 6
N o t OK
4
Check f o r v o l t a g e at t h e RG c o l o u r e d cable c o n n e c t o r E pin 12 of the j u n c t i o n unit 4 OK Restore t h e c o n t i n u i t y o f t h e RG c o l o u r e d c a b l e b e t w e e n the j u n c t i o n u n i t 4 , c o n n e c tor E & t h e l i g h t c l u s t e r 1 6
89
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Not O K
OK
The right brake light is not working (Valid for S SX-GT versions) Check t h e c o n d i t i o n o f t h e bulb Not OK Replace t h e b u l b
OK
Check t h e c o n d i t i o n o f t h e bulb h o l d e r
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
O v e r h a u l or replace t h e l i g h t cluster 1 7
Not O K
OK
Not O K
OK
90
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
The addition brake light is not working
N o t OK
Replace t h e b u l b
OK
N o t OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
Not OK
OK
Not OK
N o t OK
Overhaul t h e j u n c t i o n unit 4
4A492N
91
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The brake lights are not working, but the additional brake light is working (Valid for EL/ELX/HGT versions) Check f o r v o l t a g e at the R c o l o u r e d cable c o n n e c t o r C pin 7 o f t h e i n s t r u m e n t p a n el 6 Not OK Restore t h e c o n t i n u i t y of t h e R coloured cable between t h e i n s t r u m e n t panel 6 c o n nector C & t h e j u n c t i o n u n i t 4 c o n n e c t o r H, or o v e r h a u l t h e unit 4
OK
OK
OK
Check f o r v o l t a g e at t h e A R cable of t h e i n s t r u m e n t p a n el 6 c o n n e c t o r C p i n 4
Not OK
OK
Not OK
The left brake light is not working (Valid for EL/ELX/HGT versions )
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
92
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
C h e c k t h e c o n d i t i o n of t h e b u l b holder Not OK Overhaul or replace t h e b u l b holder
OK
OK
Not OK
C h e c k f o r v o l t a g e at t h e RG c o l o u r e d cable c o n n e c t o r E p i n 3 of t h e j u n c t i o n u n i t 4
OK
Not OK
OK
Overhaul t h e j u n c t i o n u n i t 4
Not OK
Not OK
OK
93
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
4
Check t h e c o n d i t i o n of t h e brake l i g h t s failure circuit Not OK Replace t h e brake l i g h t s f a i l ure c i r c u i t or o v e r h a u l t h e i n s t r u m e n t panel 6
The right brake light is not working (Valid for EL/ELX/HGT versions)
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
Check t h e c o n d i t i o n of t h e b u l b holder
Not OK
O v e r h a u l or replace t h e b u l b holder
OK
OK
O v e r h a u l or replace t h e l i g h t cluster 1 7
Not O K
OK
Restore t h e c o n t i n u i t y f o r t h e R N c o l o u r e d cable b e tween the junction unit 4, connector E & the light cluster 1 7
Not O K
4A495N
94
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
Bridge pin 1 connector E & pin 4 connector H of the j u n c t i o n unit 4 OK Overhaul t h e j u n c t i o n u n i t 4
Not OK
Not OK
OK
Not OK
4A496N
95
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The front courtesy light, the glove compartment light and the luggage compartment light are not working
Check t h e condition of t h e f u s e 1 0 in t h e j u n c t i o n u n i t 4
Not OK
OK
Not OK
Overhaul t h e j u n c t i o n u n i t 4
OK
OK
OK
Restore t h e c o n t i n u i t y o f t h e N coloured cable between the courtesy light 1 0 7 B & t h e left rear earth 1 8
N o t OK
Not OK
Restore t h e c o n t i n u i t y f o r the RN c o l o u r e d cable between the courtesy light 107B & the j u n c t i o n unit 4 connector G or overhaul the unit 4
OK
Not OK
Replace t h e b u l b s
OK
99
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check t h e c o n d i t i o n of t h e courtesy light 1 0 7 B N o t OK Overhaul the courtesy light 107B
The courtesy light is not working when any of the doors are opened Check t h e c o n d i t i o n of t h e b u l b in t h e courtesy l i g h t 107B Not OK Replace t h e b u l b
OK
Bridge B R / N c o l o u r e d c a bles at c o u r t e s y l i g h t 1 0 7 B
Not OK
O v e r h a u l or replace c o u r t e s y light 1 0 7 B
the
OK
N o t OK
Restore t h e c o n t i n u i t y of t h e N coloured cable between the courtesy light 1 0 7 B & the ultrasound w e l d i n g
The courtesy light does not work when the left front door is opened Bridge t h e B R / N c o l o u r e d cables at t h e left f r o n t c o u r tesy l i g h t s w i t c h 5 9 OK O v e r h a u l or replace t h e left front push button 5 9
Not O K
Not OK
OK
OK
100
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
The courtesy light does not work when the right fiont door is opened
OK
O v e r h a u l or replace t h e r i g h t f r o n t push b u t t o n 6 0
Not OK
B r i d g e t h e BR c o l o u r e d c a b l e at t h e r i g h t f r o n t push b u t t o n 6 0 w i t h a n earth
Not OK
Restore c o n t i n u i t y f o r BR coloured cable between the right front push b u t t o n 6 0 & the ultrasound w e l d i n g
OK
OK
Restore c o n t i n u i t y o f N c o l oured cable between the right front push b u t t o n 6 0 & the ultrasound w e l d i n g
The courtesy light does not work when the left rear door is opened (Only for Brava versions)
OK
Not OK
Not OK
Restore c o n t i n u i t y f o r BR coloured cable between the left rear p u s h b u t t o n 6 1 & the ultrasound w e l d i n g
OK
OK
101
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The courtesy light does not work when the right rear door is opened
OK
O v e r h a u l or replace t h e r i g h t rear p u s h b u t t o n 6 2
Not O K
Not OK
OK
OK
Check t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
OK
Not O K
Not OK
102
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
Not OK
OK
OK
Overhaul or replace t h e l u g gage compartment light p u s h b u t t o n inside t h e c o n tact board 2 7 , or o v e r h a u l the contact board 2 7
N o t OK
OK
Restore t h e c o n t i n u i t y o f t h e N coloured cable between the contact board 2 7 & t h e left rear earth 1 8
N o t OK
C h e c k f o r v o l t a g e at t h e R N c o l o u r e d cable at t h e j u n c t i o n unit 4 c o n n e c t o r G p i n 10
Not OK
Overhaul t h e j u n c t i o n unit 4
OK
Not OK
Restore t h e c o n t i n u i t y f o r t h e RN c o l o u r e d c a b l e b e tween the junction unit 4 connector G pin 10 & the rear c o n t a c t b o a r d 2 7 , or overhaul the luggage c o m partment bulb holder 6 5
103
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The ideogram lights are not working
Check t h e c o n d i t i o n of t h e fuse 2 in t h e j u n c t i o n u n i t 4
N o t OK
OK
N o t OK
Not OK
OK
OK
Replace t h e l i g h t d i m m e r 5 8
Not O K
N o t OK
Restore t h e c o n t i n u i t y for the G N coloured cable between the dimmer 58 & the j u n c t i o n unit 4 connector J
OK
4A505N
104
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
C h e c k f o r v o l t a g e at o n e o f t h e GR c o l o u r e d cables o f t h e i n s t r u m e n t panel 6 c o n nector B Not OK Restore t h e c o n t i n u i t y o f t h e GR c o l o u r e d c a b l e b e t w e e n the dimmer 5 8 (For S / S X t r i m levels), t h e j u n c t i o n unit 4 connector J pin 1 2 ) & the ultrasound w e l d i n g
OK
Not OK
Overhaul panel 6
the
instrument
The ideogram lights in the switch panel and the cigar lighter are not working
C h e c k f o r v o l t a g e at t h e G N c o l o u r e d cable o f t h e j u n c t i o n unit 4 c o n n e c t o r J p i n 11
Not OK
Overhaul t h e j u n c t i o n u n i t 4
OK
Not OK
Restore t h e c o n t i n u i t y f o r the GN coloured cable b e tween the junction unit 4 c o n n e c t o r J p i n 11 & t h e u l trasound w e l d i n g
C h e c k t h e c o n d i t i o n of t h e bulb
Not OK
Replace t h e b u l b
OK
Not OK
Restore t h e c o n t i n u i t y f o r the GN coloured cable b e tween the s w i t c h panel 3 4 & the ultrasound w e l d i n g
OK
105
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Check t h e c o n d i t i o n of t h e s w i t c h panel 3 4 N o t OK Overhaul the s w i t c h 34 panel
Check t h e c o n d i t i o n of t h e bulb
N o t OK
Replace t h e b u l b
OK
N o t OK
OK
Check t h e c o n d i t i o n of t h e cigar l i g h t e r 6 9
N o t OK
O v e r h a u l t h e cigar lighter 6 9
N o t OK
O v e r h a u l t h e j u n c t i o n unit 4
OK
N o t OK
Restore t h e c o n t i n u i t y f o r the G N coloured cable between the junction unit 4 connector J & the radio 4 8
OK
Check t h e c o n d i t i o n o f t h e radio 4 8
N o t OK
4A507N
106
Print no.
506.670/02
2 5
O Q
I
to a
< ffl < ID
8 S 8
2
O Q
C3 X
E a
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(A
o o
en o
O LU
u U)
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
The fuel level gauge is not working
OK
N o t OK
OK
N o t OK
OK
N o t OK
Bridge t h e H R c o l o u r e d c a ble at t h e i n s t r u m e n t panel 6 connector B pin 16 w i t h an earth, so that t h e i n s t r u m e n t panel 6 g a u g e K p o i n t e r s i g nals t h e e n d of scale - f u l l tank
OK
N o t OK
4AB11N
109
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
N o t OK
Extract t h e c o n n e c t o r f o r t h e engine c o o l a n t t e m p e r a t u r e sensor 1 5 8 f r o m its h o u s i n g , connect the terminal for a resistor a r o u n d 1 0 0 o h m in series t o t h e H B c o l o u r e d cable a n d c o n n e c t t h e other terminal t o earth s o t h a t t h e temperature g a u g e X in t h e i n s t r u m e n t panel s i g n a l s t h e end o f scale - m a x i m u m temperature
OK
Replace t h e e n g i n e c o o l a n t t e m p e r a t u r e sensor 1 5 8
Not O K
Extract c o n n e c t o r 5 5 f r o m its h o u s i n g , c o n n e c t t h e terminal o f a resistor a r o u n d 100 o h m in series t o t h e H B c o l o u r e d cable a n d c o n n e c t the o t h e r terminal t o e a r t h , so t h a t t h e t e m p e r a t u r e gauge X in t h e i n s t r u m e n t panel s i g n a l s t h e e n d o f scale - m a x i m u m t e m p e r a ture
OK
Not O K
4A512N
110
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Extract c o n n e c t o r A f o r t h e i n s t r u m e n t panel f r o m its housing, connect the terminal f o r a resistor a r o u n d 1 0 0 o h m in series t o p i n 1 7 o f c o n n e c t o r A , at t h e i n s t r u m e n t panel, c o n n e c t t h e o t h e r terminal t o earth so that the temperature gauge X in t h e i n s t r u m e n t panel 6 signals t h e e n d o f scale m a x i m u m temperature OK Restore c o n t i n u i t y f o r t h e H B coloured cable between the instrument panel 6 c o n nector A & connector 5 5
Not OK
C h e c k t h e c o n d i t i o n of t h e w a t e r temperature g a u g e X in t h e i n s t r u m e n t panel 6
Not OK
O v e r h a u l or replace t h e g a u g e X in t h e i n s t r u m e n t panel 6
The handbrake applied and insufficient brake fluid is not being signalled
C h e c k t h e c o n d i t i o n of t h e w a r n i n g light R in t h e i n s t r u m e n t panel 6
Not OK
Replace t h e w a r n i n g l i g h t R
OK
Bridge the BN coloured cable at t h e i n s t r u m e n t panel 6 connector B pin 6 (or pin 2) w i t h an earth
Not OK
Overhaul panel 6
the
instrument
OK
111
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
Not O K
OK
Not O K
OK
Not O K
Check t h e c o n d i t i o n of t h e i n s t r u m e n t panel 6
Not OK
Overhaul panel 6
the
instrument
OK
Replace t h e s w i t c h 8 8
Not O K
Bridge t h e N c o l o u r e d c a b l e at t h e s w i t c h 8 8 w i t h a n earth
OK
Not O K
OK
4A514N
112
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
5 5 D.
Not OK
C h e c k t h e c o n d i t i o n of t h e i n s t r u m e n t panel 6
Not OK
Overhaul panel 6
the
instrument
OK
Not OK
OK
Not OK
OK
Not OK
Not OK
Replace t h e w a r n i n g l i g h t B
OK
C h e c k the c o n d i t i o n of t h e instrument p a n e l 6
Not OK
Overhaul panel 6
the
instrument
4A515N
113
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The left front brake pad wear warning light is not working
OK
Not O K
Replace t h e left f r o n t brake pad w e a r sensor 8 9 , or restore t h e c o n t i n u i t y f o r t h e M c o l o u r e d cable b e t w e e n c o n n e c t o r 8 9 A & t h e sensor, or restore t h e c o n n e c t i o n t o earth
OK
Not O K
Check t h e c o n d i t i o n o f t h e w a r n i n g l i g h t Q in t h e i n s t u ment p a n e l 6
Not OK
Replace t h e w a r n i n g l i g h t Q
OK
Check t h e c o n d i t i o n of t h e i n s t r u m e n t panel 6
Not OK
Overhaul panel 6
the
instrument
The fiont brake pad wear warning light is not working (Only for HGT trim level)
OK
Not O K
Check t h e c o n d i t i o n o f t h e w a r n i n g l i g h t Q in t h e i n s t r u m e n t panel 6
Not OK
Replace t h e w a r n i n g l i g h t Q
OK
114
Print no.
506.670/02
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
Check t h e c o n d i t i o n o f t h e i n s t r u m e n t panel 6
Not OK
Overhaul panel 6
the
instrument
The left front brake pad wear warning light is not working (Only for HGT trim level)
OK
N o t OK
Replace t h e left f r o n t brake pad w e a r sensor 8 9 , or r e store t h e c o n t i n u i t y f o r t h e M coloured cable M b e tween connector 8 9 A & the sensor, or restore t h e c o n n e c t i o n t o earth
OK
Restore t h e c o n t i n u i t y f o r t h e BR c o l o u r e d c a b l e b e tween connector 8 9 A & the ultrasound welding (See wiring diagram)
The right front brake pad wear warning light is not working (Only foi HGT trim level)
OK
N o t OK
Replace t h e r i g h t f r o n t brake pad w e a r sensor 1 8 2 A , or restore t h e c o n t i n u i t y f o r t h e M coloured cable b e t w e e n connector 1 8 2 A and the sensor, or restore t h e c o n n e c t i o n t o earth
OK
N o t OK
OK
115
Analytical charts
Fault diagnosis
Bravo-Brava
55D.
The rev countei is not working
B r i d g e t h e L c o l o u r e d cable between the instrument panel 6 c o n n e c t o r A p i n 16 and t h e fuel i n j e c t i o n c o n trol u n i t 1 6 0 p i n 3 ( 1 9 5 pin 4 2 f o r 1 5 8 1 , 1 9 0 p i n 6 for 1998)
OK
Restore t h e c o n t i n u i t y f o r the L coloured cable bet w e e n t h e i n s t r u m e n t panel 6 c o n n e c t o r A & t h e electronic injection control unit
Not O K
Connect to diagnostic socket 1 3 9 (See electronic injection wiring diagram) and c a r r y o u t fault d i a g n o s i s w i t h t h e Fiat Lancia Tester
Bridge t h e N c o l o u r e d cable at t h e v e h i c l e speed sensor 137 w i t h an earth ( i f there are also problems w i t h t h e electronic i n j e c t i o n c o n t r o l unit sensor 1 3 7 )
OK
Not O K
Check f o r v o l t a g e at t h e C N c o l o u r e d cable for t h e i n s t r u m e n t panel 6 c o n n e c t o r A p i n 1 5 (if there are also problems w i t h the electronic i n j e c t i o n c o n t r o l u n i t sensor 137)
Not OK
Overhaul panel 6
the
instrument
OK
Not OK
116
Bravo-Brava
Fault diagnosis
Analytical charts
55D.
OK
4
Check f o r v o l t a g e at t h e C B c o l o u r e d cable for t h e v e h i cle speed sensor 1 3 7 Not OK Restore t h e c o n t i n u i t y f o r the C B c o l o u r e d c a b l e b e t w e e n t h e sensor 1 3 7 & t h e connector 55
4
OK
*
Bridge cable b e t w e e n i n s t r u m e n t panel 6 c o n n e c t o r A pin 1 3 & t h e centre p i n for sensor 1 3 7 (see t h e w i r i n g diagram f o r t h e c o l o u r ) OK Restore c o n t i n u i t y o f c a b l e between the instrument panel 5 c o n n e c t o r A & t h e centre pin f o r sensor 1 3 7
Not OK
4
Check t h e c o n d i t i o n o f t h e vehicle speed sensor 1 3 7 or rev c o u n t e r circuit in t h e i n s t r u m e n t panel 6 Not OK Replace t h e s e n s o r 1 3 7 or replace t h e rev c o u n t e r circ u i t in t h e i n s t r u m e n t panel 6
4A619N
117
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Bravo-Brava
TD
Electrical system
55.
page
Contents
1 31 36
Bravo-Brava
TD
Electrical system
55.
Wiring diagrams
Electrical symbols
Side l i g h t s
IXI
C h o k e (starter)
30
"- | I g n . s w i t c h d i s c h a r g e
-IS 1
W a t e r in fuel filter
to
Dipped headlamps
Heated seat
Plug preheating
Indicators w i t h c e n t r a l door l o c k i n g
Seat belts
Electric h o r n s
Heated rear w i n d o w
Or
Rear f o g l a m p s
Left i n d i c a t o r
Right i n d i c a t o r
A.B.S.
(O)
Engine c o o l i n g s y s t e m
i t
Hazard
ii T u r b o c o m p r e s s o r pressure
Windscreen wiper
Indicators
Electric s u n r o o f
120 Km/h
S p e e d limits
Catalytic temperature
converter
Recharging
Fuel g a u g e
Resistor
Wiring diagrams
Electrical system
Bravo-Brava
TD
55.
Electrical symbols
Differential l o c k
Bulb
Electronic tion
fuel
injec-
Fuse
Engine o i l level
00'
level
Temperature
Switch open
BRAKE
A n t i - t h e f t device
Selector switch
Doors open
Electric w i n d o w s
Button open
Door locking
Earth
'o
Coil-controlled (Relay)
switch
SPORT
consus-
N o . plate l i g h t s
<5>
Engine
Transistor
JT
Pulse (Timer)
generator
Rear w i n d o w w i p e r
Air Bag
Analogue clock
Headlamp washer
ANT I LOCK
Digital clock
STOP
Windscreen wash/wipe
Car s t o p f a u l t
Speedometer
Rear wash/wipe
window
Windscreen wiper
Rev c o u n t e r
Bravo-Brava
^ TO
Electrical system
55.
Wiring diagrams
Electrical symbols
388
Digital s p e e d o m e t e r
Digital rev c o u n t e r
_ b
iiniiiiiiii
Digital f u e l g a u g e
Ex3
tem-
Econometer
iiiiiiiiii
Digital c o o l a n t t e m p e r a ture g a u g e
v>~N-
\MA
Engine oil t e m p e r a t u r e
Engine o i l pressure g a u g e
3
Voltmeter
Wiring diagrams
Electrical system
Bravo-Brava
TD
55.
Explanation to reading wiring diagram
177 M I I I l K ' 10 11
50 50 50 80
179 ( 0 j
34
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Key to references A B C D ,E Component number Connection number Connector identification o n c o m p o n e n t Connecting pin number Ultrasound-soldered joint taped into wiring loom
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Bravo-Brava
TD
Electrical system
Connector blocks
55.
CONNECTOR BLOCKS *
INTRODUCTION
page
58 58 59
4A57ZL
31
Electrical system
Connector blocks
Bravo-Brava
TD
55.
INTRODUCTION
Light blue White Orange Yellow Grey Blue Brown Black Red Pink Green Purple Light blue-White Light blue-Yellow Light blue-Black Light blue-Red Light blue-Green
BG BL BN BR BV BZ CA CB CN GN GL GR GV HG HN HR HV
White-Yellow White-Blue White-Black White-Red White-Green White-Purple O r a n g e - L i g h t blue Orange-White Orange-Black Yellow-Black Yellow-Blue Yellow-Red Yellow-Green Grey-Yellow Grey-Black Grey-Red Grey-Green
LB LG LN LR LV MB MN NZ RB RG RN RV SN VB VN VR ZB
Blue-White Blue-Yellow Blue-Black Blue-Red Blue-Green Brown-White Brown-Black Black-Purple Red-White Red-Yellow Red-Black Red-Green Pink-Black Green-White Green-Black Green-Red Purple-White
32
Bravo-Brava
TD
Electrical system
Connector blocks
55.
236 Front/air conditioner cables connecti on Additional engine cooling fan
N172
238
u s e
r o t e c t
' 9
e r ,
gi
n e
cooling fan
239
R 127
NZ127
240
242
u e
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243
244
33
Electrical system
Connector blocks
Bravo-Brava
TD
55.
241 ^
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'P
SB 244.
245
E.G.R. solenoid
246
HV249 * HV241
247
248
Gll.(t.*V241 * -
G249 V249
AR 241 * - A R 249
34
Publication no.
506.670/06
Bravo-Brava
Electrical system
Connector blocks
55.
249
E.G.R. electronic control unit 250 Water temperature sensor for preheating control unit
r s ra ta
R n.d. BR 139 V 248 .
E I
la
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E I
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251
252
C 251
253
R '
a v
HN 127 HG55
P4A612L01
35
Key to compnents:
3 Power fuse box: A 6 0 A fuse protecting fuel injection s y s tem B 4 0 A fuse protecting ignition system C 6 0 A fuse protecting additional optional extras D 8 0 A fuse protecting fuse and relay unit 4 Fuse and relay unit: E1 Ignition switch discharge relay E2 Horn relay E3 Heated rear w i n d o w relay 6 Instrument panel: A L o w generator charge warning light B L o w engine oil pressure warning light C Left direction indicator warning light D Right direction indicator warning light E Side lights warning light F Instrument panel symbol lights G Main beam headlamps warning light H Air Bag fault warning light I Anti-lock braking system fault warning light J Fuel reserve circuit control module J1 L o w fuel level warning light K Fuel gauge L Fiat C O D E fault warning light M Fuel injection fault warning light 0 Heater plugs warning light Q Front brake pad wear warning light R Handbrake on / low brake fluid level warning light S Stop lights fault indicator electronic control module T Stop lights fault warning light U Door open warning light V Speedometer control module VI Speedometer W Rev counter
X Water temperature gauge Z Trip recorder/mileage counter Z1 Trip recorder reset button 7 Stalk unit: A Windscreen wiper speed switch B Windscreen w a s h / h e a d l a m p w a s h / rear w i n d o w w a s h switch C Rear w i n d o w wiper switch D Headlamp flasher button E Dipped beam/main beam headlamps F Side lights switch G Indicators/hazard lights intermittent switch H Direction indicators switch I Horn button 8 Front left earth 9 Front right earth 10 Battery earth on body shell 11 Battery 1 2 Ignition switch 13 Front right/left cables connection 18 Rear left earth 19 Rear right earth 2 2 Left dashboard earth 2 4 Windscreen wiper motor 2 5 Windscreen/rear w i n d o w washer pump 26 Rear w i n d o w wiper motor 27 Rear connections contact assembly with built-in boot light s w i t c h 28 Dash./longitudinal cables connection 3 4 Switch controls unit: A Alarm on warning light B Rear fog lamps switch C Rear fog lamps relay D Rear fog lamps warning light E Heated rear w i n d o w switch F Heated rear w i n d o w warning light G S w i t c h controls unit symbol light H Front fog lamps warning light I Front fog lamps switch 39 Heated rear w i n d o w 4 2 Right dashboard earth 4 6 Left horn 4 7 Right horn 5 5 Front/engine cables connection 5 5 A Front left/engine cables connection 5 5 C Front left/engine cables connection
4A64ZL
36
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Bravo-Brava
Electrical system
Contents
55
page
1 4 5 37
Bravo-Brava
Electrical system
55.
Wiring diagrams
Electrical symbols
S i d e lights
11 X
C h o k e (starter)
31)
15
ID
M a i n beam
to
Dipped headlamps
H e a t e d seat
Heater p l u g
S e a t belts
Electric h o r n s
H e a t e d rear w i n d o w
Rear f o g lamps
Left i n d i c a t o r
A.B.S.
(O)
Brake p a d wear
Engine c o o l i n g
Hazard w a r n i n g
niiiiil
i C o m p r e s s o r t u r b o pressure
Windscreen wiper
Indicators
Electric s u n r o o f
120 Km/h
Speed l i m i t s
Catalytic temperature
converter
Recharging
Fuel g a u g e
Heating element
E n g i n e oil pressure
Diode
Wiring diagrams
Electrical system
Bravo-Brava
55.
Electrical symbols
Differential lock
Bulb
Electronic i n j e c t i o n
Fuse
Engine o i l level
00'
Temperature
Switch open
BRAKE
Anti-theft device
Selector switch
Doors open
Electric w i n d o w s
Button open
Central l o c k i n g
Earth
'o
Coil-controlled (Relay)
switch
SPORT
No. plate l i g h t s
<fj>
Motor
Transistor
J ~ L
Pulse g e n e r a t o r (Timer)
Rear w i n d o w w i p e r
Air Bag
Analogue clock
flNTI
Headlamp washer
LOCK
Digital c l o c k
STOP
Screen w a s h / w i p e
Car s t o p f a u l t
Speedometer
Rear w i n . w a s h / w i p e
Windscreen wiper
Rev c o u n t e r
Bravo-Brava
Electrical system
55.
Wiring diagrams
Electrical symbols
388
D i g i t a l speedometer
IIIIIIIIIIIII
2l2
A n a l o g u e fuel g a u g e
tem-
Econometer
mini
Digital c o o l a n t t e m p e r a ture g a u g e
vEJ
Engine o i l t e m p e r a t u r e
E>3
Engine o i l pressure g a u g e
iSZ
Voltmeter
Wiring diagrams
Electrical system
Bravo-Brava
55.
How to read the wiring diagrams
177
10
63
11
n n
50 50 50
179
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94
STOP
c
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N.D.
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181
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176
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14
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174
12
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Key to references A B C D E Component number Connection number I d e n t i f i c a t i o n of c o n n e c t o r o n c o m p o n e n t Connecting pin number U l t r a s o u n d - s o l d e r e d j o i n t t a p e d in w i r i n g l o o m
180
(OJ
Publication no.
506.670/14
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Bravo-Brava
Electrical equipment
Contents
55.
page I N S T R U M E N T PANEL Removing-refitting C o n t r o l panel for versions S, SX C o n t r o l panel for versions EL, ELX C o n t r o l panel for version GT C o n t r o l panel for version H G T 1 2 4 6 9 Removing radio model A D 1 8 2 L Removing radio model A D 1 8 2 H Refitting radio models A D 1 8 2 L A D 182H - Replacing radio - O p e n i n g / c l o s u r e of cassette slot access flap FIAT CODE - Introduction - System c o m p o n e n t s - Storing codes - Connection between Fiat C O D E and e n g i n e management control u n i t s - M a n u a l fault diagnosis - Fault diagnosis using Fiat Lancia Tester - Emergency s t a r t - u p procedure - Precautions w h e n replacing Fiat CODE system c o m p o n e n t s CODE - Replacing t h e transponder - Diagrams for repairing faults in Fiat CODE system - Fiat CODE w i r i n g diagram (petrol version) - Fiat CODE w i r i n g diagram (diesel version) - R e m o v i n g - r e f i t t i n g FIAT C O D E control unit PROTECTION AND S A F E T Y D E V I C E 33 35 36 37 39 41 43 44 44 45 46 H o t wire safety device 86 58 59 63 71 72 73 74 75 76 78 83 84 85 page 55 55/1 55/2 55/2 55/3
CONTROL UNITS J u n c t i o n unit Supplementary fuses Location of i n j e c t i o n / i g n i t i o n control unit Location of hydraulic c o n t r o l unit for ABS 14 17 18 18
LIGHTING Front light cluster w i t h turn signal Replacing front light cluster b u l b s Headlamp alignment Electrical headlamp alignment device Location of c o m p o n e n t s and light beam for h e a d l a m p alignment - Side turn signal - Tail light cluster - Supplementary brake light - Fog lamps - N u m b e r plate light - Vehicle interior courtesy lights VARIOUS DEVICES Removing-refitting windscreen wiper motor Rear w i p e r motor Screen/rear w i n d o w washer p u m p Stalk unit R i g h t - h a n d stalk Ignition switch Tail-gate electrical contacts Brake lights s w i t c h Reversing lights s w i t c h R e m o v i n g - r e f i t t i n g radiator fan Fuel level gauge 19 20 21 22 22 24 24 28 29 31 31
ELECTRICALLY-OPERATED WINDOWS - Operation - R e m o v i n g - r e f i t t i n g electrically-operated w i n d o w c o n t r o l unit ELECTRICALLY-CONTROLLED SUN-ROOF Location of c o m p o n e n t s and w i r i n g harness90 88 89
CAR RADIO Radio-cassette player model A D 1 8 2 L Operating description for car radio model AD 182L Location of car radio c o m p o n e n t s model AD182L Radio-cassette player model AD 182H Operating description for car radio model AD182H Location o f car radio c o m p o n e n t s model AD182H 48 48/1 50 50/1 50/3 54 AIR BAG Introduction ECU Driver's side air bag module Passenger side air bag m o d u l e Device w i t h clock spring - Fault diagosis - Safety precautions t o be observed w h e n w o r k i n g o n vehicles w i t h A i r - B a g systems -
93 94 96 98 98 99
100
Cont.i
Copyright Fiat Auto
Electrical equipment
Contents
Bravo-Brava
55.
page - Danger t o health 103 - Effects of over-exposure 103 - Safety regulations f o r h a n d l i n g air bag modules 103 - Disposing of used air bag m o d u l e s 105 - W i r i n g diagram 1Q6. - R e m o v i n g driver's side air bag 107 - R e m o v i n g c l o c k spring 108 - Removing-refitting control unit 110 - Refitting c l o c k spring 110/2 Refitting A i r B a g R e m o v i n g - r e f i t t i n g passenger side air bag - Replacing passenger side air bag trim Removing-refitting unit air b a g c o n t r o l 110/10 110/6 110/7 110/9 - C o m p o n e n t location - Programming - Programming additional remote control units using simplified procedure - C h e c k i n g memory closure - Programming codes w i t h manual access - A u t o m a t i c activation of electronic alarm - Part notes a n d specifications - Fault diagnosis - L a y o u t diagram - A l a r m control unit input a n d o u t p u t signals - W i r i n g diagram - Receiver connector - R e m o v i n g - r e f i t t i n g alarm c o n t r o l unit PREHEATING CONTROL DEVICE - Introduction - Preheating electronic control u n i t - G l o w plug control - M a i n preheating system operational faults - Engine stop solenoid 155 155 157 157 158 page 135 136 141 144 145 149 149 149 151 152 153 154 154
RECHARGING Battery. Alterhator A l t e r n a t o r Marelli A 1 1 5 1 - 1 4 V - 3 8 / 6 5 A Alternator Marelli A 1 1 5 1 - 1 4 V - 4 0 / 7 5 A A l t e r n a t o r Marelli A 1 2 7 1 - 1 4 V - 5 0 / 8 5 A 112 112 114 118 120
STARTING - Starter motor Marelli E80 - 0.9/12 - Starter motor Marelli M70 R-1.4/12 - Starter motor Marelli E95 RL-2.2/12 - Checks - Starter motor operational f a u l t nosis 125 130 132 133 diag133
ALARM - Introduction - Emergency key - OPERATION - A c t i v a t i o n w i t h siren by-pass - R e m o t e control u n i t battery flat indication - Distance b e t w e e n sending unit a n d receiver d u r i n g p r o g r a m m i n g
W9ML
Publication no.
506.670/14
Bravo-Brava
Electrical system
Instrument panel
55.
REMOVING-REFITTING 1. Remove t h e protective cover from t h e fuse a n d relay u n i t . U n d o t h e o u t e r s c r e w s e c u r i n g t h e c o n t r o l panel f r a m e . 2. U n d o t h e o u t e r s c r e w s s e c u r i n g t h e c o n t r o l panel f r a m e . 3. W i t h d r a w t h e panel f r a m e after d i s c o n necting the t w o connectors from t h e panel l i g n t i n g rheostat a n d h e a d l a m p a d j u s t m e n t rheostat ( a r r o ) e d ) . 4. U n d o the screws securing the instrument panel t o t h e d a s h b o a r d . 5. D i s c o n n e c t t h e i n s t r u m e n t panel w i r i n g c o n n e c t i o n s a n d r e m o v e it f r o m t h e car.
Electrical system
Instrument panel
Bravo-Brava
55.
INSTRUMENT PANEL FOR S , S X VERSIONS
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Publication no.
506.670/01
Bravo-Brava
Electrical system
Instrument panel
55.
n n nnnn n n nn n n n
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Connector A Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 HB RV BR MN CL Wire colour HN BN LN R Circuit involved Generator Brake f l u i d level Inertial s w i t c h f a u l t + 3 0 battery ( f o r o d o m e t e r ) Not connected Not connected Not connected Brake pad wear Fiat C o d e Plug preheating Not connected L o w o i l pressure S p e e d o m e t e r m o d u l e signal Not connected Speedometer signal Not connected Coolant temperature Not connected Anti-lock braking system Not connected
Connector B Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wire colour VN GR GN Circuit involved M a i n beam h e a d l a m p s Panel s y m b o l l i g h t s S i d e lights Not connected Emergency brake-brake fluid level Instrument panel light M a i n earth Speedometer o u t p u t 1 Speedometer o u t p u t 2 Left d i r e c t i o n i n d i c a t o r Right direction indicator M a i n earth Not connected Earth ( e l e c t r o n i c ) Not connected Fuel g a u g + 1 5 battery A i r B a g fault Speedometer o u t p u t 3 Speedometer o u t p u t 4
BN GR N
AN A N
HG HM CN
NZ
HR AR LG
Electrical system
Instrument panel
Bravo-Brava
55.
INSTRUMENT PANEL FOR EL, ELX VERSIONS
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1. 2. 3. 4. 5. Fuel reserve w a r n i n g l i g h t Fuel g a u g e Rev c o u n t e r Direction indicators w a r n i n g lights A n a l o g u e speedometer and digital recorder 6. C o o l a n t t e m p e r a t u r e g a u g e 7. W a r n i n g l i g h t s (see p a g e 1 3 ) 8. W a r n i n g l i g h t s (see p a g e 1 3 ) trip
Publication no.
506.670/01
Bravo-Brava
Electrical system
Instrument panel
55.
IQQr
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Connector B Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wire colour VN GR GN
Wire colour HN BN LN R
_
Circuit involved Generator Brake f l u i d level Inertial s w i t c h f a u l t + 3 0 battery ( f o r o d o m e t e r ) Not connected Not connected Turbocharger
Brake pad w e a r
C i r c u i t involved Main beam headlamps Panel s y m b o l lights Side lights Not connected
Emergency brake-brake fluid level
BN GR N
I n s t r u m e n t panel l i g h t M a i n earth Speedometer output 1 Speedometer output 2 Left d i r e c t i o n i n d i c a t o r Right direction indicator M a i n earth Not connected Earth ( e l e c t r o n i c ) Not connected Fuel g a u g e + 15 battery A i r Bag f a u l t Speedometer output 3 Speedometer output 4
Fiat C o d e Plug preheating Not connected L o w o i l pressure Speedometer module signal Not connected Speedometer signal Rev c o u n t e r s i g n a l
Coolant temperature
AN A N
HG HN
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HR AR LG
Not connected
Anti-lock braking s y s t e m
RV
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Electrical system
Instrument panel
Bravo-Brava
55.
Pin no. 1 2 3 4 5 6 7 8 Wire colour VB RG RN AR N C i r c u i t involved B o n n e t / d o o r s not shut Left s t o p light f a u l t R i g h t s t o p light f a u l t + 1 5 battery Electronic earth Not connected Stop light ( + f r o m brake p e d a l ) Not connected Connector C
8 Front s i d e 1. 2. 3. 4. 5. Fuel reserve w a r n i n g light Fuel g a u g e A n a l o g u e speedometer a n d t r i p recorder D i r e c t i o n indicators w a r n i n g l i g h t s M a i n beam headlamps w a r n i n g light 6. 7. 8. 9. Rev counter Coolant temperature gauge W a r n i n g l i g h t s (see page 1 3 ) W a r n i n g lights (see page 1 3 )
Publication no.
506.670/01
Bravo-Brava
Electrical system
Instrument panel
55.
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Wiring diagram
Electrical system
Instrument panel
Bravo-Brava
55
^
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Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Circuit involved Generator Brake f l u i d level Inertial s w i t c h f a u l t Not connected Not connected Not connected Turbocharging
Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Wire colour VN GR GN
BR MN
BN GR N
I n s t r u m e n t panel l i g h t M a i n earth Speedometer output 1 Speedometer output 2 Left d i r e c t i o n i n d i c a t o r Right direction indicator M a i n earth Not connected Earth ( e l e c t r o n i c ) Not connected Fuel g a u g e + 1 5 battery A i r B a g fault Speedometer output 3 Speedometer output 4
AN A N
HG HN
NZ
CN L HB
HR AR LG
RV
Publication no.
506.670/01
Bravo-Brava
Electrical system
Instrument panel
55.
INSTRUMENT PANEL FORHGT VERSION
F r o n t side 1. 2. 3. 4. 5. Fuel reserve w a r n i n g l i g h t Fuel g a u g e A n a l o g u e speedometer a n d t r i p recorder D i r e c t i o n indicators w a r n i n g lights M a i n beam h e a d l a m p s w a r n i n g l i g h t 6. 7. 8. 9. Rev c o u n t e r Coolant temperature gauge W a r n i n g l i g h t s (see page 1 3 ) W a r n i n g l i g h t s (see page 1 3 )
Electrical system
Instrument panel
Bravo-Brava
55
10
E3
11 12
->:13
() q
14
CODE
16
()
17
ISTQPI
18
a 9^
19 ' 2 0
l - ^ l |'|r '|r|
J^
1 2 3 4 5 B 7 8 9 1011121314151617181920
1 2 3 4 5 6 7 8 9 1011121314151617181920
1 23456 7
(<p)
(o)
i fa)
10
11
12
13
m g)
14
15 I 1 6
17"
18
19
20*
Wiring diagram
10
Bravo-Brava
Electrical equipment
Instrument panel
55.
20
+ +++
++
+ + + +
Connector A N pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wiring colours HN BN LN C i r c u i t involved Generator Brake f l u i d level Inertia s w i t c h failure Not c o n n e c t e d Not c o n n e c t e d Not connected Turbocharging
Brake lining wear
BR MN
I n s t r u m e n t panel l i g h t Master earth Speedometer o u t p u t 1 Speedometer o u t p u t 2 Left-hand turn signal Right-hand turn signal Master earth Not connected Earth ( e l e t r o n i c ) Not connected Fuel level + 1 5 battery A i r - b a g failure Speedometer o u t p u t 3 Speedometer o u t p u t 4
Fiat C o d e G l o w plug preheating Not connected L o w oil pressure S p e e d o m e t e r m o d u l e signal Not connected Signal f r o m s p e e d o m e t e r Rev c o u n t e r s i g n a l Coolant temperature Not connected Anti-lock braking system
Signal indicating presence of water in fuel (diesel)
HG HN
CN L HB
RV
Connector C 1 2 3 4 5 6 7 8 VB RG RN AR N Bonnet/doors not closed Left brake l i g h t f a i l u r e Right brake l i g h t f a i l u r e + 1 5 battery Electronic earth Not connected Car brake l i g h t ( + f r o m brake p e d a l ) Not connected Connector C
R
_
11
Electrical equipment
Instrument panel
Bravo-Brava
55.
The tables b e l o w g i v e values w h i c h can be u s e d t o test v a r i o u s readings o n t h e f o l l o w i n g gauges: f u e l level a n d c o o l a n t t e m p e r a t u r e .
240 5 292.5 1 5
HR
A .
B17 B14 B16
AR
NZHR
F u e l level g a u g e w i r i n g d i a g r a m
I
+15
112
i
'
1. 2. 3. 4. 5. 6. 7. 8.
Left h a n d facia earth J u n c t i o n unit I n s t r u m e n t panel Fuel level g a u g e Fuel level c o n t r o l m o d u l e Fuel reserve w a r n i n g l i g h t Fuel level g a u g e R i g h t rear earth
Gauge scale
Indicator o f f
2000 - 500
1 7 5 15
7 4 . 5 5.5
12
version
Bravo-Brava
Electrical system
Instrument panel
55.
Warning lights for S , S X v e r s i o n s
=00= 2 1. 2. 3. 4. 5. 6. 7.
ID
3
()
o 10
CODE
11
(0)
12
13
Air Bag fault w a r n i n g light S i d e lights w a r n i n g l i g h t M a i n beam h e a d l a m p s w a r n i n g light Fuel reserve w a r n i n g l i g h t Fuel i n j e c t i o n f a u l t w a r n i n g l i g h t L o w alternator recharging w a r n i n g light L o w e n g i n e o i l pressure w a r n i n g light
8. H a n d b r a k e o n / l o w brake f l u i d level warning light 9. Brake p a d w e a r w a r n i n g l i g h t 1 0 . Fiat C o d e system w a r n i n g l i g h t 1 1 . A B S fault w a r n i n g light 1 2 . M a x i m u m t u r b o pressure w a r n i n g l i g h t 13. Plug preheating w a r n i n g light
W a r n i n g lights f o r E L , E L X v e r s i o n s
OJ
=00=
ID
a ( )M o
8 9
o
CODE
11
C) O
12
13
14
1. 2. 3. 4. 5. 6. 7.
8. D o o r s o p e n w a r n i n g l i g h t 9. H a n d b r a k e o n / l o w brake f l u i d level warning light 1 0 . Brake p a d w e a r w a r n i n g l i g h t 1 1 . Fiat C o d e system fault w a r n i n g l i g h t 12. A B S fault w a r n i n g light 1 3 . M a x i m u m t u r b o pressure w a r n i n g l i g h t 14. Plug preheating w a r n i n g light
W a r n i n g lights f o r G T v e r s i o n
E3
4
=< o
6
() (O)
7 8
CODE
(0) ;1 10 ' 1
1. 2. 3. 4. 5. 6.
7. H a n d b r a k e o n / l o w brake f l u i d level warning light 8. Brake p a d w e a r w a r n i n g l i g h t 9. Fiat C o d e s y s t e m fault w a r n i n g l i g h t 10. A B S fault w a r n i n g light 1 1 . A i r Bag f a u l t w a r n i n g l i g h t
W a r n i n g lights f o r H G T v e r s i o n
1
1. 2. 3. 4. 5.
E3
2
4
P4A013L07 P4A013L08
6. 7. 8. 9. 10. 11.
Brake p a d w e a r w a r n i n g l i g h t Fiat C o d e s y s t e m w a r n i n g l i g h t A B S fault w a r n i n g light Stop lights fault warning light Doors open warning light A i r Bag f a u l t w a r n i n g l i g h t
13
Electrical system
Fuse, relay and control units
Bravo-Brava
55.
FUSE AND RELAY UNIT R e m o v i ng - ref itti ng 1. U n d o t h e screws indicated a n d remove t h e u n i t cover. 2. D i s c o n n e c t the wiring connectors p l u g g e d i n t o t h e f r o n t of t h e u n i t . 3. U n d o t h e s c r e w s s e c u r i n g t h e u n i t t o t h e dashboard. 4 . M o v e aside t h e u n i t , d i s c o n n e c t t h e c o n n e c t o r s p l u g g e d i n t o t h e rear o f t h e u n i t and remove the unit from the dashboard.
14
Bravo-Brava
Electrical system
Fuse, relay and control units
55.
| F 1 4 ^ | | ^ F 1 5 ^ l F 5 . = l|=F3 = ||F2^ri
B
5 2 1 L.J
o n
p 1 2 ^ | = F 4 c = n | F 8 = i r ^ F 7 = ||=F6 = | T i I " i n r
B
14
fcrrd
5-
F r o n t v i e w o f f u s e a n d relay unit a n d i d e n t i f i c a t i o n o f f u s e s
i r
1 7 n ft nn n Q n.
_n_
0 J
The connectors cannot be connected incorrectly, as each is shaped differently. The letters identifying the connectors are the same as those used on the wiring diagrams.
R e a r v i e w o f f u s e a n d relay unit a n d l o c a t i o n o f r e l a y s
E1. Ignition s w i t c h discharge relay E2. H o r n relay E3. Heated rear w i n d o w Kelay
P4A016L02
15
Electrical system
Fuse, relay and control units
Bravo-Brava
55.
List of f u s e s and main protected circuits
Protected circuit
Protected circuit
SERV1ZI SERVICES
Reversing l i g h t s - S t o p l i g h t s - Additional stop light (if present) - D i r e c t i o n i n d i c a t o r s flasher - S u p p l y t o c h e c k panel i n s t r u m e n t ( i f present) - Electric w i n d o w s c o n t r o l ( i f present) - A i r B a g circuit - A B S enablement.
ID ID
10
- Main warning
10
10
Hazard w a r n i n g l i g h t s f l a s h er.
10 2 10
/
15
-00-
Front r i g h t s i d e l i g h t - Rear left side l i g h t - R i g h t n u m ber plate l i g h t - R a d i o l i g h t ing - Instrument lighting a n d side lights w a r n i n g l i g h t - S w i t c h panel l i g h t i n g . 11 20
C o u r t e s y light - L u g g a g e compartment light - Clock supply - Remote control receiver s u p p l y ( i f present) Radio supply - Glove c o m p a r t m e n t light.
12
30
Not used.
13 3 10 -00Front left side light Heater/air conditioner c o n t r o l s l i g h t i n g - Rear r i g h t s i d e l i g h t - Rear r i g h t s i d e l i g h t - Left n u m b e r p l a t e light.
20
Horns.
14
20
15
20
10
|D |D
Left d i p p e d b e a m .
10
W i n d s c r e e n w i p e r - Rear window wiper - Windscreen/rear w i n d o w washer wiper - Headlamp washer intermittent switch. Climate control fan motor a n d resistor f o r d e t e r m i n i n g its s p e e d - Relays f o r first a n d s e c o n d speeds o f c o n denser a n d radiator f a n s a n d 2 n d s p e e d delay u n i t - A i r conditioner compressor relay - Cigar lighter.
16
Bravo-Brava
Electrical system
Fuse, relay and control units
55.
D i a g r a m of f u s e a n d relay unit internal c o n n e c t i o n s
1 2T (T 6T T T T T 3 5 7
L
1 I
12 |
'TTTTTTTTTTTTTTTTTT'
1 2 3 ( 5 6 7 8 9 101112131415161718
I 1I I I I I I I I <II
2 3 4 5 6 7
9 10 11 12 13 14 15/ rki
11
El
E2 / rki
E3
iiiuuiiuniii
1 2 3 4 5 6 7 8 9 1811 121314
1 2 345
nh
li II11 i 1 li-Jrttr
1 2 3 4 5 6 7 8 9 101112
lillllilll-tr
m
1 2 3 4 5 6 7 8 9 18
iiiui l i n n uii
1 2 3 4 5 6 7 8 9 1811 121314
i l l l l 111111-i-ir
1 2 3 4 5 5 7 8 9 101112
17
Electrical system
Fuse, relay and control units
Bravo-Brava
55.
LOCATION OF F U E L INJECTION/IGNITION CONTROL UNIT
P4A018L01
LOCATION O F E L E C T R O H Y D R A U L I C C O N T R O L UNIT F O R A N T I - L O C K B R A K I N G S Y S T E M
18
Publication no.
506.670/01
Bravo-Brava
Electrical system
Lighting
55.
FRONT LIGHTS CLUSTER WITH DIRECTION INDICATOR Removing-refitting 1. U n d o the bolts securing the lights cluster t o the body shell. 2. D i s c o n n e c t t h e w i r i n g c o n n e c t o r s f r o m t h e l i g h t s cluster. 3. R e m o v e t h e c o m p l e t e w a r n i n g l i g h t f r o m t h e car. 4 . D u r i n g assembly, insert p i n A in its s e a t i n g in t h e b o d y s h e l l .
19
Electrical system
Lighting
Bravo-Brava
55.
R E P L A C I N G B U L B S ON F R O N T LIGHTS CLUSTER Dipped a n d m a i n b e a m h e a d l a m p b u l b s 1 . R e m o v e t h e plastic p r o t e c t i o n s b y p r e s s i n g o n t h e lever i n d i c a t e d w h i c h secures t h e m t o t h e l i g h t s cluster. 2. W i t h d r a w t h e b u l b c o n c e r e d (after releasing the retaining lug) f r o m the lights cluster. D i s c o n n e c t t h e b u l b f r o m its c o n n e c tor a n d replace it; d o n o t t o u c h it w i t h y o u r bare h a n d s .
S i d e light b u l b s 3. Carry o u t o p e r a t i o n 1 a n d d i s e n g a g e t h e b u l b h o l d e r f r o m t h e l i g h t s cluster a n d t h e n d i s e n g a g e the b u l b f r o m t h e h o l d e r . D i r e c t i o n i n d i c a t o r s bulb Rotate t h e b u l b holder b y 9 0 degrees a n d w i t h d r a w it f r o m t h e l i g h t s cluster. Disconnect the connector from the bulb holder a n d d i s c o n n e c t t h e b u l b f r o m t h e holder b y r o t a t i n g it.
20
Publication no.
506.670/01
Bravo-Brava
Electrical system
Lighting
55.
R e p l a c i n g rear l i g h t s c l u s t e r b u l b s 2. U n d o t h e s c r e w s i n d i c a t e d a n d r e m o v e the trim. 3. U n d o t h e s t o p s i n d i c a t e d , d i s c o n n e c t t h e c o n n e c t i o n s h o w n and r e m o v e t h e b u l b holder f r o m t h e car. 4. Remove the bulbs concerned.
25
Electrical system
Lighting
Bravo-Brava
55.
rear
lights
cluster
1. Undo the screws and remove the buttons s e c u r i n g t h e t r i m o n t h e rear c r o s s m e m b e r and remove the trim. 2. Undo the screw indicated and remove the l i g h t s cluster t r i m . 3. U n d o t h e s c r e w s s e c u r i n g t h e l i g h t s c l u s ter t o t h e b o d y shell a n d d i s c o n n e c t t h e relevant c o n n e c t o r . 4 . R e m o v e t h e l i g h t s cluster f r o m t h e car.
26
Publication no.
506.670/01
Service News
Copyright by Fiat Auto
4/96
Fiat Auto
Assistenza
S.p.A
Vendita
Fiat Brava AH v e r s i o n s
5540 A 461 A E / C C REAR LIGHT C L U S T E R instructions for replacement
55
13.96
A
T o c o m p l e t e t h e d e s c r i p t i o n in s e c t i o n 5 5 of t h e Service M a n u a l , t h e n e x t page c o n t a i n s t h e i n s t r u c t i o n s for r e p l a c i n g t h e rear l i g h t cluster o n t h e m o d e l in q u e s t i o n .
IF60D6
REAR 2/2
R e p l a c i n g r e a r light c l u s t e r 1 . Remove the rear light cluster as described o n page 2 6 - sec. 55 of t h e m a n u a l . 2 . M a k e s u r e , before f i t t i n g t h e rear l i g h t cluster, t h a t t h e f r a m e f i x i n g t h e l i g h t cluster t o t h e b o d y s h e l l , is p o s i t i o n e d at t h e c e n t r e o f t h e seal p r e - l o a d i n g a d j u s t m e n t s c r e w s ; if t h i s is n o t t h e case, a d j u s t t h e s c r e w s as s h o w n in t h e d i a gram. 3 . Correctly p o s i t i o n t h e rear l i g h t cluster on the bodyshell and tighten the fixing b o l t s s h o w n in t h e d i a g r a m . 4 . G r a d u a l l y t i g h t e n t h e b o l t s i n t h e order shown, then continue the tightening u n t i l t h e y a c t u a l l y break.
The operation described allows the right pressure rear light cluster perimeter the bodyshell.
NOTE
Complete the fitting of the elements removed, reversing the order of the operations carried out for the removal of the rear light cluster.
Brava
Electrical equipment
Lighting
55.
R e p l a c i n g tail light c l u s t e r 1 . R e m o v e t h e tail light cluster as d e s c r i b e d o n page 2 6 . 2. Before f i t t i n g t h e tail l i g h t cluster, ensure t h a t t h e f r a m e f a s t e n i n g t h e l i g h t cluster t o t h e b o d y is p o s i t i o n e d half w a y a l o n g t h e l e n g t h of t h e gasket p r e l o a d a d j u s t m e n t s c r e w s . O t h e r w i s e a d j u s t t h e s c r e w s as s h o w n in t h e f i g u r e . 3. Correctly p o s i t i o n the tail l i g h t cluster o n the body and tighten the retaining screws s h o w n in t h e f i g u r e . 4 . G r a d u a l l y t i g h t e n the s c r e w s in t h e order s h o w n , t h e n c o n t i n u e t o t i g h t e n t o break point. The above operation allows the gasket between the tail light cluster and body to be adjusted to the correct pressure.
<I>
NOTE
reversing removal.
26/1
Brava
Electrical system
Lighting
55.
R e p l a c i n g rear l i g h t s c l u s t e r b u l b s version)
(5-door
3. Replace t h e b u l b s c o n c e r n e d .
27
Electrical system
Lighting
Bravo
55.
ADDITIONAL STOP LIGHT
R e m o v i n g - r e f i t t i n g (5-door
version)
1. R e m o v e t h e t r i m b y u n d o i n g t h e s c r e w s a n d b u t t o n s s e c u r i n g it t o t h e t a i l g a t e .
3. R e m o v e t h e a d d i t i o n a l s t o p l i g h t f r o m t h e car.
28
Bravo-Brava
Electrical system
Lighting
55.
P4A029L04
P4AO29L05
29
Electrical system
Lighting
Bravo-Brava
55.
R e p l a c i n g f r o n t f o g lamp b u l b
30
Publication no.
506.670/01
Bravo-Brava
Electrical system
Lighting
55.
1
NUMBER PLATE LIGHT R e m o v i n g - refitti ng 1 . Release t h e s t o p ( a r r o w e d ) t o e n a b l e t h e lamp u n i t t o be w i t h d r a w n f r o m t h e rear bumper. 2. D i s c o n n e c t t h e c o n n e c t o r i n d i c a t e d a n d remove the lamp. COURTESY LIGHTS
R e m o v i n g - r e f i t t i n g top c o u r t e s y light 3. R e m o v e t h e cover pieces ( a r r o w e d ) . 4. Undo the screws (arrowed) securing the courtesy light t o the b o d y w o r k . 5. D i s c o n n e c t t h e w i r i n g c o n n e c t i o n s a n d r e m o v e t h e c o u r t e s y l i g h t f r o m t h e car. a
31
Electrical system
Lighting
Bravo-Brava
55.
R e p l a c i n g c o u r t e s y light b u l b s 1. Disconnect t h e connection and remove t h e part s h o w n in t h e f i g u r e . 2. R e m o v e t h e p r o t e c t i o n a n d replace t h e bulbs concerned. R e m o v i n g - r e f i t t i n g glove c o m p a r t m e n t light a n d r e p l a c i n g bulb 3. D i s e n g a g e t h e edges of t h e c o u r t e s y l i g h t a n d remove it f r o m its s e a t i n g . 4. Disconnect t h e connector s h o w n and rem o v e the light f r o m the g l o v e c o m p a r t m e n t . 5. Replace t h e b u l b c o n c e r n e d . R e m o v i n g - r e f i t t i n g a n d r e p l a c i n g luggage compartment bulb 6. Remove the courtesy light f r o m its seating, disconnect the connector and remove the light. NOTE The bulb can be replaced without moving the courtesy light from car. rethe
32
Bravo-Brava
Electrical system
Various devices
55.
REMOVING-REFITTING WIPER MOTOR WINDSCREEN
1 . R e m o v e t h e p r o t e c t i v e covers, t h e n u n d o the nuts and remove the windscreen wiper arms. 2. Raise t h e b o n n e t , u n d o t h e s c r e w s i n d i cated a n d remove the trim under t h e windscreen.
33.
Electrical system
Various devices
Bravo-Brava
55.
1. Undo the screws indicated and remove the w i n d s c r e e n w i p e r assembly f r o m t h e car. 2. U n d o t h e b o l t s a n d n u t i n d i c a t e d . 3. Separate t h e w i n d s c r e e n f r o m t h e linkage. wiper motor
34
Publication no.
506.670/01
Bravo-Brava
Electrical s e s t e m
Various devices
55.
REAR WINDOW WIPER MOTOR R e m o v i n g - ref itt i ng 1 . Raise t h e p r o t e c t i o n i n d i c a t e d i n t h e f i g ure, u n d o t h e n u t a n d r e m o v e t h e rear w i n d o w wiper arm. 2. Lift t h e tailgate, u n d o the attachment b u t tons and remove the trim. 3. D i s c o n n e c t t h e electrical c o n n e c t i o n i n d i cated, u n d o the socket-headed screws a n d r e m o v e t h e rear w i n d o w w i p e r m o t o r f r o m t h e car. Replacing rear w i n d o w wiper blade 4 . W o r k i n g o n b o t h sides o f t h e b l a d e carrier as s h o w n in t h e figure, r e m o v e t h e b l a d e f r o m t h e car.
35
Electrical system
Various devices
Bravo-Brava
55.
WINDSCREEN/REAR WINDOW WASHER PUMP
R e m o v i n g - refitting Lift t h e b o n n e t , drain t h e w i n d s c r e e n w a s h e r f l u i d in t h e reservoir a n d save it. 1 . U n d o t h e bolts s e c u r i n g t h e c o o l a n t reservoir t o t h e b o d y w o r k a n d m o v e t h e reservoir over t o o n e side.
2. D i s c o n n e c t t h e p u m p s u p p l y c o n n e c t o r .
3. R e m o v e t h e p u m p f r o m t h e car.
P4A036L03
36
Publication no.
506.670/01
Bravo-Brava
Electrical system
Various devices
55.
1 . D i s c o n n e c t t h e battery's n e g a t i v e t e r m i nal, t h e n r e m o v e t h e h o r n c o v e r after d i s c o n n e c t i n g its c o n n e c t i o n s . 2. U n d o t h e n u t ( a r r o w e d ) a n d r e m o v e t h e steering w h e e l f r o m t h e car. 3. U n d o t h e s c r e w s ( a r r o w e d ) a n d r e m o v e t h e steering c o l u m n b o t t o m s h r o u d . 4. Undo the screws (arrowed) and remove t h e steering c o l u m n u p p e r s h r o u d . 5. U n d o t h e s o c k e t - h e a d e d s c r e w a n d d i s c o n n e c t t h e relevant c o n n e c t o r s , t h e n r e m o v e t h e stalk u n i t f r o m t h e car.
37
Electrical system
Various devices
Bravo-Brava
55.
Wiring d i a g r a m of s t a l k unit
* - < > <Xi 41N X < > 4t> - < ! < > 'JM X 3> X
JLJT , J
IT [ LI
49ft 49 3 1 K R
'1
O 0 I
U
o o o i
ID
F r o n t v i e w o f s t a l k unit
R e a r v i e w o f s t a l k unit The letters indicate t h e s o c k e t s for t h e c o n n e c t o r s o f t h e c o r r e s p o n d i n g names, a n d t h e n u m b e r s i d e n t i f y the relevant first a n d last p i n s .
38
Bravo-Brava
Electrical system
Various devices
55.
IDENTIFICATION OFCONNECTOR TERMINALS Connector A Pin no. 1 2 3 4 5 6 7 8 9 ; Wire colour HN H Circuit involved W i n d s c r e e n w i p e r a n d brake W i n d s c r e e n w i p e r - H i g h speed 2 Not connected Windscreen wiper I n t e r m i t t e n t / L o w speed Bidirectional p u m p Bidirectional p u m p Headlamp washer control Earth Trailer i n d i c a t o r s w a r n i n g l i g h t 6 7 AG GV Int 3 4 5 HR LR CB D i p p e d headlamps M a i n beam h e a d l a m p s Int/A Connector B Pin Wire no. c o l o u r 1 C i r c u i t involved N o r t h e r n Europe l e g i s l a t i o n N o r t h e r n Europe l e g i s l a t i o n
HG S SN SG N
Side lights
Connector C Pin no. 1 2 3 4 5 6 Wire colour Circuit involved N o t used Rear f o g lamps e n a b l e m e n t Int/A Right direction indicator Hazard l i g h t s i n d i c a t o r Right direction indicator
Connector D Pin Wire no. c o l o u r 1 2 3 4 5 Circuit involved N o t connected +30 Horn Not connected Positive Windscreen wash/wipe-rear w i n d o w washer Rear w i n d o w w i p e r Rear w i n d o w w i p e r a n d brake
HL AG AN LR A
LB LN
CN
6 S T A L K UNIT R I G H T LEVER 7
CL CB
T h e stalk unit r i g h t lever c o n t r o l s t h e w i n d s c r e e n w i p e r ( t w o speeds + i n t e r m i t t e n t o p e r a t i o n ) a n d t h e w i n d s c r e e n w a s h e r p u m p in a c c o r d a n c e w i t h t h e f o l l o w i n g logic: - W h e n t h e right lever is m o v e d d o w n w a r d s o n e click, t h e s w i t c h is a c t i v a t e d , s w i t c h i n g o n t h e w i n d screen w i p e r i n t e r m i t t e n t f u n c t i o n at t h e rate o f a b o u t 1 5 w i p e s a m i n u t e . - W h e n t h e s w i t c h is m o v e d t w o c l i c k s d o w n w a r d s , i n t e r m i t t e n t o p e r a t i o n at a b o u t 3 5 w i p e s a m i n u t e is selected. O p e r a t i o n remains t h e same as a b o v e , e x c e p t t h a t t h e pause t i m e b e t w e e n w i p e s is r e d u c e d t o 2 s e c onds. - B y m o v i n g t h e s w i t c h three c l i c k s d o w n w a r d s , c o n t i n u o u s o p e r a t i o n o f t h e w i n d s c r e e n w i p e r is s w i t c h e d o n at 4 5 w i p e s a m i n u t e . If f r o m t h e S T O P p o s i t i o n t h e lever is p u s h e d u p w a r d s a n d h e l d in t h i s p o s i t i o n , c o n t i n u o u s o p e r a t i o n of t h e w i n d s c r e e n w i p e r is still selected, b u t w i t h t h e lever in an u n s t a b l e p o s i t i o n . In o t h e r w o r d s , t h e w i n d s c r e e n operates f o r as l o n g as t h e lever is h e l d i n t h a t p o s i t i o n , a n d s t o p s as s o o n as the lever is released.
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Windscreen wiper motor On t h e m o t o r c a s i n g , t h e r e is a c o n t a i n e r w i t h t h e s w i t c h i n g c i r c u i t , c o n s i s t i n g o f a relay a n d a s w i t c h f o r the a u t o m a t i c return o f t h e blades t o t h e rest p o s i t i o n .
Windscreen washer W h e n t h e r i g h t stalk u n i t lever is m o v e d t o w a r d s t h e driver, t h e w i n d s c r e e n w a s h e r p u m p is s u p p l i e d . W h e n t h e lever is released, t h e p u m p s t o p s w h i l e t h e w i n d s c r e e n w i p e r remains o n f o r a b o u t f o u r seconds t o f i n i s h w i p i n g t h e w i n d o w . Windscreen washer pump
The w i n d s c r e e n w a s h e r p u m p is m o u n t e d d i r e c t l y o n t h e f l u i d reservoir.
Rear w i n d o w w i p e r The rear w i n d o w w i p e r a n d p u m p are c o n t r o l l e d b y t h e r i g h t stalk u n i t lever, w h i c h has t w o a d d i t i o n a l s w i t c h e s ; o n e is of t h e r i n g t y p e f o r c o n t r o l l i n g t h e rear w i n d o w w i p e r a n d o n e c o n t r o l s t h e p u m p . T h e rear w i n d o w w i p e r m o t o r has a relay a n d a s w i t c h w h i c h c o n s t i t u t e t h e c o n t r o l / r e s e t c i r c u i t o f t h e w i p e r blade. A. W h e n t h e ring s w i t c h l o c a t e d o n t h e stalk u n i t lever is r o t a t e d , a terminal o f t h e c o n t r o l relay is c o n nected d i r e c t l y t o earth b y a cable w h i c h s u p p l i e s t h e m o t o r c o n t i n u o u s l y . B. W h e n t h e lever is p u s h e d t o w a r d s t h e d a s h b o a r d , t h e p u m p a n d rear w i n d o w w i p e r are s w i t c h e d o n s i m u l t a n e o u s l y , a n d remain o n u n t i l pressure o n t h e lever s t o p s .
Rear w i n d o w w a s h e r The p u m p is o f the b i d i r e c t i o n a l t y p e , a n d has t w o c o n n e c t i o n s t o w h i c h are c o n n e c t e d t w o p i p e s c o n veying t h e f l u i d t o t h e spray jets f o r t h e w i n d s c r e e n a n d t h e j e t f o r t h e rear w i n d o w . The d i r e c t i o n o f the f l u i d a n d so its d e s t i n a t i o n d e p e n d o n t h e d i r e c t i o n o f r o t a t i o n o f t h e p u m p , w h i c h is d e t e r m i n e d b y the p o s i t i o n t o w h i c h t h e stalk u n i t lever is p u s h e d . In other w o r d s , b y p u s h i n g t h e lever forwards in a h o r i z o n t a l d i r e c t i o n , t h e p u m p is s u p p l i e d s e n d i n g t h e positive t o t h e S N c a b l e a n d t h e negative t o t h e S c a b l e . The f l u i d is t h u s sent t o t h e rear w i n d o w a n d at t h e s a m e t i m e t h e rear w i n d o w w i p e r is o p e r a t e d u n t i l the lever is released.
Headlamp w a s h e r The h e a d l a m p w a s h e r s y s t e m c o m p r i s e s a p u m p l o c a t e d o n t h e w i n d s c r e e n w a s h e r f l u i d reservoir a d j a cent t o t h e w i n d s c r e e n w a s h e r p u m p , t o w h i c h t w o jets secured t o t h e f r o n t b u m p e r are c o n n e c t e d v i a the a p p r o p r i a t e pipes, a n d a timer. W i t h t h e d i p p e d b e a m h e a d l a m p s s w i t c h e d o n , w h e n t h e r i g h t stalk unit lever is m o v e d t o w a r d s t h e driver, in a d d i t i o n t o a c t i v a t i n g t h e w i n d s c r e e n w a s h e r f u n c t i o n , t h e h e a d l a m p w a s h e r f u n c t i o n is also activated. Operation The timer is s u p p l i e d b y a 1 2 V p o s i t i v e c o m i n g d i r e c t l y f r o m t h e battery a n d p r o t e c t e d b y a 2 0 A f u s e c o n n e c t e d t o t h e f r o n t left earth v i a a t e r m i n a l . W h e n t h e t h e d i p p e d b e a m h e a d l a m p s or f r o n t a n d rear f o g l a m p s are s w i t c h e d o n , b y means o f t h e stalk unit ring s w i t c h , a t i m e r o n its t e r m i n a l is s u p p l i e d , p r e p a r i n g t h e system f o r o p e r a t i o n .
a
<
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55.
IGNITION S W I T C H Removing-refitting D i s c o n n e c t t h e battery's n e g a t i v e t e r m i n a l and remove t h e t o p and b o t t o m steering c o l u m n s h r o u d s . Insert t h e i g n i t i o n k e y in the ignition switch block a n d s w i t c h t h e ignition O N . Press o n t h e retaining l u g as s h o w n in t h e figure. 3. W i t h d r a w t h e b l o c k f r o m t h e i g n i t i o n switch. R e m o v e t h e c i r c l i p at t h e rear o f t h e i g n i tion s w i t c h block. 5. Press t h e lever f o r s w i t c h i n g o n t h e p a r k ing lights and turn the key so that the s t e p A is p o s i t i o n e d as s h o w n in t h e f i g u r e . 1
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1 . W i t h d r a w t h e i g n i t i o n key b l o c k . R e m o v i n g - r e f i t t i n g ignition key 2. D i s c o n n e c t t h e n e g a t i v e t e r m i n a l f r o m t h e battery a n d carry o u t o p e r a t i o n 3 o n p a g e 37. Disconnect the wiring connections from the ignition switch. 3. U n d o t h e shear b o l t s ( a r r o w e d ) .
must
be renewed
during
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55.
TAILGATE ELECTRICAL CONTACTS Removing-refitting (on tailgate) 1. U n d o the screws (arrowed) a n d remove the tailgate contact block. 2. R e m o v e t h e t a i l g a t e t r i m b y u n d o i n g the attachment buttons. 3. D i s c o n n e c t t h e c o n n e c t i o n s s h o w n a n d remove t h e tailgate c o n t a c t s w i t h t h e relevant w i r i n g . R e m o v i n g - r e f i t t i n g ( o n body s h e l l ) 4 . U n d o the s c r e w s ( a r r o w e d ) a n d r e m o v e the contact block from the b o d y w o r k . 5. D i s c o n n e c t t h e s u p p l y c o n n e c t o r s a n d r e m o v e t h e c o n t a c t b l o c k f r o m t h e car.
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STOP LIGHTS SWITCH T o replace t h e s t o p l i g h t s s w i t c h , c l o s e l y f o l l o w the procedure below:
Dismantling
- D i s c o n n e c t t h e electrical c o n n e c t i o n s block; - w i t h r a w t h e s w i t c h , t u r n i n g it a n t i - c l o c k w i s e b y a b o u t 60; T h i s o p e r a t i o n is f a c i l i t a t e d if a w r e n c h is used o n t h e h e x a g o n a l s e c t i o n ( 1 ) in t h e central f i g u r e . Refitting - Fit t h e n e w s w i t c h c o m p l e t e w i t h b u s h ( 2 ) and spacer ( 3 ) in its s e a t i n g ( 4 ) as f o l l o w s : - h o l d t h e brake pedal d e p r e s s e d , t h e n f i t t h e < n e w s w i t c h in t h e e n g a g e m e n t p o s i t i o n o n the bracket ( 4 ) ; - turn t h e s w i t c h by about 60 clockwise t o t h e l i m i t o f its t r a v e l . T h e r e t a i n i n g l u g ( 5 ) s h o u l d b e heard e n g a g i n g in its s e a t i n g (6). Regulation - Release t h e brake p e d a l t o t h e rest p o s i t i o n ; t h e s w i t c h w i l l be p o s i t i o n e d a u t o m a t i c a l l y in relation t o t h e b u s h ( 2 ) ; - press t h e pedal so t h a t t h e w o r k i n g spacer ( 3 ) used as p r o t e c t i o n d u r i n g a d j u s t m e n t can b e r e m o v e d a n d s c r a p p e d . NOTE The working spacer (3) releases an inner stop lug which prevents any further movement between the switch and bush (2).
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REMOVING-REFITTING RADIATOR FAN 1 . Place t h e car o n ramps, d i s c o n n e c t t h e battery's n e g a t i v e cable, t h e n r e m o v e t h e air d u c t . 2. U n d o t h e f a n ' s t o p bolts a n d t h e c o n n e c tions indicated. 3. Lift t h e car a n d r e m o v e t h e b o t t o m s o u n d - p r o o f i n g shield f r o m t h e car. 4. U n d o the fan's bottom bolts. 5. R e m o v e t h e f a n f r o m t h e car.
The operations described above may not apply if the engine or version are not the same as that illustrated above.
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FUEL GAUGE S E N D E R UNIT Removing-refitting 1 . O p e n t h e t a i l g a t e a n d r e m o v e t h e parcel shelf. 2. Fold d o w n t h e rear seat a n d lift t h e spare w h e e l cover. 3. U n d o t h e s c r e w s ( a r r o w e d ) a n d r e m o v e t h e p r o t e c t i v e cover. 4 . D i s c o n n e c t t h e electrical c o n n e c t i o n s a n d the pipes from t h e fuel gauge sender unit.
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1860893000
Fuel gauge Values for checking calibration Pointer position 4/4 3/4 1/2 1/4 Start o f reserve ( A ) 0 V a l u e in O h m s 0 - 6 59 - 69 116-126 186 - 201 255 3 290 - 304 ,
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G R U N D I G A D 182 L R A D I O A N D C A S S E T T E PLAYER The car is f i t t e d as s t a n d a r d w i t h a radio c o m p r i s i n g t h e f o l l o w i n g m a i n c o m p o n e n t s : - G R U N D I G A D 1 8 2 L r a d i o a n d cassette player ( n o n r e m o v a b l e ) w h i c h is f i t t e d at t h e centre o f t h e i n s t r u m e n t p a n e l , a n d its c u s t o m i z e d F I A T f r o n t t r i m c o v e r is f u l l y integrated in t h e line of t h e d a s h b o a r d ; - t w o l o u d s p e a k e r s l o c a t e d o n the inner panels of t h e f r o n t d o o r s ; - f i s h p o l e aerial located at t h e centre f r o n t of t h e roof.
12
13
14
15
10
1 . K n o b f o r s w i t c h i n g o n t h e radio ( b y p r e s s i n g ) a n d a d j u s t i n g t h e v o l u m e ( b y r o t a t i n g ) ; 2. C y l i n d r i c a l b u t t o n f o r a d j u s t i n g t h e t o n e (pressure a n d r o t a t i o n ) a n d a d j u s t i n g t h e balance b e t w e e n t h e t w o loudspeakers ( b y pressure, e x t r a c t i o n a n d r o t a t i o n ) ; 3. B u t t o n f o r s e l e c t i n g t h e w a v e b a n d s ( F M 1 - F M 2 - M W - L W ) ; 4. B u t t o n f o r a u t o m a t i c or m a n u a l search ( s i n g l e press or p r o l o n g e d pressure) in order of i n c r e a s i n g f r e q u e n c y of t r a n s m i t t i n g stations; 5. B u t t o n f o r a u t o m a t i c or m a n u a l search ( s i n g l e press o n l y or p r o l o n g e d pressure) in d e c r e a s i n g o r d e r of t r a n s m i t t i n g s t a t i o n s ; 6. B u t t o n f o r preselection of t r a n s m i t t i n g s t a t i o n n 1 - s e l e c t i o n o f p r i o r i t y of i n d i c a t i o n of t i m e / r a d i o f r e q u e n c y o n the d i s p l a y ; 7. B u t t o n f o r preselecting t r a n s m i t t i n g s t a t i o n n 2 - a d j u s t m e n t i n decreasing o r d e r o f t i m e ; 8. B u t t o n f o r preselecing t r a n s m i t t i n g n" 3 - a d j u s t m e n t of t i m e in increasing order; 9. B u t t o n f o r preselecting t r a n s m i t t i n g s t a t i o n n 4 - increasing a d j u s t m e n t of m i n u t e s ; 10. B u t t o n f o r preselecting t r a n s m i t t i n g s t a t i o n n 5 - a d j u s t m e n t in d e c r e a s i n g o r d e r of m i n u t e s ; 1 1 . B u t t o n f o r s w i t c h i n g b e t w e e n d i s p l a y of r a d i o f r e q u e n c y / t i m e ( s i n g l e press o n l y ) a n d for s e l e c t i n g t i m e a d j u s t m e n t ( p r o l o n g e d pressure); 12. Point f o r pressing a n d o p e n i n g t h e f l a p c o v e r i n g t h e slot for i n s e r t i n g cassettes; 13. B u t t o n f o r fast r e w i n d o f t h e cassette t a p e a n d f o r e x p e l l i n g t h e cassette f r o m its s e a t i n g (press s i multaneously w i t h button 14); 14. B u t t o n f o r fast f o r w a r d f e e d of t h e cassette t a p e a n d for e x p e l l i n g t h e cassette f r o m its s e a t i n g (press simultaneously w i t h button 13); 15. Display o f w a v e b a n d / f r e q u e n c y of s t a t i o n b e i n g listened t o / stereo t r a n s m i s s i o n / search s e n s i tivity / time.
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R e a r v i e w o f radio
Connection
Connection
R i g h t loudspeaker R i g h t loudspeaker Left loudspeaker Left loudspeaker
DISPLAY
INFORMATION
U M (*)
P4A049L02
A . Distinctive letter o f w a v e b a n d - a c t i v a t i o n o f m a n ual search o f t r a n s m i t t i n g s t a t i o n s - s e l e c t i o n o f p r i ority of indication of time / radio frequency B. Horizontal lines i n d i c a t i n g M F b a n d s C. N u m b e r of preselected t r a n s m i t t i n g station or f o r selecting priority o f indication o f t i m e / radio frequency D. N u m b e r s i n d i c a t i n g t h e t u n i n g f r e q u e n c y E. D e c i m a l p o i n t o f f r e q u e n c y F. S y m b o l for l i s t e n i n g o f t r a n s m i s s i o n in stereo G. S y m b o l of s e n s i t i v i t y o f s e a r c h f o r t r a n s m i t t i n g stations
Copyright Fiat Auto
U U
Frequency m o d u l a t i o n 2
(*) = B u t t o n
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A F. H o u r s
B H. M i n u t e s
G. Flashing c o l o n
ADJUSTING DIGITAL CLOCK To a d j u s t t h e clock, carry o u t the f o l l o w i n g o p e r a t i o n s in t h e order stated: - Press t h e E b u t t o n f o r m o r e t h a n t w o s e c o n d s u n t i l t h e letter M a c c o m p a n i e d b y t h e n u m b e r 1 or 2 is d i s p l a y e d o n the left o f t h e display. - To a d j u s t t h e hours ( F ) press t h e b u t t o n s A a n d B ( w h i c h increase or decrease t h e n u m b e r ) . - To a d j u s t t h e m i n u t e s ( H ) press t h e b u t t o n s C a n d D ( w h i c h increase or decrease t h e n u m b e r ) . - Press t h e E b u t t o n a g a i n t o m e m o r i z e t h e n e w t i m e , w h i c h w i l l also be v i s i b l e w h e n t h e car is s t o p p e d w i t h t h e radio off, w i t h t h e c o l o n ( G ) f l a s h i n g . TECHNICAL CHARACTERISTICS REMOVING-REFITTING RADIO No. of o u t p u t c h a n n e l s Musical o u t p u t power Nominal output power Load i m p e d a n c e 2 A b o u t 8 W peak (per c h a n n e l ) at 4 W R M S 4 Ohm Fit t o o l 1 8 6 0 8 9 7 0 0 0 as s h o w n in t h e f i g u r e , t h e n lift t h e f l a p f o r i n s e r t i n g t h e cassette a n d w i t h d r a w t h e radio f r o m its s e a t i n g . After d i s c o n n e c t i n g t h e electrical c o n n e c t i o n s f r o m t h e rear, r e m o v e t h e radio f r o m t h e car.
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. Radio equipment
55.
R A D I O C A S S E T T E M O D E L A D 182 H
T h e v e h i c l e c a n be e q u i p p e d , o n request, w i t h a radio system w h i c h is c o m p o s e d o f t h e f o l l o w i n g m a i n components: - radio cassette player ( w h i c h c a n n o t b e r e m o v e d ) m o d e l A D 1 8 2 H w h i c h is f i t t e d in place o f t h e p r e v i ous one in t h e centre o f t h e d a s h b o a r d a n d t h e personalized F I A T f r o n t s e c t i o n is c o m p l e t e l y i n t e g r a t ed w i t h t h e c o n t o u r s o f t h e d a s h b o a r d ; - six speakers, t w o of w h i c h are p o s i t i o n e d at t h e side in t h e u p p e r part of t h e d a s h b o a r d , t w o b e i n g p o sitioned in t h e same place as f o r the p r e v i o u s system in t h e f r o n t d o o r panels a n d t h e last t w o are p o s i t i o n e d at t h e sides of t h e rear parcel shelf; - aerial l o c a t e d at t h e c e n t r e f r o n t s e c t i o n o f t h e roof. - cable f o r c o n n e c t i o n w i t h c o m p a c t disc player ( C D ) (if f i t t e d ) ; T h e radio cassette player m o d e l A D 1 8 2 H is e q u i p p e d w i t h t h e f o l l o w i n g f u n c t i o n s : RADIO S E C T I O N - PLL tuning w i t h F M / M W / L W frequency bands - R D S ( R a d i o Data S y s t e m ) w i t h T P (Traffic Program) - EON f u n c t i o n s - Automatic / manual station tuning - M a n u a l p r o g r a m m i n g o f 6 stations in t h e F M b a n d , 6 in t h e R D S 1 b a n d , 6 in t h e R D S2 b a n d , 6 in t h e M W b a n d a n d 6 in t h e LW band. - Automatic programming (AUTOSTORE f u n c t i o n ) of 6 stations in t h e R D S 2 b a n d - Automatic DX function (Distant: maximum sensitivity in searching f o r radio s t a t i o n s ) - Scan f u n c t i o n ( s c a n n i n g f o r s t a t i o n s p r o grammed). C O M P A C T D I S C S E C T I O N (if t h e C D player is f i t t e d ) - Disc s e l e c t i o n ( D i s c N o . ) - Track s e l e c t i o n ( f o w a r d s / b a c k w a r d s ) - Repeat F u n c t i o n ( r e p e t i t i o n o f last t r a c k or r e p e t i t i o n of C D ) - Scan F u n c t i o n ( s c a n n i n g tracks o n C o m pact D i s c ) - Random Function (random reproduction of t r a c k s ) . AUDIO SECTION Loudness Function Mute Function Pause F u n c t i o n Separate a d j u s t m e n t o f l o w / h i g h R i g h t / left a n d f r o n t / rear c h a n n e l b a l a n c ing - R a d i o o n / off l o g i c s e l e c t i o n - P r e - s e t t i n g v o l u m e level f o r T P f u n c t i o n . CLOCK SECTION - A d j u s t m e n t of h o u r s / m i n u t e s - C l o c k / Radio, Cassette or C o m p a c t Disc f u n c t i o n s priority s e l e c t i o n .
CASSETTE SECTION - Autoreverse - Fast f o r w a r d a n d r e w i n d i n g o f t h e t a p e - A u t o m a t i c r e c o g n i z i n g a n d e q u a l i z i n g of "Cr / M e " tapes w i t h o p t i m u m s o u n d r e production - M u s i c Search System f u n c t i o n ( a u t o m a t i c search f o r p r e v i o u s / n e x t t r a c k ) - Listening t o radio w h i l s t fast f o r w a r d i n g or r e w i n d i n g t h e tape. - DOLBY B (noise reduction circuit) (*)
(*)
circuit is manufactured under licence by the Dolby and the double D symbol are their registered trade
Laboratories marks.
Li-
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D e s c r i p t i o n of t h e c o n t r o l s
22 2 3 2 4
18 17 16 15
1. Switch for programming station N. 1 / selecting CD N. 1 / adjustment in decreasing order of clock hours / entering of 1st anti-theft device code figure 2. Switch for programming station N. 2 / selecting CD N. 2 / adjustment in decreasing order of clock hours / entering of 2nd anti-theft device code figure 3. Switch for programming station N. 3 / selecting CD N. 3 / adjustment in decreasing order of clock minutes / entering 3rd anti-theft device code figure 4. Switch for programming station N. 4 / selecting CD N. 4 / adjustment in increasing order of clock minutes / entering 4th anti-theft device code figure 5. Switch for programming station N. 5 / selecting CD N. 5 / selecting hour priority on display 6. Switch for programming station N. 6 / selecting CD N. 6 / selecting radio, cassette, CD function priority on display 7. Switch for automatic or manual tuning in decreasing frequency order, rewinding cassette tape, selecting previous CD track 8. Switch for selecting radio, cassette, CD operating modes 9. Switch for automatic or manual tuning in increasing frequency order, winding on cassette tape, selecting next CD track 10. Switch for selecting the following functions: traffic news (TP), CD track repetition, anti-theft mode with security code 11. Switch for selecting the following functions: medium/long wave bands, manual search for transmitter, CD track repetition 12. Switch for selecting the following functions: FM band, manual search for transmitter, random CD track repetition
4A212L
13 12 11 10
13. Switch for selecting the following functions: FM band for RDS stations only (Radio Data System), automatic programming of stations in RDS2 band 14. Display 15. Switch for changing display of radio frequency, cassette player, CD, time (impluse only) and selecting time adjustment (prolonged pressing) 16. Switch for selecting listening for 10 seconds to each of the stations programmed, automatic search for previous or next cassette track, listening for 10 seconds to various CD tracks 17. Dolby 6 function selection switch (elimination of hissing) 18 Loudness selection switch 19 Switch for adjusting functions selected with switch 20 in decreasing order 20. Audio functions selection switch: volume, low/high tones, right/left balance, front/rear and pre-setting volume level for TP (traffic information) 21 Switch for adjusting functions selected with switch 20 in increasing order 22 Switch for automatically opening cassette housing and ejecting the tape 23 Radio activating/deactivating switch 24 Reverse function selection switch 25 Pressure point for manually closing cassette housing flap 26. Switch for selecting the following functions: Mute, radio on logic
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D E S C R I P T I O N O F T H E O P E R A T I O N O F T H E R A D I O M O D E L A D 182 H RADIO ON Press t h e O N s w i t c h ( 2 3 ) o n c e : t h e e q u i p m e n t s h o u l d c o m e o n . If t h e radio is o n w h i l s t t h e e n g i n e is off, t h e n it g o e s o f f a u t o m a t i c a l l y after a r o u n d 2 0 m i n u t e s . S w i t c h i n g on / o f f w i t h e n g i n e s t a r t e d / stopped T h e radio possesses a l o g i c w h e r e b y if a c t i v a t e d it a l l o w s t h e radio t o be s w i t c h e d o n / s w i t c h e d off s i m u l t a n e o u s l y t o t h e e n g i n e b e i n g started u p / s w i t c h e d off. If t h e l o g i c is a c t i v a t e d : w h e n t h e e n g i n e is started u p / s w i t c h e d o f f , t h e radio is a u t o m a t i c a l l y s w i t c h e d o n / off. If t h e l o g i c is n o t a c t i v a t e d : t h e r a d i o c a n be s w i t c h e d o n / o f f irrespective of w h e t h e r t h e e n g i n e is s w i t c h e d o n / off. In order t o activate this logic, p r o c e e d as f o l lows: - keep t h e " M U T E " b u t t o n ( 2 6 ) pressed w i t h t h e r a d i o off u n t i l t h e w o r d s " I G N O N " a p pear o n t h e display, t h e n s w i t c h o n t h e radio w i t h the " O N " switch ( 2 3 ) . The logic is only activated radio is switched on with switch (23). when the the "ON"
T o d e a c t i v a t e this l o g i c , p r o c e e d as f o l l o w s : - keep t h e " M U T E " b u t t o n ( 2 6 ) pressed w i t h t h e r a d i o off u n t i l t h e w o r d s " I G N O F F " a p pear o n t h e display. Irrespective of w h e t h e r or n o t t h e l o g i c is a c t i v a t e d , it is possible t o s w i t c h t h e r a d i o o n / off a n d t o activate / deactivate t h e " M U T T E " f u n c t i o n , w h i c h c a n be selected w i t h t h e rad i o o n as i n d i c a t e d in t h e p a r a g r a p h " M u t e F u n c t i o n " , w i t h o u t this logic being activated or d e a c t i v a t e d . S E L E C T I N G RADIO / C A S S E T T E / COMPACT DISC FUNCTIONS / Press t h e " M O D E " s w i t c h ( 8 ) r e p e a t e d l y t o select t h e f o l l o w i n g f u n c t i o n s c y c l i c a l l y : - R A D I O : the w o r d " R A D I O " appears on the display momentarily; - C A S S E T T E (if p r e v i o u s l y s w i t c h e d o n ) : t h e w o r d " T A P E " appears o n t h e d i s p l a y m o mentarily; - C O M P A C T D I S C (if a C o m p a c t D i s c player is f i t t e d ) : t h e w o r d " C D " a p p e a r s o n t h e display momentarily.
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NOTE The functions on previously, which cannot be selected CD where it is not fitted) (for example cassette when it has not been are automatically excluded. switched PAUSE FUNCTION If w h e n l i s t e n i n g t o a cassette or a c o m p a c t disc another f u n c t i o n is selected ( f o r e x a m p l e t h e r a d i o ) , t h e r e p r o d u c t i o n is interrupted a n d w h e n r e t u r n i n g t o t h e " C a s s e t t e " or " C o m p a c t D i s c " m o d e it starts a g a i n f r o m t h e p o i n t w h e r e it w a s i n t e r r u p t e d . If w h e n listening t o t h e radio a n o t h e r f u n c t i o n is selected, o n r e t u r n i n g t o t h e " R a d i o " m o d e , t h e last s t a t i o n selected is t u n e d into. ADJUSTING THE VOLUME
- Press t h e " A U D I O + " s w i t c h ( 2 1 ) t o i n crease t h e v o l u m e a n d t h e " A U D I O - " s w i t c h ( 1 9 ) t o decrease it; - b y pressing t h e s w i t c h briefly it is p o s s i b l e t o c h a n g e g r a d u a l l y in steps; - b y pressing it for longer, it is possible t o change quickly and the w o r d " V O L " a p pears o n t h e d i s p l a y w i t h t h e v o l u m e level;
- Press t h e " A U D I O " s w i t c h ( 2 0 ) briefly a n d repeatedly u n t i l t h e w o r d s " B A S S " or " T R E B " appear o n t h e d i s p l a y ( a d j u s t m e n t of Bass or T r e b l e ) - press t h e " A U D I O + " s w i t c h ( 2 1 ) t o e m phasize t h e bass or treble or t h e " A U D I O - " s w i t c h ( 1 9 ) t o decrease t h e m ;
NOTE
are
- b y pressing t h e s w i t c h briefly it is p o s s i b l e t o c h a n g e g r a d u a l l y in steps; - b y pressing it for l o n g e r it is p o s s i b l e t o change quickly; - b y pressing t h e " A U D I O + " a n d " A U D I O - " s w i t c h e s at t h e s a m e t i m e , t h e a d j u s t m e n t in t h e central p o s i t i o n is selected a n d the zeroed bass / treble level appears o n t h e display.
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55.
ADJUSTING T H E BALANCE right a n d left s p e a k e r s ) (between
Press t h e " A U D I O " s w i t c h ( 2 0 ) b r i e f l y a n d repeatedly until t h e w o r d " B A L " appears o n t h e d i s p l a y (balance a d j u s t m e n t selection);
press t h e " A U D I O + " s w i t c h ( 2 1 ) t o e m phasize t h e s o u n d c o m i n g f r o m t h e r i g h t speakers or t h e " A U D I O - " s w i t c h ( 1 9 ) t o e m p h a s i z e t h e s o u n d c o m i n g f r o m t h e left speakers a n d t h e balance levels a p p e a r o n t h e d i s p l a y ( L = left, R = r i g h t ) b y pressing t h e s w i t c h e s b r i e f l y it is p o s s i ble t o c h a n g e g r a d u a l l y in s t e p s ; b y pressing t h e m f o r longer, it is p o s s i b l e t o change quickly;
NOTE
b y pressing t h e i " A U D I O + " a n d " A U D I O - " s w i t c h e s at t h e same t i m e , t h e a d j u s t m e n t is selected in a central p o s i t i o n a n d t h e zeroed b a l a n c e level a p p e a r s o n t h e display.
C O "7
n u
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55.
- press t h e " A U D I O + " s w i t c h ( 2 1 ) t o e m phasize t h e s o u n d c o m i n g f r o m t h e rear speakers or t h e " A U D I O - " s w i t c h ( 1 9 ) t o emphasize t h e s o u n d c o m i n g f r o m t h e f r o n t speakers a n d t h e Fader levels w i l l a p p e a r o n t h e d i s p l a y (F = f r o n t ; R = rear); - b y pressing t h e s w i t c h e s briefly, it is p o s s i ble t o c h a n g e g r a d u a l l y in steps; / >
^
r
C" I
nn nu
i i
- b y pressing t h e m f o r longer, it is p o s s i b l e t o change quickly; NOTE The "FAD F" and "FAD Ft" values which can be set are between 0 and 15.
r? > \
ip
- by pressing t h e " A U D I O + " a n d " A U D I O - " s w i t c h e s at the s a m e t i m e t h e a d j u s t m e n t in t h e central p o s i t i o n is selected a n d t h e display s h o w s t h e zeroed Fader level (see d i a g r a m at t h e f o o t o f t h e previous p a g e ) .
LOUDNESS FUNCTION
Press t h e " L O U D " s w i t c h ( 1 8 ) t o a c t i v a t e / d e - a c t i v a t e this f u n c t i o n w h i c h m a k e s it possible t o e m p h a s i z e t h e bass w h i l s t list e n i n g . If t h e f u n c t i o n is a c t i v a t e d , t h e L E D under t h e s w i t c h c o m e s o n a n d t h e w o r d " L O U D " appears o n t h e display.
MUTE FUNCTION
Press t h e " M U T E " s w i t h ( 2 6 ) t o a c t i v a t e / deactivate t h i s f u n c t i o n . If t h e f u n c t i o n is a c t i v a t e d , t h e radio d o e s n o t send a n y s i g nal t o t h e speakers a n d t h e w o r d " M U T E " appears o n t h e d i s p l a y .
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RADIO FUNCTION
A
NOTE
The reception conditions vary constantly by the presence of mountains, buildings away. When the "RADIO" ceived. function is activated,
when driving. The reception can be interfered or bridges, particularly when the transmitter
with is far
listened
to before
switching
off is de-
selecting the function A s s o o n as t h e radio is s w i t c h e d o n , t h e r a d i o is heard. T o select t h e Radio f u n c t i o n w h i l s t list e n i n g t o a cassette or a c o m p a c t d i s c , press t h e " M O D E " s w i t c h ( 8 ) repeatedly u n t i l t h e w o r d " R A D I O " appears o n t h e d i s p l a y . Selecting the band Press t h e " F M " s w i t c h ( 1 2 ) or t h e " A M " s w i t c h ( 1 1 ) briefly t o select t h e desired r e c e p t i o n b a n d ( t h e L E D under t h e s w i t c h selected s h o u l d come on). Each t i m e t h e " A M " s w i t c h ( 1 1 ) is pressed, t h e " M W " or " L W " s t a t i o n s are s e l e c t e d . If y o u w i s h t o select stations w h i c h are t r a n s m i t t e d o n t h e R D S ( R a d i o Data S y s t e m ) , see t h e d e s c r i p t i o n overleaf ( R D S F U N C T I O N ) .
Manual search tuning This makes it possible t o search m a n u a l l y f o r s t a t i o n s o n t h e pre-se - Select t h e b a n d : " F M " , " M W " or " L W " .
' P4A507L02
- keep t h e " F M " s w i t c h ( 1 2 ) pressed (if t h e F M b a n d is s e l e c t e d ) or t h e " A M " s w i t c h ( 1 1 ) (if t h e M W or L W band is s e l e c t e d ) u n t i l t h e w o r d " M A N " appears o n t h e display. - press t h e " M O D E + " s w i t c h ( 9 ) or t h e " M O D E - " s w i t c h ( 7 ) t o select t h e desired s t a t i o n ; - b y pressing t h e s w i t c h briefly it is possible t o c h a n g e f r e q u e n c y g r a d u a l l y in steps; - b y pressing it f o r l o n g e r it is p o s s i b l e t o c h a n g e f r e q u e n c y q u i c k l y . The manual search function is not activated for bands RDS1 and RDS2.
Y o u return t o t h e a u t o m a t i c t u n i n g m o d e a u t o m a t i cally ( t h e w o r d " M A N " disappers f r o m t h e d i s p l a y ) after 6 0 s e c o n d s or if o n e of t h e s t a t i o n p r o g r a m m i n g s w i t c h e s n u m b e r e d f r o m " 1 " t o " 6 " is pressed briefly. In t h e latter case t h e station p r e v i o u s l y p r o g r a m m e d w i t h this s w i t c h is t u n e d i n t o . A u t o m a t i c s e a r c h tuning T h i s makes it p o s s i b l e t o a u t o m a t i c a l l y search for s t a t i o n s in t h e pre-selected b a n d . - Select t h e b a n d : " R D S 1 " , " R D S 2 " , " F M " , " M W " or " L W " ; - press t h e " M O D E + " s w i t c h ( 9 ) or t h e " M O D E -" switch ( 7 ) ; T h e s e n s i t i v i t y o f t h e search increases s t a r t i n g f r o m t h e 2 n d stage t h r o u g h t h e entire f r e q u e n c y range ( t h e w o r d " D X " appears o n t h e d i s p l a y ) .
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P r o g r a m m i n g t h e last s t a t i o n l i s t e n e d t o The last s t a t i o n listened t o for each r e c e p t i o n b a n d is a u t o m a t i c a l l y k e p t in t h e m e m o r y a n d t h e n t u n e d into t h e m o m e n t t h e radio is s w i t c h e d o n or t h e r e c e p t i o n b a n d is c h a n g e d . R D S F U N C T I O N (Radio Data S y s t e m ) If y o u w i s h t o select s t a t i o n s w h i c h t r a n s m i t o n R D S ( R a d i o Data S y s t e m ) , press t h e " R D S " s w i t c h ( 1 3 ) briefly ( t h e L E D under the s w i t c h w i l l c o m e o n ) . Each t i m e t h e s w i t c h is pressed, t h e s t a t i o n s o n " R D S 1 " ( d i s p l a y s h o w s " R D S - " ) or " R D S 2 " ( d i s p l a y s h o w s " R D S = " ) are s e l e c t e d . The R D S system m a k e s it possible, w i t h t h e transmitters e n a b l e d , t o a u t o m a t i c a l l y t u n e into t h e o p t i m u m f r e q u e n c y f o r t h e s t a t i o n y o u have selected: y o u c a n t h e r e f o r e c o n t i n ue t o listen t o t h e s t a t i o n w i t h o u t h a v i n g t o alter t h e f r e q u e n c y w h e n c h a n g i n g areas. Naturally it must be p o s s i b l e t o receive t h e station b e i n g listened t o in t h e area o n e is passing t h r o u g h . The n a m e of t h e s t a t i o n t r a n s m i t t i n g o n R D S appears o n t h e display.
in R D S 2
band
It is p o s s i b l e t o m e m o r i z e 6 s t a t i o n s in t h e R D S 2 b a n d . If t h e R D S m o d e is set ( R D S 1 or R D S 2 ) , keep t h e " A S " s w i t c h ( 1 3 ) pressed until t h e s o u n d s w i t c h e s off. The stations transmitting programmes on R D S w i t h t h e m o s t p o w e r f u l s i g n a l at t h a t m o m e n t w i l l be a u t o m a t i c a l l y p r o g r a m m e d at buttons ( 1 ) , ( 2 ) , ( 3 ) , ( 4 ) , (5) and ( 6 ) . A m a x i m u m of 2 passages t h r o u g h t h e entire f r e q u e n c y range are m a d e w i t h i n c r e a s i n g search sensitivity. D u r i n g t h e search t h e w o r d " A S T " appears o n t h e d i s p l a y . W h e n t h e p r o g r a m m i n g is c o m p l e t e , t h e radio t u n e s in a u t o m a t i c a l l y t o the f r e q u e n c y p r o g r a m m e d f o r b u t t o n ( 1 ) .
The activating of the Autostore takes place if the RDS1 or RDS2 band is set.
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Manual station programming T h e s t a t i o n t o w h i c h y o u are l i s t e n i n g c a n be p r o g r a m m e d in t h e range s e l e c t e d u s i n g b u t tons ( 1 ) , ( 2 ) , ( 3 ) , ( 4 ) , (5) and ( 6 ) . Keep t h e b u t t o n pressed w i t h w h i c h y o u wish to programme the station until transmitter is a u d i b l e a g a i n . T h e L E D u n d e r t h e switch will come on and t h e number corres p o n d i n g t o the switch w i l l appear o n t h e display. Even if t h e s u p p l y v o l t a g e is i n t e r r u p t e d , t h e m e m o r i e s remin active.
P4A509L01
Listening to stations programmed Proceed as f o l l o w s : - Select t h e b a n d desired u s i n g s w i t c h s ( 1 1 ) , ( 1 2 ) a n d ( 1 3 ) (see page 5 0 / 7 ) ; - pressone of t h e six s t a t i o n p r o g r a m m i n g b u t t o n s briefly; T h e L E D under t h e s w i t c h w i l l c o m e o n a n d t h e n u m b e r c o r r e s p o n d i n g t o t h a t s w i t c h w i l l a p p e a r o n t h e display. For b a n d s RDS1 a n d R D S 2 , if t h e r e c e p t i o n is n o t g o o e , a n alternative f r e q u e n c y is a u t o m a t i c a l l y searched f o r ( t h e w o r d " S R C " w i l l appear o n t h e d i s p l a y d u r i n g t h e s e a r c h ) . T P Function (Traffic Programme) Several stations b e l o n g i n g t o t h e R D S 1 , R D S 2 b a n d s also t r a n s m i t i n f o r m a t i o n o n t r a f f i c c o n d i t i o n s . W i t h t h e T P f u n c t i o n (Traffic P r o g r a m m e ) it is possible: a) t o search o n l y f o r R D S s t a t i o n s w h i c h t r a n s m i t traffic i n f o r m a t i o n ; b ) t o receive traffic i n f o r m a t i o n even if t h e cassette player or C D player f u n c t i o n is s e l e c t e d ; c ) t o receive traffic i n f o r m a t i o n at a m i n i m u m pre-set v o l u m e even w i t h t h e radio v o l u m e at z e r o .
NOTE
There follows instructions for carrying out each of the operations illustrated for points a), b) and c) described previously.
Point a ) - Select a n R D S 1 , R D S 2 b a n d b y p r e s s i n g the " R D S " switch ( 1 3 ) briefly (the L E D u n der t h e s w i t c h w i l l c o m e o n ) ; - press t h e " T P " s w i t c h ( 1 0 ) b r i e f l y s o t h a t t h e w o r d " T P " appears o n t h e d i s p l a y ( t h e LED u n d e r t h e s w i t c h w i l l c o m e o n ) . If t h e t r a n s m i t t e r is n o t e n a b l e d t o s u p p l y traffic i n f o r m a t i o n , t h e n t h e radio w i l l a u t o matically t u n e into the closest o n e able t o t r a n s m i t it.
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If y o u w i s h t o search f o r other s t a t i o n s , press t h e " M O D E - " ( 7 ) or " M O D E + " ( 9 ) t u n i n g switches. T o p r o g r a m m e transmitters w i t h t h e " T P " f u n c t i o n a c t i v a t e d , carry o u t t h e p r o g r a m m i n g o p e r a t i o n s (see paragraph o n " P r o gramming a station"). A s an alternative t o t h e m a n u a l p r o g r a m m i n g , b y k e e p i n g t h e " A S " s w i t c h ( 1 3 ) pressed u n til t h e a u d i o is s w i t c h e d off, t h e a u t o m a t i c p r o g r a m m i n g w i l l b e carried o u t (see p a r a graph on "Automatic programming on RDS2 band - Autostore")
Point b ) If y o u w i s h t o receive traffic i n f o r m a t i o n , b e f o r e p u t t i n g in t h e t a p e or t h e c o m p a c t disc, t u n e in t o an RDS T P transmitter. If, w h i l s t l i s t e n i n g t o t h e t a p e or c o m p a c t disc, t h e latter t r a n s m i t s t r a f f i c i n f o r m a t i o n , t h e r e p r o d u c t i o n o f t h e t a p e or t h e c o m p a c t disc w i l l t e m p o r a r i l y be h a l t e d a n d r e s u m e d a u t o m a t i cally w h e n t h e message is over. Point c ) Even w h e n n o t listening t o t h e radio it is p o s s i b l e t o receive traffic i n f o r m a t i o n . After t u n i n g in t o an RDS T P transmitter a n d p l a c i n g t h e v o l u m e level at zero, if traffic i n f o r m a t i o n is t r a n s m i t t e d it w i l l be heard at a pre-set m i n i m u m v o l u m e .
stations
that, even
if the TP functionis
activated,
do not
P r e - s e t t i n g v o l u m e level f o r T P f u n c t i o n (Traffic Programme) - Select t h e d e s i r e d v o l u m e level using t h e " A U D I O -" ( 1 9 ) and " A U D I O + " ( 2 1 ) switches; - keep t h e " A U D I O " s w i t c h ( 2 0 ) pressed u n t i l t h e w o r d s " T A V O L X X " appear o n t h e d i s p l a y , w h e r e " X X " is t h e p r e - s e t v o l u m e level; NOTE 777e volume level which can be pre-set varies from 5 to 31 (max volume).
Tfl
I'OL DG s
TP RDS =
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Electrical equipment
Radio equipment
55.
E O N F u n c t i o n ( E n h a n c e d Other N e t w o r k ) In certain c o u n t r i e s c i r c u i t s w h i c h cover several t r a n s m i t t e r s b r o a d c a s t i n g t r a f f i c i n f o r m a t i o n are grouped together. In these cases listening t o t h e R D S T P s t a t i o n p r o g r a m m e w i l l be t e m p o r a r i l y i n t e r r u p t e d t o receive traffic i n f o r m a t i o n each t i m e it is t r a n s m i t t e d b y o n e o f t h e t r a n s m i t t e r s in t h e same c i r c u i t . In order t o exclude t h i s f u n c t i o n ( E O N ) , briefly press t h e " T P " s w i t c h ( 1 0 ) ( t h e L E D u n d e r t h e s w i t c h will go o u t ) .
Scanning programmed stations ( S C A N Function) W i t h t h i s f u n c t i o n it is possible t o c y c l i c a l l y t u n e i n , f o r 1 0 s e c o n d s at a t i m e , t o all t h e s t a t i o n s w h i c h can be received w h i c h have been p r e v i o u s l y p r o g r a m m e d o n t h i s b a n d . D u r i n g s c a n n i n g , w h e n a station is t u n e d i n t o , t h e L E D under t h e s w i t c h w h e r e it is p r o g r a m m e d c o m e s o n a n d t h e n u m b e r o f t h e s w i t c h appears o n t h e d i s p l a y . Stations w h e r e t h e s i g n a l is t o o w e a k c a n n o t b e h e a r d .
In order t o select t h e S C A N f u n c t i o n , p r o ceed as described b e l o w : - select t h e b a n d d e s i r e d ; - press t h e " S C A N " s w i t c h ( 1 6 ) ( t h e L E D under t h e switch comes o n ) .
It is p o s s i b l e t o c h a n g e t h e d i r e c t i o n o f t h e search several times b y pressing t h e " M O D E + " ( 9 ) or " M O D E - " ( 7 ) s w i t c h e s . In order t o interrupt t h e s c a n n i n g , press t h e " S C A N " s w i t c h ( 1 6 ) a g a i n : t h e L E D under the s w i t c h w i l l g o o u t a n d t h e s t a t i o n present at t h a t m o m e n t w i l l b e heard. Stereo transmitters W h e n t h e station is t r a n s m i t t i n g t h e p r o g r a m m e in s t e r e o , the s y m b o l s h o w n b y t h e a r r o w in t h e d i a g r a m b e l o w w i l l appear o n t h e display. If t h e signal arriving is w e a k , t h e r e p r o d u c t i o n w i l l b e a u t o m a t i c a l l y s w i t c h e d f r o m Stereo t o M o n o .
4A2Z1L
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55.
CASSETTE PLAYER T h e radio is e q u i p p e d w i t h a cassette player w h i c h has a n " A u t o r e v e r s e " reverse f u n c t i o n w h i c h m a k e s it possible t o listen t o b o t h sides of a t a p e w i t h o u t h a v i n g t o r e m o v e it a n d t u r n it over. A u t o m a t i c equalizing s e l e c t i o n D e p e n d i n g o n t h e t y p e of t a p e used t h e c o r rect e q u a l i z i n g o f t h e cassette player is carried o u t a u t o m a t i c a l l y . If C H R O M E ( C r 0 2 ) or M E T A L tapes are used, t h e w o r d " M e " appears o n t h e d i s p l a y . C a s s e t t e reproduction - A c t i v a t e t h e radio switch ( 2 3 ) ; b y pressing the O N
cassette
NOTE
For the correct operation of the automatic selection, only insert the cassette in the housing when the radio is working.
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- in order t o r e p r o d u c e a cassette a l r e a d y i n serted p r e v i o u s l y , w h i l s t l i s t e n i n g t o t h e rad i o or a c o m p a c t disc, press t h e " M O D E " s w i t c h ( 8 ) repeatedly u n t i l t h e w o r d " T A P E " appears o n t h e d i s p l a y ;
A t t h e e n d of t h e t a p e t h e side o f t h e cassette is c h a n g e d a u t o m a t i c a l l y ( A u t o r e v e r s e ) . T h e d i s p l a y s h o w s t h e s i d e o f t h e cassette b e i n g listened t o . The symbol s h o w n b y t h e right a r r o w illustrates t h e upper s i d e , w h i l s t t h e o n e s h o w n by t h e left a r r o w i n d i c a t e s t h e l o w e r s i d e . T o c h a n g e t h e side o f t h e cassette, b e f o r e t h e e n d o f t h e t a p e , press s w i t c h ( 2 4 ) ( R e v e r s e ) .
P4A513L03
4A2Z3L
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F a s t forward / rewind Press t h e " M O D E + " s w i t c h ( 9 ) or t h e " M O D E - " s w i t c h ( 7 ) t o fast f o w a r d or r e w i n d t h e cassette tape. T o s t o p t h e t a p e , press t h e s w i t c h used p r e v i o u s l y again.
S e a r c h i n g f o r p r e v i o u s / next t r a c k ( M u s i c Search System Function) Keep t h e " M S S " s w i t c h ( 1 6 ) pressed u n t i l t h e w o r d " M S S " appears o n t h e d i s p l a y , a t t h e same t i m e t h e LED u n d e r t h e s w i t c h w i l l c o m e o n . T h e t a p e w i l l fast f o r w a r d a u t o m a t ically until t h e next t r a c k is r e a c h e d , f r o m w h e r e it w i l l start t o play. W i t h t h e M S S f u n c t i o n a c t i v a t e d , press t h e " M O D E + " s w i t c h ( 9 ) t o listen t o t h e n e x t track o n t h e t a p e . Press t h e " M O D E - " s w i t c h ( 7 ) w h i l s t l i s teneing t o a track t o reproduce the track again f r o m t h e b e g i n n i n g ; b y pressing t h i s s w i t c h f u r t h e r it is possible t o listen t o t h e previous track.
P4A514L02
Press these s w i t c h e s several t i m e s t o g o f o r w a r d s / b a c k w a r d s several tracks e q u a l t o t h e n u m b e r of times t h e s w i t c h is pressed. To i n t e r r u p t t h e search, g e n t l y press t h e last s w i t c h selected ( M O D E + or M O D E - ) . I n these c i r c u m stances t h e r e p r o d u c t i o n w i l l b e a c t i v a t e d s t a r t i n g f r o m t h a t p o i n t . To exit f r o m t h e M S S m o d e , press t h e " M S S " s w i t c h ( 1 6 ) a g a i n : t h e L E D under t h e s w i t c h w i l l g o o u t and t h e w o r d " M S S " w i l l a p p e a r o n t h e d i s p l a y . The previous / next types of tapes: tapes tapes tapes tapes tapes track search function cannot be activated correctly with the following
recorded at l o w levels ( f o r e x a m p l e w i t h w e a k s o u n d a n d i m p e r f e c t r e c o r d i n g ) ; w i t h conversations; w i t h blank sections l a s t i n g less t h a n 3 s e c o n d s ; w i t h l o n g periods o f s i l e n c e in t h e r e c o r d i n g s ; w h i c h d o n o t have b l a n k sections o f t a p e ( f o r e x a m p l e live r e c o r d i n g s ) ;
- t a p e s w i t h a l o t of b a c k g r o u n d noise in t h e b l a n k s e c t i o n s .
4A224L
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Electrical equipment
Radio equipment
55.
Dolby B F u n c t i o n Press s w i t c h ( 1 7 ) t o activate / d e a c t i v a t e t h e D o l b y B function (device for l i m i t i n g t h e n o i s e p r o d u c e d u n d e r licence b y t h e " D o l b y Laboratories L i c e n s i n g C o r p o r a t i o n " ) ( * ) . W h e n t h e D o l b y f u n c t i o n is a c t i v a t e d , t h e LED under t h e s w i t c h c o m e s o n a n d t h e a p p r o p r i a t e s y m b o l (illustrated in t h e d i a g r a m , b o t t o m left) appears o n t h e d i s p l a y . (*) Dolby and the symbol (two Ds) are registered trade marks of the above company.
Ejecting the c a s s e t t e - Press s w i t c h ( 2 2 ) briefly t o o p e n t h e c a s sette h o u s i n g protective f l a p ; - press s w i t c h ( 2 2 ) briefly a s e c o n d t i m e t o eject t h e cassette.
NOTE
The same result is achieved ing the switch (22) pressed cassette is ejected.
by keepuntil the
- A f t e r t h e tape is ejected t h e w o r d " T A P E " appears o n t h e d i s p l a y a n d t h e r a d i o starts t o w o r k , t u n i n g in t o t h e last s t a t i o n listened to. NOTE The cassette cannot the radio off. be ejected with
Never expose cassettes to heat or to direct sunlight, but a/ways store them properly after use. It is advisable to use good quality cassettes, no longer than C-90 in order to always ensure optimum reproduction. Impurities on the head caused by tapes can result, in time, in decreased high tones during reproduction. It is therefore advisable to clean the heads periodically using a special non abrasive type head cleaning cassette.
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COMPACT DISC PLAYER FUNCTION Vehicles e q u i p p e d w i t h t h e A D 1 8 2 H radio are prepared for t h e f i t t i n g o f a C o m p a c t Disc ( C D ) player w i t h a m u l t i p o l a r cable w h i c h ends in t h e l u g g a g e c o m p a r t m e n t o n t h e left h a n d side. A kit is a v a i l a b l e f r o m F I A T Lineaccessori FIAT w h i c h includes a C o m p a c t Disc player, a n a d d i t i o n a l c o n n e c t i n g m u l t i p o l a r cable a n d a m o u n t i n g bracket f o r t h e f i t t i n g . The player has a special loader w h i c h c a n h o l d u p t o 6 c o m p a c t discs.
insert t h e c o m p a c t disc w i t h t h e label or t h e printed section facing the support. If the compact disc is placed rectly, it will not play. incor-
I n s e r t i n g loader in C o m p a c t D i s c p l a y e r
NOTE
The player cannot play 8 cm compact discs (unless special adaptors available from Hi-Fi shops are used).
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/T
<> 5
a
Eextracting player
loader
from
Compact
Disc
Extracting compact discs f r o m loader Extract t h e discs a n d s u p p o r t s f r o m t h e l o a d er. OPERATION OF THE CD PLAYER In order t o play c o m p a c t d i s c s already inserte d in t h e player p r e v i o u s l y , press t h e " M O D E " s w i t c h (8) repeatedly until t h e w o r d " C D " appears o n t h e d i s p l a y . If this f u n c t i o n is selected after i n s e r t i n g t h e loader, t h e w o r d s " C D C H E C K " a p p e a r i n stead w h i l s t t h e c o n n e c t i o n s a n d t h e c o n t e n t s of t h e loader are e x a m i n e d . Whilst listening t h e f o l l o w i n g appears o n t h e display: " C D " , t h e number of t h e track (for e x a m p l e " T 0 3 " = third t r a c k ) , t h e p l a y i n g time (for example "03:14" = 3 minutes a n d 1 4 s e c o n d s ) a n d t h e CD n u m b e r ( f o r e x a m ple " 4 " ) .
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55.
P o s s i b l e error m e s s a g e s If the loader has n o t been i n t r o d u c e d or has n o t been properly inserted in t h e C o m p a c t D i s c player, t h e n the w o r d " M A G A Z I N E " w i l l appear o n t h e display. If t h e loader does n o t c o n t a i n a n y c o m p a c t discs, t h e n t h e w o r d s " N O C D " appear o n t h e display. If a c o m p a c t disc is d a m a g e d or has n o t been i n t r o d u c e d p r o p e r l y i n t o t h e loader, t h e n t h e w o r d " S U R F A C E " appers o n t h e d i s p l a y " . If there is a break in t h e c o n n e c t i o n w i t h t h e c o m p a c t disc player t h e n t h e w o r d " C D " appears o n t h e d i s play. In t h e case of a m e c h a n i c a l fault w i t h t h e C D player t h e w o r d " M E C H A N I C " appears o n t h e display. If t h e c o m p a c t disc player overheats, t h e w o r d s " T O O H O T " appear o n t h e d i s p l a y .
above
occurs,
it is advisable
to switch
for a
Selecting disc Press o n e o f t h e f o l l o w i n g b u t t o n s ( 1 ) , ( 2 ) , ( 3 ) , ( 4 ) , ( 5 ) or ( 6 ) , t o select t h e c o m p a c t disc t o listen t o f r o m t h o s e stored in t h e l o a d er a n d t h e n u m b e r o f t h e c o m p a c t disc selected w i l l appear o n t h e display.
If there is a compact disc in the loader, the LED under the switch corresponding to the number of the compact disc will remain on, otherwise it will remain off.
Track search (forwards/backwards) - Press t h e " M O D E + " s w i t c h ( 9 ) t o play t h e n e x t track o n t h e C D t o w h i c h y o u are listening; - press t h e " M O D E - " s w i t c h ( 7 ) w h i l s t l i s t e n i n g t o a track t o play t h e t r a c k a g a i n f r o m t h e b e g i n n i n g ; b y pressing t w i c e in succession the previous track can be played; - press these s w i t c h e s several t i m e s t o g o f o r w a r d s / b a c k w a r d s as m a n y t r a c k s as t h e n u m b e r o f t i m e s t h e s w i t c h e s are pressed; NOTE / / the "RANDOM" function is activated, (see page 50/20), tracks from the compact disc to which you are listening are selected at random.
P4A614L01
4A22SL
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55.
on t h e c o m p a c t
disc
Press t h e S C A N " s w i t c h ( 1 6 ) ( t h e L E D under t h e s w i t c h w i l l c o m e o n ) t o listen t o t h e b e g i n n i n g o f all t h e tracks o n all t h e c o m p a c t discs in t h e loader s t a r t i n g f r o m t h e o n e s e lected p r e v i o u s l y for 1 0 s e c o n d s e a c h .
NOTE
It is possible to reverse the search rection several times by pressing "MODE +" (9) or "MODE -" switches.
dithe (7)
- press t h e " S C A N " s w i t c h ( 1 6 ) a g a i n t o i n terrupt t h e s c a n n i n g w h i l s t l i s t e n i n g t o a track: t h e L E D under t h e s w i t c h w i l l g o o u t and t h e c o m p a c t disc w i l l b e p l a y e d starting f r o m t h a t track.
T r a c k repetition ( R E P E A T F u n c t i o n ) Press t h e " T R K " s w i t c h ( 1 0 ) briefly ( t h e L E D under t h e s w i t c h w i l l c o m e o n ) t o listen t o t h e last track played several t i m e s . NOTE / / in the meantime another track is selected whilst remaining in the track repeat mode, it will be played again several times.
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55.
C D Repetition ( R E P E A T F u n c t i o n ) Press t h e " R P T " s w i t c h ( 1 1 ) ( t h e LED u n d e r t h e s w i t c h w i l l c o m e o n ) t o listen several t i m e s t o t h e last c o m p a c t disc p l a y e d . NOTE If in the meantime another compact disc is selected, whilst remaining in the CD repeat mode, it will be played again several times.
R a n d o m playing Function)
of t r a c k s
(RRANDOM
If t h e " R N D " s w i t c h ( 1 2 ) is pressed ( t h e L E D under the s w i t c h w i l l come o n ) a compact disc f r o m t h o s e present in t h e loader w i l l b e selected at r a n d o m a n d all t h e tracks o n t h i s c o m p a c t disc w i l l be played at r a n d o m .
Once all t h e tracks have been p l a y e d , a n o t h e r c o m p a c t disc is selected a n d s o o n . O n c e all t h e d i s c s have been heard, t h e r a n d o m p l a y i n g starts a g a i n in t h e same w a y . NOTE If the "CD Repeat" played at random. mode has been selected previously, all the tracks on the disc selected are
- press t h e " R N D " s w i t c h ( 1 2 ) a g a i n ( t h e L E D under t h e s w i t c h w i l l g o o u t ) t o exit f r o m t h e " R a n d o m playing" mode. Never expose discs to heat or direct sunlight, they must be stored in an appropriate container after use. Compact discs should be kept away from dust and you should never touch the surface of the discs with your fingers and care should be taken to ensure they are not scratched as this will affect the sound reproduction. If the surfaces of a disc is dirty, it should be cleaned with a soft cloth, working from the centre outwards. Do not insert damaged or distorted discs into the loader.
4A230L
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CLOCK FUNCTION This f u n c t i o n makes it p o s s i b l e t o d i s p l a y t h e h o u r s a n d m i n u t e s . A d o u b l e p o i n t , b e t w e e n t h e hours a n d t h e m i n u t e s , flashes o n c e a s e c o n d o n t h e d i s p l a y . W i t h t h e radio o n , if t h e c l o c k appears o n t h e display, w h i l s t t h e t i m e is b e i n g a d j u s t e d or a d i s p l a y m o d e is being s e l e c t e d , t h e L E D under t h e s w i t c h ( 1 5 ) c o m e s o n . W i t h t h e radio off, t h e c l o c k is a l w a y s d i s p l a y e d . Display m o d e s W h e n t h e r a d i o is o n , t h e r e are t w o d i s p l a y m o d e s w i t h t h e f o l l o w i n g features: a) M o d e l (M1) T h e c l o c k is d i s p l a y e d in place of the m a i n messages r e l a t i n g t o t h e Radio f u n c t i o n s ( r e c e p t i o n f r e q u e n c y ) , A u d i o cassette ( w o r d T A P E ) or C o m p a c t Disc ( n u m b e r of track a n d p l a y i n g t i m e ) . W h e n t h e radio is s w i t c h e d o n or a n y R a d i o , Cassette or C o m p a c t Disc f u n c t i o n is s e l e c t e d , t h e m e s sages f o r t h e f u n c t i o n selected are d i s p l a y e d for a r o u n d 1 0 s e c o n d s , after w h i c h t h e c l o c k reappears.
a) Mode 2 (M2) T h e messages relating t o t h e R a d i o , Cassette or C o m p a c t Disc f u n c t i o n s are d i s p l a y e d in place of t h e clock. W h e n t h e radio is s w i t c h e d o n , t h e m o d e p r e sent before t h e s w i t c h i n g o f f is a u t o m a t i c a l l y selected.
Selecting display modes - Keep t h e s w i t c h ( 1 5 ) pressed u n t i l t h e d o u b l e point on t h e display, b e t w e e n t h e hours and the minutes, stops flashing and t h e w o r d s " M 1 " or " M 2 " appear, d e p e n d ing o n the display m o d e selected;
- press s w i t c h ( 5 ) or ( 6 ) t o select d i s p l a y M o d e 1 or M o d e 2 , respectively ( t h e w o r d s " M 1 " or " M 2 " , respectively w i l l a p p e a r o n the display); - press s w i t c h ( 1 5 ) again briefly t o c o n f i r m the selection; the double point b e t w e e n the h o u r s a n d t h e m i n u t e s w i l l start t o flash again a n d t h e w o r d s " M 1 " or " M 2 " w i l l d i s appear.
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Setting the exact time - Keep t h e s w i t c h ( 1 5 ) pressed u n t i l t h e double point on the display, between t h e hours a n d t h e m i n u t e s , s t o p s f l a s h i n g a n d t h e w o r d s " M 1 " or " M 2 " appear o n t h e d i s play d e p e n d i n g o n t h e d i s p l a y m o d e s e lected; - adjust t h e h o u r s a n d m i n u t e s i n d i c a t e d o n t h e d i s p l a y , p r o c e e d i n g as described b e low: - decrease t h e hours b y pressing s w i t c h ( 1 ) ; - increase t h e hours b y pressing s w i t c h ( 2 ) ; - decrease t h e m i n u t e s b y pressing (3) ; - increase t h e m i n u t e s b y pressing (4) ; NOTE switch switch
By pressing the switches briefly, the hours and minutes are increased/decreased by one unit whilst by pressing them for longer the hours/minutes display is changed rapidly.
- O n c e t h e exact t i m e is set, press t h e s w i t c h ( 1 5 ) a g a i n briefly; t h e c o u n t i n g of t h e t i m e is started b e g i n n i n g f r o m 0 s e c o n d s a n d it is t h e r e f o r e possible t o a d j u s t t h e c l o c k e x actly. T h e d o u b l e p o i n t , b e t w e e n t h e h o u r s a n d t h e m i n u t e s , w i l l start t o flash a n d t h e w o r d s " M 1 " or " M 2 " w i l l appear o n t h e display. S w i t c h i n g priority - t i m e / f r e q u e n c y Press s w i t c h ( 1 5 ) briefly t o s w i t c h b e t w e e n t h e d i s p l a y o f t h e c l o c k a n d t h e messages r e l a t i n g t o t h e R a d i o , Cassette or C o m p a c t D i s c f u n c t i o n s f o r a d u r a t i o n o f 1 0 s e c o n d s , after w h i c h t h e i n d i c a t i o n , w h i c h has p r i o r i t y a c c o r d i n g t o t h e display m o d e selected, w i l l reappear a u t o m a t i c a l l y .
Disconnecting from the supply If t h e radio is d i s c o n n e c t e d f r o m t h e s u p p l y (even f o r a s h o r t p e r i o d ) w h e n it is c o n n e c t ed o n c e a g a i n t h e d i s p l a y w i l l s h o w " 0 0 : 0 0 " w i t h the figures flashing and the double p o i n t f i x e d t o i n d i c a t e that t h e c l o c k must b e a d justed once again.
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ANTI-THEFT PROTECTION T h e radio is e q u i p p e d w i t h a n a n t i - t h e f t p r o t e c t i o n system c o m p o s e d o f a secret 4 f i g u r e code. T h e p r o t e c t i o n system means t h a t t h e radio c a n n o t be used o n c e it is r e m o v e d f r o m t h e d a s h b o a r d if it is s t o l e n . Secret code T h e secret 4 f i g u r e c o d e is g i v e n o n t h e " S e curity Code card" w h i c h comes together w i t h the "Fiat Code Card" for t h e vehicle. T h e secret c o d e s h o u l d be k e p t in a safe place ( f o r example together with the vehicle d o c u m e n t s ) , b u t n o t in t h e v e h i c l e . Entering the secret code T h e a c t i v a t i o n o f t h e c o d e in t h e radio b e c o m e s necessary: a) w h e n t h e v e h i c l e is h a n d e d over b y t h e dealer; b ) after each t i m e t h e battery s u p p l y is interrupted. Initial entering of s e c r e t c o d e NOTE In order to clarify the procedure, make a note that the number of the secret code on the "Security Code Card" is 2073.
S w i t c h o n t h e radio b y pressing t h e ' O N ' button (23); keep t h e " T P " b u t t o n ( 1 0 ) pressed u n t i l t h e w o r d " C O D E " appears o n t h e d i s p l a y f o r about 3 seconds;
"2"
- press b u t t o n " 2 " seven t i m e s . T h e n u m b e r " 2 7 " s h o u l d appear o n t h e d i s p l a y ; - press b u t t o n " 3 " t e n t i m e s . T h e n u m b e r " 2 7 0 " should appear o n t h e display; - lastly, press b u t t o n " 4 " t h r e e t i m e s . T h e n u m b e r " 2 7 0 3 " s h o u l d appear o n t h e d i s play; - confirm the code number by keeping butt o n " T P " ( 1 0 ) pressed u n t i l t h e w o r d " S A F E " appears o n t h e d i s p l a y ; - after a b o u t 3 s e c o n d s t h e r a d i o is o p e r a t i o n a l a n d t h e c o d e is a c t i v a t e d .
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R e - e n t e r i n g t h e code Proceed as f o l l o w s : - S w i t c h o n t h e radio b y pressing t h e " O N " button ( 2 3 ) , the w o r d "SAFE" should a p pear f o r a r o u n d 3 s e c o n d s o n t h e d i s p l a y ; - key in t h e c o d e n u m b e r f o l l o w i n g t h e p r o cedure used for entering t h e code initially; - confirm t h e code number by keeping t h e " T P " b u t t o n ( 1 0 ) pressed until t h e w o r d " S A F E " appears o n t h e d i s p l a y ; - after a b o u t 3 s e c o n d s t h e radio is o p e r a t i o n a l a n d t h e c o d e is a c t i v a t e d .
If an incorrect code has been introduced, the radio remains locked and the word "SAFE" appears permanently on the displaye. A s a f u r t h e r deterrent a g a i n s t t h e f t , t h e s y s t e m p r e v e n t s repeated a t t e m p t s at e n t e r i n g t h e c o d e w i t h increasing l o n g e r intervals b e t w e e n o n e a t t e m p t a n d t h e next. D u r i n g t h e s e intervals t h e radio w i l l n o t w o r k until t h e w o r d " S A F E " disappears f r o m t h e display a n d t h e n u m b e r o f a t t e m p t s a p p e a r s in its place. T h e table at t h e side i n d i c a t e s t h e intervals b e t w e e n t h e i n d i v i d u a l a t t e m p t s .
Number of a t t e m p t s (on t h e d i s p l a y )
_
Waiting time (approx) 21 sees 1.5 m i n s 5.5 m i n s 22 mins 1.5 h o u r s 6 hours 24 hours 24 hours
- Keep t h e " T P " b u t t o n ( 1 0 ) pressed u n t i l the w o r d " S A F E " appears o n t h e d i s p l a y f o r around 3 seconds; - key in t h e c o d e n u m b e r w o r k i n g as d e s c r i b e d p r e v i o u s l y (see p r e v i o u s p a g e ) ; - c o n f i r m t h e c o d e n u m b e r b y k e e p i n g t h e " T P " b u t t o n ( 1 0 ) pressed) u n t i l t h e w o r d " C O D E " a p p e a r s on the display; - after a r o u n d 3 seconds t h e radio is o p e r a t i o n a l a n d t h e c o d e is d e - a c t i v a t e d . If an incorrect c o d e is e n t e r e d , t h e w o r d " S A F E " w i l l a p p e a r o n t h e d i s p l a y " . If t h i s is t h e case, t r y a g a i n o b s e r v i n g t h e intervals b e t w e e n t h e i n d i v i d u a l a t t e m p t s . C h e c k i n g t h e activation s t a t e of t h e c o d e To c h e c k w h e t h e r t h e radio c o d e is a c t i v a t e d , p r o c e e d as f o l l o w s : - s w i t c h o n t h e radio b y pressing t h e " O N " b u t t o n " ( 2 3 ) ; - press b u t t o n " T P " ( 1 0 ) u n t i l s o m e t h i n g appears o n t h e display; - if t h e w o r d " S A F E " appears, t h e c o d e is a c t i v a t e d , if, o n t h e o t h e r h a n d , t h e w o r d " C O D E " a p p e a r s t h e n t h e c o d e is n o t a c t i v a t e d ; b y s w i t c h i n g t h e r a d i o o f f a n d t h e n o n a g a i n , t h e w o r d " S A F E " or " C O D E " w i l l disappear.
1 2 3 4 5 6 7
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TECHNICAL INFORMATION Aerial T h e v e h i c l e is e q u i p p e d w i t h a n aerial l o c a t e d o n t h e roof. E l e c t r i c a l l y o p e r a t e d aerial a n d external a m p l i f i e r (available o n r e q u e s t f o r the A D 1 8 2 H radio) T h e radio c o m e s w i t h an a u t o m a t i c electrically o p e r a t e d aerial ( w h i c h w o r k s as s o o n as t h e r a d i o is s w i t c h e d o n a n d l o w e r s w h e n it is s w i t c h e d o f f ) a n d an external amplifier. T h e s w i t c h i n g v o l t a g e f o r t h e aerial is at c o n t a c t 5 ( c o n n e c t o r " A " ) f o r t h e radio and t h e s w i t c h i n g v o l t age f o r t h e amplifier is at c o n t a c t 3 ( c o n n e c t o r " A " ) . T h e s w i t c h i n g v o l t a g e f o r b o t h o u t l e t s is + 1 2 V w i t h a m a x i m u m c u r r e n t o f 0.5 A . S p e a k e r s for A D 1 8 2 H radio s y s t e m T h e acoustic s y s t e m is c o m p o s e d of: - 2 1 3 0 x 1 8 0 m m elliptical diffusers 3 0 W m a x . p o w e r e a c h ; - 2 t w e e t e r - d o m e diffusers 4 0 W m a x p o w e r e a c h ; - 2 1 0 3 m m diffusers 3 0 W m a x p o w e r e a c h . Fuses T h e radio is e q u i p p e d w i t h a 1 0 A protective f u s e . Information displayed A. Loudness B. RDS C. Dolby D. "Metal" band E. Stereo signal F. RDS - FREQIE G. Skip search H. Search sensitivity I. Traffic Programme L. Tape direction M. Frequency point N. RDS reception O. CD mode P. RDS1 -; RDS2 =; RDS LEVEL Q. Pre-section no.
B E F H F I
D X / TP
F N
B-
m m w m m &'* r a w m Mm Mm - M m
[^3
RDS =
o
Me MSS
D L M O F
Partial v i e w o f t h e r e a r of t h e radio
=8=5=
TECHNICAL S P E C I F I C A T I O N S
N of output channels 4 About 3 0 W peak (for each c h a n n e l ) < at 1 5 W R M S
dE2=
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sl 6|
7| 8|
,
Pin N
1 2 3 4 5 6 7 8
2D
4 Ohm
4|
Connection
+ Right rear speaker - Right rear speaker + Right front speaker - Right front speaker + Left front speaker - Left front speaker + Left rear speaker - Left rear speaker
Connection
CD data input CD (CD BUS) NC Earth CD + Supply CD + Service Earth CD AF Left channel CD Right channel CD
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L O C A T I O N O F R A D I O S Y S T E M C O M P O N E N T S F O R M O D E L A D 182 H
1 . Battery 2. J u n c t i o n u n i t 3. R a d i o
4. 5. 6. 7. 8. 9. 10. 11.
Speaker in right d o o r Speaker in left d o o r Speaker in right d a s h b o a r d Speaker in left d a s h b o a r d Right rear speaker Left rear speaker Aerial C o m p a c t Disc
Wiring d i a g r a m
s V
N Z -SN N Z
'I 4' j 1] 12 3 4 5 67
G IN N
12:12
A R B R
1
+30
7
MOID 1
13141516171819 20 } 'J
11
13
1. 2. 3. 4. 5.
6. 7. 8. 9. 10. 11.
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R E M O V I N G R A D I O M O D E L A D 182 L
NOTE
To facilitate the removal operations it is advisable to work from the passenger side. 2. M o r e t h e radio t o w a r d s t h e left, as i l l u s trated in t h e d i a g r a m , t h e n c a r e f u l l y insert t h e right e l e m e n t ( R ) o f t o o l 1 8 6 0 8 9 7 0 0 0 until it c a n b e heard t o e n g a g e t h e w i t h the actual radio s p r i n g s (see i n s e t ) . 3. Using t h e r i g h t e l e m e n t ( R ) o f the t o o l d e scribed a b o v e , s l i g h t l y extract t h e r i g h t part o f t h e radio in t h e d i r e c t i o n s h o w n b y the a r r o w . 4 . M o v e t h e radio t o w a r d s t h e right as i l l u s trated in t h e d i a g r a m , t h e n c a r e f u l l y insert t h e left e l e m e n t ( L ) o f t o o l 1 8 6 0 8 9 7 0 0 0 until it c a n b e heard e n g a g i n g w i t h t h e r a dio springs.
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G r i p b o t h e l e m e n t s of t o o l 1 8 6 0 8 9 7 0 0 0 a n d partly extrac t h e r a d i o , t h e n release t h e t w o e l e m e n t s of t h e a b o v e t o o l f r o m t h e radio. DO NOT extract the radio working working from the glove compartment, but only use the two elements of tool 1860897000, following the procedure described previously.
2. Protect t h e area o f t h e d a s h b o a r d u n d e r t h e radio u s i n g a c l o t h as illustrated in t h e diagram. 3. C o m p l e t e l y extract t h e r a d i o ; d i s c o n n e c t c o n n e c t i o n D f o r t h e aerial c a b l e a n d c o n nectors A a n d B w o r k i n g in t h e f o l l o w i n g w a y : push c o n n e c t o r s A a n d B t o w a r d s t h e radio a n d press o n t h e r e t a i n i n g s p r i n g s C s h o w n in t h e inset a n d e x t r a c t them from the housing; then remove t h e radio f r o m t h e v e h i c l e . If t h e rubber t e r m i n a l ( 1 ) f o r t h e c e n t e r i n g p i n ( 2 ) remains inserted in t h e d a s h b o a r d cross m e m b e r , r e m o v e it a n d f i t it o n t h e actual pin. R E M O V I N G RADIO M O D E L AD182H 4 . F o l l o w t h e same p r o c e d u r e d e s c r i b e d f o r t h e removal o f t h e radio m o d e l A D 1 8 2 L until the disconnection of connectors A a n d B, t h e n d i s c o n n e c t t h e c o n n e c t o r f o r t h e C o m p a c t Disc ( C D ) ( w h i c h c a n b e r e c o g n i z e d b y t h e three d i f f e r e n t c o l o u r s ) a c t i n g , at t h e same t i m e , o n t h e r e t a i n i n g s p r i n g s s h o w n in t h e inset.
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REFITTING RADIO M O D E L S A D 182 L - A D 182 H
1 . T o refit s u i t a b l y reverse t h e o p e r a t i o n s carried o u t f o r t h e r e m o v a l , m a k i n g sure that t h e r u b b e r t e r m i n a l ( 1 ) is c o r r e c t l y f i t ted o n t h e c e n t e r i n g p i n ( 2 ) . W h e n refitt i n g t h e radio in its h o u s i n g , p l a c e t h e cloth o n the c o w l i n g whilst c o n n e c t i n g the c o n n e c t o r s a n d t a k e care t o c o r r e c t l y m a t c h t h e c e n t e r i n g p i n in t h e h o u s i n g in the d a s h b o a r d ; i n t r o d u c e t h e radio s l o w l y into its h o u s i n g , k e e p i n g t h e t w o l o w e r springs s u i t a b l y l o a d e d s o t h a t w h e n t h e y enter t h e h o u s i n g t h e y d o n o t s c r a t c h t h e dashboard c o w l i n g .
R E P L A C I N G R A D I O M O D E L S A D 182 L A D 182 H 3. If there is a p r o b l e m w i t h t h e r a d i o or a break in t h e p r o t e c t i v e f u s e , s h o w n in t h e diagram, DO N O T C A R R Y O U T A N Y TYPE O F R E P A I R A N D / O R R E P L A C E M E N T O P E R A T I O N , b u t proceed as i l l u s trated b e l o w . 4. U n d o t h e c e n t e r i n g p i n a n d attach it as i l lustrated in t h e d i a g r a m , t h e n s e n d t h e c o m p l e t e radio t o t h e S u p p l i e r .
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1 . For t h e A D 1 8 2 H m o d e l it is necessary t o t a k e o u t t h e Security C o d e Card f o r t h e r a d i o r e m o v e d f r o m t h e Fiat Card e n v e l o p e a n d replace it w i t h t h e o n e e n c l o s e d w i t h the n e w radio. Attach the o l d Code Card t o t h e radio replaced. 2. Take a n e w r a d i o , t h e n a t t a c h t h e c e n t e r ing pin complete w i t h rubber terminal a n d t i g h t e n it in t h e t h r e a d e d h o u s i n g at t h e b o t t o m o f t h e radio. Proceed w i t h t h e f i t t i n g , f o l l o w i n g the instructions given o n t h e p r e v i o u s page. OPENING/CLOSING ING FLAP CASSETTE HOUS-
3. T h e o p e r a t i o n of o p e n i n g t h e cassette h o u s i n g access f l a p differs f o r t h e t w o models: - A D 1 8 2 L : exert pressure f r o m t h e t o p d o w n w a r d s at t h e p o i n t s h o w n in t h e d i a g r a m u n t i l t h e c l i c k o f t h e flap releasing c a n be h e a r d . - A D 1 8 2 H : press t h e b u t t o n s h o w n t o a u t o matically open t h e flap. 4 . In order t o close t h e f l a p ( f o r b o t h t h e A D 1 8 2 L model and the A D 1 8 2 H model), exert s l i g h t pressure at t h e p o i n t s h o w n in t h e d i a g r a m until t h e c l i c k o f t h e f l a p a t t a c h i n g c a n b e heard.
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1. DO N O T CLOSE THE CASSETTE H O U S ING ACCESS FLAP W O R K I N G A S ILL U S T R A T E D IN T H E D I A G R A M , in order n o t t o cause t h e actual f l a p t o b e c o m e d e t a c h e d a n d cause p o s s i b l e d a m a g e t o t h e guides. Refitting c a s s e t t e h o u s i n g a c c e s s flap If t h e f l a p b e c o m e s d e t a c h e d a n d t h e r e is n o t d a m a g e t o t h e g u i d e s or t h e j o i n t s , p r o c e e d w i t h t h e r e f i t t i n g w o r k i n g as d e s c r i b e d b e l o w (for greater clarity t h e o p e r a t i o n s have been carried o u t w i t h t h e radio n o t in its h o u s i n g ) : 2. Insert t h e l o w e r g u i d e s A f o r t h e f l a p in tm s l i d i n g slots B in t h e r a d i o . 3. T u r n t h e flap m a k i n g t h e s p r i n g s C o n t h e l o w e r f a c e of t h e a c t u a l f l a p c o i n c i d e w i t h the pints D for the rotating arm. 4. S i m u l t a n e o u s l y press t h e t w o s i d e s o f t h e flap between your t h u m b a n d index finger to complete the fitting.
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Radio
55.
Loudspeakers on front door 1 . R e m o v e t h e d o o r lever b y u n d o i n g t h e screws indicated. 2. R e m o v e t h e electric w i n d o w s p u s h b u t t o n u n i t a n d d i s c o n n e c t the electrical w i r i n g . 3. R e m o v e t h e d o o r panel b y u n d o i n g t h e a t tachment screws. 4. U n d o t h e s c r e w s s e c u r i n g t h e l o u d s p e a k er assembly a n d remove it f r o m t h e car. 5. Separate t h e p r o t e c t i v e g r i l l e f r o m t h e l o u d s p e a k e r b y releasing t h e r e t a i n i n g lugs.
57
Electrical system
Fiat CODE
Bravo-Brava
55.
INTRODUCTION T o increase p r o t e c t i o n a g a i n s t a t t e m p t e d t h e f t , the cars are f i t t e d w i t h a n e l e c t r o n i c system for b l o c k i n g t h e e n g i n e , c a l l e d "Fiat C O D E " , w h i c h is a u t o m a t i c a l l y a c t i v a t e d w h e n t h e i g n i t i o n key is w i t h d r a w n . The keys are f i t t e d w i t h a d e v i c e w h i c h t r a n s m i t s a c o d e d signal t o t h e Fiat C O D E c o n t r o l u n i t w h i c h , o n l y if it r e c o g n i z e s the s i g n a l , permits e n g i n e s t a r t i n g . The Fiat C O D E ( i m m o b i l i z e r ) system c o m p r i s e s : - Fiat C O D E c o n t r o l u n i t ; - electronic keys (three or f o u r d e p e n d i n g o n t h e car m o d e l ) c o n t a i n i n g a device w h i c h emits a n e l e c tronic c o d e ; - specific aerial o n i g n i t i o n s w i t c h ; - e n g i n e c o n t r o l u n i t w i t h serial line f o r c o m m u n i c a t i o n w i t h t h e Fiat C O D E c o n t r o l u n i t ; - Code C a r d w i t h secret c o d e f o r t h e e m e r g e n c y s t a r t i n g p r o c e d u r e ; - C O D E w a r n i n g light.
P4A058L01
T h e f u n c t i o n s of the Fiat C O D E c o n t r o l u n i t are: - t o r e c o g n i z e the i n t r o d u c t i o n a n d r o t a t i o n o f a key in t h e i g n i t i o n s w i t c h ; - to e m i t an e l e c t r o m a g n e t i c f i e l d t o g i v e p o w e r t o a n d activate t h e key's T R A N S P O N D E R ( c o d e e m i t ter); - t o receive t h e secret c o d e e m i t t e d f r o m t h e key; - t o m e m o r i z e a m a x i m u m o f 8 keys w i t h 8 e l e c t r o n i c c o d e s ; - t o m a n a g e t h e c h e c k i n g / p r o c e s s i n g of t h e c o d e s ; - t o m a n a g e a s i n g l e - w i r e b i d i r e c t i o n a l serial c o m m u n i c a t i o n t o w a r d s t h e e n g i n e c o n t r o l unit; - t o m a n a g e t h e l i g h t i n g u p o f a special w a r n i n g l i g h t ; - t o r e c o g n i z e t h e c o n n e c t i o n w i t h t h e F i a t / L a n c i a Tester a n d , for s o m e versions, t o prepare t h e use o f the serial line for t h e d i a g n o s i s f u n c t i o n .
58
Publication no.
506.670/01
Bravo-Brava
Electrical system
Fiat CODE
55.
T h e Fiat C O D E s y s t e m enables t h e o p e r a t i o n o f t h e e n g i n e c o n t r o l u n i t b y means o f a n e x c h a n g e o f codes. W h e n t h e i g n i t i o n is O N ( + 1 5 ) , t h e e n g i n e c o n t r o l unit s e n d s a c o d e request t o t h e Fiat C O D E c o n t r o l u n i t ; t h e latter r e s p o n d s a n d s e n d s a secret c o d e o n l y after r e c o g n i z i n g (via a n aerial) a k n o w n e l e c t r o n i c key e n t e r e d in t h e i g n i t i o n s w i t c h . A f t e r r e c o g n i z i n g t h e c o d e , t h e e n g i n e c o n t r o l u n i t c h a n g e s over t o the e n g i n e starting e n a b l e m e n t c o n dition. T h e e n g i n e c o n t r o l u n i t can o n l y m e m o r i z e t h e secret c o d e b y means o f a particular p r o c e d u r e .
r" )
0
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^CODE^^I
\Z
ELETTROSTOP
P4A069L01
1. 2. 3. 4.
DESCRIPTION OF SYSTEM Engine control unit T h e e n g i n e c o n t r o l u n i t is t h e f u n d a m e n t a l c o m p o n e n t of t h e Fiat C O D E s y s t e m as it c o n t a i n s t h e m a i n code (Master C o d e ) . D e p e n d i n g o n t h e m o d e l / v e r s i o n , t h e e n g i n e c o n t r o l u n i t c o n s i s t s of t h e f o l l o w i n g d e v i c e s : - Electronic fuel i n j e c t i o n - i g n i t i o n c o n t r o l u n i t f o r petrol v e r s i o n s w i t h i n t e g r a t e d fuel i n j e c t i o n / i g n i t i o n system. - Electronic fuel i n j e c t i o n c o n t r o l u n i t for diesel versions w i t h electronic p u m p . - Electronic d e v i c e integrated in t h e e l e c t r o s t o p valve f o r diesel versions w i t h m e c h a n i c a l f u e l i n j e c t i o n pump.
59
Fiat CODE
Electrical system
Bravo-Brava
55.
W h e n t h e i g n i t i o n is s w i t c h e d O N ( + 1 5 ) , t h e e n g i n e c o n t r o l u n i t requests a c o d e f r o m t h e Fiat C O D E control u n i t ; after receiving t h e c o d e , it c o m p a r e s it w i t h the M a s t e r C o d e stored in m e m o r y . If t h e c o m parison o f t h e c o d e gives a p o s i t i v e result, t h e e n g i n e c o n t r o l u n i t permits s t a r t i n g a n d n o r m a l o p e r a t i o n of the e n g i n e . If the Fiat C O D E c o n t r o l u n i t is f a u l t y , t h e e n g i n e c o n t r o l u n i t m a n a g e s the e m e r g e n c y s t a r t i n g p r o c e dure a c t i v a t e d b y the Fiat Lancia Tester or (for petrol versions w i t h integrated f u e l i n j e c t i o n / i g n i t i o n s y s tems a n d diesel versions w i t h e l e c t r o n i c fuel i n j e c t i o n ) by m e a n s of t h e accelerator p e d a l .
engine
control
units
be exchanged
between
cars
to
check
During diagnosis, before replacing the engine control unit, make sure that the component der examination really is faulty, because when the new engine control unit is supplied, Master Code will be memorized, rendering it entirely unusable on other cars.
unthe
Fiat C O D E control unit The m a i n f u n c t i o n of t h e Fiat C O D E is t o r e c o g n i z e t h e keys inserted in t h e i g n i t i o n s w i t c h . A t the request of t h e e n g i n e c o n t r o l unit, t h e Fiat C O D E u n i t s e n d s t o t h e f o r m e r : - the M a s t e r Code ( k e y r e c o g n i z e d ) , e n a b l i n g s t a r t i n g a n d n o r m a l o p e r a t i o n o f t h e e n g i n e ; - the d i a g n o s i s code ( k e y n o t r e c o g n i z e d ) p r e v e n t i n g e n g i n e s t a r t i n g .
The Fiat C O D E c o n t r o l u n i t also has t o d o t h e f o l l o w i n g : - manage t h e m e m o r i z a t i o n or r e m e m o r i z a t i o n o f t h e keys; - m e m o r i z e t h e Master C o d e in t h e e n g i n e c o n t r o l u n i t (at t h e request of t h e e n g i n e c o n t r o l u n i t ) ; - manage t h e C O D E w a r n i n g l i g h t . There are t w o procedures f o r d i a l o g u e b e t w e e n t h e Fiat C O D E c o n t r o l unit a n d t h e e n g i n e c o n t r o l u n i t : a. after t h e Fiat C O D E c o n t r o l u n i t has m e m o r i z e d t h e keys, d i a l o g u e w i t h t h e U N U S E D e n g i n e c o n t r o l unit b e g i n s . The e x c h a n g e of i n f o r m a t i o n ( r e g i s t r a t i o n of t h e c o d e ) b e t w e e n t h e e n g i n e c o n t r o l u n i t and t h e Fiat C O D E c o n t r o l u n i t is g u i d e d o n l y b y t h e e n g i n e c o n t r o l unit; t h e Fiat C O D E c o n t r o l u n i t is o n l y enabled t o r e s p o n d t o i n t e r r o g a t i o n s f r o m t h e e n g i n e c o n t r o l unit; b. c h e c k i n g t h e code is a s t a n d a r d p r o c e d u r e w h i c h is repeated w h e n e v e r t h e user inserts t h e e l e c t r o n i c key in t h e i g n i t i o n s w i t c h b l o c k a n d t u r n s it t o t h e O N ( + 1 5 ) p o s i t i o n ; t h e c h e c k i n g p r o c e d u r e also c o n t i n u e s w h e n t h e user m o v e s t h e key t o t h e S T A R T ( + 5 0 ) p o s i t i o n . W i t h t h e key at the O N ( + 1 5 ) p o s i t i o n , t h e Fiat C O D E c o n t r o l u n i t must r e c o g n i z e t h e e l e c t r o n i c key w i t h its relevant c o d e . T h e r e w i l l be t w o possibilities: - r e c o g n i t i o n of the c o d e b y t h e Fiat C O D E c o n t r o l u n i t ; t h e e n g i n e c o d e c o n t r o l u n i t e n a b l e s s t a r t i n g and e n g i n e operation ( t h e C O D E w a r n i n g l i g h t g o e s o u t ) ; - if t h e c o d e r e c o g n i t i o n is n e g a t i v e , t h e Fiat C O D E c o n t r o l u n i t w i l l send a c o d e t o the e n g i n e c o n t r o l unit w h i c h w i l l not p e r m i t e n g i n e s t a r t i n g ( C O D E w a r n i n g l i g h t is o n p e r m a n e n t l y ) .
60
Bravo-Brava
Electrical system
Fiat CODE
55.
P e r s p e c t i v e v i e w of the F i a t C O D E control unit a n d relevant c o n n e c t o r s
I d e n t i f i c a t i o n of c o n n e c t o r p i n s Connector A 1. Aerial 2. N o t c o n n e c t e d 3. A e r i a l earth Connector B 1. 2. 3. 4. Not connected CODE warning light + 1 2 V from battery ( + 3 0 ) Earth 5. N o t c o n n e c t e d Q serial line t o fuel injectioin c o n t r o l u n i t connected 8. + 1 2 V w i t h key in ON p o s i t i o n ( + 1 5 )
N o t
T w o t y p e s of key are s u p p l i e d w i t h t h e car. T h e key ( 1 ) w i t h m a r o o n h a n d l e is t h e M A S TER key; a s i n g l e c o p y is s u p p l i e d a n d it is used t o m e m o r i z e t h e other keys. The Master key can also carry out all the functions of the main key; however, it is not advisable to use it except in cases of emergency.
T h e k e y ( 2 ) is t h e key f o r n o r m a l use ( m a i n k e y ) ; t w o c o p i e s are s u p p l i e d a n d it serves f o r s t a r t i n g a n d o p e n i n g / c l o s i n g t h e f r o n t d o o r s , t a i l g a t e a n d g l o v e c o m p a r t m e n t , if t h e latter has a l o c k . For cars w i t h r e m o t e c o n t r o l , t h e key ( 3 ) is s u p p l i e d instead of key ( 2 ) .
61
Electrical system
Fiat CODE
Bravo-Brava
55.
The key h a n d l e c o n t a i n s a T r a n s p o n d e r , an e l e c t r o n i c d e v i c e N O T s u p p l i e d b y t h e battery; it c o n t a i n s a code a n d effects t r a n s m i s s i o n b y ether. W h e n t h e key is inserted in t h e i g n i t i o n s w i t c h , t h e T r a n s p o n d e r is a c t i v a t e d b y t h e aerial b y radio w a v e s and r e s p o n d s a u t o m a t i c a l l y b y e m i t t i n g a c o d e . Each key c o n t a i n s a T r a n s p o n d e r w i t h a secret c o d e . T h e M A S T E R key ( m a r o o n key) c o n t a i n s t h e M a s ter C o d e a n d s h o u l d b e used O N L Y f o r t h e key m e m o r i z a t i o n p r o c e d u r e . The c o d e of the M A S T E R key is t h e Master C o d e m e m o r i z e d in t h e e n g i n e c o n t r o l unit a n d Fiat C O D E control u n i t ; this links t h e engine c o n t r o l unit a n d t h e M A S T E R k e y so that t h e y are inseparable. If the M A S T E R key is lost or d a m a g e d , n o further n e w key m e m o r i z a t i o n procedures w i l l be possible; a subsequent f a u l t in the Fiat C O D E c o n t r o l u n i t w i l l make it necessary, in the absence of t h e M A S T E R key, t o replace t h e Fiat C O D E c o n t r o l unit a n d e n g i n e c o n t r o l u n i t .
The owner
to CLOSELY
follow
below:
- the CODE Card with the secret code must not be left in the car in case of theft; at the time it must be available for emergency starting; - the MASTER key is the right of ownership of the car; if the vehicle and CODE Card must be handed over to the new owner. is sold, the MASTER
same key
1 . Aerial 2. C O D E Card w i t h t h e secret c o d e Aerial The aerial has t o d o t h e f o l l o w i n g : - supply energy to the Transponder for sending the code; - receive t h e code f r o m t h e T r a n s p o n d e r a n d s e n d it t o t h e Fiat C O D E c o n t r o l u n i t . Since t h e aerial has t o be close t o t h e T r a n s p o n d e r ( b e c a u s e of t h e e l e c t r o m a g n e t i c i m m u n i t y , small size and l i m i t e d range of a c t i o n of t h e T r a n s p o n d e r ) , it is f i t t e d c o a x i a l l y in r e l a t i o n t o the i g n i t i o n s w i t c h .
CODE Card The C O D E Card is s u p p l i e d in t w o c o p i e s , c o n t a i n i n g t h e f o l l o w i n g : - Electronic C O D E , 5 - d i g i t c o d e f o r t h e e m e r g e n c y s t a r t i n g p r o c e d u r e u s i n g t h e Fiat L a n c i a Tester or, for m o d e l s w h e r e t h i s is p o s s i b l e , u s i n g t h e accelerator p e d a l ; - M e c h a n i c a l C O D E , s h o u l d t h e m e c h a n i c a l part o f t h e key n e e d t o be d u p l i c a t e d . On the b a c k of the c a r d , t h e r e are t w o spaces for a p p l y i n g t h e s e l f - a d h e s i v e labels w i t h a n y r e m o t e c o n trols w i t h t h e transmitter c o d e ( p a s s w o r d ) .
62
Bravo-Brava
Electrical system
Fiat CODE
55.
Warning light of the Fiat C O D E s y s t e m T h e C O D E w a r n i n g light is m a n a g e d b y t h e Fiat C O D E c o n t r o l unit. T h e C O D E w a r n i n g l i g h t c o n s i s t s of a l a m p o n t h e i n s t r u m e n t p a n e l . W h e n t h e i g n i t i o n is s w i t c h e d o n ( + 1 5 ) , t h e w a r n i n g l i g h t c a n i n d i c a t e one of the f o l l o w i n g conditions: - O N briefly ( 0 . 7 s ) a n d t h e n O F F : key r e c o g n i z e d , c o r r e c t o p e r a t i o n of t h e system; - F L A S H I N G : b o t h t h e e n g i n e c o n t r o l u n i t a n d t h e Fiat C O D E c o n t r o l u n i t d o n o t have a n y c o d e m e m o rized ( u n u s e d s y s t e m ) ; f o r a d e s c r i p t i o n of t h e v a r i o u s f l a s h i n g m o d e s , refer t o the " M a n u a l D i a g n o sis" sub-section. - O N : if the w a r n i n g light c o m e s o n p e r m a n e n t l y w h e n t h e i g n i t i o n is O N ( + 1 5 ) , t h i s i n d i c a t e s o n e of the f o l l o w i n g faults: a. key n o t r e c o g n i z e d by t h e Fiat C O D E c o n t r o l u n i t ( e n g i n e m a n a g e m e n t p r o h i b i t e d ) ; b. serial line n o t c o n n e c t e d or t h e e n g i n e c o n t r o l u n i t a n d Fiat C O D E c o n t r o l unit h a v e n o t s u c c e e d e d in e s t a b l i s h i n g c o m m u n i c a t i o n ; c. key r e m e m o r i z a t i o n p r o c e d u r e n o t carried o u t c o r r e c t l y .
If the CODE warning light comes on temporarily or permanently during driving or starting the car, this does not necessarily mean a fault in the system but, in certain cases, this indicates condition that may be interpreted as a tampering attempt by a thief. If this happens, to carry out a proper test on the system, stop the car, switch off the engine switch the ignition off (STOP position). Turn the ignition on again: the CODE warning should come on and go out again after about 1 second.
of a
and light
If the CODE warning light stays on after this procedure, repeat the operation, waiting with the ignition off (STOP position) for more than 30 seconds. If the Code warning light stays permanently on when the ignition is on even after this attempt, conduct a diagnosis on the Fiat CODE system.
KEY
MEMORIZATION memorization
First key
T h e first key m e m o r i z a t i o n is carried o u t in t h e f a c t o r y . T o c h e c k t h a t m e m o r i z a t i o n has been e f f e c t e d , insert a key in the i g n i t i o n s w i t c h a n d t u r n t h e i g n i t i o n ON (+15): - if t h e C O D E w a r n i n g l i g h t g o e s o u t , m e m o r i z a t i o n has been e f f e c t e d ; - if after a b o u t 2.5 s e c o n d s t h e C O D E w a r n i n g l i g h t starts f l a s h i n g a g a i n at a higher f r e q u e n c y , t h e s y s t e m is still u n u s e d . T h e c o n d i t i o n of u n u s e d Fiat C O D E c o n t r o l u n i t can also be c h e c k e d b y t h e Fiat Lancia Tester d u r i n g d i a g n o s i s of t h e e n g i n e c o n t r o l u n i t . Key memorization with unused s y s t e m A n u n u s e d system means t h e s i m u l t a n e o u s presence o n t h e car o f an e n g i n e c o n t r o l u n i t a n d a Fiat C O D E c o n t r o l u n i t w h i c h have N O m e m o r i z e d c o d e ( f o r e x a m p l e f o l l o w i n g an i n t e r v e n t i o n w h i c h has required the replacement of b o t h control units).
Before starting this procedure, make sure that the Fiat CODE control unit is really unused. The use of a Fiat CODE control unit which is faulty or a/ready memorized involves the irreversible memorization of an incorrect code in the engine control unit which will then be unusable in the future on other cars.
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Electrical system
Fiat CODE
Bravo-Brava
55.
The key m e m o r i z a t i o n p r o c e d u r e is d i v i d e d i n t o t w o successive stages: a. t h e secret c o d e of t h e e l e c t r o n i c keys is m e m o r i z e d in t h e Fiat C O D E c o n t r o l unit; b. t h e Fiat C O D E c o n t r o l unit m a n a g e s t h e m e m o r i z a t i o n o f t h e Master C o d e in t h e e n g i n e c o n t r o l u n i t ( w h e n t h e latter is u n u s e d ) . T h i s s e c o n d stage is carried o u t a u t o m a t i c a l l y w h e n the first has been c o m p l e t e d s u c c e s s f u l l y , w h e n t h e i g n i t i o n is s w i t c h e d O N a g a i n . The p r o c e d u r e p e r m i t s t h e m e m o r i z a t i o n of u p t o a m a x i m u m o f 8 a n d m i n i m u m of 3 keys, i n c l u d i n g t h e M A S T E R key. The m e m o r i z a t i o n p r o c e d u r e c a n o n l y be used after t h e test carried o u t b y t h e c o n t r o l u n i t ensures t h a t e v e r y t h i n g is p r o p e r l y c o n n e c t e d a n d o p e r a t i n g (universal c o d e activated a n d so car n o t p r o t e c t e d ) . The presence of t h e universal c o d e c a n be c h e c k e d b y the f l a s h i n g of the C o d e w a r n i n g l i g h t ; it has a f r e q u e n c y of 1.6 Hz a n d it starts 2.5 s e c o n d s after t h e i g n i t i o n has been s w i t c h e d o n ( + 1 5 ) . A f t e r t h i s check, t h e m e m o r i z a t i o n p r o c e d u r e m a y be c o m m e n c e d .
To avoid errors in the key memorization procedure, the procedure described should be carried out thoroughly, before being carried out on the car.
on the next
page
All the keys in the user's possession should be memorized in this procedure.
64
Publication no.
506.670/01
Bravo-Brava
Electrical system
Fiat CODE
55.
W h e n the CODE w a r n i n g light goes out, turn the M A S T E R key t o t h e i g n i t i o n off ( S T O P ) position.
Within 10 seconds: - w i t h d r a w t h e key ( 1 ) f r o m t h e i g n i t i o n switch block; - insert a n e w key ( 2 ) in t h e i g n i t i o n s w i t c h b l o c k a n d t u r n it t o t h e o n p o s i t i o n ( + 1 5 ) ; the C O D E w a r n i n g l i g h t w i l l c o m e o n for 0.7 s. W h e n the CODE w a r n i n g light goes out, t u r n t h e key ( 2 ) t o t h e off ( S T O P ) p o s i t i o n .
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Electrical system
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Bravo-Brava
55.
W i t h i n 10 seconds: - w i t h d r a w t h e keky ( 2 ) f r o m t h e i g n i t i o n switch block; - insert t h e M A S T E R key in t h e i g n i t i o n s w i t c h b l o c k again a n d t u r n it t o t h e O N position ( + 1 5 ) ; the CODE warning light c o m e s o n f o r 0.7 s.
T h e m e m o r i z a t i o n p r o c e d u r e is c o m p l e t e d ( m e m o r i z a t i o n of t h e Master C o d e in t h e e n g i n e c o n t r o l u n i t ) as f o l l o w s : - t u r n t h e M A S T E R key t o t h e i g n i t i o n o n ( + 1 5 ) position; - k e e p t h e M A S T E R key at t h e O N p o s i t i o n f o r about 3 seconds; - t h e C O D E w a r n i n g light c o m e s o n for 0.7 s a n d g o e s o u t d e f i n i t i v e l y if t h e p r o c e d u r e has b e e n successful (positive result); - t h e C O D E w a r n i n g l i g h t c o m e s o n for 0.7 s a n d starts f l a s h i n g a g a i n after a b o u t 2 s e c o n d s if t h e m e m o r i z a t i o n has N O T been s u c c e s s f u l ( n e g a t i v e r e s u l t ) . In this case, w i t h d r a w t h e M A S T E R key a n d repeat t h e key m e m o r i z a t i o n procedure from the beginning. A l s o refer t o t h e d i a g r a m o n t h e next p a g e .
66
Bravo-Brava
Electrical system
Fiat CODE
55.
T h e k e y m e m o r i z a t i o n p r o c e d u r e o n a n u n u s e d system - a k e y is inserted f o r 2 c o n s e c u t i v e t i m e s ; - t h e s a m e key is inserted 2 or m o r e t i m e s b e t w e e n 2 - a p e r i o d w h e n t h e key is at t h e i g n i t i o n o n p o s i t i o n - a p e r i o d w h e n t h e key is at t h e S T O P p o s i t i o n lasts is n o t s u c c e s s f u l if: insertions of a M A S T E R key; ( + 1 5 ) lasts f o r m o r e t h a n 2 s e c o n d s ; more t h a n 1 0 s e c o n d s .
O n c o m p l e t i o n o f m e m o r i z a t i o n , ensure t h a t all t h e keys s u p p l i e d start t h e e n g i n e ; if o n e o f t h e k e y s d o e s n o t start t h e e n g i n e , repeat t h e k e y m e m o r i z a t i o n p r o c e d u r e . NOTE The memorization should be applied procedure has been described for 3 keys (including the MASTER), to all the keys supplied with the vehicle, plus any additional keys. but
- If t h e p r o c e d u r e has n o t been carried o u t c o r r e c t l y , t h e m e m o r i z a t i o n p r o c e d u r e s h o u l d be r e p e a t e d very c a r e f u l l y . - If f o r a n y reason a n d at a n y t i m e d u r i n g t h e k e y m e m o r i z a t i o n p r o c e d u r e y o u n o t i c e t h a t y o u have m a d e a mistake, m o v e t h e key t o t h e o n ( + 1 5 ) p o s i t i o n f o r over 2 s or t o t h e off ( S T O P ) p o s i t i o n f o r over 1 0 s, t h e n start t h e key m e m o r i z a t i o n p r o c e d u r e f r o m t h e b e g i n n i n g .
KEY
Master
Key
1
<10 s
Key
2
< 10s
Master
Master
IGN.ON
<2s
<10s
<2s
<2s
<2s
> 3s
IGN.OFF
0,7 s
0,7 s
0,7 s
0,7 s
0,7 s
ON
OFF
0,7 s
CODE WARNING LIGHT NEG. RESULT
0,7 s
0,7 s
0,7 s
0,7 s
OFF
-2,5 s-
The d i a g r a m s h o w s h o w t h e C O D E w a r n i n g l i g h t c o m e s o n d e p e n d i n g o n t h e key m e m o r i z a t i o n .
Key m e m o r i z a t i o n w i t h U N U S E D F i a t C O D E c o n t r o l unit a n d U S E D e l e c t r o n i c fuel i n j e c t i o n c o n t r o l unit For t h e k e y m e m o r i z a t i o n p r o c e d u r e w i t h u n u s e d Fiat C O D E c o n t r o l u n i t a n d used e l e c t r o n i c f u e l i n j e c t i o n c o n t r o l u n i t , f o l l o w t h e i n s t r u c t i o n s g i v e n in t h e " k e y m e m o r i z a t i o n w i t h u n u s e d s y s t e m " d e s c r i b e d above.
67
Electrical system
Fiat CODE
Bravo-Brava
55.
Key m e m o r i z a t i o n p r o c e d u r e w i t h U S E D F i a t C O D E a n d e l e c t r o n i c fuel i n j e c t i o n c o n t r o l u n i t s This p r o c e d u r e is necessary if further keys n e e d t o be m e m o r i z e d , or if t h e key set has t o be reset b e c a u s e the n o t c h e s have been r e p l a c e d . T h e p r o c e d u r e c o n s i s t s o f m e m o r i z i n g u p t o a m a x i m u m of 8 a n d a m i n i m u m of 3 d i f f e r e n t keys ( M A S T E R key i n c l u d e d ) .
To avoid errors in the key memorization procedure, read carefully before being carried out on the car.
the procedure
described
below
should
be
Adding a new key necessarily involves rememorizing all the existing keys, as the keys not used during this procedure are deleted from memory.
68
Bravo-Brava
Electrical system
Fiat CODE
55.
W i t h i n 10 seconds: - w i t h d r a w the MASTER key f r o m the i g n i tion switch block; - insert a n e w key ( 1 ) in t h e i g n i t i o n s w i t c h b l o c k and t u r n it t o the i g n i t i o n o n ( + 1 5 ) position; the CODE warning light comes on f o r 0.7 s.
Within 10 seconds: - w i t h d r a w t h e key (1) f r o m t h e i g n i t i o n s w i t c h block; - insert a n e w key ( 2 ) in t h e i g n i t i o n s w i t c h b l o c k a n d t u r n it t o the i g n i t i o n o n p o s i t i o n ( + 1 5 ) ; the C O D E w a r n i n g l i g h t c o m e s o n f o r 0.7 s.
69
Electrical system
Fiat CODE
Bravo-Brava
55.
W i t h i n 10 seconds: - d i s c o n n e c t f r o m t h e key ( 2 ) f r o m t h e i g n i tion s w i t c h block; - insert t h e M A S T E R key in t h e i g n i t i o n s w i t c h b l o c k a g a i n a n d t u r n it t o t h e o n ( + 1 5 ) position; the CODE w a r n i n g light c o m e s o n for 0.7 s.
W h e n the CODE w a r n i n g light goes out, turn t h e M A S T E R key t o t h e off ( S T O P ) p o s i t i o n . On c o m p l e t i o n of m e m o r i z a t i o n , m a k e sure t h a t all t h e keys s u p p l i e d start t h e e n g i n e ; if o n e o f t h e keys d o e s n o t start t h e e n g i n e , repeat t h e key m e m o r i z a t i o n p r o c e d u r e . This p r o c e d u r e c a n c e l s t h e r e c o g n i t i o n o f t h e keys p r e v i o u s l y m e m o r i z e d a n d k e e p s t h e M A S T E R key w i t h t h e keys j u s t m e m o r i z e d .
The key r e m e m o r i z a t i o n p r o c e d u r e is n o t successful in t h e f o l l o w i n g cases: - a key is inserted f o r 2 successive t i m e s ; - the same key is inserted 2 or more t i m e s b e t w e e n 2 i n s e r t i o n s of a M A S T E R key; - a p e r i o d w h e n the key is at the o n ( + 1 5 ) p o s i t i o n lasts m o r e t h a n 2 s e c o n d s ; - a p e r i o d w h e n the key is at the S T O P p o s i t i o n lasts m o r e t h a n 1 0 s e c o n d s . If the p r o c e d u r e has n o t b e e n carried o u t correctly, repeate t h e m e m o r i z a t i o n p r o c e d u r e v e r y c a r e f u l l y . If for any reason a n d at a n y t i m e d u r i n g t h e m e m o r i z a t i o n p r o c e d u r e y o u n o t i c e t h a t y o u h a v e m a d e a mistake, m o v e t h e key t o t h e i g n i t i o n o n ( + 1 5 ) p o s i t i o n f o r over 2 s or t o t h e S T O P p o s i t i o n f o r over 1 0 s, t h e n start the key m e m o r i z a t i o n p r o c e d u r e f r o m t h e b e g i n n i n g . If the C O D E w a r n i n g l i g h t c o m e s o n p e r m a n e n t l y d u r i n g t h e r e m e m o r i z a t i o n p r o c e d u r e , t h i s m e a n s t h a t the p r o c e d u r e has been i n t e r r u p t e d as it has not been carried o u t correctly; in t h i s case, start t h e p r o c e dure f r o m t h e b e g i n n i n g .
If the CODE warning light comes on permanently (with MASTER key at the ignition on position) at the second consecutive insertion of the MASTER key, this does not indicate a malfunction of the system, but that the rememorization procedure has been opened (1st insertion) and then interrupted (2nd insertion). To restore correct operation of the CODE warning light, return the MASTER key to the STOP position. The memorization should be applied procedure has been described for 3 keys (including the MASTER), to all the keys supplied with the vehicle, plus any additional keys. but
NOTE
70
Publication no.
506.670/01
Bravo-Brava
Electrical system
Fiat CODE
55.
KEY
Master
Key 1
Key 2
Master IGN.ON
<2s
< 10s
<2s
< 10s
<2s
< 10s
<2s
IGN.OFF
0,7 s
CODE WARNING LIGHT
:0,7 s
i0,7s
:0,7 s
ON
OFF
P4A071L01
T h e d i a g r a m s h o w s h o w t h e C O D E w a r n i n g l i g h t c o m e s o n d e p e n d i n g o n t h e key m e m o r i z a t i o n Key memorization w i t h U S E D Fiat C O D E control unit and U N U S E D electronic fuel injection control unit If t h e e l e c t r o n i c f u e l i n j e c t i o n c o n t r o l u n i t has t o be r e p l a c e d , t h e Master C o d e inside it has t o be m e m o rized. T o m e m o r i z e t h e M a s t e r C o d e in t h e e l e c t r o n i c f u e l i n j e c t i o n c o n t r o l u n i t , s i m p l y turn a key t o t h e i g n i t i o n o n ( + 1 5 ) p o s i t i o n , after c h e c k i n g t h a t t h e Fiat C O D E c o n t r o l u n i t is w o r k i n g c o r r e c t l y .
Under no circumstances may electronic fuel injection control units be exchanged to check whether they are working. During diagnosis, before replacing the electronic fuel injection control unit, make component under examination really is faulty, because when the new electronic control unit is supplied, the Master Code will be memorized, rendering it entirely other cars.
between
cars
CONNECTION B E T W E E N FIAT CODE CONTROL UNIT AND ENGINE CONTROL UNIT T h e Fiat C O D E c o n t r o l u n i t a n d e n g i n e c o n t r o l u n i t d i a l o g u e via a serial line c o n s i s t i n g o f a s i n g l e c a b l e . T h e serial cable is o f t h e b i d i r e c t i o n a l t y p e ; t h i s m e a n s t h a t t h e i n f o r m a t i o n travels in a s e q u e n t i a l m a n n e r f r o m t h e e n g i n e c o n t r o l unit t o t h e Fiat C O D E c o n t r o l u n i t a n d vice versa. T h e i n f o r m a t i o n e x c h a n g e d b e t w e e n c o n t r o l u n i t s can relate t o the f o l l o w i n g o p e r a t i n g c o n d i t i o n s : A . C o d e c h e c k - w h e n e v e r t h e key is t u r n e d t o t h e i g n i t i o n o n p o s i t i o n ( e v e n d u r i n g s t a r t i n g ) , t h e e n g i n e c o n t r o l u n i t , before s t a r t i n g e n g i n e m a n a g e m e n t , requests t h e M A S T E R C O D E f r o m t h e Fiat C O D E control unit. B. C o d e m e m o r i z a t i o n - These o p e r a t i n g s t a g e s c o n c e r n t h e system w h e n at least o n e c o n t r o l u n i t is u n u s e d . The f o l l o w i n g cases m a y be d i s t i n g u i s h e d : - U n u s e d e n g i n e c o n t r o l u n i t a n d Fiat C O D E c o n t r o l u n i t . - Used Fiat C O D E c o n t r o l u n i t a n d u n u s e d e n g i n e c o n t r o l unit. - U n u s e d Fiat C O D E c o n t r o l u n i t a n d u s e d e n g i n e c o n t r o l unit. Refer t o t h e " K e y M e m o r i z a t i o n " s u b - s e c t i o n f o r t h e p r o c e d u r e s t o be a d o p t e d . C. S h a r i n g the serial line for d i a g n o s i s - D e p e n d i n g o n t h e v e r s i o n , t h e c o n n e c t i o n b e t w e e n t h e Fiat C O D E c o n t r o l u n i t a n d t h e d i a g n o s t i c s o c k e t m a y be c o n f i g u r e d as f o l l o w s : - For petrol v e r s i o n s w i t h B o s c h M o n o m o t r o n i c , I A W , H i t a c h i i n t e g r a t e d f u e l i n j e c t i o n - i g n i t i o n s y s t e m , the Fiat C O D E system d o e s n o t have its o w n d i a g n o s t i c s o c k e t ( F i g u r e A n e x t p a g e ) . T o c h e c k the o p e r a t i o n of t h e s y s t e m , c o n d u c t a d i a g n o s i s o n the e n g i n e c o n t r o l u n i t . - For diesel v e r s i o n s w i t h m e c h a n i c a l f u e l i n j e c t i o n p u m p , t h e Fiat C O D E system has its o w n d i a g nostic socket.
71
Electrical system
Fiat CODE
Bravo-Brava
- For p e t r o l versions w i t h B o s c h M o t r o n i c s y s t e m a n d diesel w i t h electronic f u e l i n j e c t i o n p u m p , t h e Fiat C O D E c o n t r o l u n i t shares t h e d i a g n o s i s line K w i t h t h e e n g i n e c o n t r o l u n i t ( F i g . B ) . W i t h i n t h e Fiat C O D E c o n t r o l u n i t there is a r e m o t e c o n t r o l s w i t c h w h i c h c h a n g e s over t h e c o n n e c t i o n b e t w e e n t h e e n g i n e c o n t r o l u n i t a n d d i a g n o s t i c s o c k e t or Fiat C O D E c o n t r o l u n i t . T h e s w i t c h n o r m a l l y permits d i a l o g u e b e t w e e n Fiat C O D E c o n t r o l u n i t a n d e n g i n e c o n t r o l u n i t (Default condition). A t t h e start of d i a g n o s i s , w h e n t h e F i a t / L a n c i a Tester is c o n n e c t e d and t h e i g n i t i o n is s w i t c h e d o n , t h e Fiat C O D E c o n t r o l u n i t recognizes the d i a g n o s i s c o n d i t i o n a n d drives t h e r e m o t e c o n t r o l s w i t c h so as t o c o n n e c t p i n s B 5 and B 6 t o each o t h e r , e n a b l i n g d i a l o g u e b e t w e e n t h e F i a t / L a n c i a Tester a n d t h e e n g i n e c o n t r o l unit. T h e Fiat C O D E c o n t r o l u n i t p e r m i t s c o n n e c t i o n w i t h t h e F i a t / L a n c i a Tester o n l y if: - T h r e is no activity o n t h e serial line b e t w e e n t h e Fiat C O D E c o n t r o l unit a n d t h e e n g i n e c o n t r o l unit. - T h e r e is a l o w v o l t a g e level o n p i n B 5 for a p e r i o d of t i m e b e t w e e n 5 0 0 ms a n d 5 s (a l o w level for a p e r i o d e x c e e d i n g 5 s is c o n s i d e r e d t o be a s h o r t c i r c u i t t o e a r t h ) . T h e r e m o t e c o n t r o l s w i t c h returns t o t h e " D e f a u l t " p o s i t i o n w h e n there is n o a c t i v i t y o n p i n B 5 for over 3 0 s. W h e n t h e c o n t r o l u n i t recognizes t h a t t h e F i a t / L a n c i a Tester has been c o n n e c t e d , it a c t i v a t e s t h e C O D E w a r n i n g l i g h t , i n d i c a t e d t h a t t h e r e m o t e c o n t r o l s w i t c h has c h a n g e d over c o r r e c t l y .
P4A072L01
P4A072L02
1 . D i a g n o s t i c socket
2. Fiat C O D E c o n t r o l u n i t
3. E n g i n e c o n t r o l u n i t
MANUAL DIAGNOSIS W h e n t h e C O D E w a r n i n g l i g h t stays o n p e r m a n e n t l y w i t h the i g n i t i o n key at t h e o n p o s i t i o n ( + 1 5 ) , t h e problems m a y be as f o l l o w s : - key n o t recognized b y t h e Fiat C O D E c o n t r o l u n i t ; - serial line n o t c o n n e c t e d ; - key r e m e m o r i z a t i o n p r o c e d u r e n o t carried o u t c o r r e c t l y ( p r o c e d u r e i n t e r r u p t e d ) . U n u s e d s y s t e m and ignition on A n u n u s e d system m e a n s t h e s i m u l t a n e o u s presence o n the car of an e l e c t r o n i c f u e l i n j e c t i o n system and a Fiat C O D E c o n t r o l u n i t w h i c h d o N O T have a n y m e m o r i z e d c o d e s (for e x a m p l e f o l l o w i n g a n interv e n t i o n w h i c h has r e q u i r e d t h e r e p l a c e m e n t of b o t h c o n t r o l u n i t s ) . In this case, w h e n t h e i g n i t i o n is s w i t c h e d o n , t h e C O D E w a r n i n g l i g h t can i n d i c a t e o n e of t h e f o l l o w i n g c o n d i t i o n s also s h o w n o n t h e diagram b e l o w : a. W h e n t h e C O D E w a r n i n g l i g h t c o m e s o n for 0.7 s e c o n d s a n d after a b o u t 2 s e c o n d s it starts f l a s h i n g , e v e r y t h i n g is properly c o n n e c t e d a n d w o r k i n g , t h e car is n o t p r o t e c t e d , t h e universal c o d e is a c t i v e . b. W h e n t h e C O D E w a r n i n g l i g h t flashes w i t h c o d e 1 (1 f l a s h , pause, 1 flash, e t c . ) , this m e a n s t h a t t h e serial line is not c o n n e c t e d or t h a t t h e t w o c o n t r o l u n i t s have n o t s u c c e e d e d in e s t a b l i s h i n g c o m m u nication.
72
Bravo-Brava
Electrical system
Fiat CODE
55.
c. W h e n t h e C O D E w a r n i n g l i g h t flashes w i t h c o d e 2 ( 2 flashes, pause, 2 flashes, e t c . ) , t h i s m e a n s o n e of t h e f o l l o w i n g c o n d i t i o n s : - aerial f a u l t y ; - Transponder faulty; - Transponder missing; - t h e electronic fuel i n j e c t i o n c o n t r o l u n i t has received an incorrect c o d e . Manual diagnosis for unused system
Everything is working correctly, universal code activated, car not protected or key memorization procedure with negative result
OFF
0,5 s
U n u s e d F i a t C O D E c o n t r o l unit a n d ignition o n
Aerial faulty Trasponder faulty or missing The control unit has received an incorrect code
In t h e case of cars w i t h u n u s e d Fiat C O D E c o n t r o l u n i t a n d used e l e c t r o n i c fuel i n j e c t i o n c o n t r o l u n i t , w h e n t h e C O D E w a r n i n g l i g h t c o m e s o n p e r m a n e n t l y a n d t h e i g n i t i o n is s w i t c h e d o n , t h i s i n d i c a t e s o n e of t h e f o l l o w i n g p r o b l e m s : - aerial faulty; - Transponder faulty; - Transponder missing.
FAULT DIAGNOSIS WITH FIAT LANCIA TESTER For petrol cars f i t t e d w i t h an integrated f u e l i n j e c t i o n - i g n i t i o n system a n d diesel cars w i t h e l e c t r o n i c f u el i n j e c t i o n p u m p , t h e Fiat C O D E system d o e s n o t have its o w n d i a g n o s t i c socket. T o c h e c k w h e t h e r t h e s y s t e m is o p e r a t i n g , d i a g n o s i s s h o u l d be c o n d u c t e d o n t h e electronic f u e l i n j e c t i o n - i g n i t i o n c o n t r o l u n i t (petrol cars) or fuel i n j e c t i o n c o n t r o l u n i t (diesel c a r s ) . T h e f o l l o w i n g c a n be measured w i t h t h e Fiat Lancia Tester: Parameters - STARTING PERMITTED/NOT PERMITTED T h i s means t h a t t h e e n g i n e c o n t r o l u n i t has r e c o g n i z e d t h e c o d e p e r m i t t i n g e n g i n e s t a r t i n g . - P R O G R A M M E D / N O T P R O G R A M M E D S T A T U S O F E L E C T R O N I C KEY T h e i n d i c a t i o n N O T P R O G R A M M E D m e a n s t h a t b o t h f u e l i n j e c t i o n a n d Fiat C O D E c o n t r o l u n i t s are unused (no memorized c o d e ) .
73
Electrical system
Fiat CODE
Bravo-Brava
55.
Error - E L E C T R O N I C KEY ERROR W h e n d i a g n o s e d , t h e error c a n be classified as P R E S E N T or I N T E R M I T T E N T . C o n t i n u i n g the d i a g n o s i s , it is p o s s i b l e t o d i s t i n g u i s h w h e t h e r t h e error is d u e t o e x c h a n g e d f u e l i n j e c t i o n c o n t r o l u n i t s or t o a m a l f u n c t i o n of t h e s y s t e m ' s c o m p o n e n t s . A n a l y s i n g the v a r i o u s screens d i s p l a y e d o n e after t h e other, y o u reach t h e " D O Y O U W A N T T O U N B L O C K T H E E L E C T R O N I C KEY?" screen, w h i c h permits e n g i n e starting b y e n t e r i n g t h e 5 - d i g i t c o d e ( E L E C T R O N I C C O D E ) stated o n t h e C o d e C a r d . EMERGENCY STARTING PROCEDURE
The e m e r g e n c y s t a r t i n g p r o c e d u r e makes it p o s s i b l e t o start t h e e n g i n e if t h e r e is a p r o b l e m in t h e Fiat CODE s y s t e m (Fiat C O D E c o n t r o l u n i t f a u l t y , keys u n u s a b l e , e t c . ) . The e m e r g e n c y p r o c e d u r e can o n l y be activated if t h e e n g i n e c o n t r o l u n i t is in t h e "engine management prohibited" status. T h i s p r o c e d u r e c a n be carried o u t w i t h t h e Fiat Lancia Tester or, for s o m e v e r s i o n s , also u s i n g t h e accelerator pedal. T h i s o p e r a t i o n is u s e f u l f o r s t a r t i n g t h e e n g i n e a n d d r i v i n g t h e car t o t h e closest a u t h o r i z e d w o r k s h o p f o r repair of t h e f a u l t . Emergency starting w i t h Fiat Lancia Tester The p r o c e d u r e is a c t i v a t e d b y e n t e r i n g , o n t h e Fiat Lancia Tester, t h e 5 - d i g i t c o d e ( E L E C T R O N I C CODE) on the Code Card. After a n e m e r g e n c y start, w h e n t h e i g n i t i o n is s w i t c h e d off ( S T O P p o s i t i o n ) , t h e fuel i n j e c t i o n c o n t r o l unit r e t u r n s t o t h e e n g i n e s t a r t i n g b l o c k e d c o n d i t i o n , so t o start t h e e n g i n e , t h e e m e r g e n c y s t a r t i n g p r o cedure m u s t be carried o u t a g a i n . Emergency starting procedure using accelerator pedal This p r o c e d u r e is a p p l i c a b l e o n l y t o petrol cars w i t h integrated f u e l i n j e c t i o n - i g n i t i o n s y s t e m a n d diesel cars w i t h electronic f u e l i n j e c t i o n p u m p . By m e a n s of this p r o c e d u r e it is p o s s i b l e , b y u s i n g t h e accelerator pedal, t o t r a n s m i t t h e e l e c t r o n i c c o d e to t h e e l e c t r o n i c fuel i n j e c t i o n c o n t r o l u n i t w h i c h in t u r n d e t e c t s it via t h e p o t e n t i o m e t e r l o c a t e d o n t h e t h r o t t l e v a l v e (petrol v e r s i o n or accelerator pedal (diesel v e r s i o n ) . Carry o u t t h e f o l l o w i n g o p e r a t i o n s in s e q u e n c e : 1. Read t h e 5 - d i g i t Electronic C o d e o n t h e C o d e C a r d . 2. S w i t c h the i g n i t i o n o n , press a n d h o l d d o w n t h e accelerator pedal. T h e f u e l i n j e c t i o n s y s t e m w a r n i n g l i g h t c o m e s o n f o r 4 s, t h e n g o e s o u t b r i e f l y ( a b o u t 1 5 0 m s ) and t h e n c o m e s o n a g a i n f o r a f u r ther 4 s. 3. W h e n t h e w a r n i n g l i g h t g o e s o u t , release t h e accelerator p e d a l . 4. W h e n t h e accelerator pedal is released, t h e w a r n i n g l i g h t starts f l a s h i n g ( f l a s h i n g f r e q u e n c y 0.8 Hz w i t h d u t y - cycle 2 5 % O N ) . 5. A f t e r a number of flashes e q u a l t o t h e first d i g i t o f t h e c o d e read o n t h e C o d e C a r d , f u l l y depress a n d h o l d d o w n the accelerator p e d a l . 6. T h e f u e l i n j e c t i o n f a u l t w a r n i n g l i g h t c o m e s o n a g a i n f o r 4 s a n d t h e n g o e s o u t ( f i r s t d i g i t a c quired). 7. W h e n t h e w a r n i n g l i g h t g o e s o u t , release t h e accelerator p e d a l . 8. W h e n t h e accelerator pedal is released, t h e w a r n i n g l i g h t a g a i n starts f l a s h i n g as d e s c r i b e d in p o i n t 4. 9. A f t e r a number of flashes e q u a l t o t h e s e c o n d d i g i t o f t h e c o d e , press t h e accelerator p e d a l ; t h e w a r n i n g light c o m e s o n for 4 s ( s e c o n d d i g i t a c q u i r e d ) , a n d t h e n release t h e accelerator. 10. Repeat t h e o p e r a t i o n s in p o i n t s 4 , 5 , 6 a n d 7 f o r t h e r e m a i n i n g d i g i t s of t h e e l e c t r o n i c c o d e . 1 1 . W h e n t h e accelerator pedal is released, after t h e last d i g i t has been a c q u i r e d , t h e w a r n i n g l i g h t w i l l f l a s h for 4 s at a f r e q u e n c y o f 1.6 Hz w i t h d u t y - c y c l e 5 0 % i n d i c a t i n g t h a t t h e c o d e has b e e n a c c e p t e d , or w i l l remain p e r m a n e n t l y lit if t h e c o d e has been r e f u s e d . If t h e c o d e has been a c c e p t e d , start t h e e n g i n e , o t h e r w i s e s w i t c h t h e i g n i t i o n off ( S T O P p o s i t i o n ) a n d repeat t h e p r o c e d u r e .
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55.
IGN.ON
KEY
IGN.OFF PRESSED
ACCELERATOR PEDAL . 4s POSITIVE RESULT _l FUEL INJECTION WARNING LIGHT NEGATIVE RESULT 4s
RELEASED
4s
4s
1,6 Hz 60%d.c.
ON
OFF I 150 ms ON
OFF
P4A075L01
NOTE
The diagram illustrates the actions on the accelerator pedal and the lighting up of the fuel tion fault warning light relating to an example code 42173 (Electronic Code)
injec-
After the code has been acquired, the electronic control unit permits engine of 10 minutes, after which it returns to the blocked starting status.
starting
for a
period
I M P O R T A N T N O T E S C O N C E R N I N G T H E R E P L A C E M E N T O F C O M P O N E N T S O F T H EF I AT CODE SYSTEM T h e Fiat C O D E system c o n s i s t s o f v a r i o u s c o m p o n e n t s c o n n e c t e d t o each other. Care s h o u l d b e t a k e n w h e n w o r k i n g o n a n d r e p l a c i n g o n e o f t h e s e parts. Engine control
A A
During diagnosis, before replacing the engine control unit, make sure that the component under examination really is faulty, because when the the new control unit is supplied, the Master Code is memorized rendering it entirely unusable on other cars. unit control unit entails with unused the rememorization system"procedure. of the electronic keys follow-
Fiat C O D E control
A
A
Notches kits and n e w keys If the ignition switch block has to be replaced, remove the transponder from the old key and insert it in the new key (see next page), then carry out the "Key memorization dure for used Fiat CODE and electronic fuel injection control units". MASTER proce-
75
Electrical system
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Bravo-Brava
55.
REPLACING TRANSPONDER
A
1
Use the max/mum caution to avoid breakage or loss of the Transponder (carry out the dismantling operations on a table).
Insert a small s c r e w d r i v e r in t h e key s l o t a n d use it as a lever; 2. O p e n t h e M A S T E R key w i t h care, as it consists of two half casings; the T r a n s p o n d e r is s h o w n b y t h e a r r o w ; 3. R e m o v e t h e T r a n s p o n d e r f r o m its s e a t i n g in t h e O L D M A S T E R key u s i n g a s m a l l s c r e w d r i v e r or p o i n t ; 4 . 5 . Fit the T r a n s p o n d e r f r o m t h e O L D M A S T E R key in t h e s e a t i n g in t h e N E W M A S T E R key, p o s i t i o n i n g it as illustrated in t h e f i g u r e a b o v e , t a k i n g care n o t t o d a m a g e t h e electrical c o m p o n e n t ;
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55.
- exert l i g h t pressure and j o i n t h e t w o half c a s i n g s o f t h e N E W M A S T E R key; - after c a r r y i n g o u t the a b o v e - m e n t i o n e d o p e r a t i o n , carry o u t t h e p r o c e d u r e f o r m e m o r i z i n g t h e n e w set of keys. If t h e i g n i t i o n s w i t c h block has b e e n d a m a g e d a l o n g d i s t a n c e a w a y f r o m t h e place w h e r e t h e M A S T E R key is s t o r e d , t h e f o l l o w i n g e m e r g e n c y p r o c e d u r e m u s t be carried out: - replace t h e d a m a g e d s w i t c h b l o c k ; - insert t h e n e w M A S T E R key ( 1 ) w i t h o u t t h e T r a n s p o n d e r in the i g n i t i o n s w i t c h block; - b r i n g t h e o l d key ( 2 ) w i t h T r a n s p o n d e r in contact w i t h the new M A S T E R key (1) w i t h o u t T r a n s p o n d e r inserted in t h e i g n i tion switch block. - T u r n t h e key, k e e p i n g t h e h a n d l e s in c o n tact for starting. T h e T r a n s p o n d e r c o n t a i n e d in t h e O L D M A S T E R key m u s t be transferred t o t h e seati n g in t h e h a n d l e of t h e N E W M A S T E R key as s o o n as p o s s i b l e . M A S T E R key (maroon) If the MASTER gine starting. If the MASTER key is unavailable, it will be impossible to memorize new keys which permit en-
is broken/lost,
the following
must be
replaced:
- notches kit and new keys (including the CODE CARD); - Fiat CODE control unit; - electronic fuel injection control unit. This replacement of components is carried out at the first service intervention where TER key has to be used (for example breakage of the ignition switch block). Transponder Under no circumstances may the key Transponders be handled, replaced or exchanged in cases of replacing the notches kit and new keys, and only the MASTER key). Addition of a n e w key to the k e y s supplied w i t h the c a r Adding a new key involves the rememorization of all the existing keys not used during this procedure are deleted from memory. keys supplied
the
MAS-
(except
11
Electrical system
Fiat CODE
Bravo-Brava
55.
F L O W C H A R T S O F F A U L T R E P A I R S ON F I A T C O D E S Y S T E M Master key Lost A s u b s e q u e n t f a u l t t o t h e Fiat C o d e c o n t r o l u n i t w h i c h entails t h e latter's r e p l a c e m e n t w i l l also entail r e p l a c e m e n t of t h e E n g i n e C o n t r o l U n i t a n d r e p r o g r a m m i n g of t h e s y s t e m .
Electronic f a u l t ( T r a n s p o n d e r )
M e c h a n i c a l breakage
L o s s of m a i n k e y T h e spare key is u s e d a n d p o s s e s s i o n of t h e car is r e g a i n e d . I n o r der t o a v o i d t h e k e y b e i n g f o u n d by i l l - i n t e n t i o n e d persons a n d t h e car b e i n g s t o l e n , it is a d v i s a b l e t o c o m p l e t e t h e set of keys a n d , b y means of t h e R E M E M O R I Z A TION procedure, to memorize A L L of t h e m a g a i n . G o t o t h e service centre a n d o b t a i n a m e c h a n i c a l key. R e g a i n possession of t h e car b y m e a n s o f the EMERGENCY PROCEDURE. In order t o a v o i d t h e key b e i n g f o u n d by ill-intentioned persons a n d t h e car b e i n g s t o l e n , it is a d visable t o c o m p l e t e t h e set o f keys a n d , b y m e a n s of t h e R E M E M O R I Z A T I O N procedure, t o m e m o r i z e A L L of t h e m a g a i n .
easily
yes-
no
C o d e Card available
yes
no yes> Set o f keys w i t h o l d m e c h a n i c a l c o d e available as spare no no The Fiat C o d e c o n t r o l u n i t , t h e engine control unit and key n o t c h e s m u s t be replaced a n d t h e electronic keys m u s t be m e m o rized.
yes A l l t h e key n o t c h e s m u s t b e replaced and the EMERGENCY P R O C E D U R E m u s t be a c t i v a t e d . A s s o o n as t h e M A S T E R key is r e c o v e r e d , its t r a n s p o n d e r is i n serted in the M A S T E R key of t h e kit supplied w i t h the n e w n o t c h es, a n d t h e n e w keys are m e m o rized b y means of t h e R E M E M O RIZATION procedure.
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M e c h a n i c a l breakage of main k e y (not in n o t c h )
or
easily
yes
T h e spare key is used a n d possess i o n of t h e car is r e g a i n e d . If t h e set of keys is t o b e c o m p l e t e d , m e m o r i z e t h e m A L L again b y means of t h e R E M E M O R I Z A T I O N procedure.
no r Set o f keys w i t h o l d m e c h a n i c a l c o d e available as spare no A l l t h e key n o t c h e s m u s t be r e p l a c e d . Possession of the car is regained u s i n g a m e c h a n i c a l key by b r i n g i n g t h e h a n d l e of t h e b r o k e n key up t o t h e aerial. A s s o o n as t h e M A S T E R key is r e c o v e r e d , its t r a n s p o n d e r is inserted in the M A S T E R key of t h e kit s u p p l i e d w i t h the n e w n o t c h e s , a n d t h e n e w keys are m e m o r i z e d b y m e a n s of t h e REM E M O R I Z A T I O N procedure. yes Possession of t h e car can be r e g a i n e d u s i n g an e m p t y m e c h a n i cal k e y b y b r i n g i n g t h e h a n d l e o f t h e b r o k e n key u p t o t h e aerial. If t h e set of keys is t o b e c o m p l e t e d , m e m o r i z e t h e m A L L again b y m e a n s of t h e R E M E M O R I Z A T I O N procedure.
E l e c t r o n i c fault ( t r a n s p o n d e r ) m a i n k e y
easily
yes
C o d e C a r d available
yes Regain possession o f the car b y means of the EMERGENCY PROCEDURE. After regaining possession of t h e M A S T E R key, t h e key set can be reset by m e a n s of the REMEMORIZATION PROCEDURE.
no
T h e Fiat Code c o n t r o l unit, e n g i n e c o n t r o l unit a n d p o s s i b l y t h e key n o t c h e s must be replaced and the M E M O R I Z A T I O N PROC E D U R E must be a c t i v a t e d .
79
Electrical system
Fiat CODE
Bravo-Brava
55.
M e c h a n i c a l breakage of m a i n key in door / bonnet l o c k n o t c h MASTER key easily found by the customer yes The n o t c h e s are replaced. Possession of t h e car is o b t a i n e d b y means of t h e spare key, if it is c o n s i d e r e d a p p r o p r i a t e ; t h e key set can be c o m p l e t e d by t h e R E M E M O R I Z A T I O N p r o c e d u r e u s i n g t h e o l d M A S T E R key.
no
yes-
T h e n o t c h e s are replaced. T h e t r a n s p o n d e r f r o m t h e M A S TER key of t h e o l d set m u s t be inserted in t h e M A S T E R k e y of the n e w set, a n d t h e n e w keys m u s t be m e m o r i z e d b y means of t h e R E M E M O R I Z A T I O N p r o c e d u r e . T h e n o t c h e s are replaced. Possession of t h e car is retained b y means o f t h e spare key, if it is c o n s i d e r e d a p p r o p r i a t e ; t h e key set c a n be c o m p l e t e d by t h e R E M E M O R I Z A T I O N p r o c e d u r e u s i n g the o l d M A S T E R key o n c e it has been o b tained. It is s u f f i c i e n t t o replace t h e perimetral l o c k n o t c h e s . A f t e r r e g a i n i n g possession of t h e M A S T E R key, t h e i g n i t i o n n o t c h c a n be replaced a n d t h e n e w set of keys c a n be m e m orized b y i n s e r t i n g t h e t r a n s p o n d e r of t h e M A S T E R k e y f r o m t h e o l d set in t h e M A S T E R key of t h e n e w set, a c t i v a t i n g the R E M E M O R I Z A T I O N p r o c e d u r e .
no
yes-
no
T h e n o t c h e s are replaced. Possession of t h e car is r e g a i n e d either b y t h e E M E R G E N C Y P R O C E D U R E or b y b r i n g i n g t h e h a n d l e of t h e b r o k e n key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o be d o n e u s i n g t h e M A S T E R key of t h e n e w set. O n c e t h e M A S T E R key has been reg a i n e d , t h e ket set can be c o m p l e t e d b y means of t h e R E M E M O R I Z A T I O N procedure. T h e n o t c h e s are replaced. Possession of t h e car is r e g a i n e d either b y t h e E M E R G E N C Y P R O C E D U R E or b y b r i n g i n g t h e h a n d l e of t h e b r o k e n key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o be d o n e u s i n g t h e M A S T E R key of t h e n e w set. O n c e t h e M A S T E R key has been r e g a i n e d , t h e n e w key set c a n be m e m o r i z e d b y i n s e r t i n g t h e t r a n s p o n d e r of t h e M A S T E R key f r o m t h e o l d set in t h e M A STER key of t h e n e w set a n d a c t i v a t i n g t h e R E M E M O RIZATION procedure. T h e n o t c h e s are replaced. Possession o f t h e car is r e g a i n e d o n l y b y b r i n g i n g t h e h a n d l e of the b r o k e n key u p t o t h e a e r i al w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o be d o n e w i t h t h e M A S T E R key of t h e n e w set. O n c e t h e M A S T E R key has been r e g a i n e d , t h e key set can be c o m p l e t e d b y m e a n s of the R E M E M O R I Z A T I O N p r o c e d u r e . T h e n o t c h e s are replaced. Possession of t h e car is o n l y r e g a i n e d b y b r i n g i n g t h e h a n d l e of t h e b r o k e n key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o b e d o n e w i t h t h e M A S T E R key of t h e n e w set. O n c e t h e M A S T E R key has b e e n r e g a i n e d , t h e n e w key set m u s t be m e m o r i z e d b y i n s e r t i n g t h e t r a n s p o n d e r of t h e M A S T E R key f r o m t h e o l d set in t h e M A S T E R key of the n e w set a n d a c t i v a t i n g t h e R E M E M O R I Z A T I O N procedure.
no
yes
80
Bravo-Brava
Electrical system
Fiat CODE
55.
M e c h a n i c a l b r e a k a g e of main k e y in ignition s w i t c h n o t c h
yes
T h e n o t c h e s are replaced ( e s p e c i a l l y o n t h e i g n i t i o n s w i t c h ) . Possession of t h e car is r e t a i n e d b y means o f t h e spare key, if c o n s i d ered a p p r o p r i a t e ; t h e key set can be c o m p l e t ed b y means of t h e R E M E M O R I Z A T I O N p r o c e d u r e u s i n g t h e o l d M A S T E R key.
Key set w i t h o l d m e c h a n i c a l c o d e available as spare no no T h e n o t c h e s are replaced ( e s p e c i a l l y o n ' t h e ignition s w i t c h ) . The transponder from the M A S T E R key of t h e o l d set has t o b e inserted in t h e M A S T E R key of the n e w set, a n d t h e n e w keys m u s t be m e m o r i z e d b y t h e R E M E M O R I Z A T I O N procedure. T h e n o t c h e s are replaced ( e s p e c i a l l y o n t h e i g n i t i o n s w i t c h ) . Possession of t h e car is r e g a i n e d either b y t h e E M E R G E N C Y P R O C E D U R E or b y b r i n g i n g t h e h a n d l e o f t h e b r o ken key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o be d o n e u s i n g t h e M A S T E R key of t h e n e w set. O n c e t h e M A S TER key has b e e n r e g a i n e d , t h e key set c a n be c o m p l e t e d b y means o f t h e R E M E M O RIZATION procedure. T h e n o t c h e s are replaced ( e s p e c i a l l y o n t h e i g n i t i o n s w i t c h ) . Possession of t h e car is r e gained only by bringing the handle of the b r o k e n key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , to be d o n e w i t h t h e M A S T E R key o f t h e n e w set. O n c e t h e M A S TER key has b e e n r e g a i n e d , t h e key set c a n be c o m p l e t e d b y means of t h e R E M E M O RIZATION procedure. T h e n o t c h e s are replaced ( e s p e c i a l l y o n t h e i g n i t i o n s w i t c h ) . Possession of t h e car is r e g a i n e d either b y t h e E M E R G E N C Y P R O C E D U R E or b y b r i n g i n g t h e h a n d l e of t h e b r o k e n / s p a r e key u p t o t h e aerial w h i l e s w i t c h i n g o n t h e i g n i t i o n ( + 1 5 ) , t o be d o n e u s i n g t h e M A S T E R key f r o m the n e w set. O n c e t h e M A S T E R key has been r e g a i n e d , t h e n e w k e y set m u s t be m e m o r i z e d b y i n s e r t i n g t h e t r a n s p o n d e r o f t h e M A S T E R key f r o m t h e o l d set in t h e M A S T E R key of t h e n e w set a n d activating the R E M E M O R I Z A T I O N procedure.
yes
yes
C o d e C a r d available no
no
yes C o d e Card available no T h e n o t c h e s are replaced ( e s p e c i a l l y o n t h e i g n i t i o n s w i t c h ) . Possession of t h e car is o n y r e g a i n e d b y b r i n g i n g t h e h a n d l e of t h e b r o k e n / s p a r e key u p t o t h e aerial w h i l e s w i t c h ing o n the ignition ( + 1 5 ) , to be done using t h e M A S T E R key. O n c e t h e M A S T E R key has been regained, t h e n e w key set m u s t b e m e m o r i z e d by i n s e r t i n g the t r a n s p o n d e r o f t h e M A S T E R key f r o m the o l d set in t h e M A S T E R key of t h e n e w set a n d a c t i v a t i n g the M E M O R I Z A T I O N procedure.
81
Electrical system
Fiat CODE
Bravo-Brava
55.
Aerial o n ignition s w i t c h faulty
C O D E w a r n i n g light n o t w o r k i n g
Replace t h e w a r n i n g l i g h t ; m e a n w h i l e it is not p o s s i b l e t o a c t i v a t e t h e r e m e m o r i z a t i o n p r o c e d u r e in a g u i d e d m a n n e r
Fiat C o d e c o n t r o l unit f a u l t y
Engine c o n t r o l unit f a u l t y
Replace t h e e n g i n e c o n t r o l u n i t ( t h e c o d e m e m o r i z a t i o n is a u t o m a t i c )
82
Publication no.
506.670/01
Bravo-Brava
Electrical system
Fiat CODE
55.
W I R I N G D I A G R A M O F F I A T C O D E S Y S T E M (petrol v e r s i o n s )
Fl
-113 r - ( C D ) - I 4 -112
I
+15 140
6 P
30 ^ 1 5
195 * *
48 12 P 31
+ 30 BATT.
Fuse and relay unit Instrument panel Fiat C O D E electronic c o n t r o l u n i t Fuel injection d i a g n o s t i c s o c k e t Fuel i n j e c t i o n / i g n i t i o n control (1370 cc) 1 4 8 . Earth for electronic f u e l i n j e c t i o n
unit
1 6 0 . Fuel i n j e c t i o n / i g n i t i o n c o n t r o l (1747 cc) 1 9 0 . Fuel i n j e c t i o n / i g n i t i o n c o n t r o l (1998 cc) 1 9 5 . Fuel i n j e c t i o n / i g n i t i o n c o n t r o l (1581 cc) 1 9 9 . Aerial f o r Fiat C O D E s y s t e m
83
Electrical system
Fiat CODE
Bravo-Brava
55.
W I R I N G D I A G R A M O F F I A T C O D E S Y S T E M (diesel versions)
T rBl?L (~* V co J DE
Fl
-c -112
(( )VT4b
1 5 / 5 4
200
A987 86 Trn 85 30
(TTT
1 5 / 5 4
N.D. N.D.
57
-c
+ 30 BATT.
c B3 c B4 c B5
B2
_TTT
19 56B
Al ~Q
A3
Q"
B8 B6 y
"TT"
131
226
T
1 5 / 5 4
230 229
4. 6. 19. 56B. Fuse a n d relay u n i t I n s t r u m e n t panel Rear earth Connection between front right cables/engine 57. Inertial s w i t c h 1 3 1 . Fiat C O D E e l e c t r o n i c c o n t r o l u n i t 199. 200. 226. 229. 230. Aerial f o r Fiat C O D E s y s t e m Inertial s w i t c h relay Fiat C O D E d i a g n o s t i c s o c k e t Engine c u t - o u t e l e c t r o s t o p Earth f o r Fiat C O D E
84
Publication no.
506.670/06
Bravo-Brava
Electrical system
Fiat CODE
55.
P4A085L03
P4A085L04
85
Electrical system
Protection and safety devices
Bravo-Brava
55.
HOTWIRE SAFETY DEVICE The v o l t a g e is d i s t r i b u t e d in t h e electrical system u s i n g cables suitable f o r w i t h s t a n d i n g t h e c u r r e n t a b sorbed b y t h e electrical devices. T h e cables are increased b y safety c o e f f i c i e n t s , s o t h a t t h e y are safe t o use. The safety devices w i t h h o t w i r e s p r o t e c t t h e car f r o m possible overloads, w h i c h c a n d a m a g e t h e w h o l e electrical system at t h e p o i n t s w h e r e t h e y are n o t p r o t e c t e d in t h e c o n v e n t i o n a l manner. The t e r m " h o t w i r e " m e a n s t h o s e cables w h i c h c o n n e c t t h e b a t t e r y positive t o t h e electrical d e v i c e w i t h out t h e h e l p of f u s e p r o t e c t i o n ; t h i s is possible t h a n k s t o t h e special s h e a t h w h i c h c o v e r s t h e m .
E3
f\
There are seven h o t w i r e s o n t h i s car, a n d t h e y i n v o l v e t h e f o l l o w i n g c o m p o n e n t s : ' - C o n n e c t i o n b e t w e e n t h e battery positive ( 1 ) a n d starter m o t o r ( 2 ) . - C o n n e c t i o n b e t w e e n starter m o t o r ( 2 ) a n d alternator ( 3 ) . - C o n n e c t i o n b e t w e e n t h e battery positive ( 1 ) a n d maxi f u s e b o x ( 4 ) . - C o n n e c t i o n b e t w e e n battery p o s i t i v e ( 1 ) a n d A B S fuse ( 5 ) . - C o n n e c t i o n b e t w e e n battery p o s i t i v e ( 1 ) a n d air c o n d i t i o n i n g system f u s e ( 6 ) . - Connection between battery positive (1) and fuse for radiator/condenser fan ( 7 ) . - C o n n e c t i o n b e t w e e n battery p o s i t i v e ( 1 ) a n d p r e h e a t i n g c o n t r o l unit ( 8 ) (diesel v e r s i o n s ) . T h i s car is f i t t e d w i t h a p r o t e c t i o n system u s i n g a m a x i fuse b o x ( c o n t a i n i n g six fuses, o f w h i c h three are o p t i o n a l d e p e n d i n g o n t h e version of car). T h i s system is d i f f e r e n t f r o m t h e p r e v i o u s s y s t e m s w h i c h used a single f u s e , because it m a n a g e s t h e v a r i o u s activities separately, s o as t o a v o i d seizure of t h e car if a f a u l t o c c u r s . T h e fuses used are: A . Fuel i n j e c t i o n ( 3 0 A ; 6 0 A f o r Diesel) B. I g n i t i o n ( 4 0 A ) C. Radiator f a n ( 4 0 A ) D. Fuse u n i t ( 8 0 A ) E. A d d i t i o n a l o p t i o n a l extra ( 6 0 A ) F. A i r c o n d i t i o n e r ( 5 0 A ) G. A n t i s k i d ( 6 0 A )
86
Bravo-Brava
Electrical system
Protection and safety devices
55.
Diagram of hot-wire device
0 111111
* O n l y o n diesel versions
P4A087L01
P o w e r fuse b o x B a t t e r y earth o n b o d y shell Battery 6 0 A p o w e r fuse p r o t e c t i n g electrical system 3 0 A f u s e p r o t e c t i n g air c o n d i t i o n i n g system 5 0 A p o w e r fuse p r o t e c t i n g e n g i n e c o o l i n g f a n Alternator Starter m o t o r Plug p r e h e a t i n g c o n t r o l u n i t
87
Electrical system
Electric windows
Bravo-Brava
55.
OPERATION The e l e c t r o n i c c o n t r o l u n i t o n t h e car c h e c k s t h e o p e r a t i o n of t h e driver's electric w i n d o w m o t o r ( c o n trolled b o t h m a n u a l l y a n d a u t o m a t i c a l l y ) a n d t h e passenger's electric w i n d o w m o t o r ( o n l y c o n t r o l l e d manually). M a n u a l m o d e is t h e s t a r t - u p a n d s t o p p i n g of t h e w i n d o w lift m o t o r d e t e r m i n e d by t h e user m a n u a l l y b y p r o l o n g e d pressure o n the c o n t r o l b u t t o n s ( p e r i o d b e t w e e n 6 0 and 3 0 0 m s ) . A u t o m a t i c m o d e is t h e s t a r t - u p of t h e w i n d o w lift m o t o r after a pulse ( o f over 3 0 0 m s ) has been s u p plied. T h e w i n d o w w i l l return t o t h e rest p o s i t i o n o n c e t h e w i n d o w has c o m p l e t e d its t r a v e l . The w i n d o w c a n nevertheless be s t o p p e d d u r i n g t h i s stage by a g a i n pressing o n e of the t w o b u t t o n s . The driver's p u s h b u t t o n u n i t is d o u b l e , a n d so c a n c o n t r o l t h e passenger's w i n d o w , o n l y in m a n u a l (with the ignition o n ) . The passenger's p u s h b u t t o n u n i t is single a n d o n l y carries o u t the m a n u a l f u n c t i o n . On t h e F A S T B A C K v e r s i o n , t h e driver's p u s h b u t t o n u n i t has t h e rear w i n d o w c o n t r o l a l w a y s o n m a n u a l . It can also e x c l u d e t h e rear w i n d o w p u s h b u t t o n u n i t s ( b u t t o n A ) . The p u s h b u t t o n u n i t s o n t h e rear d o o r s w o r k in t h e same w a y as the o n e o n t h e f r o n t passenger s i d e .
P4A088L01
P4A088L02
version
Brava version
N O I S E D E T E C T O R safety system If the c o n t r o l s w i t c h is pressed w h e n t h e w i n d o w has r e a c h e d t h e e n d - o f - t r a v e l p o s i t i o n , t h e e l e c t r o n i c c o n t r o l u n i t a u t o m a t i c a l l y c u t s o f f t h e s u p p l y t o t h e m o t o r . T h i s c o n d i t i o n is r e c o g n i z e d b y a n e l e c t r o n i c circuit called " N O I S E D E T E C T O R " , w h i c h c a n act b y a n a l y s i n g t h e f r e q u e n c y of t h e d i s t u r b a n c e g e n e r ated b y t h e m o t o r b r u s h e s d u r i n g r o t a t i o n . W h e n t h e m o t o r is t u r n i n g it g e n e r a t e s , by m e a n s of t h e c o m m u t a t i o n a r i s i n g b e t w e e n t h e brushes a n d c o m m u t a t o r , a d i s t u r b a n c e s i g n a l w h i c h is t r a n s m i t t e d t o t h e c o n t r o l u n i t via t h e s u p p l y l i n e , a n d w h o s e f r e q u e n c y is p r o p o r t i o n a l t o t h e e n g i n e s p e e d . If the f r e q u e n c y of t h i s signal e x c e e d s 15 5 Hz, t h e c o n t r o l u n i t recognizes t h a t t h e m o t o r is t u r n i n g freely. W h e n t h e w i n d o w reaches t h e e n d - o f - t r a v e l p o s i t i o n or t e n d s t o j a m f o r m e c h a n i c a l reasons, s u c h as t o drastically reduce t h e n o r m a l s p e e d of r o t a t i o n , t h e f r e q u e n c y of the d i s t u r b a n c e signal is r e d u c e d p r o p o r t i o n a l l y . W h e n t h i s f r e q u e n c y falls b e l o w t h e s p e c i f i e d t h r e s h o l d ( 1 5 5 H z ) , t h e N O I S E D E T E C TOR c u t s off t h e s u p p l y .
88
Bravo-Brava
Electrical system
Electric windows
55.
P4A089L04
89
Electrical system
Electric sunroof
Bravo-Brava
55.
LOCATION O F C O M P O N E N T S AND W I R I N G L O O M
Power fuse box Fuse a n d relay u n i t Battery earth Battery Ignition switch Rear earth R i g h t d a s h b o a r d earth
9 1 . P o w e r relay 9 2 . 2 0 A fuse 9 2 A . Cable c o n n e c t i o n w i t h s u n r o o f 93A. Sunroof control unit 93B. Sunroof control button 93C. Sunroof motor 9Bravo. End-of-travel s w i t c h
Wiring diagram
19 92
cc
CD
93C
930
93A
2 4 5 7 8 9
pi
92A
A + 15
90
5 4 2 1
938
UJ
Bravo-Brava
Electrical equipment
Door lock device
55.
REMOVING-REFITTING CENTRAL LOCKING E C U 1. Open t h e glove compartment a n d turn t h e levers s h o w n . 2. R e m o v e t h e c o m p a r t m e n t l i n i n g f r o m t h e car. 3 - 4 . D i s c o n n e c t c o n t r o l u n i t f r o m its h o u s ing.
91
Bravo-Brava
92
Publication no,
506.670/14
Bravo-Brava
Electrical equipment
Air bag
55.
INTRODUCTION A n A I R B A G is a passive safety d e v i c e c o n s i s t i n g of a b a g w h i c h a u t o m a t i c a l l y inflates in t h e c a s e o f f r o n t a l impact in order t o f o r m a barrier b e t w e e n the driver's b o d y a n d car structures. T h i s device w i l l n o t w o r k t o m a x i m u m e f f i c i e n c y unless t h e driver is also secured by seat belts w i t h p r e tensioners. D e c e l e r a t i o n sensors located i n s i d e t h e e l e c t r o n i c c o n t r o l u n i t are s p e c i a l l y a d j u s t e d t o d e t e c t c r a s h c o n d i t i o n s . T h e electronic c o n t r o l unit t r i g g e r s a reaction w i t h a c h e m i c a l c o m p o u n d ( s o d i u m a z i d e ) , w h i c h produces a gas c o n s i s t i n g m a i n l y of n i t r o g e n . T h i s gas i n s t a n t l y inflates s y n t h e t i c f a b r i c b a g s h o u s e d in the m i d d l e of t h e s t e e r i n g w h e e l a n d a b o v e t h e g l o v e c o m p a r t m e n t in f r o n t o f t h e p a s s e n g e r .
P4A092L01
A n air bag system consists of t h e f o l l o w i n g parts: 1 . Electronic c o n t r o l unit: - c o n t a i n s a n e l e c t r o n i c c i r c u i t w i t h t w o d e c e l e r a t i o n sensors; - assesses crash s i t u a t i o n , i m p l e m e n t s i n t e r v e n t i o n strategies, d e t e c t s a n d stores f a u l t s . 2 . Driver's side air bag m o d u l e 3 . Passenger s i d e air bag m o d u l e ( o p t i o n s ) 4 . Red w a r n i n g l i g h t o n i n s t r u m e n t p a n e l i n d i c a t i n g s y s t e m f a u l t s a n d test codes 5. S o c k e t for c o n n e c t i n g Fiat L a n c i a Tester 6. Junction unit 7 . Relay unit 8 . M e c h a n i c a l pretensioners 9. A i r bag earth
93
Electrical equipment
Air bag
Bravo-Brava
ELECTRONIC CONTROL UNIT T h e electronic c o n t r o l u n i t ( p a g e 9 5 reference 1 ) is l o c a t e d in t h e car c o n s o l e h o u s i n g a n d f a s t e n e d rigidly t o the floor pan. It is f i t t e d w i t h a 3 0 p i n c o n n e c t o r ( p a g e 9 5 reference 2 ) . N i n e pins are u s e d f o r c o n n e c t i o n t o t h e e l e c trical system. It is s u p p l i e d w i t h 1 2 V w h e n t h e i g n i t i o n k e y is t u r n e d t o M A R C I A , b u t is able t o c o n t i n u e w o r k i n g f o r a b o u t 1 0 0 m s after t h e p o w e r is c u t off, if t h i s s h o u l d o c c u r as t h e result o f a crash. T h i s is possible d u e t o t h e presence o f a buffer c o n d e n s e r inside t h e e l e c t r o n i c unit. This a c c u m u l a t e s electrical energy t o a l l o w t h e e l e c t r o n i c c o n t r o l u n i t t o w o r k n o r m a l l y a n d t o generate the i g n i t i o n s i g n a l required t o set o f f t h e e x p l o s i v e c a p s u l e . A i r - b a g o p e r a t i o n is therefore e n s u r e d even if i m p a c t causes system p o w e r t o be c u t off ( e . g . d a m a g e d or b r o k e n battery, b r o k e n s u p p l y leads e t c . ) .
T h e c o n t r o l u n i t must b e p o s i t i o n e d w i t h a r r o w ( 3 ) f a c i n g in t h e v e h i c l e ' s d i r e c t i o n of m o t i o n . T h i s p o s i t i o n m u s t b e S T R I C T L Y O B S E R V E D , because it d e t e r m i n e s t h e d i r e c t i o n in w h i c h t h e d e c e l e r a t i o n signal is d e t e c t e d a n d is u s e d t o assess i m p a c t status a n d t h u s c a u s e t h e air b a g t o o p e r a t e . T h e c o n t r o l u n i t c o n t a i n s a n a c c e l e r o m e t r i c sensor. This p r o d u c e s a s i g n a l w h i c h is processed b y a m i croprocessor t o reveal t h e severity o f i m p a c t . T h e m i c r o p r o c e s s o r t h e n d e t e r m i n e s w h e t h e r t o set o f f t h e pretensioners a n d air bags.
94
Publication no.
506.670/14
Bravo-Brava
Electrical equipment
Air bag
55.
Fault memory T h r o u g h o u t t h e p e r i o d t h e v e h i c l e is in m o t i o n , t h e e l e c t r o n c o n t r o l u n i t c o n t i n u a l l y m o n i t o r s t h e s y s tem t o check the continuity of circuits and components. D e t e c t e d f a u l t s are s t o r e d a n d a n " a i r b a g f a i l u r e " w a r n i n g l i g h t c o m e s o n o n t h e i n s t r u m e n t p a n e l . T h e F A U L T M E M O R Y m a y be c o n s u l t e d d u r i n g S e r v i c e b y c o n n e c t i n g a F I A T / L A N C I A - T E S T E R t o t h e tester p o i n t (see details b e l o w )
C r a s h memory As mentioned previously, the c o m p l e x microprocessor and control unit software monitors t h e signal f r o m t h e accelerometric sensor a n d identifies i m p a c t severity level. If t h e i m p a c t is s u f f i c i e n t l y severe, a n d t h e safety sensor sends a n e n a b l e m e n t s i g n a l , a n a c t i v a t i o n s i g n a l is sent t o t h e pretensioners or air b a g s . T h i s a c t i v a t i o n order is s t o r e d i n a special crash m e m o r y t h a t c o n t a i n s records o f i n t e r v e n t i o n t h r e s h o l d v i o l a t i o n s a n d safety sensor e n a b l e m e n t signals.
P4A096L01
95
Electrical equipment
Air bag
D R I V E R ' S S I D E AIR BAG M O D U L E
Bravo-Brava
T h e bag is m a d e o u t of s i l i c o n - c o a t e d n y l o n . Inner v o l u m e is 4 0 litres w h e n t h e b a g is fully i n f l a t e d . T h e b a g is f o l d e d i n t o a plastic case in t h e s t e e r i n g w h e e l h u b . T h e case is f i t t e d w i t h a c o v e r w i t h p r e - e s t a b l i s h e d break lines in t h e m i d d l e . This a l l o w s the c e n t r a l p a r t t o break o u t s o t h a t the b a g can emerge. Because t h e c o v e r is plastic, it must u n d e r n o c i r c u m s t a n c e s be c l e a n e d w i t h a c i d s , abrasives or s u b stances t h a t c o u l d d a m a g e t h e surface a n d affect o p e r a t i o n in a n y w a y . T h e gas g e n e r a t o r is p y r o t e c h n i c a n d l o o k s like a r i n g - s h a p e d a l u m i n i u m s o l i d . T h e generator consists of t h e f o l l o w i n g parts: - a l u m i n i u m c o n t a i n e r in t w o halves. T h e half t u r n e d t o w a r d t h e car interior is p e r f o r a t e d t o a l l o w g a s t o emerge. T h e entire system is sealed. - the s o d i u m azide is c o n t a i n e d in a r i n g - s h a p e d s o l i d a n d p r o d u c e s a c o n s i d e r a b l e q u a n t i t y of g a s w h e n h e a t e d . T h e d e t o n a t o r triggers t h e c h e m i c a l r e a c t i o n t o i n f l a t e t h e b a g .
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The passenger's Air B a g is e n c l o s e d in a c o n t a i n e r w h i c h is s e c u r e d t o a metal frame. The c o m p o n e n t s and p r i n c i p l e of o p e r a t i o n are t h e s a m e as for t h e driver's A i r B a g . The c u s h i o n is made o f s i l i c o n e - c o a t e d n y l o n , a n d w h e n f u l l y i n f l a t e d its internal v o l u m e is a b o u t 9 0 litres. It is f o l d e d in a s p e c i a l c a s i n g installed a b o v e t h e g l o v e c o m p a r t m e n t in t h e d a s h b o a r d . A t t h e c e n t r e of the c a s i n g there are p r e - d e t e r m i n e d fracture l i n e s w h i c h a l l o w t h e centre o f t h e c a s i n g t o break a n d t h e c u s h i o n t o e m e r g e . Since t h e c o v e r is m a d e o f plastic, u n d e r n o c i r c u m s t a n c e s s h o u l d it be c l e a n e d w i t h acids, abrasives or substances w h i c h c o u l d in any w a y a t t a c k t h e s u r f a c e a n d i m p a i r its f u n c t i o n a l i t y . The gas generator is o f t h e p y r o t e c h n i c t y p e a n d is a s o l i d a l u m i n i u m c y l i n d r i c a l element. DEVICE WITH SPIRAL CABLE (CLOCK SPRING)
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The C L O C K S P R I N G is a part c o n n e c t e d t o t h e stalk u n i t . It a l l o w s t h e steering w h e e l t o t u r n w h i l e e n s u r i n g electrical c o n t i n u i t y b e t w e e n t h e driver's side air b a g m o d u l e a n d its w i r i n g . The c l o c k s p r i n g consists o f a c o n t a i n e r w i t h three leads e m e r g i n g f r o m it. O n e lead is c o n n e c t e d t o electrical w i r e s f r o m t h e c o n t r o l u n i t w h i l e t h e other t w o leads are t u r n e d t o w a r d t h e car interior, w h e r e t h e y are c o n n e c t e d t o t h e h o r n a n d t h e air b a g m o d u l e . Inside t h e t w o plates, t h e m o d u l e a n d h o r n b u t t o n c o n n e c t i o n leads are w o u n d u p i n t o a c o i l s o t h a t t h e y c a n f o l l o w steering w h e e l m o v e m e n t s . T h e c l o c k s p r i n g is f i t t e d w i t h a d e v i c e w h i c h a u t o m a t i c a l l y prevents it f r o m t u r n i n g w h e n t h e s t e e r i n g w h e e l is r e m o v e d . This a c t i o n prevents t h e upper p l a t e , n o w n o l o n g e r secured t o t h e steering w h e e l , f r o m t u r n i n g freely t o w i n d u p or u n w i n d t h e leads a n d lead t o t h e p o s s i b i l i t y o f breakage. W h e n t h e steering w h e e l is f i t t e d , t h e d e v i c e is a u t o m a t i c a l l y released. When removing-refitting tion. the clock spring, ensure that the spring is refitted in its original posi-
If for some reason the upper plate of the clock spring turns in relation to the lower plate so that the position upon removal can no longer be determined, it is absolutely necessary to rep/ace the clock spring. If replacement is required, the clock spring is supplied together with the stalk unit. THE UNIT MUST BE INSTALLED WITH THE WHEELS ALIGNED WITH THE VEHICLE'S LONGITUDINAL AXIS (STRAIGHT AHEAD), because this is the corresponding position of a new part. A new device is fitted with an safety key which keeps it locked. This key must be removed when the steering wheel is installed to allow the system to turn correctly.
FAULT DIAGNOSIS W h i l e t h e v e h i c l e is in m o t i o n , t h e e l e c t r o n i c c o n t r o l u n i t a u t o m a t i c a l l y m o n i t o r s the air b a g s y s t e m a n d stores any faults. W h e n a f a u l t is d e t e c t e d , t h e u n i t stores it a n d t u r n s o n t h e air b a g w a r n i n g l i g h t o n t h e i n s t r u m e n t panel.The w a r n i n g l i g h t c o m e s o n f o r a b o u t 4 s e c o n d s (initial test stage) u p o n start u p a n d t h e n goes off. If t h e w a r n i n g l i g h t d o e s N O T c o m e o n or d o e s N O T g o o f f after 4 s e c o n d s , t h e air b a g system m u s t be f a u l t y . S y s t e m a c t i v a t i o n s f o l l o w i n g crashes o f particular severity are also s t o r e d in t h e control unit.
Diagnosis using a F i a t / L a n c i a T e s t e r Faults stored in t h e c o n t r o l u n i t c a n b e a n a l y s e d u s i n g a F I A T / L A N C I A T E S T E R or o t h e r d i a g n o s t i c t o o l . A n o m a l i e s stored in t h e c o n t r o l u n i t m a y b e deleted o n c e t h e f a u l t has been repaired u s i n g a F I A T / L A N C I A TESTER or a n o t h e r d i a g n o s t i c t o o l .
NOTE
/ / a crash causes the system to be activated, the control unit memory cannot be deleted and the unit must be replaced in all cases. The control panel warning light also stays on permanently.
If module lines need to be tested for breaks during fault diagnosis, nected from the wiring and replaced with appropriate dummy
must be
discon-
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SAFETY PRECAUTIONS TO BE OBSERVED WHEN WORKING ON VEHICLES WITH AIR-BAG SYSTEM The following regulations MUST ABSOLUTELY BE OBSERVED during any operations
carried out on vehicles fitted with an air bag. I N T E R V E N T I O N S ON V E H I C L E Note that air bag modules s h o u l d be handled w i t h caution. Their u s e , transport and storage are g o v e r n e d by legal regulations c o v e r i n g e x p l o s i v e s a p p l i c a b l e in t h e c o u n t r y w h e r e t h e v e h i c l e i s s o l d . B e f o r e b e g i n n i n g t o carry o u t : - repairs t o t h e b o d y ; - welding work; - w o r k w h e r e it is necessary t o r e m o v e t h e air b a g m o d u l e s , p r e t e n s i o n e r s or t h e c o n t r o l u n i t . A T u r n t h e i g n i t i o n key t o S T O P a n d r e m o v e . D i s c o n n e c t t h e battery, i.e. D I S C O N N E C T T E R M I N A L S (- a n d + ) f r o m their respective poles a n d T H O R O U G H L Y I N S U L A T E u s i n g tape. B D i s c o n n e c t t h e c o n t r o l u n i t c o n n e c t o r a n d w a i t f o r at least 1 0 m i n u t e s after r e m o v i n g t h e b a t t e r y . f a n air b a g inflation d e v i c e is r e m o v e d , strictly observe t h e f o l l o w i n g p r o c e d u r e :
1 . W a i t for a t least 1 0 m i n u t e s after d i s c o n necting t h e battery before b e g i n n i n g t o r e move the module. 2 . U n s c r e w t h e retaining b o l t s . 3. Disconnect connector p i n of inflation d e vices. 4 . Replace t h e devices w i t h t h e c o v e r f a c i n g u p , in a l o c k e d steel c a b i n e t . T h i s c a b i n e t is d e s i g n e d solely f o r t h i s p u r p o s e a n d s h o u l d never be used t o s t o r e o t h e r t y p e s of materials, particularly if i n f l a m m a b l e . T h e c a b i n e t m u s t be d e s i g n e d t o s t o r e p y r o t e c h n i c charges (steel, i m p a c t - r e s i s t a n t cabinet w i t h grilles t o a l l o w n a t u r a l v e n t i lation i n s i d e ) . It must b e m a r k e d in a c c o r d a n c e w i t h current l e g i s l a t i v e r e q u i r e ments ( D A N G E R EXPLOSIVES - D O AOJ USE N A K E D F L A M E S - N O T T O B E OPENED BY U N A U T H O R I Z E D PERSONNEL).
NOTE
All connectors wired to air bag modules contain a short-circuit clip. The unit cannot be activated in any way until the air bag modules are connected to an appropriate power source by means of the proper connector.
If any system component is NOT activated as a result of an accident, it must be considered still active. Components which are unexp/oded due to faults, because they have reached the end of their warranty term or because they require replacement for other reasons must be returned to the centre using the procedure described below.
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A
NOTE
Safety system components must be fitted and removed ONL Y by skilled, authorised technical personnel. The system could be activated when not required and lead to personal injury or unnecessary repairs to the system if the following rules are not respected. IT IS STRICTLY PROHIBITED TO DISMANTLE AIR BAG MODULES
All system components have been designed specifically to work on a car of a particular make and type. Modules and pretensioners cannot therefore be adapted, reused or installed on other cars, but only on the cars for which they have been designed and built. Any attempt to re-use, adapt or install on another type of vehicle may lead to injury to occupants in the case of an accident.
R e p l a c i n g an A i r B a g (due t o d e f e c t s o r w a r r a n t y e x p i r y ) If a n air b a g m o d u l e is replaced d u e t o d e f e c t s or e x p i r y o f t h e term o f w a r r a n t y , p r o c e e d as f o l l o w s : 1 . R e m o v e the a d h e s i v e label f r o m t h e n e w m o d u l e , a p p l y t o a special f i l e ( c h a r g e / d i s c h a r g e r e g i s t e r ) w i t h t h e v e h i c l e d a t a (chassis n o . registration date, m o d e l etc.) and a d d t h e o l d m o d u l e serial n u m ber. T h e file w i t h t h e registration data m u s t b e k e p t f o r t h e purposes o f f u t u r e c h e c k s . 2. B e f o r e the p l a t e is s t u c k over t h e o r i g i n a l p l a t e , it m u s t b e perforated f o r t h e m o n t h a n d year t e n years after m o d u l e i n s t a l l a t i o n d a t e ( e . g . t h e year 2 0 0 6 w h e n t h e m o d u l e is f i t t e d in 1 9 9 6 ) . 3. C o n n e c t t h e m o d u l e t o t h e c o n n e c t o r w h i c h e m e r g e s f r o m t h e steering w h e e l . 4 . Fit t h e air b a g m o d u l e in its h o u s i n g o n t h e steering w h e e l a n d c h e c k t h a t t h e c o n n e c t i o n lead is p r o p e r l y arranged. T i g h t e n r e t a i n i n g b o l t s t o t h e s p e c i f i e d t o r q u e .
R e p l a c i n g control u n i t T h e electronic c o n t r o l u n i t m u s t A L W A Y S b e r e p l a c e d in t h e case of a crash i n v o l v i n g a c t i v a t i o n o f t h e system. MCT Never attempt to reuse the electronic control unit in any way.
NOTE
After
working
on the system,
check
operation
by means
of a FIA TI LANCIA
TESTER.
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A c c i d e n t s w i t h o r w i t h o u t a c t i v a t i o n of t h e a i r b a g s y s t e m S o m e c o m p o n e n t s o f t h e safety s y s t e m s h o u l d b e i n s p e c t e d if t h e system has been a c t i v a t e d , if t h e s y s t e m has been o n l y partly a c t i v a t e d o r if t h e s y s t e m has n o t b e a c t i v a t e d at a l l . These c o m p o n e n t s are as f o l l o w s : - steering c o l u m n ; - steering c o l u m n m o u n t s ; - electronic c o n t r o l u n i t a n d m o d u l e a n c h o r a g e area; - clock spring contact; - facia ( i n passenger air b a g m o d u l e area). T h e c o m p o n e n t s h o u l d be replaced if f o u n d t o b e d i s t o r t e d , b r o k e n or b e n t . A c c i d e n t s involving a c t i v a t i o n o f t h e a i r bag s y s t e m S o m e c o m p o n e n t s o f t h e safety s y s t e m must be r e p l a c e d if t h e v e h i c l e experiences a h e a d - o n c o l l i s i o n i n v o l v i n g a c t i v a t i o n o f t h e safety s y s t e m . These c o m p o n e n t s are as f o l l o w s : - air b a g m o d u l e s ; - electronic c o n t r o l u n i t . W i r i n g a n d c o n n e c t o r s m u s t be i n s p e c t e d t o i d e n t i f y signs o f b u r n i n g , m e l t e d o u t e r i n s u l a t i o n or d a m age d u e t o excess heat. C o m p o n e n t s must be replaced if s i g n s o f d a m a g e are n o t e d o n t h e c l o c k s p r i n g a n d e l e c t r o n i c c o n t r o l u n i t or air b a g m o d u l e a n c h o r a g e areas.
Painting operations N o particular safety p r e c a u t i o n s n e e d t o o b s e r v e d in t h e case o f p a i n t i n g a n d s u b s e q u e n t s t o v e d r y i n g , because the safety s y s t e m (air b a g s a n d p r e t e n s i o n e r s ) is d e s i g n e d t o remain u n d a m a g e d w h e n t h e o u t e chicle surfaces are heated u s i n g n o r m a l p a i n t d r y i n g s y s t e m s .
It is forbidden to use naked flames near to modules. Ail electronic control units (including the air bag system control unit) must nevertheless moved if there is a likelihood of their being heated to 85C or over).
be re-
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DANGER T O HEALTH Observe t h e f o l l o w i n g p r e c a u t i o n s w h e n h a n d l i n g a c t i v a t e d m o d u l e s : 1 . Use p r o t e c t i v e g l o v e s a n d safety g o g g l e s . 2. W a s h h a n d s and e x p o s e d b o d y parts after t o u c h i n g a n a c t i v a t e d air b a g .
EFFECTS OF OVER-EXPOSURE There is n o p o t e n t i a l risk o f e x p o s u r e t o p r o p e l l a n t b e c a u s e t h e s y s t e m is f u l l y sealed. The p r o p e l l a n t m i x t u r e is in t h e s o l i d state a n d c a n n o t b e i n h a l e d even if t h e gas g e n e r a t o r c a r t r i d g e s h o u l d break. There is n o danger t o h u m a n health if a n y gas s h o u l d e m e r g e . A s a p r e c a u t i o n , a v o i d c o n t a c t w t i h t h e skin a n d d o n o t ingest t h e p r o p e l l a n t .
In the case of - Contact with the skin: wash - Contact with eyes: rinse -
immediately with soap and water. the eyes immediately with running water for at least
15 min-
utes. Inhalation: take the patient out into the open air immediately. Swallowing: induce vomiting if the person is conscious. Always call a doctor under these circumstances.
SAFETY REGULATIONS FOR HANDLING AIR BAG M O D U L E S Under n o r m a l c o n d i t i o n s , driver a n d passenger s i d e air b a g s are a c t i v a t e d after r e c e i v i n g a n e l e c t r o n i c trigger c o m m a n d d u r i n g i m p a c t . T h e g a s p r o d u c e d u n d e r these c o n d i t i o n s is m a i n l y n o n - t o x i c n i t r o g e n . It is therefore i m p o r t a n t t o ensure t h a t p e r s o n n e l c a r r y i n g o u t w o r k o n t h e d e v i c e w h e n f i t t e d t o t h e v e h i cle carefully observe t h e f o l l o w i n g safety reglations. Personnel w o r k i n g o n t h e devices m u s t b e specially t r a i n e d .
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- W h e n r e m o v i n g a n d replacing o p e n ( e x p l o d e d ) air b a g m o d u l e s , handle o n l y o n e m o d u l e at a t i m e a n d use gloves a n d g o g gles f o r r e m o v a l . A f t e r t h e o p e r a t i o n s are c o m p l e t e d , w a s h h a n d s t h o r o u g h l y u s i n g neutral s o a p a n d rinse eyes i m m e d i a t e l y in p l e n t y o f r u n n i n g w a t e r if t h e y c o m e i n t o c o n t a c t w i t h p o w der residues. T h e m e t a l l i c parts o f a recently d e t o n a t e d air b a g are very h o t . A v o i d t o u c h i n g t h e s e c o m p o n e n t s f o r several m i n u t e s ( a b o u t 2 0 m i n u t e s ) after t h e A i r - B a g is a c t i v a t e d .
A When removing and replacing UN EXPLODED air bags, always rest the air bag module w i t h the opening flap and pre-marked tear lines turned upward. Never place anything above the flap. B D o n o t s u p p l y t h e air b a g m o d u l e w i t h electric c u r r e n t in a n y w a y .
It is prohibited by dummy
of system
components
unless
modules
have been
replaced
- Never install air bag m o d u l e s o n a v e h i c l e o n c e t h e y have been d r o p p e d or s h o w a n y signs o f d a m a g e . is f o r b i d d e n t o keep air b a g m o d u l e s t o g e t h e r w i t h i n f l a m m a b l e material o r f u e l . - The gas generators m u s t n o t c o m e i n t o c o n t a c t w i t h a c i d , grease or heavy m e t a l s . C o n t a c t w i t h s u c h substances c o u l d lead t o t h e p r o d u c t i o n o f p o i s o n o u s or h a r m f u l g a s a n d e x p l o s i v e c o m p o u n d s . - Store parts in their o r i g i n a l p a c k i n g . D u r i n g t e m p o r a r y s t o r a g e , f o l l o w t h e s a m e p r o c e d u r e f o r a n air bag m o d u l e removed f r o m t h e v e h i c l e b u t n o t a c t i v a t e d , i.e. a l w a y s use a l o c k e d steel c a b i n e t w h i c h is suitably d e s i g n e d (steel i m p a c t - r e s i s t a n t c a b i n e t w i t h grilles t o a l l o w natural v e n t i l a t i o n i n s i d e ) . T h e c a b i n e t m u s t be e q u i p p e d w i t h s p e c i a l w a r n i n g s i g n s ( D A N G E R E X P L O S I V E S - D O N O T U S E NAKED FLAMES - N O T T O BE OPENED BY U N A U T H O R I Z E D P E R S O N N E L ) . - N o - o n e w o r k i n g o n a v e r s i o n f i t t e d w i t h a n air b a g is a l l o w e d t o w o r k f r o m t h e f r o n t seats w i t h o u t firstly r e n d e r i n g t h e s y s t e m i n o p e r a t i v e b y t u r n i n g t h e i g n i t i o n k e y t o S T O P a n d t h e n d i s c o n n e c t i n g and insulating the battery, a n d then w a i t i n g for 1 0 minutes. - If w a t e r a n d m u d reach t h e level o f d e v i c e c o m p o n e n t s as a result o f e x c e p t i o n a l a t m o s p h e r i c c o n d i tions (floods, high tides e t c . ) , the device must be replaced.
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DISPOSING OF U S E D AIR BAG M O D U L E S Air b a g m o d u l e s f i t t e d t o a v e h i c l e m u s t n o t be d e m o l i s h e d w i t h t h e v e h i c l e b u t must be r e m o v e d b e forehand. Air b a g s c a n n o t be s c r a p p e d w i t h o u t first b e i n g a c t i v a t e d . If the air b a g m o d u l e d o e s n o t g o o f f d u r i n g an a c c i d e n t , the d e v i c e must b e c o n s i d e r e d s t i l l set t o g o off. A l l u n e x p l o d e d material must be sent t o G E M C A in Chivasso, i n d i c a t i n g t h e f o l l o w i n g w o r d i n g o n t h e delivery n o t e : " A I R B A G / P R E T E N S I O N E R D E V I C E C O N T A I N I N G P Y R O T E C H N I C C H A R G E T O BE D E - A C T I V A T ED". Devices m u s t be sent t o G E M C A in t h e o r i g i n a l packs in w h i c h t h e parts w e r e received. If t h e s e are n o t available, t h e e m p t y p a c k can be o r d e r e d f r o m t h e Volvera parts store. If air b a g - pretensioner devices are r e p l a c e d , t h e o r i g i n a l pack m u s t be kept t o use w h e n f o r w a r d i n g u n activated devices t o G E M C A .
Failure to respect the instructions listed here may cause air bags quired and lead to personal injury. Unactivated air bags must NOT refuse disposal channels. Unactivated air bags contain harmful personal injury if the sealed container is damaged during disposal. in accordance with these instructions could constitute a breach
to be activated when not rebe disposed of via the normal substances that could cause Failure to dispose of air bags of current legislation.
Ordering procedure If necessary, devices m a y be o r d e r e d as r e q u i r e d f r o m t h e Parts A f t e r - s a l e d e p a r t m e n t in V o l v e r a u s i n g o n l y t h e V O R p r o c e d u r e because Dealers s h o u l d n o t h o l d a s t o c k of s u c h parts. In a n y case, d u r i n g i n ternal h a n d l i n g t h e y s h o u l d be e n t e r e d in a c h a r g e / d i s c h a r g e register w h i c h s h o w s m o d u l e i d e n t i f i c a t i o n n u m b e r s a n d v e h i c l e data (chassis n o . , r e g i s t r a t i o n d a t a , m o d e l etc.)
NOTE
For foreign
markets,
check
current
legislation
and inform
dealers
accordingly.
105
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H5WIRING DIAGRAM
Fl
116
1 C 14 C
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15A
115
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133 213
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15/54.
C o n n e c t i o n variant f o r v e r s i o n s E L / E L X / H G T
4. 6. 114. 5. 116.
Tester s o c k e t f o r air b a g 5 A f u s e f o r air b a g system Air bag earth Clock spring connection
106
VI 96
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REMOVING DRIVER'S SIDE AIR BAG Safety m e a s u r e s Operations on air bag system components must be carried out by specially trained personnel and the following safety measures must be STRICTLY adhered to. During removal and replacement operations, it is necessary to use polythene gloves and protective goggles. Do not use naked flames near the air bag and air bag system components. The metal components of an air bag are very hot immediately after activation. Wait at least 20 minutes following activation before touching these parts. Individual damaged or defective parts must not be repaired or tampered with in any way but replaced as a whole unit. See section beginning on page further information on safety dures. 99 for proce-
Operation s e q u e n c e 1 . D i s c o n n e c t battery t e r m i n a l s a n d p r o t e c t w i t h insulating tape. W a i t 1 0 minutes a n d t h e n p r o c e e d as f o l l o w s . 2. U n s c r e w t h e t w o 5 m m h e x a g o n a l - h e a d ed s o c k e t s c r e w s l o c a t e d t o t h e rear o f t h e steering w h e e l . T u r n t h e s t e e r i n g w h e e l and p o s i t i o n as s h o w n i n t h e f i g u r e t o g a i n access t o e a c h s c r e w . Lift t h e air b a g o u t o f t h e s t e e r i n g w h e e l . T u r n t h e air b a g a n d m a i n t a i n i n a v e r t i c a l position. Then disconnect t h e yellow t w o - w a y connector.
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77777777777777777777?
Following removal, unactivated air bag modules should immediately be placed in a specially marked cabinet and locked away. The module should be placed with the metal part resting on the surface as shown in the figure.
REMOVING CLOCK SPRING Preliminary o p e r a t i o n s R e m o v e the air b a g as d e s c r i b e d o n t h e p r e v i o u s page. T h e n p r o c e e d as f o l l o w s . 2. A l i g n t h e w h e e l s a n d l o c k t h e s t e e r i n g c o l u m n t h r o u g h o u t all c l o c k s p r i n g r e moval and refitting operations. 3. D i e s e l v e r s i o n s : u n s c r e w s c r e w r e t a i n i n g advance h a n d l e t o a l l o w r e m o v a l o f t h e l o w e r steering c o l u m n t r i m . 4 . D i s c o n n e c t t h e l o w e r steering c o l u m n trim and u n s c r e w t h e three cross-headed screws indicated b y t h e arrows.
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R e m o v i n g the s t e e r i n g w h e e l Proceed with great care when carrying out the following operations. 1 . R e m o v e t h e h o r n c o n n e c t o r f r o m its seat. 2. D i s c o n n e c t t h e h o r n c o n n e c t o r . 3. W i t h d r a w t h e y e l l o w cable f r o m t h e r u b ber slot. 4 . R e m o v e t h e r u b b e r cover f i t t e d t o t h e n u t r e t a i n i n g t h e steering w h e e l t o t h e steering column. 5. U n s c r e w n u t r e t a i n i n g t h e s t e e r i n g w h e e l t o t h e steering c o l u m n .
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<>
P4A110L06
1 . M a r k t h e p o s i t i o n o f t h e steering w h e e l h u b in relation t o t h e steering c o l u m n . 2. Fully r e m o v e t h e s t e e r i n g w h e e l . T a k e care not t o w i t h d r a w t h e t w o c l o c k s p r i n g leads. Take care not to knock the steering wheel during the removal operation. 3. R e m o v e t h e h o r n s u p p l y lead w i t h w h i t e c o n n e c t o r f r o m the slot o n steering w h e e l h u b . 4 . R e m o v e t h e air b a g s u p p l y lead w i t h yellow t w o - w a y connector from the o n t h e steering w h e e l h u b and r e m o v e steering w h e e l f r o m t h e vehicle. Removing w a t c h spring 5. R e m o v e t h e u p p e r s t e e r i n g c o l u m n t r i m b y unscrewing both cross-headed retaining screws. the the the slot the
110
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55.
P4A110L12
1. Disconnect the yellow connector f r o m the n i t i o n s w i t c h bracket, 2. isconnect the yellow connector c o n n e c t i n g t h e air b a g c o n t r o l u n i t t o t h e clock spring. 3. Release t h e c l o c k s p r i n g lead f r o m its r e t a i n i n g leads. U n d o t h e three cross-headed screws retaining t h e clock spring and remove f r o m the vehicle.
The clock spring is fitted with a system to prevent rotation (clip A fig. 5). This operates when the steering wheel is removed. For greater safety, prevent t h e c l o c k s p r i n g f r o m t u r n i n g by u s i n g a c l i p or a d h e s i v e t a p e as i n d i c a t e d by t h e a r r o w .
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If t h e c l o c k s p r i n g d o e s n o t require r e p l a c e m e n t , r e m o v e t h e adhesive t a p e or clip fitted previously w i t h o u t turning t h e upper r i n g . The upper c l o c k s p r i n g case is i d e n t i f i e d by one of t w o d i f f e r e n t c o l o u r s : -Green for v e h i c l e s w i t h p o w e r s t e e r i n g . - R e d for v e h i c l e w i t h o u t p o w e r s t e e r i n g . 3. Position t h e c l o c k s p r i n g o n t h e stalk u n i t , t h e n fasten b y t i g h t e n i n g the three c r o s s headed s c r e w s . If a n e w c l o c k s p r i n g is f i t t e d , t u r n t h e safety key u n t i l it c o m e s c o m p l e t e l y a w a y after f a s t e n i n g t h e s p r i n g t o t h e stalk u n i t .
110/2
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55.
1 . R e p o s i t i o n t h e y e l l o w c o n n e c t i o n lead in t h e r e t a i n i n g c l i p o n t h e stalk u n i t . 2. Secure t h e c o n n e c t i o n lead t o t h e r e t a i n ing block o n the ignition. 3. C o n n e c t t h e c l o c k spring lead t o t h e c o n n e c t i o n l e a d i n g f r o m t h e air b a g c o n t r o l u n i t a n d secure t o the bracket. 4 . Refit t h e u p p e r steering c o l u m n t r i m b y s c r e w i n g in t h e t w o c r o s s - h e a d e d r e t a i n ing screws. Refitting the steering wheel 5. C a r e f u l l y t h r e a d t h e y e l l o w air b a g s u p p l y lead t h r o u g h t h e square s l o t o n t h e steering wheel hub.
110/3
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W W "
Bravo-Brava
1 . Carefully thread t h e horn s u p p l y lead t h r o u g h t h e same s l o t on t h e s t e e r i n g wheel. 2. Fit t h e steering w h e e l a n d a l i g n t h e reference marks m a d e p r e v i o u s l y . 3. Fit t h e steering w h e e l retaining n u t a n d t i g h t e n t o a t o r q u e o f 5.5 da N m . 4 . Fit t h e rubber c o v e r over t h e s t e e r i n g w h e e l retaining nut. 5. C o n n e c t the c o n n e c t o r s h o w n in t h e f i g ure t o t h e h o r n c o n n e c t o r .
the horn lead through around the edge of wheel compartment fouling.
the the to
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55.
Completing assembly 1. Fit t h e c o n n e c t o r and c o n n e c t i o n l e a d i n t o their seat u n d e r the h o r n plate. Carefully pass t h e y e l l o w t w o - w a y air b a g s u p p l y line t h r o u g h the r u b b e r s l o t . 3. Release t h e s t e e r i n g c o l u m n . 4. D i e s e l v e r s i o n s : tighten the advance h a n d l e r e t a i n i n g bolt. Refit t h e l o w e r steering s h a f t t r i m a n d tighten the three cross-headed bolts i n d i cated b y a r r o w s .
110/5
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F5.
<> 1
REFITTING AIR BAG Safety measures Operations oh air bag system components must be carried out by specially trained personnel and safety measures set out in the section beginning on page 99 must be STRICTLY adhered to. Operation sequence 1 . Before r e f i t t i n g t h e air b a g , c h e c k t h a t t h e y e l l o w lead a t t a c h e d t o t h e c l o c k s p r i n g passes t h r o u g h t h e rubber slot. 2. B r i n g t h e d r i v e r ' s air b a g u p t o its f i t t i n g p o s i t i o n o n t h e steering w h e e l a n d t i l t a s necessary. 3. C o n n e c t t h e y e l l o w t w o - w a y c o n n e c t o r leading f r o m . t h e c l o c k s p r i n g t o t h e air bag connector. 4 . Position t h e air b a g carefully in its seat and then tighten both 5 m m h e x a g o n a l headed s o c k e t s c r e w s r e t a i n i n g t h e air b a g t o t h e steering w h e e l .
by off.
ensuring
After refitting, check the system is working properly by means of a FIAT/ LANCIA TESTER or other diagnostic instrument.
110/6
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Bravo-Brava
55.
SIDE REPEATER Removing-refitting 1 . Use a s c r e w d r i v e r at t h e p o i n t s h o w n b y the a r r o w t o d i s e n g a g e the s i d e repeater f r o m t h e b o d y shell. 2. D i s c o n n e c t t h e s u p p l y cables c o n n e c t o r f r o m t h e b u l b holder, a n d rotate t h e h o l d e r t o release it f r o m t h e lens. REAR LIGHTS C L U S T E R Removing-refitting door v e r s i o n ) r e a r lights c l u s t e r ( 3 -
3. U n d o t h e s c r e w s a n d remove t h e b u t t o n s s e c u r i n g t h e rear c r o s s m e m b e r t r i m a n d remove t h e t r i m . 4. Undo the screws (arrowed) and remove the l i g h t s cluster t r i m . 5. U n d o t h e n u t s i n d i c a t e d a n d r e m o v e t h e lights cluster f r o m its seating.
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55.
Operation A d j u s t m e n t is electrical a n d is effected w h e n t h e d i p p e d beam h e a d l a m p s are s w i t c h e d o n . T h e m o v e m e n t is a c h i e v e d by t w o m o t o r s ( 4 3 - 4 4 ) m o u n t e d d i r e c t l y o n t h e l i g h t clusters. T h e c o n t r o l ( 4 5 ) is a p o t e n t i o m e t e r c o n t r o l l e d b y a k n o b l o c a t e d o n the d a s h b o a r d , w h i c h can be set t o f o u r d i f f e r e n t p o s i t i o n s c o r r e s p o n d i n g t o t h e f o u r p o s i t i o n s t h a t can be a s s u m e d b y t h e l i g h t s clusters. T h e w i r i n g d i a g r a m s h o w s t h e c o n n e c t i o n s of t h e v a r i o u s d e v i c e s w h i c h c o n s t i t u t e t h e s y s t e m . T h e system is s u p p l i e d b y a v o l t a e of 1 2 V c o m i n g f r o m t h e i g n i t i o n s w i t c h , a n d is p r o t e c t e d b y t h e fuse ( F 5 ) l o c a t e d o n t h e f u s e a n d relay u n i t ( 4 ) . T h e a c t u a t o r consists of a m o t o r o n w h i c h a p o t e n t i o m e t r i c p o s i t i o n t r a n s d u c e r is m o u n t e d , a n d an e l e c t r o n i c c o n t r o l unit.
W i r i n g d i a g r a m s h o w i n g c o n n e c t i o n of h e a d l a m p a l i g n m e n t d e v i c e
P4A023L01
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55.
ELECTRIC HEADLAMP ADJUSTER T h e vertical a l i g n m e n t of t h e f r o n t l i g h t s c l u s ters is a d j u s t e d in a c c o r d a n c e w i t h t h e car load by m e a n s of a p o t e n t i o m e t e r l o c a t e d o n t h e i n s t r u m e n t panel. Four n u m b e r s are engraved o n t h i s p o t e n tiometer, c o r r e s p o n d i n g t o four d i f f e r e n t l o a d conditions. - P o s i t i o n 0: driver o n l y or w i t h passenger o n f r o n t seat. - P o s i t i o n 1: all seats o c c u p i e d ( 5 persons). - P o s i t i o n 2: all seats o c c u p i e d p l u s load in t h e l u g g a g e compartment. - P o s i t i o n 3: driver p l u s m a x i m u m p e r m i t t e d l o a d in l u g gage c o m p a r t m e n t .
3(C). 50A fuse protection additional o p t i o n al extras 4 . Fuse a n d relay u n i t 5. M a i n b e a m relay 7. Stalk u n i t 1 0 . Battery earth o n b o d y shell 1 1 . Battery
Ignition switch R i g h t / l e f t cable c o n n e c t i o n Left d a s h b o a r d e a r t h R i g h t d a s h b o a r d earth Left h e a d l a m p a d j u s t m e n t m o t o r Right headlamp adjustment motor H e a d l a m p adjuster c o n t r o l
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HEADLAMP ALIGNMENT
The car m u s t be c o m p l e t e w i t h spare w h e e l , t o o l s , f l u i d s a n d f u e l reserve, t h e t y r e s m u s t be at n o r m a l o p e r a t i n g pressure a n d t h e d r i v er m u s t be o n b o a r d . Place t h e car o n f l a t g r o u n d w i t h t h e lights cluster lenses 1 0 m a w a y f r o m a screen or o p a q u e surface o n w h i c h the f o l l o w i n g lines have been d r a w n : V - V : vertical line c o r r e s p o n d i n g t o t h e plane of s y m m e t r y of t h e car. C - C : c o r r e s p o n d i n g t o t h e vertical planes passing t h r o u g h t h e reference centres of t h e l i g h t s clusters. H C - H C : h o r i z o n t a l line c o r r e s p o n d i n g t o t h e h e i g h t f r o m t h e g r o u n d of t h e reference c e n tres of t h e lights clusters. A C - A C : h o r i z o n t a l line 1 0 c m b e l o w t h e line H e - H e (value for cars w h i c h are n e w , b u t settled d o w n , c o r r e s p o n d i n g t o a 1 % d r o p ) . A l i g n t h e lights clusters o n t h e d i p p e d b e a m . Using the headlamp alignment device, proceed as f o l l o w s :
Vertical alignment Line u p t h e h o r i z o n t a l s e c t i o n of t h e d e m a r c a t i n g line b e t w e e n t h e dark area a n d t h e area i l l u m i n a t e d b y t h e l i g h t b e a m , w i t h t h e line A C - A C d r a w n o n t h e screen. Horizontal a l i g n m e n t Line u p t h e i n t e r s e c t i n g p o i n t of t h e t w o d e m a r c a t i n g lines, t h e h o r i z o n t a l line a n d t h e a n g l e d line, w i t h t h e respective i n t e r s e c t i o n s of t h e lines C - C a n d A C - A C o n t h e s c r e e n . If the screen has t o be p l a c e d at a s h o r t e r d i s t a n c e , t h i s value m u s t be r e d u c e d p r o p o r t i o n ally.
M a n u a l a d j u s t m e n t of f r o n t f o g l a m p s T h e f r o n t f o g l a m p b e a m is a d t u s t e d u s i n g a w r e n c h w h i c h s h o u l d be inserted in t h e a p p r o p r i a t e l h o l e (see F i g u r e ) .
21
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Electrical equipment
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55.
REMOVING-REFITTING PASSENGER SIDE AIR BAG Safety measures Operations on air bag system components must be carried out by specially trained personnel and the following safety measures must be STRICTLY adhered. During removal and replacement operations, it is necessary to use polythene gloves and protective goggles. Do not use naked flames near the air bag and air bag system components. The metal parts of a recently-detonated air bag are very hot, avoid touching these parts for at least 20 minutes after bag activatlndividual damaged or defective parts must not be repaired or tampered with in any way but replaced as a whole uniSee section beginning on page 99 for further information on safety procedures.
Operation s e q u e n c e 1 . D i s c o n n e c t a n d insulate b a t t e r y t e r m i n a l s . Wait 10 minutes. Then open the glove c o m p a r t m e n t a n d t u r n t h e k n o b s s h o w n in the f i g u r e . 2. R e m o v e t h e upper part of t h e t r i m f r o m i n side t h e g l o v e c o m p a r t m e n t . 3. Prise off t h e courtesy l i g h t in t h e g l o v e c o m p a r t m e n t b y means of t h e r e t a i n i n g tabs. 4. Disconnect the glove c o m p a r t m e n t courtesy l i g h t after d i s c o n n e c t i n g t h e c o n n e c tor s h o w n in t h e f i g u r e .
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55.
Unscrew the bolts fastening the glove c o m p a r t m e n t a n d remove f r o m t h e car. Disconnect supply connector f r o m the c o n t r o l unit. leading
A
NOTE
Following removal, unactivated air bag modules should immediately be placed in a specially marked cabinet and locked away. The module should be placed with the metal part resting on the surface as shown in the figure. Refit the air bag by carrying moval instructions in reverse out reorder.
IS
BATTERY COM-
NOTE
After refitting, check system operation by means of a FIAT I LANCIA TESTER or other diagnostic instrument.
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55.
REPLACING PASSENGER SIDE AIR BAG TRIM
Safety measures
<*>iA
Operations on air bag system components must be carried out by specially trained personnel and the following safety measures must be STRICTLY adhered to. During removal and replacement operations, it is necessary to use polythene gloves and protective goggles. Do not use naked flames near the air bag and air bag system components. Individual damaged or defective parts must not be repaired or tampered with in any way but replaced as a whole unitSee page 99 onward for further information on safety procedures.
Operation s e q u e n c e The metal parts of a recently-detonated air bag are very hot. Avoid touching these parts for at least 20 minutes after bag activation.
R e m o v e t h e air bag as d e s c r i b e d f r o m page 1 1 0 / 8 o n w a r d . R e m o v e t h e facia t r i m as d e s c r i b e d f r o m page 3 0 o n w a r d in S e c t i o n 7 0 - B o d y work. R e m o v e t h e passenger side air b a g t r i m by unscrewing the four cross-headed screws a n d six r e t a i n i n g rivets i n d i c a t e d .
Carefully check that the seats of the four bolts and six rivets on the facia trim are undamaged. Also check that the trim itself is undamaged. Never fit a new air bag trm to a damaged facia trim. In this case, always replace the facia trim.
NOTE
Refit the air bag trim by carrying removal instructions in reverse der.
out or-
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55.
REMOVING-REFITTING CONTROL UNIT AIR BAG S Y S T E M
Disconnect and insulate the battery terminals, then carefully observe the safety rules described from page 99 onward.
Unscrew the bolt and u n d o the fastening s t u d s . T h e n d i s c o n n e c t t h e t r i m panel l o c a t e d b e n e a t h t h e i n s t r u m e n t facia ( t h e r i g h t h a n d panel is s h o w n in t h e f i g u r e . Repeat t h e p r o c e d u r e for t h e left h a n d panel).
A
110/10 11-98 - Supersedes previous version
Bravo-Brava
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55.
NOTE Check the insulation retaining bracket is correctly positioned, then refit the control unit by carrying out removal instructions in reverse order.
O p e r a t i o n s e q u e n c e for f i t t i n g c o n t r o l u n i t e a r t h lead braid 4. Proceed as f o l l o w s to fit t h e c o n t r o l u n i t earth lead b r a i d : i n s u l a t i o n retaining bracket ( 1 ) Earth braid ( 2 ) - S c r e w ( 3 ) .
Tighten bolt (3) to a torque of 0.8 daNm. Pass the earth terminal between the two anti-rotation tabs on the sound insulation retaining bracket.
NOTE
After the operation, check the system using a FIA TI LANCIA TESTER or other diagnostic tool.
4A251L
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Electrically-operated rearview mirrors
55.
EXTERNAL
1 . R e m o v e t h e internal t r i m o f t h e r e a r v i e w mirror.
2. D i s c o n n e c t t h e electrical s u p p l y c o n n e c tor.
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BATTERY T h e batteries f i t t e d o n all versions of this v e hicle are t h e ES t y p e (Energia Sigillata Sealed Energy) a n d are m a i n t e n a n c e - f r e e . These t y p e of battery have t h e f o l l o w i n g a d vantages compared w i t h conventional ones: - r e d u c e d electrolyte c o n s u m p t i o n d u e t o t h e use of a n e w t y p e of a l l o y in t h e c o n s t r u c t i o n of the.grilles and t h e , plates; - reduced self-discharge w h i c h improves s t a r t i n g for a period of 7 m o n t h s a n d t h e r e f o r e these batteries lend t h e m s e l v e s t o p r o l o n g e d storage (at t e m p e r a t u r e s b e l o w 28C); - a r e d u c e d v o l u m e of gases d e v e l o p e d d u r i n g c h a r g i n g w h i c h are t h e o n e s w h i c h cause c o r r o s i o n a n d c o n s e q u e n t p o o r c o n t a c t at t h e terminal poles. Ifthebatteryappearsto bedischarged, a f t e r h a v i n g left i t w i t h a n o p e n c i r c u i t f o r a t l e a s t t w o h o u r s , measure t h e v o l t a g e w i t h n o l o a d , c o n n e c t i n g a d i g i t a l v o l t m e t e r t o t h e terminals: if it is less t h a n 1 2 . 3 0 V it is 5 0 % c h a r g e d ; if it reaches 1 2 . 4 8 V it is 7 5 % c h a r g e d ; if it reaches 1 2 . 6 6 V it is 1 0 0 % c h a r g e d . // the level of the electrolyte in one or more of the battery cells is lower than the minimum level line on the plastic container, open the cover on the series of caps and add distilled, de-ionized water (as for ordinary batteries). NOTE Never subject the battery to rapid recharging high recharging amperages. at voltages in excess of 15.5 V, nor high currents or
ALTERNATOR Check t h e v o l t a g e a n d t h e m a x i m u m c u r r e n t i n tensity s u p p l i e d by t h e alternator u s i n g a d i g i t a l m u l t i m e t e r a n d a H A L L effect ammeter pliers. Description and u s e of ammeter pliers These are pliers c o n n e c t e d t o a m u l t i m e t e r w h i c h make it p o s s i b l e t o measure: the b a t t e r y c h a r g e a n d d i s c h a r g e current, t h e current c o n t r o l l e d b y t h e SCR ( s i l i c o n c o n t r o l l e d d i o d e ) , c u r r e n t a b s o r b e d b y starter m o t o r s , f r o m 1 0 t o 6 0 0 A w i t h o u t h a v i n g t o i n t e r r u p t t h e c i r c u i t . Before s t a r t i n g t h e m e a s u r e m e n t s it is necessary t o : - place t h e ' L O - H I ' h i g h s w i t c h o n " L O " f o r m e a s u r e m e n t s of u p t o 2 0 0 A or o n " H I " f o r m e a s u r e ments of b e t w e e n 2 0 0 a n d 6 0 0 A . T h e r e a d i n g is o b t a i n e d in b o t h p o s i t i o n s for a n y value, b u t t h e c h a n g e in p o s i t i o n is necessary t o ensure greater precision of t h e d i s p l a y r e a d i n g . - W i t h t h e pliers c o n n e c t e d t o t h e m u l t i m e t e r it is necessary t o set t h e m u l t i m e t e r at the r a n g e 2 0 0 m V or 2V, a l t e r n a t i n g or d i r e c t a c c o r d i n g t o t h e c u r r e n t t o be m e a s u r e d . If t h e range selected is 2 0 0 m V t h e n t h e reading w i l l be in A m p e r e , if the range is 2V t h e n t h e r e a d i n g w i l l be m u l t i p l i e d b y a t h o u s a n d . - A t t h i s p o i n t it is necessary t o zero t h e reading a c t i n g o n t h e " Z E R O A D J U S T " k n o b . W h e n there is reason t o suspect t h e existence of m a g n e t i c f i e l d s it is advisable t o adjust t h e zeroing k n o b w i t h t h e pliers b e t w e e n 5 a n d 1 0 c m f r o m t h e c o n d u c t o r . In t h e case of direct c u r r e n t m e a s u r e m e n t s , t h e p h e n o m e n o n o f hysteresis m a k e make it i m p o s s i b l e t o zero t h e device. In s u c h a case, o p e n a n d close t h e pliers several t i m e s a n d t h e n carry o u t t h e z e r o i n g .
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NOTE
To remove the cover (1) (positioned on the positive battery terminal), act gently using a screwdriver in the position shown by the arrow, until the fixing pins come out.
1. C h e c k i n g c u r r e n t i n t e n s i t y - Fit the a m m e t e r plierson t h e a l t e r n a t o r c a ble/junction unit - start u p t h e e n g i n e a n d let it r u n at b e tween 3000 and 4000 rpm; - s w i t c h o n all t h e available c o n s u m e r s ; - measure t h e m a x i m u m c u r r e n t i n t e n s i t y supplied on the multimeter display. If this v a l u e is m o r e t h a n 5 A b e l o w t h e reco m m e n d e d f i g u r e , o v e r h a u l t h e alternator.
2. C h e c k i n g voltage - Place t h e m u l t i m e t e r p r o b e s in c o n t a c t w i t h t h e battery terminals; - start u p t h e e n g i n e a n d let it run at b e tween 3000 and 4000 rpm; - g r a d u a l l y s w i t c h o n several c o n s u m e r s until t h e a b s o r b t i o n is a b o u t half t h e m a x i m u m load. Under these circumstances t h e v o l t a g e r e a d ing s h o u l d be b e t w e e n t h e m a x i m u m a n d m i n i m u m values (see d i a g r a m s ) d e p e n d i n g o n the a m b i e n t temperature of t h e e l e c t r o n i c regulator (alternator). Voltage (V) Voltage B D i a g r a m A refers t o an RT 1 2 1 A e l e c t r o n i c r e g ulator w h i c h is i n c o r p o rated in M . M a r e l l i alternators, w h i l s t d i a g r a m B refers t o t h e EL 1 4 V 4C electronic regulator w h i c h is i n c o r p o r a t e d in B o s c h alternators.
-40 -20
+10
+110
C
P4A113L06
40 - 2 0
+2 0
4 0 +60 +80 10 0C
+
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Before carrying out the removal procedures, described in this chapter, disconnect the negative battery terminal. M A R E L L I A 1 1 5 1 1 4 V 38/65A A L T E R N A T O R (on 1 3 7 0 1 2 V ; 1929D v e r s i o n s ) Removing-refitting (137012V) 1 . M o v e t h e air inlet hose a w a y , u n d o i n g t h e nuts and the band s h o w n . 2. L o o s e n t h e t e n s i o n of the belt u n d o i n g t h e n u t f i x i n g the belt tensioner. 3. U n d o t h e nut f i x i n g t h e alternator m o u n t i n g bracket a n d t h e n u t f i x i n g t h e latter t o t h e e n g i n e at t h e t o p . 4 . R e m o v e t h e belt tensioner f r o m t h e e n g i n e a n d remove t h e belt f r o m t h e pullies. 5. U n d o t h e l o w e r f i x i n g bolt, d i s c o n n e c t t h e electrical c o n n e c t i o n , t h e n r e m o v e t h e a l t e r n a t o r f r o m t h e vehicle.
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Overhauling
In the case of failed or irregular a l t e r n a t o r recharging, completely dismantle the alternator and carry o u t t h e f o l l o w i n g c h e c k s :
- c h e c k t h e belt t e n s i o n ; - c h e c k t h e t i g h t e n i n g of t h e n u t at t h e p o s i tive alternator terminal ( B + ), m a k i n g sure t h a t t h e w a s h e r is f i t t e d ; - c h e c k t h e t i g h t e n i n g of t h e n u t at t h e energizing t e r m i n a l ( D + ) , m a k i n g sure t h a t t h e w a s h e r is f i t t e d ; - c h e c k t h e t i g h t e n i n g of t h e n u t s at t h e p o s itive c o n n e c t o r b l o c k in t h e e n g i n e c o m partment; - c h e c k t h e t i g h t e n i n g of t h e b o l t s f i x i n g t h e negative battery terminal o n t h e b o d y s h e l l ; - c h e c k t h a t t h e battery t e r m i n a l s are clean and p r o p e r l y t i g h t e n e d . 1 . Position t h e alternator as s h o w n a n d rem o v e t h e plastic p r o t e c t i o n a c t i n g o n t h e tabs s h o w n . 2. U n d o t h e nuts s h o w n in t h e d i a g r a m ; . 3. U n d o t h e b o l t s s h o w n in t h e d i a g r a m . 4 . U s i n g a m e t a l - c u t t e r d i s c o n n e c t all t h e c o n t a c t s s h o w n a n d r e m o v e t h e plate.
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1 . Insert t h e p r o b e s of an o h m m e t e r as i l l u s trated in t h e d i a g r a m . NOTE The readings at the three exciter diode terminals should show infinite resistance (the current does not flow). Reversing the position of the instrument probes should give the diode resistance reading (the current does flow). Checking positive diodes
2 . T u r n t h e d i o d e plate. Insert t h e probes o f a n o h m m e t e r as illustrated in t h e d i a g r a m . NOTE The readings at the three positive diode terminals should show infinite resistance (the current does not flow). Reversing the position of the instrument probes will give the diode resistance reading (the current does flow). Checking negative diodes
3. Insert t h e probes o f a n o h m m e t e r as i l l u s trated in t h e d i a g r a m . NOTE The readings at the three positive diode terminals show show infinite resistance (the current does not flow). Reversing the position of the instrument probes should give the diode resistance value (the current does flow). Dismantling 4 . Proceed as s h o w n in t h e d i a g r a m in o r d e r , to undo the nut fixing t h e pulley and then r e m o v e t h e latter.
P4A116L03
P4A116L04
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1 . U n d o t h e bolts s h o w n f i x i n g t h e a l t e r n a t o r assembly. 2. D i s m a n t l e t h e f o l l o w i n g a l t e r n a t o r c o m ponents: A . Rear s u p p o r t plate w i t h stator w i n d ings B. R o t o r C. Front s u p p o r t plate 3. C h e c k i n g i n d u c t o r (rotor) w i n d i n g r e s i s t a n c e a t t h e s l i p rings - Place t h e t w o p r o b e s of an o h m m e t e r (set o n a scale of Q x 1 ) in c o n t a c t w i t h t h e r o tor slip rings ( s h o w n by t h e a r r o w s ) : t h e i n s t r u m e n t reading s h o u l d s h o w a c e r t a i n resistance v a l u e .
NOTE
/ / the res/stance value is infinite (broken circuit)rrotto), then the rotor has to be replaced.
4. C h e c k i n g s t a t o r w i n d i n g i n s u l a t i o n
Place t h e t w o p r o b e s of an o h m m e t e r (set o n a scale of Q x 1) in c o n t a c t w i t h t h e w i n d i n g s a n d t h e stator c a s i n g , r e s p e c t i v e ly; t h e resistance reading o n t h e i n s t r u m e n t s h o u l d be i n f i n i t e , if this is n o t t h e case replace t h e rotor.
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<>
1 . C h e c k i n g insulation of stator w i n d i n g s : - place t h e probes of an o h m m e t e r (set o n a scale of D x 1) in c o n t a c t w i t h t h e w i n d i n g s a n d t h e stator c a s i n g ; - the r e a d i n g o n t h e i n s t r u m e n t s h o u l d be i n f i n i t e resistance, if t h i s is n o t t h e case replace t h e rotor. 2. C h e c k i n g c o n t i n u i t y of stator w i n d i n g s : - place t h e probes of an o h m m e t e r (set o n a scale of D x 1) in c o n t a c t w i t h t h e s t a tor w i n d i n g s ( 1 - 2 ) , ( 3 - 4 ) , ( 5 - 6 ) ; - for each measurement there s h o u l d be a certain resistance r e a d i n g o n t h e i n s t r u ment.
<>
// the resistance value does not move from the start of the scale (infinite resistance) or reaches the end of the scale (nil resistance) then this means that the phase being measured is broken or short circuited and that the stator must be replaced. M A R E L L I A115114V 40/75A A L T E R N A T O R (versions with 1580 16V; 1747 16V engines)
16V
version)
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P4A119L04
P4A119L05
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M A R E L L I A127114V 50/85A A L T E R N A T O R (versions with 1747 16V; 1998 20V; 1910 TD engines) R e m o v i n g - r e f i t t i n g (1747 16V version)
1 . P o s i t i o n t h e v e h i c l e o n a lift a n d d i s c o n nect t h e c o n n e c t o r f o r t h e L a m b d a sensor. 2. U n d o t h e b o l t s h o w n a n d release t h e w i r i n g for t h e L a m b d a sensor. 3. Raise t h e vehicle a n d r e m o v e t h e w h e e l arch liner after h a v i n g u n d o n e t h e f i x i n g bolts, t h e n remove t h e belt. 4 . R e m o v e t h e f i x i n g t h e first s e c t i o n of t h e e x h a u s t p i p e t o t h e catalytic c o n v e r t e r . 5. U n d o t h e n u t s f i x i n g t h e first s e c t i o n of t h e e x h a u s t pipe t o t h e exhaust m a n i f o l d .
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1 . U n d o t h e n u t s f i x i n g t h e first s e c t i o n of t h e exhaust p i p e t o the p o w e r u n i t a n d rem o v e it f r o m t h e vehicle. 2. Position t h e h y d r a u l i c j a c k u n d e r t h e p o w e r u n i t as s h o w n in t h e d i a g r a m . 3. U n d o t h e r e a c t i o n s u p p o r t b o l t . L o w e r t h e hydraulic jack to allow the p o w e r unit t o be m o v e d t o extract t h e alternator. 4 . O p e n the p r o t e c t i v e cover a n d d i s c o n n e c t t h e electrical c o n n e c t i o n s f o r t h e a l t e r n a tor. 5. U n d o t h e b o l t s f i x i n g t h e alternator t o t h e p o w e r u n i t a n d remove it f r o m t h e v e h i c l e .
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P4A122L02
R e m o v i n g - r e f i t t i n g (1998 20V version) P o s i t i o n t h e vehicle o n a lift a n d d r a i n t h e c l i mate c o n t r o l system (see s e c t i o n 5 0 - A u x i l iary u n i t s ) . R e m o v e t h e right l i g h t cluster f o l l o w i n g t h e i n s t r u c t i o n s g i v e n o n page 1 9 . 1 . Raise t h e v e h i c l e a n d loosen t h e belt t e n s i o n e r b e a r i n g , after h a v i n g r e m o v e d t h e l o w e r protective s h i e l d (see p a g e 4 5 ) . 2. L o w e r t h e v e h i c l e a n d remove c o m p r e s s o r p r o t e c t i o n s h o w n in t h e d i a g r a m . 3. D i s c o n n e c t t h e electrical c o n n e c t i o n a n d t h e p i p e for t h e c l i m a t e c o n t r o l system shown. 4. Disconnect the pipe for the climate c o n t r o l system f r o m t h e compressor, w o r k i n g f r o m t h e h o u s i n g f o r t h e l i g h t c l u s t e r previously removed. 5. L o o s e n t h e f i x i n g b o l t for t h e alternator m o u n t i n g bracket.
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1 . U n d o t h e u p p e r bolts f i x i n g t h e c o m pressor. 2. U n d o t h e l o w e r b o l t s f i x i n g t h e c o m pressor. 3. R e m o v e t h e belt a n d extract t h e c o m pressor f r o m t h e right l i g h t cluster h o u s ing. 4.5. U n d o the bolts fixing the compressor s u p p o r t plate a n d m o v e it s l i g h t l y t o o n e side.
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2. U n d o t h e l o w e r b o l t f i x i n g t h e alternator.
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Before carrying out the removal procedures, described in this chapter, disconnect the negative battery terminal.
R e m o v i n g - r e f i t t i n g (1370
12V
engine)
1 . P o s i t i o n t h e v e h i c l e o n a lift a n d lift u p t h e b o n n e t . U n d o t h e upper b o l t s f i x i n g t h e starter m o t o r t o t h e p o w e r u n i t . 2. Raise t h e v e h i c l e , t h e n d i s c o n n e c t t h e electrical c o n n e c t i o n s f o r t h e starter m o tor. 3. U n d o t h e l o w e r b o l t f i x i n g t h e starter m o tor t o t h e p o w e r unit. 4 . Extract t h e starter m o t o r f r o m t h e v e h i c l e .
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R e m o v i n g - r e f i t t i n g (1580 P o s i t i o n t h e v e h i c l e o n a lift.
16V
engine)
2. D i s c o n n e c t t h e s u p p l y c o n t a c t s for t h e starter m o t o r .
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Overhauling at the bench 1 . P o s i t i o n t h e starter m o t o r as s h o w n in t h e d i a g r a m a n d u n d o the n u t s s h o w n . 2. U n d o t h e b o l t s s h o w n a n d r e m o v e t h e metal p r o t e c t i o n f o r the starter m o t o r . 3. R e m o v e t h e pressure exerted o n t h e blades p o s i t i o n i n g t h e t a b s as i l l u s t r a t e d in the diagram. 4 . U n d o t h e n u t s h o w n f i x i n g t h e electrical connection.
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P4A128L04
P4A128L05
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of re-
Starter motor components A. B. C. D. E. F. G. H. Front s u p p o r t Electro-magnet Spring guide bush Saftey buffer Pinion engagement fork Rear s u p p o r t S t a t o r / b r u s h h o l d e r plate a s s e m b l y R o t o r / p i n i o n w i t h free w h e e l a s s e m b l y
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MARELLI STARTER MOTOR M 7 0 R - 1 . 4 / 1 2 (versions with 1998 20V engines) 1747 16V;
R e m o v i n g - r e f i t t i n g (1747
16V
engine)
1. U n d o the nut s h o w n and remove the battery f r o m t h e vehicle. NOTE When removing the cover positioned on the positive battery terminal, act as described on page 113.
2. R e m o v e t h e f l o w meter f r o m t h e b o d y s h e l l u n d o i n g the bolts s h o w n . 3. D i s c o n n e c t t h e c o n n e c t i o n s a n d t h e b a n d s , t h e n remove t h e f l o w meter c o m plete w i t h pipes f r o m t h e v e h i c l e . 4. U n d o the bolts fixing the butterfly casing a n d m o v e it aside.
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1. Disconnect the connector s h o w n a n d m o v e t h e b u t t e r f l y casing in s u c h a w a y as t o b e able t o g a i n access t o t h e starter m o tor. 2. Use t o o l 1 8 5 0 1 6 7 0 0 0 t o u n d o t h e u p p e r b o l t s f i x i n g t h e starter m o t o r t o t h e p o w e r unit. 3. Raise t h e v e h i c l e a n d u n d o t h e l o w e r b o l t f i x i n g t h e starter m o t o r t o t h e p o w e r u n i t . 4. R e m o v e t h e starter m o t o r f r o m t h e v e h i c l e .
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1 . R e m o v e t h e battery, u n d o t h e b o l t s a n d the b a n d s h o w n a n d extract t h e resonator. NOTE When removing the cover positioned on the positive battery terminal, act as described on page 113. U n d o t h e bands a n d d i s c o n n e c t t h e c o n n e c t i o n s s h o w n , t h e n extract t h e air d u c t w h i c h c o n n e c t s t h e f l o w meter t o t h e air filter. D i s c o n n e c t the c o n n e c t i o n s at t h e f l o w meter. U n d o t h e bolts f i x i n g t h e f l o w meter, m o v e it aside a n d u n t o t h e u p p e r b o l t s f i x i n g t h e starter m o t o r . Raise t h e vehicle r e m o v e t h e s u p p l y c o n nections, undo the lower fixing bolt and r e m o v e t h e starter m o t o r f r o m t h e v e h i c l e .
2.
3. 4.
5.
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CHECKS T h e starter m o t o r c o m p o n e n t s s h o u l d be s u b j e c t e d t o t h e tests listed b e l o w : rotor: contintuity test, short-circuit and insulation to earth s t a t o r : continuity test and insolation to earth b r u s h holder s u p p o r t : insulation to earth s o l e n o i d valve: continuity test and insulation to earth
the starter
motor; makes
noises
during
starting,
the pinion
I free wheel
must
be
re-
\
/
- starter motor s u p p l y cable t e r m i n a l b r o k e n or o x i d i z e d ; - battery completely discharged; - lack of c o n t a c t f o r rotor arms at c o m m u t a t o r ; - p o s i t i v e rotor arm short c i r c u i t e d ; starter s w i t c h c o n t a c t s o x i d i z e d , w o r n or i n s u l a t e d t h r o u g h f r a g m e n t s ; r o t o r or i n d u c t o r t o earth; rotor or c o m m u t a t o r c e n t r i f u g e d ; p i n i o n e n g a g e m e n t s o l e n o i d w i n d i n g b r o k e n or t o earth.
- c o m m u t a t o r b r u s h e s and b l a d e s w o r n ; - part of i n d u c t o r or rotor w i n d i n g coils s h o r t c i r c u i t e d ; - b a t t e r y terminals o x i d i z e d ; - b a t t e r y state of c h a r g e very l o w or o n e or m o r e elements d e t e r i o r a t e d . 3. E x c e s s i v e n o i s e during s t a r t i n g T h e cause may be: - p i n i o n free w h e e l m e c h a n i s m w o r n ; - p o o r a l i g n m e n t b e t w e e n m o t o r a n d f l y w h e e l ring gear; - several f l y w h e e l ring gear t e e t h excessively w o r n o n t h e e n g a g e m e n t s i d e ; - s p e e d r e d u c t i o n gear d e f e c t i v e or excessively w o r n .
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INTRODUCTION The alarm is a system w>iich offers v o l u m e t r i c and perimeter p r o t e c t i o n : in e f f e c f i t is?capable of c a r r y i n g out a c h e c k o n fb.e p o s i t i o n of the d o o r s a n d for t h e presence o f a m o v i n g oiftectMnside t h e passenger c o m p a r t m e n t . In A d d i t i o n , insan carry o u t t h e f u n c t i o n of e x c l u d i n g t h e a u d M e alarm (siren) a n d t h a t of signalling t h a t t h e r e m o t e c o r r a p l battery is d i s c h a r g e d by t h e LED in t h e r^mo^e c o n t r o l a n d t h e o n e in the d a s h b o a r d c o m i h g o n . In particular it is c a p a b l e of: - a d a p t i n g its o p e r a t i o n ^ t h e l a w s \ n force in t h e v a r i o u s markets g o y e r n i / g t h e use of alarm systems; - d i s t i n g u i s h i n g p e r m a n e n t or i n t e r m i t t e n t errors or faults; - memorizing the number o^alarms implemented; - d e t e c t i n g faults or problems\at t h e c o n n e c t i n g cables for t h e s w j f c h and key f o r d e - a c t i v a t i n g t h e system. The alarm system basically c o m p r i s e s : a r a d i o V r e q u e n c y receiver located in the courtesy l i g h t , a radio f r e q u e n c y transmitter in t h e i g n i t i o n keys w h i o h c o m e w j t ' h / t h e X/ehicle, t w o v o l u m e t r i c sensors a n d s w i t c h e s o n the d o o r s a n d t h e b o n n e t a n d b o o t litis a n d lastly the^electronic c o n t r o l unit ( l o c a t e d in t h e driver's s i d e wheel a r c h ) w h i c h is integrated withNan alaYm si rem. The alarm is e x c l u d e d b y pressing the ren\ote controlN^jitt/on tqn a l o n g t i m e when t h e alarm s w i t c h e s o n (see p a g e 1 3 4 / 2 ) . EMERGENCY KEY The s w i t c h and key f o r t h e e m e r g e n c y c i r c u i t aW lefcatf/d rfear t h e j u n c t i o n u n i t . This makes it possible t o e x c l u d e the alarm if itns/actix/ated \ n a c c o u n t of a f a u l t in t h e s y s t e m .
/ /\ /
De-activation Activation
By t u r n i n g the e m e r g e n c y key' tpe c o n t r o l u n i t \ m i t s an a u d i b l e signal t o i n d i c a t e that t h e alarm is d e - a c t i v a t e d (O/ryposmon). By t u r n i n g t h e e m e r g e n c y key ^ e / c o n a r o l uNjt r e m a i n s \ i l e n t i n d i c a t i n g that t h e alarm is a c tivated ( O N p o s i t i o n ) .
P4A16AL01
Circuit s w i t c h w i t h
switch
is only accessible
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OPERATION S w i t c h i n g on - S w i t c h i n g off T h e alarm is s w i t c h e d on b y pressing t h e transmitter ( r e m o t e c o n t r o l ) s w i t c h and t h e fact t h a t it is o n is s i g n a l l e d b y the d i r e c t i o n i n d i c a t o r s c o m i n g o n for a r o u n d 2.5 s e c o n d s a n d a c o r r e s p o n d i n g a u d i b l e s i g nal ( b e e p ) . T h e o p e r a t i n g range is a b o u t 1 0 metres. T h e alarm is s w i t c h e d off b y t h e transmitter ( r e m o t e c o n t r o l ) s w i t c h b e i n g pressed a g a i n a n d t h i s is s i g n a l l e d b y t h e d i r e c t i o n i n d i c a t o r s f l a s h i n g t w i c e for 0.5 s e c o n d s a n d t w o c o r r e s p o n d i n g a u d i b l e s i g n a l s (beeps). It is not possible to switch on the alarm with the ignition the OFF or PARK positions. switch in the ON position, but only in
T h e s w i t c h i n g o n or off is also s i g n a l l e d b y t h e LEDs a n d , in c o u n t r i e s w h e r e the l a w p e r m i t s , also b y t h e a b o v e m e n t i o n e d visual a n d a u d i b l e s i g n a l s (for e x a m p l e : I t a l y ) . E x c l u d i n g the s y s t e m If t h e transmitter batteries are d i s c h a r g e d or t h e system fails it is p o s s i b l e t o deactivate t h e alarm u s i n g t h e e m e r g e n c y key l o c a t e d b e h i n d t h e l o w e r d a s h b o a r d cover, driver's s i d e ( O F F p o s i t i o n ) . W h e n t h e vehicle is d e l i v e r e d , c h e c k t h a t t h e e m e r g e n c y key is in t h e O N p o s i t i o n . T u r n t h e key t o t h e OFF p o s i t i o n if t h e v e h i c l e is n o t used f o r l o n g p e r i o d s ( m o r e t h a n a m o n t h ) . By p l a c i n g the key in the O N p o s i t i o n a g a i n , if t h e battery is n o t s u f f i c i e n t l y c h a r g e d or if t h e c o n t r o l u n i t has been d i s c o n n e c t e d , t h e alarm w i l l g i v e an i n t e r m i t t e n t a u d i b l e s i g n a l lasting 1 0 beeps ( e x c l u d i n g c e r t a i n c o u n t r i e s w h e r e t h i s is n o t a l l o w e d ) . Surveillance D u r i n g surveillance t h e LED flashes at a f r e q u e n c y of 0.8 Hz. In t h i s state the alarm system surveys: - t h e d o o r s , t h e b o n n e t lid a n d t h e b o o t l i d ; - o n e d i s c o n n e c t i o n of t h e b a t t e r y / c a b l e s c u t ; - t h e n o n a u t h o r i z e d insertion of the i g n i t i o n s w i t c h ; - m o v e m e n t s inside the passenger c o m p a r t m e n t ( v o l u m e t r i c s u r v e i l l a n c e ) . Alarm state T h e alarm is t r i g g e r e d off w h e n o n e of t h e surveillance sensors (see p r e v i o u s list) d e t e c t s an irregular situation. T h e alarm state is d i s p l a y e d b y t h e a c t i v a t i n g of the alarm for a m a x i m u m of 3 2 6 s e c o n d c y c l e s , o n l y if t h e cause of t h e alarm persists a n d by t h e d i r e c t i o n i n d i c a t o r s for a m a x i m u m of 4.7 m i n u t e s still if t h e cause of the alarm persists ( o n l y in c o u n t r i e s w h e r e t h e l a w p e r m i t s ) . T o exit f r o m t h e alarm s i t u a t i o n : - press the transmitter b u t t o n ; - use t h e e m e r g e n c y key ( N . B . T h e alarm o n c o n d i t i o n , h o w e v e r , r e m a i n s m e m o r i z e d inside t h e c o n t r o l u n i t . O n l y use this p r o c e d u r e if y o u d o n o t m a n a g e t o escape f r o m t h e alarm s i t u a t i o n ) .
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Bravo-Brava
55.
S W I T C H I N G O N A L A R M E X C L U S I O N ( T o be c a r r i e d o u t c o m p u l s o r i l y e a c h t i m e it i s s w i t c h e d o n ) It is p o s s i b l e to e x c l u d e t h e o p e r a t i o n of the alarm w h e n s w i t c h i n g o n t h e alarm by p r e s s i n g t h e r e m o t e c o n t r o l s w i t c h f o r 4 s e c o n d s . S t r a i g h t after t h e a u d i b l e / v i s u a l signals t h a t it has been s w i t c h e d o n (see previous page) t o i n d i c a t e t h a t it has been e x c l u d e d 5 a u d i b l e signals ( b e e p s ) f o l l o w in q u i c k s u c c e s sion.
SIGNALLING REMOTE CONTROL BATTERIES DISCHARGED The f a c t t h a t the r e m o t e c o n t r o l batteries are d i s c h a r g e d is s i g n a l l e d by a s i n g l e 2 0 0 ms ( m i l l i s e c o n d ) flash of t h e remote c o n t r o l LED each t i m e t h e s w i t c h is pressed. W h e n t h i s signal o c c u r s it is necessary t o c h a n g e t h e r e m o t e c o n t r o l batteries as s o o n as possible DISTANCE B E T W E E N T R A N S M I T T E R AND R E C E I V E R DURING P R O G R A M M I N G The d i s t a n c e of t h e r e m o t e c o n t r o l f r o m the receiver in t h e c o u r t e s y l i g h t is a b o u t 4 0 c m .
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Alarm
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LOCATION OF COMPONENTS
3. P o w e r fuse box 41. J u n c t i o n unit 6 C . I n s t r u m e n t panel ( c o n n e c t o r C ) 9. R i g h t f r o n t earth 10. Earth f o r battery o n b o d y s h e l l 1 1 . Battery 12. Ignition switch 1 3 . Front r i g h t / l e f t cables c o n n e c t i o n 1 8 . Left rear earth 2 2 . Left dashboard earth 2 7 . Rear c o n n e c t i o n s c o n t a c t b o a r d w i t h luggage compartment light switch incorporated 2 8 . D a s h b o a r d / l o n g i t u d i n a l cables c o n n e c tion 34. Switch control unit 3 5 . D a s h b o a r d / l e f t f r o n t d o o r cables c o n nection 3 6 . D a s h b o a r d / r i g h t f r o n t d o o r cables c o n nection 4 2 . Right d a s h b o a r d earth 70. Dashboard/front cables connection
8 6 . L o n g i t u d i n a l / l e f t rear d o o r c a b l e s c o n nection 8 7 . L o n g i t u d i n a l / r i g h t rear d o o r c a b l e s c o n nection A l a r m d e v i c e electronic c o n t r o l u n i t D i a g n o s t i c s o c k e t for alarm 1 0 4 . A arm 1 5 A protective f u s e 1 0 5 . A arm d e v i c e off s w i t c h 1 0 6 . A arm o n s w i t c h 1 0 7 A . Central l o c k i n g remote c o n t r o l receiver 1 0 8 . Left rear central l o c k i n g / a l a r m o n s w i t c h 1 0 9 . R i g h t rear central l o c k i n g / a l a r m on switch 1 1 0 . Left f r o n t central l o c k i n g / a l a r m on switch 1 1 1 . R i g h t f r o n t central l o c k i n g / a l a r m o n switch
W.
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PROGRAMMING Initially t h e v e h i c l e alarm system c o m e s w i t h a c o d e w h i c h is activated b y a universal r e m o t e c o n t r o l w h i c h a l l o w s t h e v e h i c l e t o b e tested a n d m o v e d inside t h e f a c t o r y . D u r i n g t h e p r e - d e l i v e r y stage it is therefore necessary t o p r o g r a m m e t h e receiver w i t h t h e c o d e f o r t h e transmitter w h i c h c o m e s w i t h t h e vehicle. The alarm signal m o d e s may v a r y a c c o r d i n g t o t h e l a w s in f o r c e in t h e c o u n t r y of r e g i s t r a t i o n . It m a y therefore be necessary t o p r o g r a m m e t h e s y s t e m b y e n t e r i n g t h e C o u n t r y c o d e . There are t w o p r o g r a m m i n g m o d e s : - before e n t e r i n g t h e p a s s w o r d : S I M P L I F I E D P R O G R A M M I N G - after e n t e r i n g t h e p a s s w o r d : P R O T E C T E D P R O G R A M M I N G . Each transmitter has a paper c a r d w i t h the f o u r f i g u r e p a s s w o r d for p r o t e c t i o n against n o n a u t h o r i z e d p r o g r a m m i n g ( p r o t e c t e d p r o g r a m m i n g ) . This card s h o u l d b e r e m o v e d b y t h e c u s t o m e r at t h e t i m e o f purchase a n d p l a c e d in t h e special space at t h e back of t h e C o d e Card.
- Given the importance of programming it is advisable tially, with the help of a second person. - The programming closed. Simplified programming of remote controls should
at least
ini-
be carried
out with
the doors
of the
vehicle
A t t h e t i m e of delivery t h e alarm c o m m a n d s f o r t h e v e h i c l e s h o u l d be m e m o r i z e d .
P4A18AL02
1. 2. 3. 4.
Programming button Radio f r e q u e n c y receiver in c o u r t e s y light LED in courtesy l i g h t Radio frequency remote control
5. Transmitter L E D 6. P a s s w o r d c o d e ( 4 n u m b e r s ) 7. C o n t r o l b u t t o n o n t r a n s m i t t e r
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T h e p r o g r a m m i n g of a t r a n s m i t t e r s h o u l d be c a r r i e d o u t w i t h t h e : 1) the emergency 2) the anti-theft 3) the igntion L E D off key is in the ON device is switched position; off via the remote or has been control; removed. L E D on c o n s t a n t l y
4
P4A19AL04
f=H
S t a r t of simplified p r o g r a m m i n g ( f i r s t remote c o n t r o l ) T h e s i m p l i f i e d p r o g r a m m i n g can o n l y b e used w h e n t h e m e m o r y has n o t y e t been closed (see c h a p t e r o n " P r o t e c t e d p r o g r a m m i n g " ) . T h e s y s t e m " r e c o g n i z e s " t h e c o d e f o r an u n l i m i t e d n u m b e r o f r e m o t e c o n trols, b u t o n l y t h e last e i g h t r e m o t e c o n t r o l s remain p r o g r a m m e d ( w h e n t h e 9 t h r e m o t e c o n t r o l is e n tered t h e first o n e is e x p e l l e d f r o m t h e m e m o r y ) .
1) Press t h e p r o g r a m m i n g b u t t o n o n t h e r e ceiver; t h e LED f o r t h e receiver w i l l start t o F L A S H i n d i c a t i n g " a w a i t i n g t o receive a code"; If the LED remains off when the button is pressed, this means that: a) the alarm is ON. If this is the case, it can only be switched off using the UNIVERSAL REMOTE CONTROL; b) the receiver is faulty or there is no supply.
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2) - Keep t h e receiver b u t t o n pressed; - hold the remote control about 40 c m away; - press a n d release t h e r e m o t e c o n t r o l b u t ton; - t h e LED in t h e c o u r t e s y l i g h t c o m e s o n c o n s t a n t l y s i g n a l l i n g t h a t t h e c o d e has been p r o g r a m m e d .
3) W h e n the b u t t o n for t h e receiver is released t h e LED in t h e c o u r t e s y l i g h t g o e s o u t . A t t h i s p o i n t t h e r e are t w o possibiities: a) T o p r o g r a m m e t h e alarm t o operate in t h e c o u n t r y w h e r e it w i l l be w o r k i n g ( c o u n t r y code). b) Not to modify the previously programmed operation. To maintain the default operating m o d e (ITALY)
Code 1 2 3 4 5
Code 6 7 8 9 10
Country Belgium Holland EEC ( E u r o p e ) TURIN ( t o n e d d o w n al.) TEST In order t o p r o g r a m m e t h e alarm f o l l o w i n g t h e i n s t r u c t i o n s in p o i n t " a " it is necessary t o press t h e p r o g r a m m i n g b u t t o n , w i t h i n t h r e e s e c o n d s of t h e LED g o i n g o u t , as m a n y t i m e s as i n d i c a t e d in t h e t a b l e at t h e side.
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x 6 = OK
A t t h e e n d of t h e procedure if t h e L E D : - F L A S H E S 6 t i m e s , this means t h a t t h e c o d e has b e e n c o r r e c t l y p r o g r a m m e d ; - F L A S H E S 18 t i m e s , this m e a n s t h a t t h e s e rial line b e t w e e n t h e receiver a n d t h e alarm is b r o k e n or t h a t a previously p r o g r a m m e d c o d e has r e m a i n e d in t h e a l a r m m e m o r y ( f a i l u r e t o accept n e w c o d e ) . If t h i s s h o u l d o c c u r , p r o c e e d as described b e l o w .
x 1 8 = N O OK
If the programming button in the courtesy light is not pressed the ITAL Y operating mode will be recognized automatically if this operation is being carried out for the first time. If, on the other hand, this operation has already been carried out previously, then the system will arrange the mode already programmed. NOTE In order to programme try, use the following the country procedure. code and recognize the operating mode of the actual Coun-
press t h e b o n n e t lid b u t t o n ( A ) 7 t i m e s in rapid succession; This last manoeuvre should be carried out in less than 10 seconds.
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- 5 a u d i b l e signals i n d i c a t e t h e e n t r y M A N U A L DIAGNOSIS;
into
4) - d u r i n g these 5 a u d i b l e signals press t h e b o n n e t lid s w i t c h ( A ) a n d keep it pressed; - a last "beep" will signal t h a t this m a n o u e v r e has been a c c e p t e d ;
5) - keep t h e s w i t c h ( A ) pressed for t h e entire d u r a t i o n of t h e last " b e e p " : t h i s o p e r a t i o n signals t h e entry i n t o t h e C o u n t r y p r o g r a m m i n g state and c o n s e q u e n t l y t h e p o s s i b i i t y of e n t e r i n g t h e c o u n t r y c o d e (see t a b l e o n page 1 3 8 ) ;
- release s w i t c h A ; - w i t h i n t h e next 1 0 s e c o n d s press a n d release t h e s w i t c h f o l l o w i n g t h e i n s t r u c t i o n s g i v e n in t h e t a b l e o n page 1 3 8 ( e a c h t i m e the b u t t o n is pressed t h e r e w i l l be an a u d i ble c o n f i r m a t i o n ) . NOTE In order to programme the countrycode it is possible to use the procedure with the Fiat-Lancia Tester.
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PROGRAMMING FURTHER REMOTE CONTROLS USING THE SIMPLIFIED PROCEDURE In o r d e r t o p r o g r a m m e further r e m o t e c o n t r o l s , repeat t h e p r o c e d u r e f o r t h e s i m p l i f i e d p r o g r a m m i n g . It is possible t o p r o g r a m m e an u n l i m i t e d n u m b e r of r e m o t e c o n t r o l s , b u t t h e c o u r t e s y l i g h t w i l l o n l y keep t h e last eight in its m e m o r y . T h i s procedure is v a l i d u n t i l t h e f o l l o w i n g c o n d i t i o n s o c c u r : a) t h e central l o c k i n g / a l a r m system has b e e n s w i t c h e d o n / s w i t c h e d o f f correctly via t h e r e m o t e c o n t r o l 2 5 6 times; b ) t h e p a s s w o r d for one of t h e r e m o t e c o n t r o l s already p r o g r a m m e d has been entere (see p a r a g r a p h o n M A N U A L ACCESS P R O G R A M M I N G ) .
The simplified programming procedure courtesy light and alarm control unit.
definitvely
cancels
the universal
codes
present
in
the
P r o t e c t e d p r o g r a m m i n g - m a n u a l c l o s i n g of the m e m o r y In order t o prevent strangers f r o m b e i n g able t o enter t h e i r c o d e it is necessary t o p r o t e c t ( c l o s e ) t h e m e m o r y . This o p e r a t i o n takes place: a) a u t o m a t i c a l l y after the alarm system has been s w i t c h e d o n / s w i t c h e d off 2 5 6 t i m e s ; b ) if t h e user so desires b y e n t e r i n g t h e p a s s w o r d ( 4 f i g u r e c o d e o n t h e transmitter c a r d ) b e f o r e t h e alarm has been s w i t c h e d o n / o f f 2 5 6 t i m e s , for e x a m p l e o n a n e w v e h i c l e after all t h e r e m o t e c o n t r o l c o d e s given t o t h e C u s t o m e r have been i n t r o d u c e d .
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55.
5 impulses
3. I m m e d i a t e l y press t h e b u t t o n for t h e r e ceiver as m a n y t i m e s as i n d i c a t e d b y t h e first d i g i t of t h e p a s s w o r d ( f o r e x a m p l e : 5 times); it s h o u l d be n o t e d t h a t f o r each i m p u l s e t h e LED w i l l c o m e o n briefly t o give a v i sual c o n f i r m a t i o n .
142
Bravo-Brava
Electrical equipment
Alarm
55.
^ ^ ^ ^
tt
0 impulses
When a "zero" appears in the password, the button in the receiver should not be pressed, but you should wait for a new request to enter the figure indicated by the flashing.
9. I m m e d i a t e l y press t h e b u t t o n f o r t h e r e ceiver as m a n y times as i n d i c a t e d b y t h e last d i g i t o f t h e p a s s w o r d ( f o r e x a m p l e : 3 times); it s h o u l d b e n o t e d t h a t f o r each i m p u l s e the LED w i l l come on briefly t o give a v i sual c o n f i r m a t i o n . A f t e r h a v i n g entered t h e f o u r f i g u r e s o f t h e p a s s w o r d , t h e L E D in t h e receiver m a y b e have in t h e f o l l o w i n g w a y : a) c o m e o n f l a s h i n g (for 1 0 s e e s ) ; t h i s i n d i cates t h a t t h e P a s s w o r d has been e n t e r e d correctly a n d belongs t o o n e of t h e c o d e s for t h e remote controls p r o g r a m m e d ; b) c o m e o n c o n s t a n t l y f o r several s e c o n d s ( 1 0 sees) t o indicate t h a t t h e p a s s w o r d has n o t been correctly e n t e r e d or t h a t it does n o t correspond t o any o f t h e codes for t h e r e m o t e c o n t r o l s p r o g r a m m e d . If t h i s is t h e case, after t h e L E D g o e s o u t , t h e correct password should be reintroduced starting f r o m point 1 ; - w h e n t h e p a s s w o r d has been c o r r e c t l y entered, t h e memory w i l l be " c l o s e d " .
ca
VII-95
143
Electrical equipment
Alarm
Bravo-Brava
55.
CHECKING THAT T H E M E M O R Y IS C L O S E D If a r e m o t e c o n t r o l is p r o g r a m m e d w i t h the m e m o r y c l o s e d , as illustrated b e l o w , at the e n d of t h e operations t h e LED w i l l remain off i n d i c a t i n g that t h e o p e r a t i o n has n o t been a c c e p t e d .
For
example
1. Press the p r o g r a m m i n g b u t t o n in the receiver. The L E D f o r t h e receiver w i l l start t o flash i n d i c a t i n g " w a i t i n g t o receive a code".
After having transmitted the n e w code the LED in the c o u r t e s y light w i l l s t o p f l a s h i n g i n d i c a t i n g t h e failure of t h e o p e r a t i o n . If t h i s is the case, in order t o enter t h e c o d e f o r a n e w r e m o t e c o n t r o l it is necessary t o use t h e c o d e p r o g r a m m i n g w i t h m a n u a l access.
144
Bravo-Brava
Electrical equipment
Alarm
55.
PROGRAMMING CODES WITH MANUAL ACCESS F r o m t h e m o m e n t the m e m o r y is " c l o s e d " , t h e i n t r o d u c t i o n of f u r t h e r r e m o t e c o n t r o l c o d e s takes place b y " m a n u a l l y o p e n i n g t h e m e m o r y " . T h i s o p e n i n g s h o u l d be carried o u t f o l l o w i n g t h e i n s t r u c t i o n s g i v e n in p o i n t s 1 t o 1 2 w o r k i n g in rapid s u c c e s s i o n .
S t a r t of m a n u a l opening of t h e (entering a k n o w n p a s s w o r d )
memory
5 impulses
145
Electrical equipment
Alarm
Bravo-Brava
55.
5. I m m e d i a t e l y press the b u t t o n for t h e receiver as m a n y t i m e s as i n d i c a t e d by t h e second digit of the password (for e x a m ple: 2 t i m e s ) ; it s h o u l d be n o t e d that f o r each i m p u l s e t h e LED w i l l c o m e o n briefly t o g i v e a v i sual c o n f i r m a t i o n .
7. When a "zero" appears in the password" the button in the receiver should not be pressed, but you should wait for a new request to enter the figure indicated by the subsequent flashing.
146
Bravo-Brava
Electrical equipment
Alarm
55.
I m m e d i a t e l y press the b u t t o n f o r t h e receiver as m a n y times as i n d i c a t e d b y t h e last d i g i t of t h e p a s s w o r d ( f o r e x a m p l e : 3 times); it s h o u l d be n o t e d t h a t f o r each i m p u l s e the LED w i l l c o m e o n briefly t o g i v e a v i sual c o n f i r m a t i o n .
I3HJSID
After h a v i n g entered the f o u r f i g u r e s of t h e p a s s w o r d , t h e LED in the receiver s h o u l d b e have in t h e f o l l o w i n g w a y : a) it s h o u l d start t o flash f o r 1 0 sees if t h e p a s s w o r d has been c o r r e c t l y e n t e r e d ( o p e n i n g of t h e m e m o r y ) ; b ) it s h o u l d c o m e o n c o n s t a n t l y f o r 1 0 seco n d s t o i n d i c a t e t h a t t h e p a s s w o r d has n o t been c o r r e c t l y entered or t h a t it d o e s n o t c o r r e s p o n d t o any of t h e c o d e s f o r t h e r e m o t e c o n t r o l s p r o g r a m m e d . If t h i s is t h e case, after t h e LED g o e s o u t , t h e c o r r e c t p a s s w o r d s h o u l d be r e i n t r o d u c e d s t a r t i n g from point 1.
147
Electrical equipment
Alarm
Bravo-Brava
55.
1 1 . Still k e e p i n g t h e receiver b u t t o n pressed, t h e operator s h o u l d h o l d t h e n e w r e m o t e control about 4 0 cm away; then they s h o u l d press a n d release t h e r e m o t e c o n trol button. T h e LED in t h e c o u r t e s y l i g h t s h o u l d come on constantly signalling that the c o d e has been p r o g r a m m e d .
p.
.. .
^
1 2 . Release t h e b u t t o n : t h e LED in t h e c o u r tesy l i g h t s h o u l d G O O F F .
x 6 = OK
o
x 18 = NOT OK
A t t h e end of t h e p r o c e d u r e if t h e LED: - F L A S H E S 6 t i m e s t h e n t h e c o d e has been correctly p r o g r a m m e d ; - F L A S H E S 1 8 t i m e s , t h e n t h i s means t h a t t h e serial line b e t w e e n t h e receiver a n d t h e alarm is b r o k e n . automat-
After having entered the new remote control code the memory becomes closed again ically. In order to enter a new remote control repeat the procedure from point 1.
148
Bravo-Brava
Electrical equipment
Alarm
55.
E L E C T R O N I C A U T O - S W I T C H I N G O N F U N C T I O N ( B e l g i a n a n d United K i n g d o m m a r k e t s o n l y ) V e h i c l e s w i t h electronic alarms f o r t h e Belgian a n d U n i t e d K i n g d o m markets are e q u i p p e d w i t h a " p a s s i v e " a u t o - s w i t c h i n g o n f u n c t i o n . This f u n c t i o n ensures t h a t t h e alarm is a u t o m a t i c a l l y s w i t c h e d o n s h o r t l y ( 2 8 s e c o n d s ) after t h e v e h i c l e is left b y t h e user. T h e surveillance in t h e " p a s s i v e " o p e r a t i n g m o d e is exactly t h e s a m e as f o r t h e normal o n e , it c a n be a c t i v a t e d via t h e remote c o n t r o l , b u t t h e d o o r s are n o t l o c k e d . T h e a u t o m a t i c s w i t c h i n g o n takes place 2 8 s e c o n d s after t h e f o l l o w i n g c o n d i t i o n s are e s t a b l i s h e d : - i g n i t i o n key t u r n e d f r o m O N t o O F F ; - o p e n i n g a n d s u b s e q u e n t c l o s i n g of t h e last d o o r . T h e o p e n i n g of the driver's d o o r or t h e b o n n e t l i d , before t h e d e l a y p e r i o d ( 2 8 seconds) has e l a p s e d , s t o p s t h e c o u n t i n g . T h e c o u n t i n g starts again f r o m zero w h e n t h e d o o r / l i d is closed. In o r d e r to regain p o s s e s s i o n of t h e v e h i c l e a f t e r t h e a u t o - s w i t c h i n g o n , t h e user s h o u l d p r e s s t h e b u t t o n in the t r n a s m i t t e r remote c o n t r o l o n c e . N O T E S AND S P E C I A L F E A T U R E S The a l a r m system is c a p a b l e of s i g n a l l i n g any irregularities in t h e system t o t h e User b y t h e LED c o m i n g o n c o n s t a n t l y or f l a s h i n g . T h e t r a n s m i t t e r signals t h a t the battery is d i s c h a r g e d by its o w n L E D f l a s h i n g o n c e q u i c k l y w h e n t h e r e m o t e c o n t r o l b u t t o n is pressed. 1. W h e n switching o n : - L E D o n c o n s t a n t l y t o i n d i c a t e f a u l t s in t h e v o l u m e t r i c sensor c i r c u i t s ; - L E D o n i n t e r m i t t e n t l y s l o w l y f o r f a u l t s w i t h t h e d o o r a n d lid b u t t o n s ; 2. W h e n s w i t c h i n g off: - i m p u l s e cycles ( n u m b e r of i m p u l s e s f r o m 1 t o 1 0 ) t o i n d i c a t e t h e cause of the alarm (see d e c o d i n g in t a b l e 2 o n page 1 5 0 ) . If t h e LED signals irregularities, t h e User s h o u l d seek assistance f r o m t h e Fiat Service N e t w o r k . T h e L E D c o m i n g o n c o n s t a n t l y i n d i c a t e s that t h e remote c o n t r o l batteries are d i s c h a r g e d . T h e s i g n a l lasts a r o u n d 2 m i n u t e s .
it should be borne in mind that each individual vehicle becomes an integral part of it, therefore cles, even if they are the same model.
component (in the alarm system) fitted on the it should not be fitted or tested on other vehi-
FAULT DIAGNOSIS
F a u l t d i a g n o s i s w i t h the F i a t - L a n c i a T e s t e r T h e s y s t e m is e q u i p p e d w i t h a s p e c i a l d i a g n o s t i c s o c k e t for c o n n e c t i o n w i t h t h e F i at-Lancia-Tester. Before connecting the Fiat-Lancia-Tester make sure that the emergency switch key is in the ON position.
L o c a t i o n of alarm s y s t e m d i a g n o s t i c s o c k e t
149
Electrical equipment
Alarm
Bravo-Brava
55.
Autodiagnosis W h e n s w i t c h e d o n t h e system carries o u t an a u t o d i a g n o s i s w h i c h c a n be r e c o g n i z e d b y t h e LED f l a s h ing at 4 Hz a n d if there is a p r o b l e m or f a u l t in t h e s y s t e m , the LED w i l l signal it in a c c o r d a n c e w i t h t h e m e t h o d s d e s c r i b e d in t a b l e 1 . Table 1. A u t o d i a g n o s i s d i s p l a y BLINK CODES 8 Hz, d u r a t i o n 2.5 sees Light c o n s t a n t , d u r a t i o n 2.5 sees MEANING D o o r / b o n n e t / b o o t left o p e n or s w i t c h f a u l t y V o l u m e t r i c sensors f a u l t y
If a fault is d e t e c t e d for t h e v o l u m e t r i c sensors, t h e n t h e a p p r o p r i a t e sensor is e x c l u d e d f r o m t h e s u r v e i l lance a n d a n a u d i b l e w a r n i n g signal ( b e e p ) is e m i t t e d a s e c o n d after s w i t c h i n g o n . W h e n it is s w i t c h e d off, t h e system indicates, via t h e flashing of t h e L E D , w h i c h sensor has set off the alarm d u r i n g t h e surveillance (see table 2 ) . Table 2. S i g n a l l i n g c a u s e of alarm N of I M P U L S E S 1 impulse 2 impulses 3 impulses 4 impulses 5 impulses 6 impulses 7 impulses 8 impulses 9 impulses 10 i m p u l s e s Liqht c o n s t a n t MEANING Right front door Left f r o n t d o o r R i g h t rear d o o r Left rear d o o r A d d i t i o n a l sensors - v o l u m e t r i c sensors Bonnet Boot + 15 +30 A t least 3 causes of alarm T r a n s m i t t e r batterv d i s c h a r g e d
The b l i n k c o d e s are g i v e n in order. These c o d e s have an interval of 1.5 s e c o n d s b e t w e e n t h e m . Manual d i a g n o s i s It is also p o s s i b l e t o carry o u t a M A N U A L D I A G N O S I S b y o p e n i n g t h e lid a n d t u r n i n g t h e i g n i t i o n key from the O N p o s i t i o n t o t h e O F F p o s i t i o n ; t h e lid p r o t e c t i v e b u t t o n m u s t be pressed w i t h i n 1 5 s e c o n d s 7 times in r a p i d succession in less t h a n 1 0 s e c o n d s ; 5 beeps w i l l signal t h e start of t h e m a n u a l d i a g n o s i s procedure. A f t e r 1 0 s e c o n d s t h e LED or t h e d i r e c t i o n indicators w i l l flash o n c e . By entering i n t o this m o d e t h e a u t o d i a g n o s t i c p r o c e d u r e for the v o l u m e t r i c sensors c o n n e c t e d t o t h e control u n i t w i l l a u t o m a t i c a l l y be a c t i v a t e d . If the test d o e s n o t indicate, irregularities, t h e n t h e d i r e c t i o n i n d i c a t o r s w i l l flash 3 t i m e s a n d t h e r e w i l l be 3 beeps of t h e alarm. After this first stage, each t i m e the state of t h e s w i t c h e s is altered t h e r e w i l l be a c o r r e s p o n d i n g q u i c k flash of t h e d i r e c t i o n i n d i c a t o r s and a b e e p , a c c o m p a n i e d by the LED in t h e c e n t r e c o n s o l e f l a s h i n g . If the key is t u r n e d t o t h e O N p o s i t i o n , t h e alarm w i l l s o u n d briefly ( 5 0 0 msecs) a n d t h e d i r e c t i o n i n d i c a tors w i l l f l a s h (2.5 sees). This last o p e r a t i o n indicates t h e exit f r o m m a n u a l d i a g n o s i s p r o c e d u r e . It is also possible t o leave t h e M A N U A L D I A G N O S I S b y n o t c a r r y i n g o u t a n y a c t i o n s f o r 3 0 s e c o n d s : t h e exit is s i g n a l l e d b y t h e d i r e c tion i n d i c a t o r s c o m i n g o n f o r a r o u n d 2.5 sees a n d a b e e p .
150
Bravo-Brava
Electrical equipment
Alarm
55.
MAIN WIRING DIAGRAM
D D
21
o-y
c C
9 ~ V
+ 15
20
-o
o->
22
19
o->
Q.
A4 A7 B14 fll BIO Bl 1 A6 > A9 > B5 > B6 > A3 > B12t> ftlO 3
AA
F/L TESTER
18
17
4 4
-
+30 +15 9
A8 All A12 A5 B2 Bl
i !
B7
16
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14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12
11
T
+ 30
Central locking control unit Courtesy light w i t h receiver, ultrasound sensors Ignition switch Check panel Warning light (LED) signalling anti-theft device on Function for t w i n LED (function not activated) Diagnostic socket for Fiat-Lancia-Tester Preparation for relay (outlet + 5 0 starter motor supply) Preparation for serial line (injection control unit) A n t i - t h e f t device 15A protective fuse Right direction indicators
Left direction indicators Anti-lifting Expansions Switch signalling bonnet lid open Switch signalling boot lid open Switch signalling right rear door Preparation for relay (inhibiting diesel pump electrostop, heater p l u g s / + 1 5 injection w i r i n g , fuel pump) Switch signalling left rear door Switch signalling right front door Switch signalling left front door V.A.S. anti-theft device control unit
151
Electrical equipment
Alarm
Bravo-Brava
55.
INPUT AND OUTPUT SIGNALS F R O M T H E A N T I - T H E F T D E V I C E C O N T R O L UNIT PIN B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 I/O OUT OUT OUT IN OUT IN IN IN IN OUT IN IN IN OUT IN IN IN IN OUT I/O IN IN OUT I/O OUT OUT IN I/O OUT IN 1 Max (A) 6 6 8 8 8 8 12
#
FUNCTION Relay n.a. contact: right direction indicators operation Relay n.a. contact: left direction indicators operation Preparation for relay n.c. contat: inhibition of diesel pump electrostop + heater plugs / + 15 injection wiring / petrol pump Preparation for relay n.c. contact: + 1 5 for B3 Preparation for relay n.c. contact: outlet + 5 0 starter motor supply Preparation for relay n.c. contact: + 5 0 for B5 and B10 Direction indicators relay common contact: + 3 0 direction indicators supply Left front door open (=closed) switch Right front door open (=closed) switch Preparation for t w o coloured LED operation Preparation required for operating t w o coloured LED by Fiat CODE Positive controlled by the ignition ( + 15) Remote key: common Operation of check: signalling door/s open Switch signalling left rear door open (=closed) Switch signalling right rear door open (=closed) Switch signalling boot lid open (=closed) Switch signalling bonnet lid open (=closed) Operation of ( t w o coloured) LED flashing VAS serial line from courtesy light Direct positive supply ( + 3 0 ) Remote key: internal supply Anti-lifting modules positive supply Line K-Fiat tester Remote key: external supply Volumetric modules supply positive VAS control unit earth Preparation for serial line (supply control unit) External modules earth Alarm signal from external modules ( l o w = alarm)
0,04 0,04 2
*
0,3
* * *
#
0,04
*
#
0,03
* *
0,03 2
#
0,06
#
P4A35AL01
152
Print no.
506.670/01
Bravo-Brava
Electrical equipment
Alarm
55.
WIRING DIAGRAM
a. 9
13 0
_15_
+ 3 0
1G7A
3 4
N.D. N.D. N.D. N.D.
7 0
-C-+-
70i 2 2 10 0
9
10 1
~0
II B A T. T 7 0 -0+ c+7 0
+3 0
N.D.
-
N.D.
15/54
2 2 4 2 - +5 1
! Q.
nn
n n
7 0 -c+-+ c9
Kt f
7U 0
K>
t
9 9 9
N.D.
111
27
18 0
6. 9. 18. 22. 27. 34. 42. 70. 100. Instrument panel Right front earth Left rear earth Left dashboard earth Contact board for rear connections w i t h luggage compartment light switch incorporated Switch unit: alarm warning light on Right dashboard earth Connection for dashboard cables/front Alarm electronic control unit 103. 104. 105. 106. 107A. 108. 109. 110. 111.
16 0
Diagnostic socket for alarm Alarm 15A protective fuse Alarm off switch Alarm on switch Central locking remote control receiver Left rear central locking/alarm on switch Right rear central locking/alarm on switch Left front central locking/alarm on switch Right front central locking/alarm on switch
153
Electrical equipment
Alarm
Bravo-Brava
55.
RECEIVER CONNECTOR T h e receiver is a m o d u l e h o u s e d in the r o o f o f t h e v e h i c l e b e h i n d t h e c o u r t e s y light, w h i c h has an 8 w a y c o n n e c t o r w i t h t h e f o l l o w i n g connections: 1. Not connected 2. Serial line t o w a r d s t h e a n t i - t h e f t device 3. Positive f r o m b a t t e r y ( + 3 0 ) 4. Earth 5. C o m m a n d t o c e n t r a l l o c k i n g t o u n l o c k 6. C o m m a n d t o c e n t r a l l o c k i n g t o l o c k 7. Positive f r o m i g n i t i o n s w i t c h ( + 1 5 ) 8. N o t c o n n e c t e d REMOVING-REFITTING TROL UNIT ALARM CON
P o s i t i o n t h e v e h i c l e o n a lift a n d remove t h e left w h e e l . 1. U n d o the fixing bolts and remove the front s e c t i o n of t h e w h e e l arch liner. 2. U n d o t h e f i x i n g b o l t s a n d r e m o v e t h e rem a i n i n g part of t h e w h e e l arch liner. 3. D i s c o n n e c t t h e electrical c o n n e c t i o n s , u n d o t h e n u t s s h o w n a n d remove t h e alarm c o n t r o l u n i t f r o m t h e v e h i c l e .
154
Bravo-Brava
Electrical system
Preheating control system
55.
INTRODUCTION T h e p r e h e a t i n g c o n t r o l s y s t e m brings t h e temperature of t h e p r e c h a m b e r s u p t o a t e m p e r a t u r e t o p e r m i t s e l f - i g n i t i o n , a n d it consists o f t h e f o l l o w i n g c o m p o n e n t s : - a p r e h e a t i n g electronic c o n t r o l u n i t l o c a t e d in t h e e n g i n e c o m p a r t m e n t ; - f o u r rapid g l o w p l u g s ; - a w a i t - t o - s t a r t w a r n i n g l i g h t l o c a t e d o n t h e i n s t r u m e n t panel. L o c a t i o n of preheating c o m p o n e n t s in c a r
P4A155L01
4 . Preheating c o n t r o l unit 5. G l o w p l u g s 6. M a n u a l d e v i c e f o r i n j e c t i o n a d v a n c e w h e n c o l d
T h e purpose of t h e e l e c t r o n i c c o n t r o l u n i t in t h e e n g i n e c o m p a r t m e n t is t o carry o u t t h e f o l l o w i n g : - deliver current f r o m t h e b a t t e r y t o t h e spark p l u g s f o r a l e n g t h o f t i m e v a r y i n g in a c c o r d a n c e w i t h t h e e n g i n e c o m p a r t m e n t t e m p e r a t u r e , b e f o r e starting. T h i s t e m p e r a t u r e is recorded b y a n e g a t i v e t e m p e r a ture coefficient ( N T C ) g a u g e l o c a t e d in t h e e l e c t r o n i c c o n t r o l u n i t ; - keep t h e w a i t - t o - s t a r t w a r n i n g l i g h t o n f o r a p e r i o d of t i m e d e p e n d i n g o n t h e e n g i n e c o m p a r t m e n t temperature ( f r o m 1.5 t o 4 . 5 s e c o n d s at a t e m p e r a t u r e o f 7 0 C , f r o m 2 0 t o 2 7 s e c o n d s at a t e m p e r a t u r e of - 2 0 C ) ; - ensure for a s o - c a l l e d " d i s t r a c t i o n " t i m e ( a b o u t 2 0 s e c o n d s ) t h a t t h e g l o w plugs remain s u p p l i e d if t h e e n g i n e does n o t start, a n d if t h e e n g i n e d o e s start, t o i n t e r r u p t t h e delivery of current at t h e e n d o f t h e distraction t i m e ; - if o n e of t h e g l o w p l u g s or t h e c u r r e n t cable a c c i d e n t a l l y shorts t o e a r t h , i m m e d i a t e l y s t o p t h e d e l i v e r y of current.
155
Electrical system
Preheating control system
Bravo-Brava
55.
Wiring d i a g r a m
Pin W i r e No. c o l o u r 1 2 3 4 5 6 7 N
C i r c u i t involved Car earth Not connected Ignition switch ( + 15) Ignition switch ( + 5 0 ) Wait-to-start w a r n i n g light Glow plugs Battery positive
C R CL M R
C h a n g e s in preheating time o f t h e g l o w plugs A . Time period d u r i n g w h i c h t h e w a r n i n g light is o n and preheating is o n . B. Tolerance range in w h i c h t h e w a r n i n g light g o e s o u t , w i t h preheating o n . C. Period w i t h p r e h e a t i n g o n a n d w a r n i n g light off. This stage is characterized by a period o f 15 - 2 0 s e c o n d s o f c o n s t a n t i n t e r v e n t i o n , a n d is c o u n t e d f r o m t h e m o ment w h e n t h e w a r n i n g light g o e s o u t . D. P O S T - H E A T I N G p e r i o d , w i t h g l o w p l u g s on a n d w a r n i n g l i g h t off. This stage, characterized by a period of 15 - 2 0 s e c o n d s of c o n s t a n t i n t e r v e n t i o n , is c o u n t e d f r o m t h e end of t h e starting phase w i t h t h e e n g i n e running. E. Period w i t h w a r n i n g light o f f a n d post - h e a t i n g off. T($80 I'-f1
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39-rk
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-30 - 20 - 1 0 1) 1 0
w i n mmss.
20 30 40 50
60 7o .
156
Bravo-Brava
Electrical system
Preheating control system
55.
CHECKING GLOW PLUGS If there are difficulties in s t a r t i n g , m a k e sure t h a t all t h e plugs are w o r k i n g properly. T h e electrical c o n t i n u i t y o f each p l u g s h o u l d be c h e c k e d using a d i g i t a l o h m m e t e r ( O h m = 0 . 6 at 2 0 C ) . It is a d v i s a b l e t o carry o u t this check w i t h t h e p l u g s f i t t e d t o t h e c y l i n d e r head, as t h e f a u l t y p l u g m a y n o t a p p e a r t o be f a u l t y if c h e c k e d w h e n d i s m a n t l e d f r o m its s e a t i n g , w i t h o u t t h e d e f o r m i n g effect caused b y t h e pressure of assembly. A l s o c h e c k t h a t t h e e n g i n e s t o p s o l e n o i d o n t h e f u e l i n j e c t i o n p u m p is n o t s h o r t - c i r c u i t e d , b r o k e n or d i s c o n n e c t e d . NOTE Remember that difficulties in starting may be due to an engine with excessively faulty starter motor or a discharged or badly connected battery. worn seals, a
P4A157L01
M A I N O P E R A T I N G F A U L T S IN T H E P R E H E A T I N G S Y S T E M
Fault
Cause
Remedy
insufficient
Replace c o n t r o l u n i t
Electronic c o n t r o l u n i t n o t earthed O n e or several plugs f a u l t y Circuit b e t w e e n i g n i t i o n s w i t c h a n d t a g t e r m i n a l 3 ( + 1 5 ) of c o n t r o l unit b r o k e n Circuit between ignition s w i t c h and e n gine stop solenoid on p u m p broken Ignition s w i t c h faulty
Replace f a u l t y p l u g s
Restore t h e c o n n e c t i o n Replace i g n i t i o n s w i t c h
157
Electrical system
Preheating control system
Bravo-Brava
55.
ENGINE CUT-OUT SOLENOID
C h e c k i n g o p e r a t i o n of e n g i n e c u t - o u t s o l e noid (on fuel injection p u m p ) T u r n t h e i g n i t i o n o n t o energize t h e e n g i n e cut-out solenoid on the fuel injection p u m p . T h e s o u n d o f t h e s o l e n o i d c l i c k i n g s h o u l d be perceived f r o m t h e e n g i n e c o m p a r t m e n t . If not, check t h e operation of t h e solenoid a n d , if t h i s is satisfactory, c h e c k w h e t h e r t h e c o n n e c t i n g cable b e t w e e n t h e i g n i t i o n s w i t c h a n d e n g i n e c u t - o u t s o l e n o i d is b r o k e n .
Wiring d i a g r a m
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229 230
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3. A. 6. 0. 9.
158
Publication no.
506.670/02
Bravo-Brava
Bodywork
Contents
70.
page page
BUMPERS
- Front bumpers - Rear bumpers (5D) - Rear bumpers (3D) 1 2 3
FRONT DOOR
- Removing-refitting front door 4 - Adjustments 4 - Removing-refitting panel and protective door trim 5 - Removing-refitting door outer handle 6 - Replacing door lock barrel 6 - Removing-refitting door lock 7 - Removing-refitting door opening mechanism 7 - Removing-refitting descending w i n d o w glass 8 - Removing-refitting w i n d o w mechanism 8 - Removing-refitting door mirror 9 - Removing-refitting door finish trim 10 - Removing-refitting door moulding 10
WINDOW GLASSES
- Introduction - Equipment - Replacing windscreen glass ( w i n d screen) - Replacing rear w i n d o w glass (3D) (rear window) - Replacing rear w i n d o w glass (5D) (rear window) - Replacing rear quarter light
REAR DOOR
- Removing-refitting panel and protective door trim 11 - Removing-refitting descending w i n d o w glass 12 - Removing-refitting w i n d o w mechanism 12
SUN-ROOF
Introduction Removing-refitting roof assembly Dismantling-fitting roof assembly Adjustments during refitting 59 61 62 63
BONNET LID
- Removing-refitting bonnet lid - Adjustments - Removing-refitting engine bay catch striker - Removing-refitting windscreen washer pipes - Removing-refitting front grille 13 13 14 14 14
TAIL-GATE
Removing-refitting tail-gate (5D) Removing-refitting tail-gate (3D) Adjustments Removing refitting tail-gate lock Replacing lock barrel ( 5 D ) Replacing lock barrel (3D) 15 16 17 18 18 19
SEATS
Removing-refitting Dismantling-fitting Removing-refitting Removing-refitting Removing-refitting Dismantling-fitting cushion - Dismantling-fitting squab front seat front seat covers front seat guides seat raise device rear seat one-piece rear one-piece rear 24/4 20 21 24 24/1 24/2 24/3
INTERIOR TRIM
- Removing-refitting rear side panel ( 3D) - Roof panel trim - Roof panel trim for versions w i t h sun-roof - Removing-refitting dashboard - Removing-refitting rear belts
4A00OIV1
BODY SHELL
25 26 29/1 30 36
- Specified dimensions
Bravo-Brava
Bodywork
Bumpers
70.
P4A001M02
FRONT BUMPER Removing-refitting 1 . Raise the b o n n e t l i d , t h e n u n d o t h e u p p e r bolts f i x i n g t h e b u m p e r s t o t h e f r o n t cross m e m b e r cover. 2. U n d o the b o l t s f i x i n g t h e f r o n t w h e e l a r c h liner. 3. U s i n g t o o l 1 8 7 8 0 7 7 0 0 0 r e m o v e t h e f i x i n g b u t t o n a n d extract the f r o n t w h e e l arch liner. 4 . U n d o the b o l t s f i x i n g t h e b u m p e r t o t h e front w i n g . 5. R e m o v e t h e f r o n t b u m p e r f r o m t h e b o d y s h e l l , u n d o i n g the l o w e r f i x i n g b o l t s s h o w n by t h e arrows. NOTE To refit, simply reverse the order of the operations carried out for the removal.
P4A001M05
Bodywork
Bumpers
Bravo-Brava
5 P.
70.
REAR BUMPER R e m o v i ng - ref itti ng 1. U n d o t h e bolts f i x i n g t h e b u m p e r s t o t h e w h e e l arch liner. 2. R e m o v e t h e w h e e l arch liner, u n d o i n g t h e fixing nut s h o w n by the arrow. 3. U n d o t h e b o l t f i x i n g t h e b u m p e r s t o t h e rear w i n g . 4. Lift u p t h e b o o t l i d , t h e n u n d o t h e b o l t s f i x i n g t h e b u m p e r s t o the rear cross m e m ber cover. 5. R e m o v e t h e b u m p e r s after h a v i n g d i s c o n nected the connections for the number plate lights. NOTE To refit simply reverse the order of the operations carried out for the removal.
Bravo-Brava
3 P.
Bodywork
Bumpers
70.
REAR BUMPER Removing-refitting 1 . U n d o t h e bolts f i x i n g t h e b u m p e r t o t h e w h e e l a r c h liner. 2. R e m o v e t h e w h e e l arch liner, u n d o i n g t h e fixing nuts. 3. U n d o t h e b o l t f i x i n g t h e b u m p e r t o t h e rear w i n g . 4. Lift u p t h e rear t a i l g a t e , t h e n u n d o t h e b o l t s f i x i n g the b u m p e r t o t h e rear cross member lining. 5. R e m o v e t h e b u m p e r s after h a v i n g d i s c o n n e c t e d t h e c o n n e c t i o n s for t h e n u m b e r plate lights. NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A003M05
Bodywork
Front door
Bravo-Brava
70.
REMOVING-REFITTING DOOR
- Disconnect the supply connector for t h e d o o r electrical devices; - remove t h e f l e x i b l e p i n f o r t h e d o o r c h e c k strap, u s i n g t o o l 1 8 7 8 0 8 1 0 0 0 ; - r e m o v e t h e d o o r after h a v i n g u n d o n e t h e fixing bolts s h o w n ;
NOTE
To refit, simply reverse the order of the operations carried out for the removal, tightening the bolts fixing the hinges to the door to the recommended torque (1.5 daNm).
ADJUSTMENTS
A d j u s t i n g f r o n t door - L o o s e n t h e nuts f i x i n g t h e h i n g e t o t h e door, using tool 1 8 6 0 8 9 0 0 0 0 . - a d j u s t t h e p o s i t i o n of t h e d o o r ; - w h e n t h e a d j u s t m e n t has b e e n carried o u t , tighten the nuts fixing t h e hinge to the door to the recommended torque (4.5 d a N m ) .
NOTE
A d j u s t i n g p o s i t i o n of d o o r l o c k s t r i k e r
NOTE
P4A004M03
Bravo-Brava
Bodywork
Front door
70.
P4A005M02
PANEL
1 . R e m o v e t h e d o o r o p e n i n g c o n t r o l lever u n d o i n g t h e f i x i n g bolts s h o w n in t h e d i a gram. 2. R e m o v e t h e w i n d o w o p e n i n g c o n t r o l p a n e l , t h e n d i s c o n n e c t t h e relevant c o n nections. 3. R e m o v e t h e d o o r lining p a n e l , u n d o i n g t h e f i x i n g bolts s h o w n in t h e d i a g r a m . 4. U s i n g t o o l 1 8 7 8 0 7 7 0 0 0 , r e m o v e t h e f i x i n g b u t t o n s s h o w n , extract t h e side b l o c k s f r o m t h e d o o r , t u r n i n g t h e m as s h o w n in the diagram. 5. R e m o v e t h e p r o t e c t i v e d o o r l i n i n g . NOTE To refit, simply reverse the order of the operations carried out for the removal.
P4A00SM04
Bodywork
Front door
Bravo-Brava
70.
REMOVING-REFITTING HANDLE OUTER DOOR
R e m o v e t h e d o o r panel l i n i n g as d e s c r i b e d o n page 5. 1. Undo the bolt and the nut fixing the h a n dle t o t h e d o o r . 2. D i s c o n n e c t t h e d o o r o p e n i n g c o n t r o l r o d s releasing t h e m f r o m t h e a t t a c h m e n t p o i n t s , t h e n remove t h e h a n d l e f r o m t h e door. NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A006M01
REPLACING DOOR LOCK BARREL 3. R e m o v e t h e outer d o o r h a n d l e f o l l o w i n g t h e i n s t r u c t i o n s g i v e n a b o v e , insert t h e key in t h e l o c k barrel, t h e n remove t h e f i x ing spring. 4 . R e m o v e t h e retaining s p r i n g , t h e n e x t r a c t t h e l o c k barrel. NOTE When refitting suitably reverse the order of the operations carried out for the removal.
P4A006M04
Bravo-Brava
Bodywork
Front door
70.
REMOVING-REFITTING DOOR LOCK
Remove the outer d o o r handle f o l l o w i n g t h e i n s t r u c t i o n s g i v e n o n page 6. 1. U n d o the bolts fixing the l o c k t o t h e door. 2. Remove the lock from t h e door d i s c o n n e c t i n g t h e c o n n e c t o r s s h o w n b y t h e arrows and the door opening control rod. NOTE To refit simply reverse the order of the operations carried out for the removal.
REMOVING-REFITTING DOOR OPENING LEVER Remove the door panel lining f o l l o w i n g t h e i n s t r u c t i o n s g i v e n o n page 5. 3. U n d o t h e n u t s f i x i n g t h e d o o r o p e n i n g c o n t r o l lever. 4 . R e m o v e t h e d o o r o p e n i n g c o n t r o l lever f r o m its h o u s i n g releasing i t f r o m t h e l o c k operating rod s h o w n . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A007M02
P4A007M03
P4A007M04
Bodywork
Front door
Bravo-Brava
70.
REMOVING-REFITTING LOWERING WINDOW GLASS
R e m o v e t h e d o o r panel a n d p r o t e c t i v e c o v e r , as s h o w n o n page 5. 1 . Release t h e w i n d o w f r o m its d e v i c e . 2. R e m o v e t h e outer a n d inner d o o r p e r i m e ter t r i m , t h e n extract t h e w i n d o w . NOTE To refit simply reverse the order of the operations carried out for the removal.
REMOVING-REFITTING WINDOW OPENING DEVICE 3. Release t h e w i n d o w f r o m its d e v i c e as d e scribed above, then u n d o the boltsfixing t h e w i n d o w o p e n i n g device t o t h e d o o r . 4 . Extract t h e w i n d o w o p e n i n g d e v i c e f r o m its h o u s i n g . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A0O8M02
P4A008M04
Bravo-Brava
Bodywork
Front door
70.
2 ^ ^ ^ ^ ^ ^ ^ v
qM
Iff /
1 . R e m o v e t h e r u b b e r trim. 2. U n d o t h e f i x i n g r i n g nut s h o w n in t h e d i a gram. 3. R e m o v e t h e f i x i n g cover f o r t h e m i r r o r a c t i n g o n t h e r e t a i n i n g tabs. 4 . U n d o t h e b o l t s f i x i n g t h e mirror t o t h e bodyshell. 5. R e m o v e t h e external rear v i e w mirror c o m plete w i t h plastic trim. NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A009M04
Bodywork
Front door
Bravo-Brava
70.
R E M O V I N G - R E F I T T I N G DOOR TRIM
1 . R e m o v e t h e external rear v i e w mirror f o l l o w i n g t h e instructions given on t h e previous page. 2. R e m o v e t h e t r i m f r o m t h e d o o r . NOTE To refit simply reverse the order of the operations carried out for the removal.
R E M O V I N G - R E F I T T I N G DOOR REAR PILLAR T R I M 3. W o r k i n g f r o m t h e o u t s i d e o f t h e car, m o v e t h e t r i m s a n d t h e perimeter t r i m f o r t h e w i n d o w h o u s i n g partly t o o n e side. 4. R e m o v e t h e d o o r t r i m u n d o i n g t h e f i x i n g bolts s h o w n by the arrows. NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A010M02
P4A010M03
to
Bravo-Brava
Bodywork
Rear door
70.
REMOVING-REFITTING DOOR PANEL AND P R O T E C T I V E LINING
1 . R e m o v e t h e d o o r o p e n i n g c o n t r o l lever u n d o i n g t h e f i x i n g bolts s h o w n i n t h e d i a gram. 2. U s i n g t o o l 1 8 7 8 0 3 4 0 0 0 , r e m o v e t h e s p l i t p i n r e t a i n i n g t h e crank t o t h e w i n d o w opening pin. 3. U n d o t h e b o l t s f i x i n g t h e d o o r l i n i n g p a n el. 4. Using tool 1 8 7 8 0 7 7 0 0 0 , remove t h e b u t tons fixing the lining panel t o the door, t h e n remove t h e p r o t e c t i v e d o o r l i n i n g . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A011M02
P4A011M03
11
Bodywork
Rear door
Bravo-Brava
70.
REMOVING-REFITTING LOWERING WINDOW GLASS
R e m o v e t h e d o o r panel a n d p r o t e c t i v e c o v e r , p r o c e e t l i n g as d e s c r i b e d on page 1 1 . 1 . Release t h e w i n d o w f r o m its d e v i c e . 2. L o o s e n t h e f i x i n g b o l t s s h o w n b y t h e arr o w s a n d extract t h e w i n d o w g u i d e . 3. R e m o v e t h e d o o r o u t e r and inner p e r i m e ter t r i m , t h e n e x t r a c t t h e w i n d o w . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A012M01
REMOVING-REFITTING WINDOW OPENING DEVICE 4 . Release t h e w i n d o w f r o m t h e w i n d o w o p e n i n g d e v i c e a c t i n g as d e s c r i b e d a b o v e , t h e n u n d o t h e f i x i n g nuts s h o w n b y t h e arrows a n d extract t h e w i n d o w o p e n i n g device. NOTE To refit simply reverse the order of the operations carried out for the removal.
12
Bravo-Brava
Bodywork
Bonnet lid
70.
REMOVING-REFITTING BONNET LID
1 . Raise t h e b o n n e t lid t h e n d i s c o n n e c t the w i n d s c r e e n w a s h e r pipes. 2. U n d o t h e b o l t s f i x i n g t h e h i n g e s s h o w n by the a r r o w s t h e n , w i t h t h e help of a s e c o n d operator, r e m o v e t h e b o n n e t lid f r o m the vehicle. NOTE To refit simply reverse the order of the operations carried out for the removal.
ADJUSTMENTS A d j u s t i n g b o n n e t lid position 3. L o o s e n t h e b o l t s f i x i n g t h e h i n g e s , t h e n adjust t h e p o s i t i o n of t h e b o n n e t l i d . NOTE The arrows indicate movements for the the possible adjustment.
A d j u s t i n g b o n n e t lid closing device 4 . W o r k i n g as illustrated in t h e d i a g r a m , a d just t h e vertical p o s i t i o n of the b o n n e t lid; this a d j u s t m e n t can also be carried o u t by r o t a t i n g t h e r u b b e r m o u n t i n g s at the edges of t h e e n g i n e c o m p a r t m e n t . NOTE The arrows indicate the possible movements for the adjustment.
P4A013M04
13
Bodywork
Bonnet lid
Bravo-Brava
70.
REMOVING-REFITTING BONNET LID STRIKER
1 . D i s c o n n e c t t h e b o n n e t release, t h e n r e m o v e t h e striker u n d o i n g t h e f i x i n g b o l t . NOTE To refit simply reverse the order of the operations carried out for the removal.
REMOVING-REFITTING WINDSCREEN WASHER PIPES 2. Using tool 1 8 7 8 0 7 7 0 0 0 , remove the f i x i n g b u t t o n s a n d remove t h e s o u n d - i n s u l a tion lining for the bonnet lid. 3 . R e m o v e t h e w i n d s c r e e n w a s h e r pipes, r e leasing t h e m f r o m t h e b o n n e t lid after h a v ing removed the bands and having d i s c o n n e c t e d t h e m f r o m t h e jets. NOTE To refit simply reverse the order of the operations carried out for the removal.
REMOVING-REFITTING FRONT GRILLE 4 . Raise t h e b o n n e t l i d , t h e n r e m o v e t h e f r o n t grille u n d o i n g t h e f i x i n g nuts s h o w n in t h e d i a g r a m . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A014M02
14
Bravo-Brava
5 P.
Bodywork
Rear tailgate
70.
P4A015M02
REMOVING-REFITTING TAILGATE
t 551
551
1. U n d o t h e bolts fixing t h e tailgate inner lining. 2. R e m o v e t h e tailgate inner l i n i n g , r e m o v i n g the f i x i n g b u t t o n s using t o o l 1 8 7 8 0 7 7 0 0 0 . 3. D i s c o n n e c t t h e pipe f r o m t h e rearscreen w a s h e r , t h e n fasten a p p r o p r i a t e l y t o f a c i l i tate t h e s u b s e q u e n t r e f i t t i n g i n s i d e t h e tailgate. 4 . R e m o v e t h e p i p e f r o m t h e rearscreen w a sher, t h e n d i s c o n n e c t t h e s h o c k a b s o r b e r s supporint t h e tailgate f r o m t h e upper mounting. 5. U n d o t h e b o l t s f i x i n g t h e h i n g e s s h o w n b y the a r r o w s , t h e n r e m o v e t h e t a i l g a t e , w i t h the h e l p o f a s e c o n d o p e r a t o r . NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A015M03
P4A016M05
15
Bodywork
Rear tailgate
Bravo-Brava
3 P.
70.
P4A016M02
REMOVING-REFITTING TAILGATE 1. U n d o the bolts fixing the tailgate perimeter interior l i n i n g s and r e m o v e t h e m in t h e order g i v e n . 2. R e m o v e t h e t a i l g a t e inner l i n i n g r e m o v i n g the fixing buttons using t o o l 1 8 7 8 0 7 7 0 0 0 and undoing the fixing bolts. 3. D i s c o n n e c t t h e pipe f o r t h e rearscreen washer from the operating motor. 4 . R e m o v e t h e p i p e for t h e rearscreen w a s h er a n d t h e w i r i n g for t h e a d d i t i o n a l b r a k e l i g h t s f r o m t h e inside of t h e tailgate. 5. D i s c o n n e c t t h e s h o c k absorbers s u p p o r ing the tailgate from the upper m o u n t i n g , t h e n r e m o v e t h e rear t a i l g a t e w i t h t h e h e l p of a s e c o n d operator. NOTE To refit simply reverse the order the operations carried out for the moval. of re-
16
Bravo-Brava
Bodywork
Rear tailgate
70.
ADJUSTMENTS A d j u s t i n g p o s i t i o n of t a i l g a t e b u f f e r s 1 . Rotate t h e rubber m o u n t i n g s p o s i t i o n e d at the e d g e s of t h e tailgate . An incorrect adjustment of the buffers involves forcing the tailgate or clearance for the closing mechanism, causing damage to the tailgate. A d j u s t i n g horizontal p o s i t i o n o f t a i l g a t e 2. U n d o t h e b o l t s f i x i n g t h e t r i m s o n t h e r o o f lining, then loosen the bolts f i x i n g the h i n g e s a n d adjust the p o s i t i o n o f t h e t a i l gate. N O T E The arrows indicate the possible movements for the adjustment. If the hinges are removed-refitted, it is necessary to apply a suitable air drying acrylic sealant such as IV1854.210 or an equivalent product between the hinges and the bodyshell; if only the tailgate is being adjusted, apply the sealant along the perimeter of the hinge with the bodyshell, after having removed the old sealant. A d j u s t i n g p o s i t i o n of tailgate l o c k s t r i k e r 3. U n d o t h e f i x i n g bolts a n d u s i n g t o o l 1 8 7 7 8 0 7 7 0 0 0 remove t h e f i x i n g b u t t o n s , then remove the luggage compartment lining. 4 . L o o s e n t h e b o l t s f i x i n g t h e striker a n d a d j u s t its p o s i t i o n . N O T E The arrows indicate the possible movements for the adjustment.
P4A017M01
4lA
P4A017M02
P4A017M04
17
Bodywork
Rear tailgate
Bravo-Brava
70.
REMOVING-REFITTING TAILGATE LOCK
5 P.
The procedure is carried out on the 5 door version; as far as the 3 door version is concerned, the procedure is the same. R e m o v e t h e t a i l g a t e inner l i n i n g (see p a g e 1 5 ) , then u n d o the bolts fixing the lock s h o w n by t h e arrows. 2. R e m o v e t h e l o c k releasing t h e r o d j o i n e d w i t h t h e l o c k barrel. NOTE To refit simply reverse the order of the operations carried out for the removal.
3. R e m o v e t h e t a i l g a t e inner l i n i n g (see p a g e 1 5 ) , loosen the fixing bolts s h o w n by t h e a r r o w s , t h e n r e m o v e t h e barrel f r o m t h e lock disconnecting the j o i n i n g rod. 4 . Insert t h e key in t h e barrel, lift u p t h e r e taining spring s h o w n by the arrow, then extract t h e barrel a n d replace it. NOTE To refit simply reverse the order of the operations carried out for the removal.
P4A018M04
18
Bravo
Bodywork
Tail-gate
70.
REPLACING LOCK BARREL
1 . R e m o v e the t a i l - g a t e interior t r i m as d e s c r i b e d o n p a g e 16 a n d t h e l o c k as d e s c r i b e d o n p g a e 18. T h e n w o r k f r o m i n side t h e tail a . e t o u n s c r e w t h e o p e n i n g h a n d l e r e t a i n i n g bolts. 2. U n d o the f a s t e n i n g b l o c k t a b s a n d r e m o v e the tail-gate opening handle. 3. Insert the key in the l o c k barrel, t h e n lift the retaining clip indicated by the arrow. 4. R e m o v e t h e l o c k barrel a n d replace.
M
NOTE
Reverse to refit.
removal
operation
sequence
P4A019M02
P4A019M03
P4A019M04
19
Bodywork
Seats
Bravo-Brava
70.
REMOVING-REFITTING SEAT FRONT
- r e m o v e t h e seat f r o m t h e car . NOTE Reverse the order of removal operations to refit. Tighten the retaining bolts to a torque of 2.4 daNm.
P4A020M03
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Publication no.
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Bravo-Brava
Bodywork
Seats
70.
DISMANTLING-FITTING COVERS FRONT SEAT
P4A021 M06
2. U n s c r e w s c r e w A retaining interior t r i m B. R e m o v e t r i m B t o remove w a s h e r D. T a k e care n o t t o break. Push c a p C o u t f r o m t h e inside after r e m o v i n g t h e t r i m . R e c o v e r w a s h e r D. 3. Take off t h e plastic m o u l d i n g f r o m t h e rear as s h o w n in t h e figure. 4 . R e m o v e plastic m o u l d i n g B, b e g i n n i n g at t h e rear s i d e . Release w i t h t h e a i d of a s c r e w d r i v e r , t h e n remove t h e c u s h i o n .
P4A021 M07
P4A021 M08
P4A021M09
21
Bodywork
Seats
Bravo-Brava
70.
Remove any remaining parts of the hooks connected to the padding to prevent damage to the new cover.
P4A022M08
P4A022M09
22
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506.670/15
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Bodywork
Seats
70.
2. W i t h d r a w t h e cover, t h e n r e m o v e r e t a i n i n g h o o k s A ; release elastic B a n d t h e n u p per e d g e C. 3. T u r n s p r i n g s a n d head restraint A , t h e n r e m o v e head restraint. 4. Release b o t h links A f r o m t h e p i p e a n d rem o v e t h e cover. NOTE Reverse removal Fasten cushion 1878077000. instructions to refit. hooks using tool
Use new
P4A023M07
hooks.
P4A023M09
23
Bodywork
Seats
Bravo-Brava
70.
REMOVING-REFITTING FRONT SEAT GUIDES
NOTE
Upholstering quired.
operations
are not
re-
1 . R e m o v e the seat f r o m the car. P o s i t i o n t h e seat o n the b e n c h . Push t h e g u i d e s forw a r d u s i n g a release c o n t r o l b o w . O n l y for B R A V O version, release m e m o r y A c o n t r o l lever s p r i n g u s i n g a p p r o p r i a t e pliers. U n s c r e w rear g u i d e retaining b o l t s B.
3. R e m o v e the g u i d e s .
A
NOTE
Do not remove the control bow before removing the guides in order to prevent deformation that could impair operation.
24
Publication no.
506.670/15
Bravo-Brava
Bodywork
Seats
70.
REMOVING-REFITTING SEAT RAISE DEVICE
not be removed
from
2. R e m o v e panel C c o v e r i n g seat raise lever fastener. Take care n o t t o break t h e tabs. R e m o v e t h e l o w e r part b y h a n d ( b o x 1) and t h e n use a s c r e w d r i v e r t o prise u p t h e upper t a b ( b o x 2 ) a n d r e m o v e t h e p a n e l . 3. R e m o v e lever D a n d d r i l l off t h e h e a d of rivets E. 4 . U n s c r e w b o l t s F r e t a i n i n g t h e seat raise device a n d t h e n r e m o v e . IMOTE Reverse Tighten of 1.2 removal instructions to refit. retaining bolts to a torque daNm.
P4A024M10
P4A024M11
P4A024M12
V - 9 8 - Update
24/1
Bodywork
Seats
Bravo-Brava
70.
REMOVING-REFITTING REAR SEAT
2. L o w e r t h e s q u a b , t h e n u n s c r e w t h e b o l t s w i t h associated w a s h e r s . 3. Use t o o l 1 8 7 8 0 7 7 0 0 0 t o u n d o t h e s t u d s fastening the boot trim to the squab. 4. Remove t h e s q u a b f r o m t h e car.
NOTE
To refit, carry out removal instructions in reverse order. Tighten retaining bolts to a torque of 2.4 daNm.
P4A024M14
P4A024M15
P4A024M16
24/2
V - 9 8 - Update
Publication no.
506.670/15
Bravo-Brava
Bodywork
Seats
70.
DISMANTLING-FITTING REAR CUSHION ONE-PIECE
F o l d back t h e cover a n d use c u t t i n g pliers to cut hooks B fastening the p a d d i n g cover a r o u n d t h e edges of t h e u p h o l s t e r y .
Then remove all residual parts of the hooks attached to the padding to prevent damage to the new cover.
IMOTE
when hooks
refitting
Use new
hooks.
ONE-PIECE
V - 9 8 - Update
24/3
Bodywork
Seats
Bravo-Brava
70.
R e m o v e side fasteners b y u n s c r e w i n g bolts A . Take off t h e central belt carrier b y u n s c r e w i n g bolts B. R e m o v e t h e t w o side head restraints a n d t h e central h e a d restraint b y p u s h i n g key C o n t h e plastic bushes.
P4A024M20
Release cover plastic m o u l d i n g s A f r o m the r e i n f o r c e m e n t c h a n n e l . R e m o v e p l a s tic bushes B by m o v i n g t h e p a d d i n g a n d u n d o i n g t h e clip. R e m o v e the u p h o l s t e r e d squab module.
P4A024M21
all residual parts of hooks to the padding to prevent to the new cover.
NOTE
Reverse order of removal instructions to refit. Fasten the hooks using tool 1878077000.
Use new
P4A024M22
hooks.
24/4
V - 9 8 - Update
Publication no.
506.670/15
Bravo-Brava
3 P.
Bodywork
Interior fittings
70.
P4A025M01
P4A025M02
REMOVING-REFITTING REAR SIDE PANEL 1 . R e m o v e t h e seat c u s h i o n f o l l o w i n g t h e i n structions given on the previous page, t h e n r e m o v e t h e seat belt a t t a c h m e n t bracket u n d o i n g t h e f i x i n g b o l t s . 2. Lift u p t h e r u n n i n g board t r i m , t h e n u n d o the bolt underneath. 3. U n d o t h e b o l t f i x i n g t h e rear seat b e l t a n d t h e b o l t s f i x i n g t h e panel t o t h e f l o o r . 4. L o w e r t h e seat backrest, t h e n u n d o t h e b o l t s f i x i n g t h e panel t o t h e b o d y s h e l l . 5. G e n t l y r e m o v e t h e door seal, t h e n u s i n g t o o l 1 8 7 8 0 7 7 0 0 0 remove t h e rear s i d e p a nel f r o m t h e v e h i c l e . NOTE To refit simply reverse the order the operations carried out for the moval. of re-
P4A025M04
P4A026M05
25
Bodywork
Interior fittings
Bravo-Brava
5 P.
70-
P4A026M01
M A 0 2 6 M 0 2
1.
2.
3.
4. 5.
The procedure is carried out on the 5 door version; as far as the 3 door version is concerned, the procedure is the same. Undo the fixing bolts s h o w n and remove the s u n visors w i t h t h e relevant a t t a c h m e n t systems. Remove the fixing covers and u n d o the bolts underneath then remove the courtesy l i g h t d i s c o n n e c t i n g t h e a p p r o p r i a t e connector. Remove the fixing covers and u n d o the bolts u n d e r n e a t h , t h e n r e m o v e t h e p a s senger g r a b handles. Using tool 1 8 7 8 0 7 7 0 0 0 remove the butt o n s f i x i n g t h e roof l i n i n g t o t h e b o d y s h e l l . M o v e t h e d o o r h o u s i n g t r i m aside a n d use tool 1 8 7 8 0 7 7 0 0 0 to remove the front pillar c o v e r s .
26
Bravo-Brava
5 P.
Bodywork
Interior fittings
70.
P4A027M01
1 . R e m o v e t h e f i x i n g cover a n d u n d o t h e f r o n t seat belt h e i g h t a d j u s t m e n t n u t . 2. U n d o t h e b o l t f i x i n g t h e pillar c o v e r . 3. U n d o t h e b o l t f i x i n g t h e r u n n i n g b o a r d . 4. U n d o the lower bolts fixing t h e centre p i l lar cover a n d t h e b o l t f i x i n g t h e seat belt. 5. R e m o v e t h e c e n t r e pillar c o v e r u s i n g t o o l 1878077000.
P4A027M04
27
Bodywork
Interior fittings
Bravo-Brava
5 P.
70.
P4A028M02
R e m o v e t h e f i x i n g cover a n d u n d o t h e b o l t f i x i n g the rear seat belt. U n d o t h e bolts s h o w n a n d r e m o v e t h e rear pillar cover. U n d o t h e bolts s h o w n a n d r e m o v e t h e rear access t r i m s for t h e t a i l g a t e h i n g e f i x i n g s . Heat t h e r o o f f r o m t h e o u t s i d e u s i n g an i n fra red l a m p t o assist w i t h t h e s e p a r a t i o n of t h e b o d y s h e l l l i n i n g : Avoid temperatures exceeding in order not to damage the work. 90 C paint-
5. C u t t h e l i n i n g in a l o n g i t u d i n a l d i r e c t i o n t o a l l o w t h e s u b s e q u e n t removal o f t h e r o o f panel f r o m the v e h i c l e , t h e n e x t r a c t it t h r o u g h the tailgate housing. ( D o not pull t h e r o o f panel d o w n w a r d s so as n o t t o distort it).
28
Brava
Bodywork
Interior trim
70:
Refitting
1. Clean t h e r o o f panel t h o r o u g h l y u s i n g d i s posable paper i m p r e g n a t e d in h e p t a n e . 2.3 A p p l y t h e s p e c i f i e d a d h e s i v e t o t h e area shaded in the figure. Observe the d i m e n sions s h o w n . N O T E It is advisable to use a water-based adhesive, e.g. TIVOCOLL 4769/59 manufactured by TIVOLI, or an equivalent GURIT or ESSEX product.
5 d
2.3 Heat t h e r o o f p a n e l t r i m f o r a b o u t 5 - 6 m i n u t e s u s i n g an i n f r a - r e d l a m p a n d p o sition t h e trim o n t h e roof panel. Do not allow the temperature to exceed 90 C, then fit the passenger grap handles and retaining studs. Press the trim so that it adheres to the roof, working from the centre outwards, then finish refitting by reversing removal instructions.
P4A029M02
335 Ss^2> y^
: ;
475
P4A029M03 4A029M
VII
S3 7
SutiMP'i<io.'- i i r c v i d U t .i .urn
29
Bodywor
Interior trim
ROOFPANELTRIM
FORVERSIOI
SUN-ROOF
IS WITH
T h e roof panel t r i m ( A ) f o r v e r s i o n s w i t h s u n - r o o f is f a s t e n e d r o u n d t h e o u t s i d e as in o t h e r v e r s i o n s a n d in t h e centre (as s h o w n in c r o s s s e c t i o n in f i g u r e 1) by m e a n s of six v e l c r o c i r cles ( C ) a r r a n g e d in t w o parallel lines ( f i g u r e 3 ) , w h i c h are j o i n e d t o t h e s a m e n u m b e r of blocks (D) ( w i t h velcro) fitted on beam ( B ) ) of t h e s u n - r o o f assembly. T h i s t y p e of f a s t e n i n g a l l o w s t h e roof p a n e l t r i m t o be reused w h e n t h e s u n - r o o f a s s e m b l y is repaired a n d it is able t o a b s o r b v i b r a tions.
Removing
P4A029 M05
A f t e r r e m o v i n g t h e various parts d e s c r i b e d o n t h e p r e v i o u s pages, insert a 4 - 5 c m w i d e blade between the sun-roof frame and the r o o f panel t r i m ( f i g u r e 2 ) . T a k i n g care n o t t o d a m a g e t h e t r i m , separate t h e v e l c r o inserts (C) from the blocks ( D ) . T h e n r e m o v e t h e roof panel t r i m f r o m t h e v e h i c l e t h r o u g h t h e rear t a i l - g a t e c o m p a r t m e n t (see page 6 0 )
Refitting
P o s i t i o n roof p a n e l trim ( 4 ) c o r r e c t l y i n s i d e t h e v e h i c l e roof, a n d t h e n f a s t e n a r o u n d t h e e d g e after p r e s s i n g velcro a p p l i c a t i o n p o i n t s ( C ) . Refit t h e v a r i o u s parts b y c a r r y i n g o u t t h e o p e r a t i o n s described in t h e p r e v i o u s pages in reverse order.
P4A029M06
P4A029M07
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VI h 97 - Update
Publication no.
506.670/12
Bravo-Brava
Bodywork
Interior trim
70.
T h e r o o f panel t r i m ( A ) is n o w f a s t e n e d r o u n d t h e e d g e as w i t h t h e o t h e r v e r s i o n s a n d in t h e c e n t r e (as s h o w n in c r o s s s e c t i o n in f i g u r e 1 ) b y means of t w o s t u d s t h a t s c r e w i n t o b o l t s ( G ) a p p l i e d t o b e a m s ( B ) of t h e s u n - r o o f assembly. T w o vibration-damping foam washers (F) are f a s t e n e d t o t h e r o o f p a n e l t r i m o n t h e t h r o u g h holes used f o r t h e f a s t e n i n g s t u d s .
Removing F E G A B R e m o v e t h e v a r i o u s parts d e s c r i b e d in t h e p r e v i o u s pages, w h i c h are u s e d t o f a s t e n t h e roof panel trim r o u n d then edge. T h e n u n s c r e w s t u d s (E, f i g u r e 2 ) r e t a i n i n g t h e t r i m t o t h e s u n - r o o f b e a m , t a k i n g care n o t t o d a m a g e the t r i m . Lastly, r e m o v e t h e r o o f panel t r i m f r o m t h e vehicle through the tail-gate c o m p a r t m e n t (see i l l u s t r a t i o n o n p a g e 6 0 ) .
P4A029 M09
Refitting P o s t i o n t h e r o o f panel t r i m c o r r e c t l y i n s i d e t h e v e h i c l e roof s o t h a t t h e t w o h o l e s (arr o w e d in f i g u r e 3 ) c o i n c i d e w i t h b o l t s ( G ) a p p l i e d t o b e a m s ( B ) of t h e s u n - r o o f a s s e m bly. Fit s t u d s ( E ) o n t o b o l t s ( G ) a n d t h e n carry o n f a s t e n i n g t h e r o o f t r i m by r e f i t t i n g t h e v a r i o u s parts d e s c r i b e d p r e v i o u s l y a n d c a r r y i n g o u t the o p e r a t i o n s d e s c r i b e d o n t h e p r e v i o u s pages in reverse order.
P4A029M10
Bravo-Brava
*7 ^)
P4A030 M01
P4A030M02
REMOVING-REFITTING
DASHBOARD
R e m o v e t h e stalk u n i t f r o m t h e v e h i c l e as d e scribed in s e c t i o n 5 5 - Electrical e q u i p m e n t . 1 . Prise t h e p r o t e c t i v e b o o t f r o m t h e gear lever. 2. Lift t h e o b j e c t m a t a n d u n s c r e w t h e u n d e r l y i n g bolt. 3. R e m o v e t h e ashtray a n d u n s c r e w t h e u n d e r l y i n g bolts. 4 . U n d o t h e r e t a i n i n g t a b s a n d lift t h e p a n e l shown. 5. D i s c o n n e c t t h e d o o r m i r r o r c o n t r o l c o n nector a n d r e m o v e t h e p a n e l .
P4A030 M03
P4A030M04
P4A030M05
30
Publication no.
506.670/72
Bravo-Brava
Bodywork
Interior fittings
70.
1. Remove the clips, undo the bolts s h o w n and remove the tunnel cover f r o m the v e hicle. 2. A c t i n g at t h e p o i n t s s h o w n , r e m o v e t h e protection for the junction unit. 3. U n d o t h e b o l t i n s i d e t h e j u n c t i o n u n i t p r o tection. 4. U n d o t h e b o l t s s h o w n , t h e n r e m o v e t h e i n s t r u m e n t panel c o w l i n g . 5. L o o s e n t h e f i x i n g bolts s h o w n , d i s c o n n e c t t h e c o n n e c t o r s at the rear o f t h e i n s t r u m e n t p a n e l , t h e n remove t h e latter f r o m the dashboard.
P4A031M03
P4A031M04
P4A031M05
31
Bodywork
Interior fittings
Bravo-Brava
70.
R e m o v e t h e radio f r o m t h e v e h i c l e f o l l o w i n g t h e i n s t r u c t i o n s in s e c t i o n 5 5 - Electrical equipment. 1 . U n d o t h e b o l t s f i x i n g t h e heater c o n t r o l panel a n d v a r i o u s s w i t c h e s . 2. Extract t h e v e n t i l a t i o n c o n t r o l k n o b t h e n undo the bolt underneath. 3. R e m o v e t h e heater c o n t r o l panel a n d v a r i ous s w i t c h e s f r o m t h e d a s h b o a r d after h a v i n g d i s c o n n e c t e d t h e relevant c o n n e c tions. 4 . U n d o t h e l o w e r b o l t s f i x i n g t h e ashtray t o the d a s h b o a r d . 5. U n d o t h e u p p e r b o l t s s h o w n in t h e d i a g r a m , d i s c o n n e c t t h e c o n n e c t o r for t h e cigar lighter, t h e n r e m o v e t h e ashtray f r o m the dashboard.
32
Bravo-Brava
Bodywork
Interior fittings
70.
1 . U n d o t h e b o l t s in t h e a s h t r a y h o u s i n g f i x i n g t h e d a s h b o a r d t o t h e heater. 2. U n d o t h e b o l t s f i x i n g t h e d a s h b o a r d t o t h e heater. 3. L o o s e n t h e f i x i n g bolts s h o w n in t h e d i a gram and remove the glove compartment. 4 . R e m o v e t h e left a n d r i g h t s i d e air v e n t s u n d o i n g t h e f i x i n g bolts. 5. U n d o t h e b o l t s h o w n f i x i n g t h e d a s h b o a r d t o t h e b o d y s h e l l o n b o t h sides.
33
Bodywork
Interior fittings
Bravo-Brava
70.
1. U n d o the bolt s h o w n and move the u n d e r d o o r l i n i n g f r o m b o t h sides t o o n e side. 2. W o r k i n g as a p p r o p r i a t e , u n d o t h e b o l t u n derneath the underdoor lining f r o m both sides f i x i n g the dashboard to the bodyshell. 3. A c t i n g o n t h e r e t a i n i n g t a b s , r e m o v e t h e speaker grille f r o m b o t h sides. 4 . R e m o v e t h e left a n d r i g h t speakers, u n d o ing the fixing bolts a n d connectors. 5. U n d o t h e b o l t in left a n d r i g h t speaker housings fixing the dashboard to the bodyshell.
P4A034M04
34
Bravo-Brava
Bodywork
Interior fittings
70.
Bodywork
Interior fittings
Bravo-Brava
70.
P4A036M02
1.
2. 3. 4.
5.
The procedure is carried out on the 5 door version; as far as the 3 door version is concerned, the procedure is the same. F o l d over the rear seat c u s h i o n a n d remove the fixing cover s h o w n , then undo t h e l o w e r b o l t f i x i n g t h e belt. Remove the fixing cover and u n d o the u p per b o l t f i x i n g t h e belt. R e m o v e the speaker griller, a c t i n g o n t h e appropriate retaining tabs. M o v e t h e l u g g a g e c o m p a r t m e n t inner l i n i n g aside, t h e n u n d o t h e b o l t f i x i n g t h e reel. R e m o v e the belt t h r o u g h t h e s l o t in t h e rear pillar cover, t h e n r e m o v e t h e belt c o m p l e t e w i t h reel.
36
Bravo-Brava
Bodywork
Seat belt pre-tensioner
70.
INTRODUCTION T h e seat belt P R E - T E N S I O N E R is a d e v i c e integrated in t h e reel w h i c h , in t h e case o f a f r o n t a l i m p a c t , recovers t h e i n e v i t a b l e l e n g t h e n i n g of t h e belt d u e t o t h e a c t i o n of t h e w e i g h t of t h e b o d y o f t h e p e r s o n in t h e seat, e n s u r i n g that t h e y adhere t o t h e backrest. It is, in effect, vital t h a t the belt remains a d h e r i n g as c l o s e l y as possible t o t h e b o d y o f t h e p e r s o n in o r d e r t o gradually absorb the kinetic energy assumed during t h e impact. T h e l e n g t h e n i n g of t h e belt c a n b e d u e t o t h e f o l l o w i n g causes: - d e l a y in t h e o p e r a t i o n o f t h e inertia l o c k i n g device; - s t r e t c h i n g o f t h e belt fibres; - w r a p p i n g o f t h e belt a r o u n d t h e reel ( s p o o l i n g e f f e c t ) ; - g a r m e n t s o f a certain t h i c k n e s s w h i c h increase t h e d i s t a n c e b e t w e e n t h e belt a n d t h e chest. OPERATION T h e p r e - t e n s i o n e r f i t t e d o n t h e v e h i c l e is e q u i p p e d w i t h a bracket (see p a g e 3 8 ) w h i c h has t h e task o f m a k i n g t h e s y s t e m a c t i v e . T h i s takes place because t h e e n d o f t h e a b o v e m e n t i o n e d bracket acts on t h e p u l l e y ( 1 4 ) o v e r c o m i n g the spring ( 1 2 ) loading and pushing t h e p u l l e y ( 1 4 ) t o o t h ( 1 3 ) in t h e d i r e c t i o n o f t h e a r r o w s h o w n in detail in t h e d i a g r a m , r e l e a s i n g t h e o s c i l l a t i n g mass ( 1 ) t h e r e b y a l l o w i n g it t o act. S u d d e n d e c e l e r a t i o n , caused b y an i m p a c t , causes t h e a d v a n c e o f t h e o s c i l l a t i n g mass ( 1 ) a n d t h e c o m p r e s s i o n of t h e o p p o s i n g s p r i n g ( 2 ) . In t h e case of s u f f i c i e n t l y r a p i d d e c e l e r a t i o n t h e o s c i l l a t i n g mass is p l a c e d in s u c h a p o s i t i o n t h a t t h e gas generator ( 4 ) is released f r o m its r e t a i n i n g system ( 3 ) a n d m o v e s d o w n w a r d s through the action of the thrust spring ( 5 ) and impacts w i t h the percussion-pin (6) w h i c h causes t h e e n g a g e m e n t of t h e i g n i t i o n c h a r g e T h i s gives rise t o t h e c o m b u s t i o n of t h e p y rotechnic charge w h i c h activates t h e main c h a r g e a n d t h e d e v e l o p m e n t o f t h e g a s in t h e chamber ( 7 ) w h i c h f l o w s t h r o u g h the special o p e n i n g to t h e piston (8) causing t h e rapid movement along the expansion chamber. T h e metal r o d ( 9 ) , f i x e d o n o n e s i d e t o t h e p i s t o n a n d on the other wrapped around a pulley f i t t e d o n t h e s a m e axis of t h e belt ( 1 1 ) w i n d i n g ( 1 0 ) roller, causes t h e rotary m o v e m e n t r e q u i r e d f o r t h e latter t o r e w i n d . A t t h e e n d o f t h e o p e r a t i o n t h e reel l o c k s in t h e m a x i m u m return p o s i t i o n f o r t h e a c t u a l belt o n the body of the occupant of the appropriate seat.
P4A037M01
The locked belt is an indication that the pre-tensioner has been activated, or of a malfunction of the reel. In both cases, the device must be replaced by authorized personnel.
37
Bodywork
Seat belt pre-tensioner
Bravo-Brava
70.
REMOVING BRACKET The removal of the bracket (3 in the diagram overleaf) prevents the pyrotechnic device from accidentally being activated. This operation should be carried out each time a service operation which may cause the accidental activation of the device is carried out. The bracket should ALWAYS ONL Y BE REFITTED with the pre-tensioner unit fitted on the vehicle in order to prevent injury to the personnel carrying out the operation
3 door version ( A ) D i r e c t i o n o f travel Break t h e p r o t e c t i v e collar ( 5 ) ( g u a r a n t e e seal), u n d o the f i x i n g bolt ( 4 ) a n d remove t h e bracket ( 3 ) (also see d i a g r a m at t h e t o p o f the page overleaf). U n d o t h e bolt ( 2 ) w h i c h f i x e s t h e p r e - t e n sioner ( 1 ) t o t h e b o d y s h e l l a n d extract t h e p r e - t e n s i o n e r f r o m i n s i d e t h e pillar.
5 door version ( A ) D i r e c t i o n o f travel Break t h e p r o t e c t i v e collar ( 5 ) ( g u a r a n t e e seal), u n d o the fixing bolt ( 4 ) a n d remove t h e bracket ( 3 ) (see d i a g r a m a t t h e f o o t of t h e page o v e r l e a f ) . U n d o the bolts ( 2 ) fixing t h e pre-tensioner support t o the bodyshell and remove the supp o r t ( 6 ) assembly a n d t h e p r e - t e n s i o n e r ( 1 ) f r o m t h e pillar a n d separate t h e t w o c o m p o nents. 38
Print no. 506.670
Bravo-Brava
Bodywork
Seat belt pretensioner
70.
FITTING SEAT BELT WITH PRETENSIONER W h e n f i t t i n g pretensioner assembly ( 1 ) t o t h e car, firstly secure pretensioner ( 1 ) a n d bracket ( 6 ) ( t h e latter is o n l y f i t t e d o n t h e 5 d o o r v e r s i o n ) t o t h e b o d y b y means o f b o l t s ( 2 ) , w h i c h m u s t b e t i g h t e n e d t o a t o r q u e o f 4 d a N m . T h e n secure f i r i n g bracket ( 3 ) b y means o f d o u b l e - h e a d e d b o l t w i t h p r e - e s t a b lished break p o i n t ( 4 ) . T i g h t e n t o 0 . 4 d a N m . NOTE Note that the system will only work correctly if the head of bolt (4) breaks in the required area. The bolt and firing bracket (3) are supplied as a single part and must be replaced whenever the pretensioner is removed.
P4A039M02
39
Bodywork
Seat belt pretensioner
Bravo-Brava
70.
S A F E T Y R U L E S FOR HANDLING SEAT B E L T UNIT W I T H PRETENSIONER Pretensioners are e x p l o s i v e parts a n d must t h e r e f o r e be h a n d l e d , m o v e d a n d stored c o r r e c t l y in order t o prevent d a m a g e or injury U n d e r n o r m a l c o n d i t i o n s , t h e pretensioner is activated o n l y d u r i n g i m p a c t . T h e g a s p r o d u c e d under these c o n d i t i o n s is m a i n l y non-toxic nitrogen.
The following rules must ABSOLUTELY be observed to ensure operator safety and prevent damage to the seat belt pretensioner unit. Remove the firing bracket before each intervention.
P4A040M01
A . Never m o v e pretensioners b y h o l d i n g them by t h e pipe. B. Never m o v e t h e pretensioner by h o l d i n g the belt. C. Never t a m p e r w i t h pretensioners or a t t e m p t t o repair t h e m . S e n d all d e f e c t i v e pretensioners back t o t h e m a n u f a c t u r e r . D. Never s u b j e c t pretensioners t o p e r c u s s i o n , d r i l l i n g , m a c h i n i n g or h e a t i n g d u e t o welding. E. Never a l l o w t h e unit t o d r o p or s u b j e c t it t o impact. Pretensioners w h i c h have b e e n d r o p p e d f r o m a h e i g h t greater t h a n 1 m e tre must n o t be used b u t s e n t back t o t h e manufacturer. W h e n o p e r a t i o n s carried o u t o n a v e h i c l e require t e m p o r a r y r e m o v a l of t h e unit, use a steel c a b i n e t w h i c h meets legal r e q u i r e ments f o r t h e h o u s i n g o f e x p l o s i v e charges. F. Never b r i n g naked f l a m e s , l i q u i d s , s o l vents or l u b r i c a n t s close t o t h e device a n d d o not expose to a temperature higher t h a n 1 1 0 C. W i t h t e m p e r a t u r e s h i g h e r t h a n 180 C, t h e gas g e n e r a t o r m a y self -ignite. W h e n h a n d l i n g a d e v i c e t h a t has been a c t i v a t e d , use g l o v e s a n d p r o t e c t i v e g o g gles. If t h e d e v i c e has g o n e o f f , A L W A Y S leave at least 2 0 m i n u t e s f o l l o w i n g a c t i v a t i o n before t o u c h i n g t h e d e v i c e . W a s h h a n d s w i t h s o a p a n d w a t e r after h a n d l i n g t h e device.
P4A040M02
40
Bravo-Brava
Bodywork
Seat belt pre-tensioner
70.
4
^^^^
P4A041M01
If on account of exceptional atmospheric conditions (floods, sea-storms etc.) the water and mud reaches such a height that the device components are affected, it must be replaced. The pre-tensioner is maintenance-free and should definitely not be lubricated. Any modifications invalidate its efficiency.
Bodywork operations G. D o n o t s u b j e c t t h e area s u r r o u n d i n g t h e p r e - t e n s i o n e r ( 6 0 - 7 0 c m r a d i u s ) t o great i m p a c t s d u e t o b o d y w o r k repairs ( f o r e x a m p l e t h e use of a h a m m e r ; if necessary, remove the complete pre-tensioner unit. If it is necessary t o use h e a t i n g l a m p s o n t h e p a i n t w o r k in t h e area s u r r o u n d i n g t h e p r e - t e n s i o n e r or t o carry o u t w e l d i n g or brazing, then the complete pre-tensioner reel assembly has t o be r e m o v e d .
P4A041M02
If a v e h i c l e w i t h o n e or m o r e p r e - t e n s i o n e r s has t o b e m o v e d , t h e n t h e y s h o u l d be p l a c e d in t h e l u g g a g e c o m p a r t m e n t a n d n o t in t h e passenger c o m p a r t m e n t w h i c h is f o r b i d d e n . A p r e - t e n s i o n e r w h i c h has n o t b e e n a c t i v a t e d in t h e case o f an a c c i d e n t s h o u l d b e c o n s i d ered still active; therefore if t h e y h a v e n o t e x p l o d e d because t h e y are d e f e c t i v e o r have reached t h e e n d o f their w a r r a n t y or f o r o t h e r reasons, t h e y s h o u l d be r e p l a c e d a n d r e turned (the complete device) t o t h e special Centre f o l l o w i n g t h e same p r o c e d u r e as d e s c r i b e d f o r A i r B a g m o d u l e s (see s e c t i o n 5 5 Electrical e q u i p m e n t ) .
Ordering instructions F o l l o w t h e same p r o c e d u r e s already d e s c r i b e d f o r o r d e r i n g A i r B a g m o d u l e s (see s e c t i o n 5 5 - Electrical equipment). NOTE Pre-tensioners have been specially designed to be fitted on each individual type and marque of vehicle on account of which they cannot be adapted, reused or fitted on other vehicles, but only on those for which they were designed and produced. Any attempts to reuse, adapt or fit pre-tensioners on different types of vehicles could cause serious or fatal injuries to the occupants of the vehicle both in the case of an accident or in the case of normal usage. After being fitted the pre-tensioner bracket can be activated if it receives an impact of sufficient force.
41
Bodywork
Seat belt pre-tensioner
Bravo-Brava
70.
R E M O V I N G - R E F I T T I N G (3 d o o r v e r s i o n ) 1 . U n d o t h e b o l t w h i c h fixes t h e u n d e r d o o r l i n i n g at t h e f r o n t t o t h e b o d y s h e l l w h i c h is l o c a t e d u n d e r t h e left l o w e r part o f t h e dashboard. 2. U n d o t h e b o l t s h o w n w h i c h fixes t h e u n d e r d o o r l i n i n g t o t h e b o d y s h e l l at t h e rear and remove the lining from the vehicle. 3. U n d o t h e b o l t s s h o w n w h i c h fix t h e pillar cover a n d t h e seat b e l t l o w e r f i x i n g b r a c k et t o t h e b o d y s h e l l . A c c e s s c a n b e g a i n e d t o t h e f i x i n g b o l t s after r e m o v i n g t h e b o l t covers. 4 . R e m o v e t h e rear seat c u s h i o n a n d d i s c o n nect t h e c o n n e c t o r f o r t h e A B S s y s t e m ( i f fitted).
42
Bravo-Brava
Bodywork
Seat belt pre-tensioner
70.
P4A043M01
1. U n d o t h e lower bolts fixing t h e side panel. 2. R e m o v e t h e p r o t e c t i v e t r i m a n d u n d o t h e l o w e r b o l t u n d e r n e a t h f i x i n g t h e seat belt. 3. R e m o v e t h e t r i m s a n d u n d o t h e b o l t s u n d e r n e a t h w h i c h f i x t h e side p a n e l at t h e centre. 4. U n d o t h e bolt fixing the side lining a n d m o v e t h e seat a t t a c h m e n t d e v i c e t r i m t o o n e side. U n d o t h e b o l t s f i x i n g t h e seat a t t a c h m e n t device.
P4A043M03
P4A043M04
43
Bodywork
Bravo-Brava
70.
P4A044M01
1 . R e m o v e t h e side p a n e l f r o m t h e v e h i c l e . 2. R e m o v e t h e s p r i n g a n d r e m o v e t h e r e t a i n ing p i n s h o w n , t h e n release t h e belt. 3. R e m o v e t h e upper t r i m f o r t h e seat belt and u n d o t h e f i x i n g n u t u n d e r n e a t h . 4. U n d o t h e bolt fixing t h e pre-tensioner t o the b o d y s h e l l ( t o r e m o v e t h e bracket, p r o ceed as d e s c r i b e d o n p a g e 3 8 ) . 5. R e m o v e t h e p r e - t e n s i o n e r f r o m t h e v e h i cle.
P4A044M03
44
Bravo-Brava
Bodywork
Window glasses
70.
INTRODUCTION
ThewindowsontheBravo-Brava meelindustrial standards concerning the m e t h o d s of removi n g / r e f i t t i n g f i x e d w i n d o w glasses. T h i s system is greatly a d v a n t a g e o u s , b o t h in t e r m s o f q u a l i t y because it ensures p e r f e c t p e r m e a b i l i t y a n d resistance t o air a n d in t e r m s of safety because it m a k e s t h e s t r u c t u r e s t r o n g e r a n d quieter. In a d d i t i o n t o t h e w i n d s c r e e n a n d t h e rearscreen t h e 3 d o o r v e r s i o n also has b o n d e d side rear w i n d o w s .
P4A045M01
EQUIPMENT In o r d e r t o r e m o v e a n d refit b o n d e d w i n d o w s t h e p r o d u c t s a n d e q u i p m e n t d e s c r i b e d b e l o w m u s t b e used C o m p o s i t i o n of K i t 1. 2. 3. 4. 5. 6. C a r t r i d g e o f G U R I T B E T A S E A L sealant 1 / 2 Cartridge o f G U R I T B E T A S E A L sealant A d h e s i o n p r o m o t e r ( p r i m e r ) f o r glass Container of de-greasing p r o d u c t Cloth for de-greasing W a d for applying adhesion promoter (primer) 7. W i r e 8. N 2 diffusors
6
P4A045 M02
The previous adhesive marketed by Direzione M a r k e t i n g e C o m m e r c i a l e V o l v e r a h a s been replaced w i t h a n i m p r o v e d p r o d u c t . It is B E T A S E A L 1 7 0 3 S p r i n t , in s i n g l e c o m p o u n d p o l y u r e t h a n e w i t h rapid p o l y m e r i z a t i o n . T h i s is u n d o u b t e d l y an a d v a n t a g e b e c a u s e t h e greater t h e h a r d e n i n g s p e e d o f t h e a d h e sive, t h e less t i m e t h e w i n d o w has t o b e r e t a i n e d w i t h special e q u i p m e n t . In a d d i t i o n t h e repaired v e h i c l e can b e r e t u r n e d s o o n e r t o the Customer. T h e m e c h a n i c a l characteristcis c o n f o r m w i t h C a p i t o l a t o Fiat A u t o S.P.A.
45
Bodywork
Window glasses
Bravo-Brava
70.
Thermal knife This c o n s i s t s of a piece o f e q u i p m e n t w h i c h t h e r m a l l y heats a blade t o f a c i l i t a t e c u t t i n g t h e sealant. It is p o s s i b l e t o a d j u s t t h e t e m p e r a t u r e o f t h e b l a d e u p t o 7 0 0 C, b u t it is a d v i s a b l e t o l i m i t t h e t e m p e r a ture o f t h e k n i f e in use t o a r o u n d 1 5 0 C t o a v o i d b u r n i n g t h e sealant a n d p r o d u c i n g h a r m f u l f u m e s . T h e knife is e q u i p p e d w i t h a f u m e a s p i r a t i o n s y s t e m . Different s h a p e d b l a d e s are available t o suit d i f f e r e n t c u t t i n g c o n d i t i o n s . It is i m p o r t a n t d u r i n g c u t t i n g that t h e blade s h o u l d a l w a y s be k e p t perfectly parallel t o t h e w i n d o w t o prevent excessive f o r c e a n d t h e risk o f b r e a k i n g t h e actual w i n d o w .
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.
Blades for c u t t i n g Blade for levelling Blade cleaning brush F u m e inlet C o n t a c t lever
46
Bravo-Brava
Bodywork
Window glasses
70.
Vibrating knife T h e v i b r a t i n g k n i f e is m a d e u p o f s p e c i a l shears a n d a suitable set o f v i b r a t i n g b l a d e s w i t h electrically a d j u s t a b l e o s c i l l a t i o n n u m bers. It c a n b e used t o c u t p o l y u r e t h a n e s e a l a n t s . It is i m p o r t a n t t h a t w h e n c u t t i n g t h e b l a d e is a l w a y s k e p t parallel t o the w i n d o w a n d t o t h e b o d y w o r k , t o prevent b r e a k i n g t h e b l a d e .
Do not use lubricants during ting. The blades should always be ened.
cutsharp-
P4A047M03
47
Bodywork
Window glasses
Bravo-Brava
70.
r-ti
nr.-=i-'
Y
ui-
1. Traction handle 2. R e t a i n i n g t o o l
I n s t r u c t i o n s f o r u s i n g w i r e c o n t a i n e d in K i t
Cut a segment of wire about 5 0 c m long a n d introduce one e n d of the w i r e (part 1 detail A ) t h r o u g h t h e b e a d o f sealant (heat t h e w i r e a n d use pliers t o facilitate t h i s o p e r a t i o n ) . Fix t h e e n d o f t h e w i r e t o t h e r e t a i n i n g t o o l inside t h e vehicle a n d the other end t o t h e traction handle outside t h e vehicle. The o p erator inside t h e v e h i c l e s h o u l d i n t r o d u c e t h e r e t a i n i n g t o o l i n t o t h e b e a d o f sealant ( F I G . B) about 30 c m from the point where t h e w i r e passes ( d e t a i l A ) .
The other operator outside the vehicle s h o u l d p u l l t h e h a n d l e f o l l o w i n g t h e line o f t h e w i n d s c r e e n s u r r o u n d a n d c u t t h e bead o f sealant. Repeat t h e o p e r a t i o n at 3 0 c m s e c t i o n s , s u i t a b l y r e d u c i n g t h e l e n g t h at t h e corners o f t h e w i n d o w , until t h e sealant b e a d is c o m p l e t e l y cut.
48
Bravo-Brava
Bodywork
Window glasses
70.
REPLACING FRONT WINDOW GLASS (WINDSCREEN) Removing vehicle trims and protection T h e c o m p o n e n t s s h o w n in t h e e x p l o d e d d i a g r a m are n u m b e r e d in t h e order in w h i c h t h e y s h o u l d be removed.
1. 2. 3. 4. 5. 6. 7.
Pillar covers S u n visors Sun blind attachment Courtesy light Rear v i e w mirror Grab handle Roof f i x i n g t r i m
S l i g h t l y l o w e r t h e l i n i n g u n d e r t h e r o o f w i t h o u t d i s t o r t i n g it Protect t h e d a s h b o a r d a n d t h e seats w i t h a cover or s u i t a b l e paper. Press o n t h e r e t a i n i n g m o u n t i n g s ( 3 ) a n d m o v e t h e m d o w n w a r d s . Protect t h e perimeter o f t h e w i n d s c r e e n h o u s i n g w i t h a d h e s i v e t a p e The window perimeter trim should always be replaced.
49
Bodywork
Window glasses
Bravo-Brava
70
NOTE
The film of sealant remaining on the windscreen housing will act as a support for the subsequent adhesion.
Preparing t h e w i n d s c r e e n If t h e w i n d o w w h i c h has been r e m o v e d is b e i n g reused: - U s i n g a s u i t a b l e b l a d e , c u t a n d level t h e b e a d o f sealant t r y i n g t o r e d u c e t h e t h i c k ness t o a m i n i m u m . It is n o t necessary t o r e m o v e t h e sealant c o m p l e t e l y . A v o i d t o u c h i n g t h e surfaces o f t h e s e a l a n t r e m a i n i n g . Take care n o t t o d a m a g e t h e black s e r i g r a p h y o n t h e w i n d o w perimeter. - De-grease t h e s e r i g r a p h e d s e c t i o n o f t h e windscreen using heptane. - A p p l y the adhesion promoter (primer) for glass t o t h e s e r i g r a p h e d area u s i n g t h e w a d s u p p l i e d in t h e kit. T h e p r o d u c t d o e s n o t have t o b e a p p l i e d t o t h e r e m a i n i n g s e a l a n t . - W a i t for 1 5 minutes before proceeding w i t h the operations t o allow the evaporat i o n of t h e adhesion promoter (primer) thinner.
P4A0S0M03
P4A050M04
50
Bravo-Brava
Bodywork
Window glasses
70.
Refitting - Fit t h e t r i m o n t h e w i n d s c r e e n a v o i d i n g t o u c h i n g t h e area w h e r e t h e a d h e s i o n p r o m o t e r (primer) has been a p p l i e d w i t h y o u r fingers. - Carry o u t a test f i t t i n g t o c e n t r e t h e w i n d screen perfectly a n d make reference marks.
The sliding retaining mountings located in the lower part should support the windscreen towards the top and keep it aligned with the roof.
Using a pneumatic g u n , extrude a bead of sealant a l o n g t h e perimeter o f t h e w i n d screen as evenly as possible (if t h e r e is e x cess, level t h e b e a d u s i n g a slice o f p o t a t o ) .
In the lower part of the windscreen apply the sealant scrupulously following the figures given in the diagram to prevent it ending up on the retaining mountings.
P4A051M04
51
Bodywork
Window glasses
Bravo-Brava
70.
- U s i n g t h e special s u c t i o n pads, place t h e w i n d s c r e e n in p o s i t i o n i m m e d i a t e l y after a p p l y i n g t h e sealant. - U s i n g s u i t a b l e belts a n d s h i m s , exert s l i g h t pressure o n t h e w i n d s c r e e n so t h a t t h e t r i m is c o r r e c t l y a l i g n e d w i t h t h e pillars. Keep t h e glass u n d e r pressure f o r at least 1 hour. D u r i n g this period it is possible t o let w a t e r run over t h e w i n d o w t o locate a n y p o s s i b l e p e n e t r a t i o n p o i n t s a n d accelerate t h e p o l y m e r i z a t i o n o f t h e sealant.
P4A052M01
- A n y excess sealant inside t h e pillars c a n b e r e m o v e d w h e n t h e sealant has h a r d e n e d , c u t t i n g it w i t h a blade a n d r e m o v i n g it w i t h pliers. Take care not to damage the serigraphed area of the windscreen with the blade.
52
Bravo
Bodywork
Window glasses
70.
REPLACING REAR WINDOW GLASS (REARSCREEN) R e m o v i n g v e h i c l e t r i m s and p r o t e c t i o n T h e c o m p o n e n t s s h o w n in t h e e x p l o d e d d i a g r a m are n u m b e r e d in t h e order in w h i c h t h e y are r e m o v e d .
- Protect t h e perimeter o f t h e rearscreen h o u s i n g w i t h a d h e s i v e t a p e - Protect t h e carpets w i t h a c l o t h or suitable paper. NOTE If the rearscreen is being reused, cut the adhesive with the vibrating the tailgate so as not to ruin the pressed perimeter seal. knife working from inside
53
Bodywork
Window glasses
Bravo
70.
Refitting - In order t o prepare t h e tailgate w i n d o w t o be r e f i t t e d , f o l l o w t h e i n s t r u c t i o n s g i v e n f o r the w i n d s c r e e n (see page 5 0 ) . - A s far as a p p l y i n g t h e sealant is c o n c e r n e d , there are n o d i f f i c u l t i e s relating t o t h e d i s t a n c e t o be m a i n t a i n e d f r o m t h e e d g e o f t h e w i n d o w . In effect, t h e sealant is a p p l i e d d i rectly o n t h e inner e d g e o f the seal w h i c h is the pressed t y p e .
54
Brava
Bodywork
Window glasses
70.
REPLACING REAR WINDOW GLASS (REARSCREEN) Removing vehicle trims and protection T h e c o m p o n e n t s s h o w n in t h e e x p l o d e d d i a g r a m are n u m b e r e d i n t h e order in w h i c h t h e y are r e m o v e d .
P4A055M01
- Protect the perimeter o f t h e rearscreen h o u s i n g w i t h a d h e s i v e tape. - Protect the carpets w i t h a c o v e r or s u i t a b l e paper. NOTE / / the window tailgate. is being reused, cut the sealant with the vibrating knife working from inside the
55
Bodywork
Window glasses
Brava
70.
Refitting Before r e f i t t i n g , prepare b o t h t h e w i n d o w a n d t h e h o u s i n g in t h e tailgate, f o l l o w i n g t h e i n s t r u c t i o n s f o r the w i n d s c r e e n <see p a g e 5 0 ) . To ensure t h a t t h e rearscreen is c o r r e c t l y a l i g n e d w i t h t h e b o d y s h e l l , refit t h e t r i m ( 1 ) at t h e base o f t h e w i n d o w a n d t h e trims ( 2 ) at t h e inner edges o f t h e tailgate. Take t h e p o s i t i o n o f t h e o p e n i n g in t h e w i n d s c r e e n w i p e r m o t o r p i n into c o n s i d e r a t i o n . T h e n a p p l y t h e references ( 3 ) .
P4A056M01
56
Bravo-Brava
Bodywork
Window glasses
70.
REPLACING THIRD FIXED WINDOW Removing trim and protection from vehicle T h e d i a g r a m b e l o w s h o w s t h e c o m p o n e n t s t o be r e m o v e d before m o v i n g o n t o t h e s u b s e q u e n t preparat i o n stages. - Protect t h e outer perimeter o f t h e t h i r d glass h o u s i n g w i t h adhesive t a p e - S l i g h t l y l o w e r t h e r o o f l i n i n g , t h e n p o s i t i o n t h e a p p r o p r i a t e spacers.
P4AO57M01
1. 2. 3. 4.
Rear panel inner l i n i n g Centre pillar cover Rear pillar cover Passenger g r a b h a n d l e It is preferable to cut the sealant working prevent scratching the bodywork. Open the retaining clips (7) before
NOTE
from inside
the vehicle
using
an appropriate
blade
to
cutting
the
sealant.
57
Bodywork
Window glasses
Bravo-Brava
70.
Refitting For t h e p r e p a r a t i o n o f t h e glass a n d t h e h o u s i n g , refer t o t h e i n s t r u c t i o n s already d e s c r i b e d p r e v i o u s l y (see p a g e 5 0 ) . The rear w i n d o w glass has an e x t r u d e d trim ( 1 ) a l o n g t h e entire perimeter. T h e sealant ( 2 ) w h i c h sticks the w i n d o w glass t o t h e bodyshell is applied t o t h e trim in a c o n t i n u o u s b e a d a l o n g t h e entire perimeter. The measurements f o r the d i m e n s i o n s of the b e a d and t h e distance f r o m t h e edge of t h e t r i m are g i v e n in inset B.
P4A058M01
There are t w o h o u s i n g s ( 3 ) at t h e t w o f r o n t c o r n e r s of t h e w i n d o w f o r f i t t i n g t h e t h r e a d e d pins ( 4 ) w h i c h act as references for t h e c e n t e r i n g . T h e s e c t i o n o f t h e w i n d o w c o r r e s p o n d i n g t o t h e t h r e a d e d pins is s h o w n in inset C. The t h r e a d e d pins are available as spares a n d it is advisable t o m o d i f y t w o o f t h e m , r e m o v i n g the t a b s t o use t h e m as reference pins d u r i n g t h e o p e r a t i o n o f o f f e r i n g u p t h e w i n d o w w h e n d r y . To l o c k t h e w i n d o w , d u r i n g t h e h a r d e n i n g o f t h e sealant, f o l d back t h e c l i p s ( 5 ) as s h o w n in inset A .
58.
Bravo-Brava
Bodywork
Sun roof
70.
INTRODUCTION
T h e s u n r o o f is electrically o p e r a t e d . T h e c l o s i n g f l a p is in glass w h i c h m e a n s t h a t t h e t r a n s m i s s i o n of light and e n e r g y e q u a l s 2 5 % . It can be o p e n e d , c o m p l e t e l y or p a r t l y , b y a push b u t t o n (1) positioned on t h e upper c o u r t e s y light. T h e s u n b l i n d is o p e n e d m a n u a l l y a n d irres p e c t i v e l y of the o p e r a t i o n of t h e s u n roof.
Emergency procedure If t h e electrically operated d e v i c e f a i l s , it is possible t o operate the s u n r o o f m a n u a l l y , p r o c e e d i n g as f o l l o w s : - r e m o v e t h e seals a n d b o l t s ( 2 ) ; - extract t h e special key ( 3 ) f r o m i n s i d e t h e c o u r t e s y light; - insert it in t h e special s p l i n i n g f o r t h e electric m o t o r , t h e n rotate a n d m o v e t h e roof.
P4A059M03
P4A059M04
59
Bodywork
Sun roof
Bravo-Brava
70.
Removing trim To r e m o v e the t r i m for t h e s u n roof, remove t h e c o m p o n e n t s s h o w n in t h e d i a g r a m .
P4A060M01
1. 2. 3. 4. 5.
6. Rearscreen pillar covers 7. Tailgate h i n g e covers a n d r o o f l i n i n g f i x ing plugs 8 Flap t r i m 9; Tailgate h o u s i n g t r i m 1 0 . Roof l i n i n g the tailgate housing
IM O T E
Extract the roof lining from the passenger compartment passing it through after having removed the upper and side part of the trim (see detail A).
60
Bravo-Brava
Bodywork
Sun roof
70.
REMOVING-REFITTING C O M P L E T E ROOF After r e m o v i n g the t r i m f o r t h e internal c o m p o n e n t s (see p r e v i o u s p a g e ) , p r o c e e d w i t h t h e r e m o v a l of t h e c o m p l e t e roof, f o l l o w i n g the i n s t r u c t i o n s g i v e n b e l o w : - d i s c o n n e c t t h e w a t e r d r a i n a g e pipes ( 1 ) ; - o n t h e f r o n t cross m e m b e r for t h e f r a m e u n d o t h e centre b o l t ( 2 ) a n d t h e n u t s ( 3 ) ; - w o r k i n g f r o m the side, r e m o v e t h e n u t s ( 4 ) a n d t h e bolts ( 5 ) ;
P4A061M01
NOTE
(6) are connected to the roof rib (7); disconnected (see detail A)
to remove
frame
they
61
Bodywork
Sun roof
Bravo-Brava
70.
DISMANTLING-REASSEMBLING COMPLETE ROOF To d i s m a n t l e t h e sun roof, p r o c e e d as d e s c r i b e d b e l o w : - R e m o v e t h e crystal ( 1 ) f r o m t h e pullies ( 6 ) t h r o u g h t h e bolts ( 9 ) . R e m o v e t h e rain g u t t e r ( 8 ) . R e m o v e t h e s u n visor panel ( 2 ) releasing it f r o m t h e g u i d e s (see detail A ) . - R e m o v e t h e electric m o t o r ( 3 ) . - R e m o v e t h e terminals ( 4 ) ( w a t e r d r a i n a g e ) s t u c k w i t h Betaseal t y p e p o l y u r e t h a n e sealant. - U n d o t h e t w o e n d of travel bolts ( 5 ) . - Extract t h e pullies ( 6 ) after h a v i n g m o v e d t h e m i n t o t h e e n d of travel p o s i t i o n . - Remove the b o w d e n cable ( 1 0 ) . - R e m o v e t h e deflector ( 7 ) .
P4A062M01
The bolts (9) securing the glass are treated with special glue. After the bolt has completed six travels this feature is worn out. BOLTS SHOULD BE USED. NOTE The following components can be removed with the assembly crystal (1); trim (detail B); electric motor (3); sun blind panel When refitting lubricate equivalent product. the sliding components with MOLYHOTE fitted (2).
ONLY
THESE
SPECIAL
on the
vehicle:
PG 30 L type grease
or an
62
Bravo-Brava
Bodywork
Sun roof
70.
A D J U S T M E N T S DURING REFITTING
A d j u s t m e n t of o p e n i n g d e v i c e . For a correct s y n c h r o n i s m b e t w e e n t h e e l e c trical o p e r a t i o n a n d t h e o p e n i n g / c l o s i n g of t h e r o o f t h e parts c o n c e r n e d m u s t be a d j u s t e d as f o l l o w s : 1 . p o s i t i o n t h e rollers (1) f o r t h e p u l l i e s e x a c t l y at t h e start of the s l i d i n g d u c t ( 2 ) , b e f o r e the reference mark s h o w n b y t h e arrow; 2. refit t h e electric motor w i t h reference A corresponding to the m i c r o - s w i t c h ( 3 ) ; - lastly, refit t h e w i n d o w . A d j u s t i n g the w i n d o w 3. If necessary, a d j u s t the a l i g n m e n t of t h e w i n d o w w i t h t h e profile of t h e r o o f u s i n g t h e slots in t h e frame ( 4 ) . A d j u s t i n g the s p o i l e r
63
Bodywork
Replacing body panels
Bravo-Brava
70.
INTRODUCTION General i n s t r u c t i o n s f o r t h e repair For safety reasons a n d f o r a better q u a l i t y repair, it is f o r b i d d e n : - T o replace a side m e m b e r , half b l o c k or b l o c k , w i t h o u t using a repair b e n c h . T h e use of t h e b e n c h makes it possible t o ensure t h e r e s t r u c t u r i n g of t h e vehicles w i t h t h e o r i g i n a l m a n u f a c t u r i n g d i s t a n c e s , e n s u r i n g t h e correct p o s i t i o n i n g of t h e e l e m e n t s o f b o t h t h e f r o n t s e c t i o n a n d t h e rear s e c t i o n . - C u t a n d w e l d any e l e m e n t o f t h e b o d y w o r k a n d its r e i n f o r c e m e n t , e d g e t o e d g e , a l o n g t h e s a m e line (see f i g u r e 1 ) . - Heat t h e side members f o r s t r a i g h t e n i n g .
64
Bravo-Brava
Bodywork
Replacing body panels
70
GRAPHIC INDEX
Replacement operation
R e f e r e n c e in Manual
Front w i n g
Rear w i n g 3 P
P4A065MO2
Rear w i n g 5 P
R e p l a c i n g roof panel
Rear cross m e m b e r c o v e r 3 P Replacing b o d y panels 5 door version: page 89 3 door version: page 93
P4A066MO6
A.'^r!
nnfa|\rjD.
\v
-TT
fangs~-k
65
Bodywork
Replacing body panels
Bravo-Brava
70.
SYMBOLS CUTTING W I T H HACK S A W I N G M A C H I N E CHECKING GAPS A N D ALIGNMENTS
CUTTING W I T H BLADE S A W
CIRCULAR
SPOT W E L D I N G
MIG WELDING
OXYACETY-
REMOVING SPOT WELDS WITH DRILL DRILLING FOR M I G W E L D I N G REMOVING PANEL WITH CHISEL DRILLING FOR M I G W E L D I N G A P P L Y I N G ELECTROW E L D A B L E PROTECTIVES
GRINDING
(gig}
f\
APPLYING SEALANTS
APPLYING PROTECTIVES
UNDERBODY
CENTERING
COMPONENTS
. <
APPLYING
PAINTS
MEASURING
FIXING C O M P O N E N T S
F I X I N G T H R E A D E D RIVETS
<
\
APPLYING FOAM
PRODUCTS
S Y M B O L S IN I L L U S T R A T I O N S CUTTING LINE SPOT W E L D I N G . . . . M I G W E L D I N G FOR FILLING UUUUUUU CONTINUOUS M I G WELDING "mmm BRAZING
66
Print no.
506.670/01
Bravo-Brava
Bodywork
Replacing body panels
70.
FRONT WING Removing R e m o v e t h e f r o n t light cluster as s h o w n i n S e c t i o n 5 5 - Electrical e q u i p m e n t . 1 . U n d o t h e bolts and the b u t t o n f i x i n g t h e front wheel arch liner using tool 1878077000. 2. R e m o v e t h e f r o n t w h e e l a r c h liner, u n d o i n g t h e f i x i n g bolts. 3. R e m o v e t h e side d i r e c t i o n i n d i c a t o r a c t i n g o n t h e r e t a i n i n g tabs a n d d i s c o n n e c t i n g the connector. 4 . U n d o t h e bolts f i x i n g t h e b u m p e r s t o t h e f r o n t w i n g a n d t h e bolts f i x i n g t h e w i n g t o t h e f r o n t side panel. 5. U n d o t h e b o l t s f i x i n g t h e w i n g t o t h e u n derdoor lining.
P4A067M03
P4A067M05
67
Bodywork
Replacing body panels
Bravo-Brava
70.
P4A068M02
1. U n d o t h e upper bolts fixing t h e w i n g t o the vehicle a n d t h e lower w i n d o w lining. 2. U n d o t h e b o l t f i x i n g t h e w i n g t o t h e f r o n t pillar cover, t h e n separate t h e w i n g f r o m t h e adhesive sealant. Refitting 3. R e m o v e t h e o l d sealant f r o m t h e area in contact w i t h t h e vehicle. 4. A p p l y sealant t o t h e c o n t a c t area b e t w e e n the w i n g and t h e vehicle. 5. Place t h e r e p l a c e m e n t part in p o s i t i o n , tighten the bolts fixing the w i n g t o the v e hicle, t h e n refit all t h e c o m p o n e n t s p r e v i ously removed. NOTE Use SIKAFLEX221 (made by SIKA) sealant which hardens at ambient temperature or an equivalent prod uct.
68
Bravo
Bodywork
Replacing body panels
70.
REPLACING REAR W I N G (7090A 5 4 ) *
(*)
operation manual.
Establish t h e e x t e n t of t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t figures. Carry o u t any s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l using s u i t a b l e m e t h o d s ( j i g s , t e m p l a t e s or g a u g e s ) , before c u t t i n g t h e c o m p o n e n t . A f t e r t h i s o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g r e p l a c e d are intact. PRECAUTIONS/WARNINGS AND PRELIMINARY DISMANTLING Protect t h e seats a n d t h e parts w h i c h c o u l d be d a m a g e d u s i n g c l o t h s . R e m o v e t h e fuel t a n k , d i s c o n n e c t t h e battery a n d all t h e electrical a n d electronic c o m p o n e n t s b e c a u s e t h e currents p r o d u c e d d u r i n g t h e w e l d i n g o p e r a t i o n s c o u l d cause serious damage. REMOVING AND REFITTING OPERATING C Y C L E T h e replacement o f t h e panels c a n be " t o t a l or " p a r t i a l " ; t h i s s e c o n d s o l u t i o n is preferable w h e n t r y i n g t o a v o i d damage t o a n o t h e r panel w h i c h has been assembled t h r o u g h w e l d i n g . C u t the w i n g u s i n g a p o w er s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w . W e s h o w t h e s e c t i o n s of t h e panels at t h e c u t t i n g p o i n t s t o a l l o w t h e operator t o adjust t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g .
When carrying out the operations described, adhere strictly to the safety procedures. shoes, ear-muffs and gloves should be worn during the cutting operations, masks during the we/ding and painting operations.
Copyright by Fiat Auto
and
Protective gloves
69
Bodywork
Replacing body panels
Bravo
70
Using t h e s a w , c u t t h e u n d e r d o o r s i d e member, t h e centre a n d rear pillars; these parts w i l l b e later w e l d ed " e d g e t o e d g e " u s i n g t h e c o n t i n u o u s w e l d i n g m a c h i n e . It is advisable neath. to cut the wing using a hand saw so as not to affect the reinforcements under-
P4A070M01
Remove t h e s p o t w e l d s u s i n g a special remover. The c u t t e r f o r r e m o v i n g t h e s p o t w e l d s acts o n t h e panel w h i c h m a k e s u p t h e e l e m e n t t o b e replaced as far as t h e panel u n d e r n e a t h t h e r e b y e l i m i n a t i n g t h e w e l d s p o t as s h o w n in t h e right inset.
70
Print no.
506.670/01
Bravo
Bodywork
Replacing body panels
70.
W h e r e it is n o t possible t o use a s p o t w e l d remover, use a special c u t t e r a n d an o r d i n a r y drill ( i t is also p o s s i b l e t o use a normal drill m o d i f i e d as s h o w n in t h e d i a g r a m u n d e r n e a t h .
mm0,4~
^ 3
I
P4A071M01
P4A071M03
// there are difficulties when removing the wing, it is advisable to heat the section of sealant in the area of the wheel arch and the foam in the upper part of the rear pillar using a hot air blower.
71
Bodywork
Replacing body panels
Bravo
70.
- Place t h e spare part in p o s i t i o n o n t h e v e hicle a n d c h e c k t h e a l i g n m e n t w i t h t h e a d j a c e n t e l e m e n t s , t h e n f i x it u s i n g t h e special s e l f - l o c k i n g c l a m p s ; - after h a v i n g m a d e sure t h a t it is perfectly superimposed (pillar and underdoor p a n e l ) , mark t h e parts t o be r e m o v e d o n t h e b o d y s h e l l u s i n g a tracer p o i n t .
P4AO72M03
72
Bravo
Bodywork
Replacing body panels
70
R e m o v e t h e replacement part f r o m t h e v e h i c l e a n d r e m o v e t h e o f f c u t s f r o m t h e pillars a n d t h e u n d e r d o o r panel.
P4A073M01
1 . Drill t h e replacement part at t h e p o i n t s w h e r e t h e c o n t i n u o u s w e l d i n g m a c h i n e w i l l insert t h e rivets. 2. G r i n d t h e s p o t w e l d residues a n d bare all t h e inner a n d o u t e r surfaces in t h e areas t o b e w e l d e d ( a v o i d t h e b u r n t p a i n t e d b o x s e c t i o n s n o t p e r f e c t l y a n c h o r e d t o t h e panels adversely a f f e c t i n g t h e subsequent protection operations). 3. A p p l y e l e c t r o - w e l d a b l e a n t i - r u s t p r o t e c t i v e t o t h e inner edges t o be w e l d e d .
P4A073M02
P4A073M03
73
Bodywork
Replacing body panels
Bravo
70.
Place sealant b e t w e e n t h e w h e e l arch a n d t h e w i n g a l o n g t h e s e c t i o n i n d i c a t e d in t h e d i a g r a m .
1
P4A074M02
74
Print no.
506.670/01
Bravo
Bodywork
Replacing body panels
70
P4A075M01
Carry o u t electrical s p o t w e l d i n g in t h e areas s h o w n . When carrying out electrical spot welding it is neceesary that the parts to be welded fectly matched and that the panels are scrupulously clean to avoid excessive resistance to burning and the consequent fragility of the welding. are perleading
P4A075M04
75
Bodywork
Replacing body panels
Bravo
70
P4A076M01
Carrying o u t t h e f i l l i n g ( r i v e t i n g ) in t h e h o l e s m a d e p r e v i o u s l y in t h e r e p l a c e m e n t part.
76
Bravo
Bodywork
Replacing body panels
70
P4A077M01
P4A077M02
11
Bodywork
Replacing body panels
Bravo
70.
PROTECTION OF REPAIRED PARTS
To a v o i d a n y p r o b l e m s in t h e f u t u r e it is i m p o r t a n t , after r e p l a c i n g or repairing a b o d y w o r k e l e m e n t , t o restore t h e correct p r o t e c t i o n , b o t h internal a n d e x t e r n a l , so t h a t t h e i d e n t i c a l characteristics t o t h e o r i g i nal o n e s are restored t o ensure t h e q u a l i t y of t h e repair a n d g u a r a n t e e it a g a i n s t c o r r o s i o n . The r e p l a c e m e n t parts are s u b j e c t e d t o t h e same c y c l e as t h e b o d y s h e l l . Per conservare le qualita a n t i c o r r o s i v e d i o r i g i n e , q u e s t i e l e m e n t i d e v o n o essere smerigliati s o l o d o v e strettamente necessario.
1 . Preparing t h e areas w e l d e d or repaird b y d r y s a n d i n g w i t h P 1 0 0 grade abrasive paper. This o p e r a t i o n is d e s i g n e d t o r e m o v e a n y layers o f p a i n t w h i c h are n o t p r o p e r l y a n c h o r e d t o t h e panel a n d , at t h e same t i m e , t o level t h e u n e v e n e s s o r " s t e p s " . 2. Dry s a n d i n g of t h e replaced part a n d t h e s u r r o u n d i n g p a i n t w o r k t h e P 3 2 0 abrasive paper. S i m p l y m a k e t h e r e p l a c e m e n t part " o p a q u e " a n d level a n y i m p e r f e c t i o n s , g r o o v e s , l u m p s or s c r a t c h es, a v o i d i n g , as far as possible, r e m o v i n g t h e o r i g i n a l t r e a t m e n t . 3. B l o w t h r o u g h t h o r o u g h l y a n d w a s h w i t h d i l u e n t because t h e d u s t c o u l d s e r i o u s l y affect t h e a d h e sion o f t h e p r o d u c t s t o be a p p l i e d . 4. P h o s p h a t i n g : a p p l y a n a n t i - r u s t p h o s p h a t i n g p r o d u c t t o t h e e x p o s e d areas, if necessary u s i n g a b r u s h , w h i c h as w e l l as p r e v e n t i n g c o r r o s i o n i m p r o v e s t h e a d h e s i o n o f t h e s u b s e q u e n t p r o d u c t s . 5. Finish o f f w i t h metal filler t o perfect a n d e l i m i n a t e a n y g r o o v e s a n d / o r d e p r e s s i o n s in t h e w e l d e d or repaird panels. The a p p l i c a t i o n u s i n g a spatula o f a suitable t h i c k n e s s o f polyester filler, is carried o u t in o n e or m o r e goes. Take care n o t t o carry o u t excess catalysis, w h i c h c o u l d s h o w u p o n t h e p a i n t w o r k as y e l l o w m a r k s d u e t o peroxide. 6. Dry s a n d using P 8 0 - 1 0 0 paper. To r e m o v e t h e excess filler a p p l i e d p r e v i o u s l y , w o r k m a n u a l l y u s i n g rubber o r w o o d e n buffers or m a nual s a n d e r s . The s a n d i n g s h o u l d b e d o n e s k i l l f u l l y , a b o v e all i n t h e areas s u r r o u n d e d b y p a i n t w o r k t o a v o i d large scratches. A n y o v e r h a u l i n g of u n e v e n areas, g r o o v e s , p o r o u s n e s s , etc. s h o u l d b e carried o u t n o w using t h e same filler t o a v o i d later o p e r a t i o n s . Finish o f f w i t h a finer grade abrasive p a per ( P 3 2 0 ) . B l o w a n d degrease very t h o r o u g h l y . 7. F i n i s h i n g c o a t ( w i t h t w o c o m p o n e n t s ) . Protect t h e parts n o t i n v o l v e d in t h e a p p l i c a t i o n o f t h e coat. T h e a p p l i c a t i o n o f t h e f i n i s h i n g base c o a t s h o u l d b e carried o u t f o l l o w i n g t h e m a n u f a c t u r e r s i n s t r u c t i o n s t o t h e letter. A very light layer of b l a c k paint, a t o m i z e d b y h a n d , a p p l i e d t o t h e base c o a t w i l l s h o w u p a n y i m p e r f e c t i o n s d u r i n g t h e s a n d i n g so t h a t t h e y can b e r e m o v e d . 8. Dry or w a t e r s a n d i n g w i t h P 5 0 0 - P 6 0 0 abrasive paper. 9. B l o w i n g / d e g r e a s i n g . ( D u s t a n d h u m i d i t y h a v e a s e r i o u s adverse affect o n t h e a d h e s i o n o f t h e p a i n t p r o d u c t s ) .
78
Bravo
Bodywork
Replacing body panels
70.
1 0 . S e a l i n g . Protect t h e j o i n s f o r t h e c o m p o n e n t s s u p e r i m p o s e d , t h e l o w e r part of t h e w h e e l a r c h a n d t h e u n d e r d o o r panel w i t h a t w o c o m p o n e n t sealant, a p p l i e d b y brush or b y s p r a y i n g .
Bodywork
Replacing body panels
Bravo
70.
1 1 . D a m p e r panels. Fit t h e d a m p i n g panels t o t h e inside o f t h e w i n g . 12. F o a m . A p p l y t h e f o a m t h r o u g h t h e o p e n i n g s s h o w n . 13. P r e p a r i n g any j o i n s t o be s h a d e d a n d / o r p r e p a r i n g t h e e l e m e n t s a d j a c e n t t o t h e s h a d i n g , w e t s a n d i n g w i t h P 1 2 0 0 g r a d e abrasive paper or w i t h abrasive p o l i s h . 14. P r o t e c t i o n (after c h e c k i n g t h e t i n t ) . Use industrial paper w h i c h d o e s n o t release v o l a t i l e i m p u r i t i e s . 15. B l o w i n g a n d p r e p a r i n g for p a i n t i n g . W a s h w i t h a n t i - s i l i c o n d i l u e n t a n d d r y , lastly clean w i t h a c h e m i c a l w a d . 16. P a i n t i n g . F o l l o w t h e t e c h n i c a l s p e c i f i c a t i o n s a n d t h e i n s t r u c t i o n s f o r a p p l y i n g e n a m e l s , r e c o m m e n d e d in t h e t e c h n i c a l charts f r o m t h e m a n u f a c t u r e r s o f t h e p r o d u c t u s e d .
80
Print no.
506.670/01
Brava
Bodywork
Replacing body panels
70.
REPLACING REAR W I N G (7090A 5 4 ) *
(*)
operation manual.
Establish t h e e x t e n t o f t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g suitable m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s r e q u i r e d t o t h e b o d y s h e l l before c u t t i n g t h e c o m p o n e n t . A f t e r this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are in tact. PRELIMINARY DISMANTLING
R e m o v e t h e m o v i n g parts o f t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . REMOVING C u t t h e rear w i n g o f t h e v e h i c l e u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w a n d remove t h e s p o t w e l d s a l o n g t h e s e c t i o n of t h e d o o r striker h o u s i n g . T h e m o s t i m p o r t a n t s e c t i o n s o f t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g so as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
81
Bodywork
Replacing body panels
Brava
70.
R e m o v i n g off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. Remove the w e l d points along t h e entire perimeter of the edge of the bodyshell, using a special cutter. 2. 3. 4. 5. R e m o v e t h e metal o f f cuts u s i n g pliers. Straighten t h e edges w i t h a hammer and dolly block. R e m o v e t h e w e l d residues u s i n g a disc g r i n d e r . A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas previously g r o u n d .
A d j u s t i n g t h e r e p l a c e m e n t part 1 . C u t t h e upper s e c t i o n o f t h e r e p l a c e m e n t part t h e n place it i n p o s i t i o n s o t h a t it adheres perfectly t o the bodyshell. 2. C h e c k t h a t t h e w i n g is s u p e r i m p o s e d 5 0 - 6 0 m m over t h e b o d y s h e l l . 3. Fix t h e r e p l a c e m e n t part u s i n g t h e special s e l f - l o c k i n g c l a m p s . 4 . C u t t h e t w o e d g e s of t h e panel s o t h a t t h e j o i n is perfectly a l i g n e d .
82
Brava
Bodywork
Replacing body panels
70.
Preparing t h e s p a r e part a n d c h e c k i n g t h a t it i s c o r r e c t l y p o s i t i o n e d on t h e b o d y s h e l l 1 . M a k e e q u i d i s t a n t holes in t h e e d g e s o f t h e r e p l a c e m e n t part as s h o w n in t h e d i a g r a m . 2 . R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter o f t h e inside a n d t h e o u t s i d e o f t h e rep l a c e m e n t part u s i n g a special g r i n d e r . 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e edges in c o n t a c t w i t h t h e b o d y s h e l l . 4 . Use t h e M I G w e l d e r t o fill t h e holes m a d e p r e v i o u s l y b e t w e e n t h e w i n g a n d the f u e l l f i l l e r h o u s i n g . 5. Tack t h e r e p l a c m e n t part using several s p o t w e l d s . 6. Fit t h e b o o t l i d , close t h e d o o r a n d c h e c k t h e a l i g n m e n t a n d t h e eveness o f t h e s u r r o u n d i n g g a p .
P4A083M01
1 . Carry o u t s p o t w e l d i n g a l o n g t h e e d g e s of t h e d o o r seal, w h e e l arch a n d rear l i g h t c l u s t e r h o u s i n g . 2. Use t h e M I G w e l d e r b e t w e e n t h e u n d e r d o o r side m e m b e r a n d t h e w i n g a n d b e t w e e n t h e w i n g a n d the b o d y s h e l l . 3. Weld using brass a n d t h e oxyacetylene canister by t h e rearscreen housing and t h e luggage c o m p a r t m e n t . 4 . Fill t h e holes m a d e p r e v i o u s l y in t h e part b y w e l d i n g .
83
Bodywork
Replacing body panels
Brava
70.
Finishing operations 1 . Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a hammer a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc g r i n d e r .
P4A084M01
Protections 1 . A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e w i n g a n d t h e b o d y s h e l l u s i n g IVI 8 5 4 2 1 0 transparent acrylic sealant or a n equivalent product. 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g s t a g e .
84
Print no.
506.670/01
Bravo-Brava
Bodywork
Replacing body panels
70.
REPLACING UNDERDOOR S I D E M E M B E R (7090G 6 2 ) *
(*)
operation manual.
PRELIMINARY PROCEDURES Establish t h e extent of t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , using s u i t a b l e m e t h o d s (jigs, templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g t h e c o m p o n e n t . After this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are in tact. PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . REMOVING C u t the v e h i c l e u n d e r d o o r side m e m b e r u s i n g a h a m m e r a n d chisel ( u p p e r area) a n d a p o w e r s a w ( l o w e r area), f o l l o w i n g t h e c u t t i n g lines s h o w n in t h e d i a g r a m b e l o w . T h e most i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P4A08SM02
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
85
Bodywork
Replacing body panels
Bravo-Brava
70.
R e m o v i n g off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. 2. 3. 4. 5. Remove the w e l d points along the entire perimeter of t h e edge of t h e bodyshell, using a special cutter. R e m o v e t h e metal off c u t s u s i n g pliers. S t r a i g h t e n t h e edges w i t h a hammer a n d d o l l y b l o c k . R e m o v e t h e w e l d residues using a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e primer o r a n e l e c t r o - w e l d a b l e g a l v a n i z e d paint or a n e q u i v a l e n t p r o d u c t , t o t h e areas previously g r o u n d .
P4A086M01
A d j u s t i n g r e p l a c e m e n t part a n d f i n i s h i n g t h e e d g e s o f t h e b o d y s h e l l 1 . Place t h e replacement part in p o s i t i o n after h a v i n g degreased it s u i t a b l y a n d f i x it u s i n g t h e s p e c i a l self-locking clamps. 2. T r a c e t h e profile o f t h e r e p l a c e m e n t p a r t o n t h e b o d y s h e l l u s i n g a tracer p o i n t . 3. R e m o v e t h e replacement part a n d c u t t h e excess f r o m t h e edges o f t h e b o d y s h e l l a l o n g t h e line d r a w n previously using b o d y w o r k shears.
P4A086M02
86
Bravo-Brava
Bodywork
Replacing body panels
70.
Preparing t h e s p a r e part a n d c h e c k i n g t h a t it i s c o r r e c t l y p o s i t i o n e d o n t h e b o d y s h e l l 1 . M a k e e q u i d i s t a n t holes a l o n g t h e entire l o w e r e d g e o f t h e r e p l a c e m e n t part. 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entireperimeter o f t h e inside a n d t h e o u t s i d e o f t h e r e p l a c e m e n t part u s i n g a special grinder. 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e edges in c o n t a c t w i t h t h e b o d y s h e l l . 4 . Position t h e r e p l a c e m e n t part in place a n d f i x it u s i n g t h e special s e l f - l o c k i n g c l a m p s . 5. Fit t h e d o o r , t h e n c h e c k t h e a l i g n m e n t a n d eveness of t h e s u r r o u n d i n g g a p .
Welding the spare part 1 . Carry o u t spot w e l d i n g o n t h e u p p e r a n d l o w e r e d g e s of t h e u n d e r d o o r side member w e l d i n g it t o t h e bodyshell. 2. Use t h e M I G w e l d e r b y t h e b o d y s h e l l pillars. 3. Use t h e M I G w e l d e r t o fill t h e holes m a d e p r e v i o u s l y in t h e r e p l a c e m e n t part
87
Bodywork
Replacing body panels
Bravo-Brava
70.
Finishing operations 1. Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc g r i n d e r .
P4A088M01
Protections 1 . A p p l y t h e e l e c t r o - p h o r e t i c t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e u n d e r d o o r s i d e m e m b e r a n d t h e b o d y s h e l l , u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. 4. A p p l y w a x based oil p r o t e c t i v e inside t h e u n d e r d o o r side member.
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REPLACING VEHICLE R O O F P A N E L (7090A 58)"
(*)
operation manual.
PRELIMINARY PROCEDURES Establish t h e e x t e n t o f t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t figures, u s i n g suitable m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g the c o m p o n e n t . After t h i s o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are in tact. PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . REMOVING Cut t h e vehicle r o o f panel u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w . T h e m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
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70.
R e m o v i n g off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. R e m o v e t h e w e l d p o i n t s a l o n g t h e entire perimeter of t h e e d g e o f t h e b o d y s h e l l , u s i n g a special c u t ter. -jt' 2 . R e m o v e t h e metal o f f c u t s u s i n g pliers. 3. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . 4. R e m o v e t h e w e l d residues u s i n g a disc grinder. 5. R e m o v e t h e centre r i b , u n d o i n g t h e f i x i n g b o l t s . 6. A p p l y t h e I V I Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or a n e q u i v a l e n t p r o d u c t , t o t h e areas previously g r o u n d .
P4A090M01
Preparing t h e s p a r e part 1. A p p l y a base coat u s i n g a spray g u n . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e e n t i r e perimeter o f t h e inside a n d t h e o u t s i d e o f t h e rep l a c e m e n t part using a disc grinder. 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e e d g e s in c o n t a c t w i t h t h e b o d y s h e l l .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1 . R e n e w t h e sealant o n t h e b o d y s h e l l ribs, u s i n g IVI 8 5 4 2 1 0 transparent acrylic sealant or a n e q u i v a lent p r o d u c t . 2. - Carefully place t h e r e p l a c e m e n t part in p o s i t i o n . 3. C h e c k t h a t t h e r o o f panel is perfectly p o s i t i o n e d o n t h e b o d y s h e l l . 4 . Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g clamps.
P4A091M01
Welding the spare part 1 . Carry o u t t h e brass w e l d i n g u s i n g an o x y a c e t y l e n e canister b y t h e corners of t h e f r o n t a n d rear r o o f pillars. 2. U s i n g a c o n t i n u o u s w e l d e r c o n t i n u e t h e o p e r a t i o n o n t h e entire c o n t a c t edge b e t w e e n t h e r o o f a n d the bodyshell.
P4A091M02
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Bravo-Brava
70.
Finishing operations 1. C o r r e c t a n y d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag using a disc grinder. 3. R e n e w t h e sealant o n t h e rib r e m o v e d p r e v i o u s l y , t h e n refit it o n t h e b o d y s h e l l m a k i n g sure t h a t it a d heres perfectly t o t h e roof.
P4A092M01
Protections 1. A p p l y t h e e l e c t r o - p h o r e t i c t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e roof a n d t h e b o d y s h e l l u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an equivalent product. 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage.
P4A092M02
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REPLACING REAR CROSS M E M B E R L I N I N G (7090G 7 6 ) *
(*)
operation manual.
T h e c o m p o n e n t for w h i c h t h e r e p l a c e m e n t p r o c e d u r e is g i v e n is h i g h l i g h t e d in t h e d i a g r a m at t h e side.
P4A093M01
PRELIMINARY PROCEDURES Establish t h e e x t e n t of t h e d a m a g e , c h e c k if there are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , using s u i t a b l e m e t h o d s (jigs, templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l b e f o r e c u t t i n g t h e c o m p o n e n t . A f t e r this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are in tact. PRELIMINARY DISMANTLING
R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . < . REMOVING C u t t h e v e h i c l e rear cross m e m b e r cover u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a gram below. T h e most i m p o r t a n t s e c t i o n s o f t h e b o d y panel are s h o w n in order t o a l l o w the operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P4A093M02
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
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Bravo
70.
R e m o v i n g off c u t s a n d preparing e d g e s of b o d y s h e l l 1. R e m o v e t h e w e l d p o i n t s a l o n g t h e entire perimeter of t h e e d g e of t h e b o d y s h e l l a n d t h e r e i n f o r c e m e n t b e l o w t h e l i g h t cluster h o u s i n g as s h o w n in t h e inset u s i n g a special cutter. 2. R e m o v e the metal off cuts u s i n g pliers. 3. S t r a i g h t e n t h e e d g e s w i t h a h a m m e r a n d d o l l y block. 4. R e m o v e t h e w e l d residues u s i n g a disc g r i n d e r . 5. A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or a n e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
P4A094M01
P r e p a r i n g the s p a r e part 1. M a k e e q u i d i s t a n t holes in t h e edges o f t h e r e p l a c e m e n t part s h o w n i n t h e d i a g r a m . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter of t h e inside a n d t h e o u t s i d e of t h e r e p l a c e m e n t part u s i n g a disc g r i n d e r . 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e e d g e s p r e v i o u s l y t r e a t e d .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1. 2. 3. 4. 5. Carefully place t h e replacement part in p o s i t i o n . Check t h a t t h e cross m e m b e r l i n i n g is perfectly p o s i t i o n e d . Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g c l a m p s . Tack t h e r e p l a c e m e n t part m a k i n g several s p o t w e l d s . Close t h e b o o t l i d a n d c h e c k t h e a l i g n m e n t a n d t h e eveness of t h e s u r r o u n d i n g g a p .
P4A095M01
Welding t h e spare part 1 . Carry o u t s p o t w e l d i n g at t h e c o n t a c t edges b e t w e e n t h e rear cross m e m b e r l i d i n g a n d t h e w i n g a n d the internal r e i n f o r c e m e n t . 2. C o n t i n u e t h e s p o t w e l d i n g o n t h e c o n t a c t e d g e s near t h e spare w h e e l a r c h h o u s i n g a n d t h e side edges. 3. U s i n g a M I G w e l d e r fill t h e holes m a d e p r e v i o u s l y in t h e r e p l a c e m e n t part.
P4A095M02
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Brava
70.
Finishing operations 1 . Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a hammer a n d d o l l y b l o c k . 2. R e m o v e any w e l d slag u s i n g a disc g r i n d e r .
P4A096M01
Protections 1. A p p l y t h e e l e c t r o - p h o r e t i c t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e rear cross m e m b e r cover a n d t h e b o d y s h e l l u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g s t a g e .
P4A096M02
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REPLACING REAR CROSS M E M B E R LINING (7090A46)*
(*)
operation manual.
The component for w h i c h t h e replacem e n t p r o c e d u r e is given is h i g h l i g h t e d in t h e d i a g r a m at t h e side. PRELIMINARY PROCEDURES Establish t h e extent o f t h e d a m a g e , c h e c k if there are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g t h e c o m p o n e n t . After t h i s o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are in tact. PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts o f t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or b e d a m a g e d d u r i n g t h e m . REMOVING Cut t h e v e h i c l e rear cross m e m b e r cover u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a gram b e l o w , remove t h e s p o t w e l d s f o r t h e f l o o r panel side m e m b e r s . The m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in o r d e r t o a l l o w t h e operator t o a d j u s t t h e p o sition a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P4A097M01
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
97
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R e m o v i n g o f f c u t s a n d preparing e d g e s of b o d y s h e l l
Brava
1. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter o f t h e edge o f t h e b o d y s h e l l , u s i n g a special cutter. 2. 3. 4. 5. R e m o v e t h e metal o f f c u t s u s i n g pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues u s i n g a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e p r i m e r or an e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
P4A098M01
Preparing t h e s p a r e part 1 . R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter o f t h e inside a n d t h e o u t s i d e of t h e r e p l a c e m e n f p a r t using a disc grinder. 2. Use t h e e l e c t r o - g a l v a n i z i n g p a i n t o n t h e edges p r e v i o u s y t r e a t e d .
P4A098M02
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Positioning the replacement part 1 . C a r e f u l l y place t h e r e p l a c e m e n t part in p o s i t i o n w o r k i n g f r o m inside t h e l u g g a g e c o m p a r t m e n t . . 2. C h e c k t h a t t h e c r o s s m e m b e r l i n i n g is c o r r e c t l y p o s i t i o n e d a n d in particular t h a t t h e t a b s o n t h e b o d y shell a n d t h e o p e n i n g s in t h e l i g h t cluster h o u s i n g a n d in t h e cross m e m b e r l i n i n g r e i n f o r c e m e n t are as s h o w n in t h e inset. 3. Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g clamps. 4 . T a c k t h e r e p l a c m e n t part u s i n g several s p o t w e l d s . 5. Close t h e b o o t l i d a n d c h e c k t h e a l i g n m e n t a n d t h e eveness of t h e s u r r o u n d i n g g a p .
W e l d i n g t h e s p a r e part 1. 2. 3. 4. Carry o u t s p o t w e l d i n g b y t h e l i g h t clusters. C o n t i n u e t h e s p o t W e l d i n g at t h e c o n t a c t e d g e s near t h e spare w h e e l h o u s i n g a n d t h e rear w i n g s . U s i n g a M I G w e l d e r carry o u t c o n t i n u o u s w e l d i n g as s h o w n in t h e d i a g r a m . Carry o u t brass w e l d i n g u s i n g an o x y a c e t y l e n e canister b y t h e c o n t a c t edges b e t w e e n t h e c r o s s member and t h e wings.
P4A099M02
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Bodywork
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70.
Finishing operations 1. C o r r e c t a n y d i s t o r t i o n s t o t h e p a n e l using a h a m m e r a n d d o l l y block. 2. R e m o v e a n y w e l d slag using a disc grinder.
P4A100M01
Protections 1. A p p l y t h e e l e c t r o - p h o r e t i c t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e rear cross m e m b e r c o v e r a n d t h e b o d y s h e l l u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or a n e q u i v a l e n t p r o d u c t . 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage.
100
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Replacing body panels
70.
REPLACING REAR L I G H T C L U S T E R H O U S I N G (7090G 8 6 ) '
(*)
operation manual.
T h e c o m p o n e n t for w h i c h t h e r e p l a c e ment p r o c e d u r e is g i v e n is h i g h l i g h e d in t h e d i a g r a m at t h e side. PRELIMINARY PROCEDURES Establish t h e e x t e n t of t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t figures. Carry o u t any s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l using s u i t a b l e m e t h o d s ( j i g s , t e m p l a t e s or g a u g e s ) , before c u t t i n g t h e c o m p o n e n t . A f t e r t h i s o p e r a t i o n check t h a t t h e c o m p o n e n t s n o t b e i n g r e p l a c e d are in t a c t . PRECAUTIONS/WARNINGS AND PRELIMINARY DISMANTLING Protect t h e parts w h i c h c o u l d be d a m a g e d u s i n g c l o t h s . R e m o v e t h e fuel t a n k , d i s c o n n e c t t h e battery a n d all t h e electrical a n d e l e c t r o n i c c o m p o n e n t s b e c a u s e t h e currents p r o d u c e d d u r i n g t h e w e l d i n g o p e r a t i o n s c o u l d cause serious d a m a g e . REMOVING AND REFITTING OPERATING CYCLE T h e replacement o f t h e b o d y panels c a n b e " t o t a l or " p a r t i a l " ; this s e c o n d s o l u t i o n is preferable w h e n it prevents d a m a g e o f another panel w h i c h is a s s e m b l e d b y w e l d i n g , c u t t h e l i g h t cluster h o u s i n g u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w . T h e sections of t h e b o d y panels at t h e c u t t i n g p o i n t s are g i v e n t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g .
P 4 A 1 0 0 M 0 3
P4A100M04
When carrying out the operations described, adhere strictly to the safety procedures. shoes, ear-muffs and gloves should be worn during the cutting operations, masks during the welding and painting operations.
Copyright by Fiat Auto
101
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Bravo
70.
R e m o v i n g off c u t s a n d preparing e d g e s of b o d y s h e l l 1. 2. 3. 4. 5. 6. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter o f the e d g e o f t h e b o d y s h e l l , using a special cutter. R e m o v e t h e metal o f f c u t s u s i n g pliers. M a k e e q u i d i s t a n t h o l e s in t h e e d g e of t h e rear w i n g as s h o w n in t h e d i a g r a m . S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y block. R e m o v e t h e w e l d residues u s i n g t h e disc g r i n d e r . A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
Preparing t h e s p a r e p a r t 1. M a k e e q u i d i s t a n t holes in t h e e d g e s of t h e r e p l a c e m e n t panel as s h o w n in t h e d i a g r a m . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter o f t h e inside a n d o u t s i d e o f t h e r e p l a c e m e n t panel u s i n g a disc g r i n d e r . 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e edges p r e v i o u s l y t r e a t e d .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1. 2. 3. 4. 5. 6. Place sealant o n t h e w i n g a l o n g t h e s e c t i o n s h o w n in t h e d i a g r a m . Carefully place t h e replacement part in p o s i t i o n . Check t h a t t h e l i g h t cluster h o u s i n g is perfectly p o s i t i o n e d . Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l using t h e special s e l f - l o c k i n g c l a m p s . Tack t h e r e p l a c e m e n t part m a k i n g several s p o t w e l d s . Close t h e b o o t lid a n d c h e c k t h e a l i g n m e n t a n d t h e eveness of t h e s u r r o u n d i n g g a p .
P4A100M07
P4A100M08
103
Bodywork
Replacing body panels
Bravo
70.
Finishing operations 1 . Correct any d i s t o r t i o n s t o t h e panel u s i n g a hammer a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
\ \
Protections 1 . A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e w i n g a n d t h e b o d y s h e l l u s i n g IVI 8 5 4 2 1 0 transparent acrylic sealant or a n equivalent product. 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage.
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GRAPHIC INDEX
Replacement operation
R e f e r e n c e in Manual
C o m p l e t f r o n t panel
page 1 1 7
P4A101MO2 P4A101M03
Centre pillar 5 P
page 1 2 5
U n d e r d o o r rear r e i n f o r c e m e n t 3 P
page 1 3 3
P4A101MO6
105
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SYMBOLS CUTTING WITH HACK SAWING MACHINE CHECKING G A P S AND ALIGNMENTS
SPOT W E L D I N G
MIG WELDING
OXYACETY-
R E M O V I N G SPOT W E L D S W I T H DRILL DRILLING FOR MIG WELDING R E M O V I N G PANEL W I T H CHISEL DRILLING FOR M I G WELDING A P P L I C A T I O N OF ELECTROW E L D A B L E PROTECTIVES
GRINDING
APPLYING SEALANTS
APPLYING PROTECTIVES
UNDERBODY
CENTERING C O M P O N E N T S
A P P L Y I N G PAINTS
MEASURING
FIXING C O M P O N E N T S
<
A P P L Y I N G W A X BASED PROTECTIVES
_
S Y M B O L S IN T H E I L L U S T R A T I O N S CUTTING LINE SPOT WELDING . . . . M I G W E L D I N G FOR F I L L I N G UUUUUUU CONTINUOUS MIG WELDING WMM BRAZING
106
Bravo-Brava
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70.
REPLACING FRONT CROSS M E M B E R L I N I N G (7090G 0 7 ) *
(*)
operation manual.
PRELIMINARY PROCEDURES Establish t h e extent o f t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g t h e c o m p o n e n t . After t h i s o p e r a t i o n c h e c k that t h e c o m p o n e n t s n o t b e i n g replaced are i n t a c t . PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts o f t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or b e d a m a g e d d u r i n g t h e m . REMOVING Cut t h e v e h i c l e f r o n t cross member c o v e r using a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n i n t h e d i agram b e l o w . The m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o sition a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
107
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Bravo-Brava
70.
R e m o v i n g off c u t s a n d p r e p a r i n g e d g e s o f b o d y s h e l l 1. 2. 3. 4. 5. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter o f t h e edge o f t h e b o d y s h e l l , u s i n g a special c u t t e r . R e m o v e t h e metal o f f c u t s u s i n g pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues using a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e primer or an e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or a n e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
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P o s i t i o n i n g the f r o n t c r o s s m e m b e r a n d w e l d i n g 1. 2. 3. 4. C o r r e c t l y p o s i t i o n t h e f r o n t cross m e m b e r o n t h e b o d y s h e l l . C h e c k t h a t t h e r e p l a c e m e n t part is perfectly p o s i t i o n e d . Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g clamps. Carry o u t s p o t w e l d i n g o n t h e edges of t h e b o d y s h e l l .
1. 2. 3. 4.
C o r r e c t l y p o s i t i o n t h e f r o n t l i n i n g o n t h e cross member. C h e c k t h a t t h e r e p l a c e m e n t part is perfectly p o s i t i o n e d . Fix the replacement part t o the cross member and to the bodyshell using the special self-locking clamps. Carry o u t s p o t w e l d i n g o n t h e e d g e s of t h e cross m e m b e r a n d t h e b o d y s h e l l .
P4A105M02
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70.
Finishing operations 1 . Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
P4A106M01
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REPLACING COMPLETE F R O N T S I D E P A N E L (7090G 10)*
(*)
operation manual.
Establish t h e e x t e n t of t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t figures, u s i n g suitable m e t h o d s (jigs, templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g . After t h i s o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are intact. PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . R e m o v e t h e f r o n t pillar (see: " R e p l a c i n g s t r u c t u r a l b o d y panels - R e p l a c i n g Front P i l l a r " ) . REMOVING Carry o u t t h e c u t t i n g u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n b e l o w and r e m o v e t h e b r a c k ets inside t h e e n g i n e c o m p a r t m e n t r e m o v i n g t h e s p o t w e l d s u s i n g a d r i l l . T h e m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
111
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Replacing structural body panels
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70.
R e m o v i n g off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. 2. 3. 4. 5. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter o f t h e edge o f t h e b o d y s h e l l , u s i n g a special c u t t e r . R e m o v e t h e metal o f f c u t s using pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues using a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e primer or an e l e c t r o - w e l d a b l e g a l v a n i z e d p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
P4A108M01
Preparing t h e r e p l a c e m e n t internal panel 1. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter of t h e inside a n d t h e o u t s i d e o f t h e rep l a c e m e n t part u s i n g a disc g r i n d e r . 2. Use e l e c t r o - g a l v a n i z i n g p a i n t t o t h e edges p r e v i o u s l y treated.
P4A108M02
112
Bravo-Brava
Bodywork
Replacing structural body panels
70.
P o s i t i o n i n g t h e r e p l a c e m e n t internal panel 1 . Correctly p o s i t i o n t h e internal panel u s i n g t h e t e m p l a t e . 2. C h e c k t h a t t h e internal panel is perfectly p o s i t i o n e d . 3. Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g c l a m p s .
P4A109M01
P4A109M02
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Bodywork
Replacing structural body panels
Bravo-Brava
70.
Preparing t h e r e p l a c e m e n t o u t e r panel 1. R e m o v e the a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter o f the inside a n d t h e o u t s i d e of t h e rep l a c e m e n t part u s i n g a disc g r i n d e r . 2. U s e e l e c t r o - g a l v a n i z i n g p a i n t o n t h e edges p r e v i o u s l y t r e a t e d .
114
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Replacing structural body panels
70.
W e l d i n g r e p l a c e m e n t o u t e r panel 1 . Carry o u t s p o t w e l d i n g o n t h e edges in c o n t a c t w i t h t h e internal p a n e l . 2. C o n t i n u e t h e s p o t w e l d i n g w o r k i n g f r o m inside t h e v e h i c l e , c o n t i n u i n g t h e w e l d i n g o n t h e i n t e r n a l panel a n d o n t h e edges of t h e b o d y s h e l l . 3. Carry o u t s p o t w e l d i n g o n t h e edges of t h e f r o n t cross member.
P4A111M01
Preparing and welding t h e brackets 1 . M a k e e q u i d i s t a n t holes in t h e edges of t h e brackets. 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter o f t h e inside a n d t h e o u t s i d e o f t h e r e p l a c e m e n t part u s i n g a r o t a t i n g b r u s h . 3. A p p l y t h e e l e c t r o - g a l v a n i z i n g paint t o t h e areas p r e v i o u s l y t r e a t e d . 3. U s i n g t h e M I G w e l d e r carry o u t w e l d i n g f i l l i n g t h e holes m a d e p r e v i o u s l y .
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70.
Finishing operations 1. Correct any d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y block. 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
P4A112M01
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REPLACING FRONT P I L L A R (7090G 3 0 ) *
(*)
operation manual.
PRELIMINARY PROCEDURES Establish t h e e x t e n t of t h e d a m a g e , c h e c k if there are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s ( j i g s , templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s r e q u i r e d t o t h e b o d y s h e l l b e f o r e c u t t i n g t h e c o m p o n e n t . A f t e r this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are intact. PRELIMINARY DISMANTLING
R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . REMOVING C u t t h e v e h i c l e f r o n t pillar u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w . T h e most i m p o r t a n t s e c t i o n s o f t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
117
Bodywork
Replacing structural body panels
Bravo-Brava
70.
R e m o v i n g off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter of t h e e d g e o f t h e b o d y s h e l l , u s i n g a special c u t t e r a n d o n t h e internal r e i n f o r c e m e n t . 2. R e m o v e t h e metal o f f c u t s u s i n g pliers. 3. S t r a i g h t e n t h e e d g e s w i t h a h a m m e r a n d d o l l y b l o c k . 4. R e m o v e t h e w e l d residues u s i n g a disc g r i n d e r . 5. A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e g a l v a n i z e d paint or a n e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
P4A114M01
Adjusting the replacement part 1. Place t h e pillar i n p o s i t i o n , u s i n g t h e special s e l f - l o c k i n g c l a m p s a n d c h e c k t h a t t h e r e p l a c e m e n t p a r t is s u p e r i m p o s e d a b o u t 5 0 m m b e y o n d t h e b o d y s h e l l . 2. Trace t h e profile of t h e r e p l a c e m e n t part o n t h e u n d e r d o o r side m e m b e r l i n i n g u s i n g a tracer p o i n t . 3. C u t t h e t w o edges o f t h e p a n e l o n t h e w i n d s c r e e n pillar t o o b t a i n a perfect j o i n line. 4. R e m o v e t h e excess o n t h e b o d y s h e l l .
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P r e p a r i n g t h e r e p l a c e m e n t parts a n d c h e c k t h a t t h e y a r e c o r r e c t l y p o s i t i o n e d o n t h e b o d y s h e l l 1 . M a k e e q u i d i s t a n t holes in t h e r e p l a c e m e n t parts as s h o w n in t h e d i a g r a m . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e e n t i r e perimeter o f t h e inside a n d t h e o u t s i d e o f t h e r e p l a c e m e n t part u s i n g a special g r i n d e r . 3. Use e l e c t r o - g a l v a n i z i n g paint o n t h e edges in c o n t a c t w i t h t h e b o d y s h e l l . 5. Offer u p t h e r e p l a c e m e n t parts a n d f i x t h e m u s i n g t h e special s e l f - l o c k i n g c l a m p s 4 . Fit t h e f r o n t d o o r h i n g e s a n d t h e d o o r seal a n d c h e c k t h e a l i g n m e n t a n d t h e eveness o f t h e s u r r o u n d ing g a p .
Welding replacement parts 1. 2. 3. 4. 5. 6. 7. Place t h e internal r e i n f o r c e m e n t in p o s i t i o n a n d s p o t w e l d t h e side edge. Use t h e M I G w e l d e r a n d fill t h e holes made p r e v i o u s l y . R e m o v e a n y w e l d slag a n d a p p l y t h e e l e c t r o - w e l d a b l e g a l v a n i z i n g paint. Place t h e pillar in p o s i t i o n a n d s p o t w e l d t h e perimeter edges. Use t h e M I G w e l d e r at t h e edges. Use t h e M I G w e l d e r a n d fill t h e holes made p r e v i o u s l y . Carry o u t brass w e l d i n g o n t h e c o n t a c t edges b e t w e e n t h e r e p l a c e m e n t part a n d t h e w i n d s c r e e n housing.
P4A115M02
119
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Replacing structural body panels
Bravo-Brava
70.
Finishing operations 1. Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
Protections 1. A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e f r o n t pillar a n d t h e b o d y s h e l l , u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. 4. A p p l y w a x based oil p r o t e c t i v e t o t h e inside of t h e f r o n t pillar.
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REPLACING CENTRE P I L L A R (7090G 4 0 ) *
(*)
operation manual.
PRELIMINARY PROCEDURES Establish t h e extent o f t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s required t o t h e b o d y s h e l l before c u t t i n g t h e c o m p o n e n t . After t h i s o p e r a t i o n c h e c k that t h e c o m p o n e n t s n o t b e i n g replaced are i n t a c t . PRELIMINARY DISMANTLING
R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or b e d a m a g e d d u r i n g t h e m . REMOVING Cut t h e v e h i c l e centre pillar u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w . The m o s t i m p o r t a n t s e c t i p n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o sition a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P4A117M02
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
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70.
Removing off c u t s a n d preparing e d g e s o f b o d y s h e l l 1. 2. 3. 4. 5. R e m o v e t h e spot w e l d s a l o n g t h e entire perimeter o f t h e e d g e o f t h e b o d y s h e l l , u s i n g a special c u t t e r . R e m o v e t h e metal o f f c u t s u s i n g pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues using a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e primer or an e l e c t r o - w e l d a b l e galvanized p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
A d j u s t i n g t h e outer c e n t r e pillar 1. Carefully p o s i t i o n t h e o u t e r centre pillar. 2. Fix t h e replacement part t o t h e b o d y s h e l l a n d f i x it u s i n g s e l f - l o c k i n g pliers. 3. C u t t h e edges of t h e excess panel s u p e r i m p o s e d o n t h e b o d y s h e l l .
P4A118M02
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70.
Preparing the replacement parts 1 . M a k e e q u i d i s t a n t holes in t h e r e p l a c e m e n t parts as s h o w n in t h e d i a g r a m . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimeter of t h e o u t s i d e of t h e r e p l a c e m e n t part u s i n g a disc g r i n d e r . 3. U s e t h e e l e c t r o - g a l v a n i z i n g p a i n t o n t h e e d g e s treated previously.
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P4A119M01
Welding replacement parts 1. 2. 3. 4. P o s i t i o n t h e inner pillar a n d carry o u t c o n t i n u o u s w e l d i n g o n t h e u p p e r e d g e . C o n t i n u e t h e w e l d i n g f i l l i n g t h e holes m a d e p r e v i o u s l y in t h e u n d e r d o o r side m e m b e r r e i n f o r c e m e n t . Carry o u t s p o t w e l d i n g o n t h e u n d e r d o o r side m e m b e r edges. P o s i t i o n t h e i n t e r m e d i a t e pillar inserting it inside t h e r e m a i n s of t h e u p p e r b o d y s h e l l , carry o u t c o n t i n u o u s w e l d i n g o n t h e u p p e r edge a n d fill t h e holes m a d e previously. 5. P o s i t i o n t h e o u t e r centre pillar a n d carry o u t c o n t i n u o u s w e l d i n g o n t h e o u t e r edges, f i l l i n g t h e h o l e s m a d e p r e v i o u s l y i n t h e r e p l a c e m e n t part a n d s p o t w e l d i n g a l o n g t h e entire perimeter o f t h e r e p l a c e m e n t part.
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Finishing operations 1. Correct a n y d i s t o r t i o n s t o t h e panel using a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc grinder. Checking alignments 1. C h e c k t h e parallelism, o p e n i n g s a n d angles ( t h i s involves f i t t i n g t h e m o v i n g c o m p o n e n t s p r e v i o u s l y r e m o v e d w i t h seals a n d parts w h i c h , o n c e f i t t e d , make it p o s s i b l e t o c h e c k t h a t t h e o p e r a t i o n s have been carried o u t c o r r e c t l y ) .
Protections 1. A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . 2. Seal t h e j o i n s b e t w e e n t h e r e p l a c m e n t panels a n d t h e b o d y s h e l l , u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . 3. Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. 4. A p p l y w a x based o i l p r o t e c t i v e .
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REPLACING UNDERDOOR SIDE MEMBER FRONT R E I N F O R C E M E N T (7090G 30)*
(*)
operation manual.
The c o m p o n e n t for w h i c h t h e r e p l a c e ment p r o c e d u r e is g i v e n is h i g h l i g h t e d in the d i a g r a m at t h e side. PRELIMINARY PROCEDURES Establish t h e e x t e n t of t h e d a m a g e , c h e c k if there are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s (jigs, templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s r e q u i r e d t o t h e b o d y s h e l l b e f o r e c u t t i n g . A f t e r this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are intact. PRELIMINARY DISMANTLING Remove t i o n s or Remove ber"). Remove t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a be d a m a g e d d u r i n g t h e m . t h e u n d e r d o o r side m e m b e r (see: " R e p l a c i n g b o d y panels - R e p l a c i n g U n d e r d o o r side m e m t h e f r o n t pillar (see: " R e p l a c i n g s t r u c t u r a l b o d y panels - R e p l a c i n g Front p i l l a r " ) .
REMOVING C u t using t h e p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n b e l o w . T h e most i m p o r t a n t sections o f t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the we/ding operations, and a protective mask and gloves during the painting operations.
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70.
R e m o v i n g off c u t s a n d preparing e d g e s of b o d y s h e l l 1. 2. 3. 4. 5. 6. R e m o v e the s p o t w e l d s a l o n g t h e entire perimeter of t h e e d g e o f the b o d y s h e l l , using a s p e c i a l cutter, R e m o v e t h e m e t a l o f f c u t s u s i n g pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues u s i n g a disc grinder. M a k e e q u i d i s t a n t holes in t h e e d g e of t h e u n d e r d o o r s i d e m e m b e r rear r e i n f o r c e m e n t . A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e galvanized p a i n t or an e q u i v a l e n t p r o d u c t , t o t h e areas ^previously g r o u n d .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1 . Carefully place t h e r e p l a c e m e n t part in p o s i t i o n , f r o m t h e inside of t h e u n d e r d o o r s i d e m e m b e r rear reinforcement. 2. Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l using t h e special s e l f - l o c k i n g clamps.
1 i
P4A123M02
Proceed w i t h f i t t i n g t h e f r o n t pillar a n d t h e u n d e r d o o r side m e m b e r (see: " R e p l a c i n g s t r u c t u r a l b o d y panels - R e p l a c i n g Front pillar" a n d " R e p l a c i n g b o d y panels - R e p l a c i n g u n d e r d o o r side m e m b e r " ) .
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Finishing operations 1. C o r r e c t any d i s t o r t i o n s t o t h e p a n e l u s i n g a h a m m e r a n d d o l l y block. 2. R e m o v e any w e l d slag u s i n g a disc grinder.
P4A124M01
Protections 1. 2. 3. 4. A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e reas previ ousl y i n v o l v e d in t h e w e l d i n g . Seal t h e j o i n lines, u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. A p p l y w a x based o i l p r o t e c t i v e t o t h e inside o f t h e u n d e r d o o r side m e m b e r .
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REPLACING UNDERDOOR SIDE M E M B E R REAR R E I N F O R C E M E N T (7090G 5 4 ) '
C)
operation manual.
The component for w h i c h t h e replacem e n t p r o c e d u r e is g i v e n is h i g h l i g h t e d in t h e d i a g r a m at t h e side. PRELIMINARY PROCEDURES Establish t h e extent of t h e d a m a g e , c h e c k if there are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s ( j i g s , templates or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s r e q u i r e d t o t h e b o d y s h e l l b e f o r e c u t t i n g . After this o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are intact. PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts o f t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d i m p e d e t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . R e m o v e t h e u n d e r d o o r side m e m b e r (see: " R e p l a c i n g b o d y panels - R e p l a c i n g U n d e r d o o r s i d e m e m ber"). Remove t h e rear w i n g (see: " R e p l a c i n g b o d y panels - R e p l a c i n g rear w i n g " ) . REMOVING Cut u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n b e l o w . T h e m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h of t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P 4 A 1 2 5 M 0 1
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the we/ding operations, and a protective mask and gloves during the painting operations.
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R e m o v i n g off c u t s a n d p r e p a r i n g e d g e s of b o d y s h e l l 1. 2. 3. 4. 5. 6. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter of t h e e d g e of t h e b o d y s h e l l , u s i n g a special cutter. Remove t h e metal off c u t s u s i n g pliers. Straighten t h e edges w i t h a hammer a n d d o l l y b l o c k . Remove t h e w e l d residues u s i n g a disc grinder. M a k e e q u i d i s t a n t holes in t h e edge of t h e pillar r e i n f o r c e m e n t . A p p l y t h e I V I Epox e p o x i d e t y p e primer or an e l e c t r o - w e l d a b l e g a l v a n i z e d paint or an e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
Preparing t h e s p a r e part 1. M a k e e q u i d i s t a n t holes in t h e side e d g e . 2. R e m o v e t h e a n t i - c o r r o s i o n t r e a t m e n t f r o m t h e entire perimter of t h e inside a n d t h e o u t s i d e of replacem e n t part u s i n g a disc g r i n d e r . 3. Use e l e c t r o - g a l v a n i z i n g p a i n t o n t h e e d g e s p r e v i o u s l y t r e a t e d .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1 . C a r e f u l l y place t h e replacement part i n p o s i t i o n , f r o m inside t h e pillar r e i n f o r c e m e n t . 2. Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g c l a m p s .
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Finishing operations 1. Correct a n y d i s t o r t i o n s t o t h e panel u s i n g a h a m m e r a n d d o l l y b l o c k . 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
P4A128M01
Protections 1. 2. 3. 4. A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . Seal t h e j o i n lines, u s i n g IVI 8 5 4 2 1 0 t r a n s p a r e n t acrylic sealant or an e q u i v a l e n t p r o d u c t . Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. A p p l y w a x based o i l p r o t e c t i v e t o t h e inside o f t h e u n d e r d o o r side member.
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REPLACING REAR W H E E L A R C H (7090G 7 2 ) *
(*)
operation manual.
T h e c o m p o n e n t for w h i c h t h e r e p l a c e m e n t p r o c e d u r e is given is h i g h l i g h t e d in t h e d i a g r a m at t h e side. PRELIMINARY PROCEDURES Establish t h e e x t e n t o f t h e d a m a g e , c h e c k if t h e r e are d i s t o r t i o n s t o t h e c o n n e c t e d c o m p o n e n t s b y c h e c k i n g t h e b o d y s h e l l a l i g n m e n t f i g u r e s , u s i n g s u i t a b l e m e t h o d s (jigs, t e m p l a t e s or g a u g e s ) . Carry o u t a n y s t r a i g h t e n i n g o p e r a t i o n s r e q u i r e d t o t h e b o d y s h e l l before c u t t i n g . A f t e r t h i s o p e r a t i o n c h e c k t h a t t h e c o m p o n e n t s n o t b e i n g replaced are i n t a c t . PRELIMINARY DISMANTLING R e m o v e t h e m o v i n g parts of t h e b o d y w o r k a n d interior f i t t i n g s , w h i c h c o u l d impede t h e repair o p e r a t i o n s or be d a m a g e d d u r i n g t h e m . R e m o v e t h e rear w i n g (see: " R e p l a c i n g b o d y panels R e p l a c i n g rear w i n g ) . REMOVING C u t u s i n g a p o w e r s a w f o l l o w i n g t h e d o t t e d lines s h o w n in t h e d i a g r a m b e l o w , t h e n r e m o v e t h e s p o t w e l d s s h o w n in t h e d i a g r a m . T h e m o s t i m p o r t a n t s e c t i o n s of t h e b o d y panel are s h o w n in order t o a l l o w t h e operator t o a d j u s t t h e p o s i t i o n a n d t h e d e p t h o f t h e c u t t i n g s o as n o t t o d a m a g e t h e panels u n d e r n e a t h .
P 4 A 1 2 9 M 0 1
When carrying out the operations described, adhere strictly to the safety procedures. Protective shoes, ear-muffs and gloves should be worn during the cutting operations, welding masks and gloves during the welding operations, and a protective mask and gloves during the painting operations.
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70.
R e m o v i n g off c u t s a n d preparing e d g e s of b o d y s h e l l 1. 2. 3. 4. 5. R e m o v e t h e s p o t w e l d s a l o n g t h e entire perimeter o f t h e e d g e o f t h e b o d y s h e l l , using a special cutter. R e m o v e t h e metal o f f c u t s using pliers. S t r a i g h t e n t h e edges w i t h a h a m m e r a n d d o l l y b l o c k . R e m o v e t h e w e l d residues using a disc grinder. A p p l y t h e IVI Epox e p o x i d e t y p e primer or a n e l e c t r o - w e l d a b l e galvanized p a i n t or a n e q u i v a l e n t p r o d u c t , t o t h e areas p r e v i o u s l y g r o u n d .
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P o s i t i o n i n g t h e r e p l a c e m e n t part 1 . C a r e f u l l y place t h e replacement part in p o s i t i o n . 2. Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l u s i n g t h e special s e l f - l o c k i n g clamps.
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Finishing operations 1. Correct a n y d i s t o r t i o n s t o t h e p a n e l using a h a m m e r a n d d o l l y block. 2. R e m o v e a n y w e l d slag u s i n g a disc grinder.
P4A132M01
Protections 1. 2. 3. 4. A p p l y t h e e l e c t r o - p h o r e t i c p r o t e c t i v e t r e a t m e n t t o t h e areas p r e v i o u s l y i n v o l v e d in t h e w e l d i n g . Seal t h e j o i n lines, u s i n g IVI 8 5 4 2 1 0 transparent acrylic sealant or a n e q u i v a l e n t p r o d u c t . Proceed w i t h t h e p a i n t i n g a n d w a x i n g stage. A p p l y w a x based o i l p r o t e c t i v e t o t h e inside o f t h e u n d e r d o o r side member.
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TYPICAL MEASUREMENTS
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M e a s u r i n g d i m e n s i o n s of c e n t r e a n d rear pillar h o u s i n g (5 d o o r v e r s i o n )
P4A134M03
P4A134M04
F i g u r e s f o r c h e c k i n g d i s t a n c e b e t w e e n c e n t r e p i l l a r s for d o o r s m e a s u r e d by t h e s e a t b e l t a t t a c h ment n u t s a n d b e t w e e n t h e l o c k s t r i k e r s (5 d o o r v e r s i o n )
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Measuring door housing dimensions
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F i g u r e s f o r c h e c k i n g d o o r h o u s i n g s (5 d o o r v e r s i o n )
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M e a s u r i n g d i m e n s i o n s of c e n t r e pillar h o u s i n g and d o o r h o u s i n g s (3 door v e r s i o n )
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Bodyshell
"
M e a s u r i n g door h o u s i n g d i m e n s i o n s
707
P4A137M01
141
Bodywork
Bodyshell
Bravo-Brava
70.
M e a s u r i n g rear tailgate h o u s i n g d i m e n s i o n s (5 door v e r s i o n )
P4AT38M01
142
Bravo-Brava
Bodywork
Bodyshell
70
F i g u r e s f o r a d j u s t i n g moveable p a r t s (5 door v e r s i o n )
P4A139M01
143
Bodywork
Bodyshell
Bravo-Brava
70.
F i g u r e s f o r a d j u s t i n g m o v e a b l e p a r t s (5 door v e r s i o n )
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Bodywork
Replacing structural body panels
7
Bravo-Brava
o.
GRAPHIC INDEX replacement operation R e f e r e n c e in M a n u a l
Partial f r o n t panel
R e p l a c i n g s t r u c t u r a l b o d y panels p a g e 1 4 7
P4A146M01
Rear f l o o r c o m p l e t e w i t h s i d e m e m b e r s
R e p l a c i n g s t r u c t u r a l b o d y panels p a g e 1 5 2
P4A146M0Z
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Bravo-Brava
Bodywork
Replacing structural body panels
70.
PARTIAL R E P L A C E M E N T OF FRONT PANEL
Preliminary procedures a n d safety regulations - Stick t o w h a t has been described previously for t h e other c o m p o n e n t s . Preliminary dismantling
Removing - C u t t h e part t o b e r e p l a c e d a n d r e m o v e it f r o m t h e v e h i c l e .
147
Bodywork
Replacing structural body panels
Bravo-Brava
70.
R e m o v i n g o f f c u t s a n d preparing e d g e s o f b o d y s h e l l 1. Straighten any distortions t o the bodyshell.
P4A148M02
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Bravo-Brava
Bodywork
Replacing structural body panels
70.
Positioning the replacement part 1 . P o s i t i o n t h e r e p l a c e m e n t part o n t h e v e h i c l e a n d o n t h e t e m p l a t e a n d , after h a v i n g c h e c k e d t h a t it is p e r f e c t l y s u p e r i m p o s e d , mark t h e parts t o be r e m o v e d o n t h e v e h i c l e ( 1 ) a n d o n t h e r e p l a c e m e n t r e inforcement ( 2 ) .
Copyright
by Fiat
Auto
149
Bodywork
Replacing structural body panels
Bravo-Brava
70.
W e l d i n g t h e s p a r e part 1 . R e p o s i t i o n t h e r e p l a c e m e n t part o n t h e v e h i c l e a n d o n t h e t e m p l a t e , c h e c k t h a t it is p e r f e c t l y a l i g n e d and then w e l d the panel a n d then the reinforcement.
UU U U C o n t i n u o u s M I G w e l d i n g uUU
Preparing a n d positioning the replacement part 1 . R e m o v e t h e excess f r o m t h e r e p l a c e m e n t part s o t h a t it is a b o u t 2 0 m m l o n g e r t h a n t h e part p r e v i o u s ly r e m o v e d f r o m t h e v e h i c l e . 2. P o s i t i o n o n t h e t e m p l a t e a n d o n t h e v e h i c l e m a r k i n g it o n t h e v e h i c l e w i t h t h e c u t t i n g line ( 1 ) . 3. R e m o v e t h e area p r e v i o u s l y m a r k e d b y t h e c u t t i n g line ( 1 ) f r o m t h e v e h i c l e .
P4A150M02
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Bodywork
Replacing structural body panels
70.
Welding t h e outer panel replacement part 1 . R e p o s i t i o n t h e r e p l a c e m e n t part o n t h e t e m p l a t e a n d o n t h e b o d y s h e l l , a l i g n it c o r r e c t l y , t h e n w e l d it as i l l u s t r a t e d in t h e d i a g r a m .
Carry out the three welds illustrated are therefore offset to one another
so that they are not positioned along (see page 59 in this manual).
UUUU C o n t i n u o u s M I G w e l d i n g UUUU
Spot welding Finishing operations 1 . R e m o v e a n d s m o o t h o u t t h e w e l d residues.
P4A161 M 0 2
151
Bodywork
Replacing structural body panels
Bravo-Brava
70.
PARTIAL REPLACEMENT O F REAR FLOOR
Preliminary procedures and safety regulations - Refer t o t h e p r e v i o u s d e s c r i p t i o n f o r t h e o t h e r c o m p o n e n t s . Preliminary dismantling - R e m o v e t h e rear cross m e m b e r (see: " R e p l a c i n g b o d y p a n e l s - R e p l a c i n g rear cross m e m b e r )
Removing - U s i n g a p o w e r s a w , c u t a l o n g t h e d o t t e d lines s h o w n b e l o w .
P4A152M01
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Bodywork
Replacing structural body panels
COMPLETE REPLACEMENT OF A SIDE MEMBER 1. Remove t h e lower a n d upper spot w e l d s for t h e side member. 2. O p e n t h e t a b a n d r e m o v e t h e s i d e m e m b e r o f f c u t s . 3. S t r a i g h t e n t h e e d g e s o f t h e b o d y s h e l l . 4 . R e m o v e t h e w e l d residues.
P4A1S3M02
Copyright
by Fiat
Auto
153
Bodywork
Replacing structural body panels
Bravo-Brava
70.
Preparing t h e spare part 1 . T r a c e a n d d r i l l t h e n e w side m e m b e r w i t h a 2. C l e a n t h e areas a f f e c t e d b y t h e w e l d i n g . 5 m m p o i n t , as s h o w n in t h e d i a g r a m .
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Bodywork
Replacing structural body panels
70.
Welding t h e s p a r e part 1 . Carry o u t t h e s p e c i f i c w e l d s as s h o w n in t h e d i a g r a m .
P4A1S5M01
P4A155M02
155
Bodywork
Replacing structural body panels
Bravo-Brava
70.
PARTIAL REPLACEMENT OF A SIDE MEMBER Preparing t h e spare part 1 . R e m o v e t h e excess f r o m t h e r e p l a c e m e n t part s o t h a t it is a b o u t 2 0 m m l o n g e r t h a n t h e part r e m o v e d f r o m t h e vehicle.
P4A156M01
P4A156M02
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Bravo-Brava
Bodywork
Replacing structural body panels
70.
Welding the spare part a n d finishing off 1. Proceed w i t h the c o n t i n u o u s M I G w e l d i n g . 2 . R e m o v e a n d level t h e w e l d residues.
P4A157WI01
Preparing the spare part 1 . R e m o v e t h e excess f r o m t h e r e p l a c e m e n t part s o t h a t it is a b o u t 2 0 m m l o n g e r t h a n t h e part r e m o v e d from the vehicle.
157
Bodywork
Replacing structural body panels
, Bravo-Brava
_
70.
1. 2. 3. 4.
Positioning the replacement part Place t h e rear f l o o r in p o s i t i o n . C h e c k t h a t t h e panels are c o r r e c t l y s u p e r i m p o s e d in t h e j o i n area. M a r k t h e part t o b e r e m o v e d o n t h e b o d y s h e l l . T r a c e t h e p o i n t s t o b e d r i l l e d a l o n g t h e c o n t a c t area w i t h t h e side m e m b e r s u n d e r n e a t h a n d t h e w h e e l arches i n o r d e r t o b e a b l e t o carry o u t t h e M I G w e l d i n g f o r f i l l i n g . 5. R e m o v e t h e r e p l a c e m e n t part, r e m o v e t h e excess f r o m t h e b o d y s h e l l a n d drill t h e spare part. A l s o d r i l l t h e s i d e s o f t h e r e p l a c e m e n t part w h i c h w i l l b e s u b s e q u e n t l y w e l d e d t o t h e w h e e l arches.
P4A158M01
Welding t h e spare part 1. 2. 3. 4. C o r r e c t l y r e p o s i t i o n t h e r e p l a c e m e n t part a n d l o c k it w i t h c l a m p s . Fix t h e r e p l a c e m e n t part t o t h e b o d y s h e l l t a c k i n g it t o t h e parts t o be w e l d e d , e d g e t o e d g e . W e l d a n d fill t h e holes m a d e p r e v i o u s l y in t h e r e p l a c e m e n t part. Finish o f f t h e w e l d i n g , e d g e t o e d g e .
P4A158M02
P4A158M03
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Bodywork
70.
Finishing operations 1 . R e m o v e a n d level o f f t h e w e l d residues.
Protections Refer t o t o t h e p r e v i o u s d e s c r i p t i o n f o r t h e o t h e r c o m p o n e n t s .
159