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Fiat Bravo/a Service Manual Volume 2

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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)

Page Nos. 1 + 43 1-154

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)

U p d a t e : A D 1 8 2 H radio U p d a t e : alarm U p d a t e : code W i r i n g diagrams update U p d a t e : connections

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

Climate control Radio e q u i p m e n t Alarm Alarm Roof l i n i n g

506.670/12
(VII/1997)

55

23 6

70

Copyright by Fiat Auto

Summary

Bravo-Btava

P r i n t N

Sections 55

Page Nos. 6 26 1+6 19-24 24/1 - 2 4 / 4 Alarm Air bag

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

WORKSHOP MANUAL COMPOSITION


A s of M a y 1 9 9 8 , the B r a v o - B r a v a m a n u a l v o l u m e 2 is made u p of the f o l l o w i n g parts: Publication n o . Sections 50 506.670/01 W i t h binder (V/1995) 55 1 - 55 70 1-145 16 4 506.670/02 (V/1995) 55 1-103 105-161 1-117 506.670/05 ( 11 9 ) 1/96 W i r i n g diagrams Removal and refitting - Replacing panels Updated alarm system Preheating W i r i n g diagrams Connector blocks Electrical equipment diagnosis Page numbers 1 - 43 1-154 Notes Heater - Air conditioner Electrical equipment

55

11

Updated radio 4 D 1 8 2 L

32 20 506.670/06 (IV/1996) 55 1 3 1 506.670/10 (1/1997) 506.670/11 (VI/1997)

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

Air conditioner Car radio Alarm Alarm Roof panel trim

506.670/12 (VI1/1997)

55

23 6

70

Copyright Fiat Auto

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

506.670/14 (1/98 1 11 9 ) 55 55 506.670/15 (V/1998) 70 Update: Seats

Publication no. 506.670/15

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

W i r i n g diagrams Connector blocks Electrical equipment fault diagnosis

105-161 1 506.670/05
(11/1996)

117

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 A l a r m update Code update W i r i n g diagrams update Connections update

55

1 3 1

506.670/10
(1/1997)

55

W i r i n g diagrams update

Copyright by Fiat Auto

Bravo-Brava

Summary

WORKSHOP MANUAL COMPOSITION


A s of M a r c h 1 9 9 8 , the B r a v o - B r a v a v o l u m e 2 manual is made of the f o l l o w i n g parts: P u b l i c a t i o n no. Sections 50 506.670/01 W i t h binder
(V/1995)

Page numbers 1 - 43 1-154

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

1-103 105-161 1 - 117

506.670/05
(11/1996)

55

11

Updated radio 4 D 182L

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

Air conditioner Car radio Alarm Alarm Roof panel trim

506.670/12
(VII/1997)

55

23 6

70

Copyright Fiat Auto

Summary

Bravo-Brava

4A03SV

P u b l i c a t i o n no.

Sections 55

Page numbers 6 26 Alarm Air bag

Notes

506.670/14 (1/98 1 11 9 ) 55

Publication no. 506.670/14

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

1-103 105-161 1-117

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

Copyright by Fiat Auto

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

Copyright by Fiat Auto

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

the powei systems. in other

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

T H I S P U B L I C A T I O N H A S B E E N P R O D U C E D IN A L O O S E L E A F F O R M A T T O F A C I L I T A T E T H E OPERATION OF UPDATING THE MODEL.

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.

chart which 46/1992)

the

Copyright by Fiat Auto

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.

l l t - 9 6 - Cancels and replaces

Print no.

506.670/06

Bravo-Brava

Graphic representations and symbols

t 1==]

Remove Disconnect Refitting Connect Dismantling Disassemble Refitting Composition

Q (

Inlet

E ^ I

Exhaust

( ^ )

Operation

.
A

mSM

Tolerance Difference in w e i g h t

Tighten to torque

Pre-loading

Tighten to torque plus angle

Rotation

Fully t i g h t e n fc\ M Oversize Greater t h a n .... Maximum

Compression ratio Selection Classes ^ Undersize Smaller than.... Idling

Stake n u t

IBB

p A ^ 1

Adjustment Regulation Visual i n s p e c t i o n Check

^ > ^ (^^)

<

<1>

N u m b e r o f revs

A
aaPa

Warning

_ T _

Ratio

Lubricate Grease

Pressure

jgEfcg
TAJ

Replace
G e n u i n e spares Bleed b r a k i n g system Y >^< ,

Temperature Temperature Cold Winter Temperature Hot Summer <0C

W B C l J H ^ 9 M l N M j l M

i_] ^.

W o r k surface M a c h i n e d surface Interference Force f i t D i s t a n c e t o be m e a s u r e d Measurement - Check T h i c k n e s s - Clearance Rolling torque

>0C

Windscreen wiper w i t h electric washer p u m p -y. E^D Rearscreen w i p e r w i t h electric washer p u m p Engine

^ *'

P
w

Copyright by Fiat Auto

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.

refer to Electrical 134 and

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

1 . A l a r m control u n i t 2. Emergency key s w i t c h 3. Receiver o n f r o n t central c o u r t e s y l i g h t 4 . V o l u m e t r i c sensors o n f r o n t central c o u r tesy light

5. D o o r s / b o n n e t / b o o t / f u e l f l a p o p e n i n d i cator s w i t c h e s 6. R e m o t e c o n t r o l integrated in t h e i g n i t i o n key 7. W a r n i n g l i g h t / dissuasion LED

Copyright Fiat Auto

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

Publication no. 506.670/14

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

From J a n u a r y 1 9 9 8 , t h e alarm systems o n cars i n t e n d e d for t h e U n i t e d K i n g d o m m a r k e t m a r k e t n o longer have t h e e m e r g e n c y key s w i t c h , so t h e c o n t r o l u n i t is p e r m a n e n t l y in t h e a c t i v a t e d state.

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.

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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

COUNTRY CODE ( p r e s s e s of button) 1 2 3 4

COUNTRY OF OPERATION ITALY GERMANY FRANCE SWITZERLAND

COUNTRY CODE ( p r e s s e s of button) 5 6 7 8

// 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

Publication no. 506.670/14

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.

Copyright Fiat Auto

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.

Transmitter w a r n i n g l i g h t ( L E D ) 4 - d i g i t access c o d e ( P a s s w o r d ) C o n t r o l b u t t o n o n transmitter W a r n i n g light (LED) on courtesy light Programming button

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

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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)

Parking l i g h t s a n d w a r n i n g lamp - D i p p e d b e a m h e a d lamps - M a i n beam headlamps a n d w a r n i n g l i g h t - Parking l i g h t s - N u m b e r plate lights

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 - G T - H G T C h a r t (page 27) 3 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

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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

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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

Print no. 506.670/02

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Fault diagnosis
Analytical charts

55D.
The outside lights are not working

C h e c k c o n d i t i o n o f steering column switch unit 7

Not OK

Overhaul or r e p l a c e s t e e r i n g column switch unit 7

OK

Check the condition of the ignition switch 12

Not OK

Overhaul or r e p l a c e t h e i g n i tion switch 12

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

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 replace 2 and 3

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

Check the c o n d i t i o n of the c o n t r o l u n i t 4 , o v e r h a u l it or replace it

Not 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 f o r t h e i g n i tion switch 12

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

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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

Check f o r v o l t a g e at t h e G V c o l o u r e d c a b l e for t h e i g n i tion s w i t c h 12

OK

Check t h e c o n d i t i o n of t h e ignition switch 12, overhaul it or replace it

Not O K

Check f o r v o l t a g e at t h e G V coloured cable connector B steering c o l . s w i t c h u n i t 7

OK

Restore c o n t i n u i t y f o r G V coloured cable between steering c o l u m n s w i t c h u n i t 7 and ignition switch 12

Not O K

Check f o r v o l t a g e at t h e A G c o l o u r e d c a b l e for t h e i g n i tion s w i t c h 12

OK

Restore c o n t i n u i t y f o r A G c o l o u r e d cable b e t w e e n i g n i t i o n s w i t c h 1 2 a n d steering c o l u m n s w i t c h u n i t 7

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

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 fuse 2

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 or replace t h e c o n t r o l unit 4

The left front side light is not working

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

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 f o r t h e left f r o n t l i g h t cluster 1

OK

Overhaul or replace t h e l i g h t cluster 1

4A406N

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Fault diagnosis
Analytical charts

Bravo-Brava

55D.

4
Not O K

Check f o r v o l t a g e at t h e G N coloured cable connector D pin 1 7 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 f o r the G N coloured cable bet w e e n the junction unit 4 a n d t h e l i g h t cluster 1

Not O K

Check t h e c o n d i t i o n of t h e junction unit 4

Not OK

O v e r h a u l or replace j u n c t i o n unit 4

the

The right front light is not working

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

Check f o r v o l t a g e at t h e GR c o l o u r e d cable for t h e r i g h t front l i g h t cluster 2

OK

O v e r h a u l or replace t h e light cluster 2

Not O K

4
6
Print no. 506.670/02

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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

O v e r h a u l or replace junction unit 4

the

The left rear side light is not working

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

Overhaul or replace t h e b u l b holder

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 f o r t h e left rear light cluster 1 6

OK

Overhaul or replace t h e l i g h t cluster 1 6

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

Copyright by Fiat Auto

Fault diagnosis
Analytical charts

Bravo-Brava

55D.
Not O K

Check t h e c o n d i t i o n o f t h e junction unit 4

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

The right rear side light is not working

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

Check f o r v o l t a g e at t h e G R c o l o u r e d cable of t h e r i g h t rear l i g h t cluster 17

OK

O v e r h a u l or replace t h e right rear l i g h t cluster 1 7

Not O K

Check f o r v o l t a g e at t h e GR coloured cable connector G pin 8 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 GR 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 unit 4 a n d the r i g h t rear light cluster 1 7

Not O K

Check t h e c o n d i t i o n o f t h e junction unit 4

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

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, c o n n e c t o r J pin 3 of t h e junction unit 4

Not OK

O v e r h a u l or r e p l a c e junction unit 4

the

OK

Check 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, c o n n e c t o r B pin 3 of t h e instrument panel 6

Not OK

Restore t h e c o n t i n u i t y f o r the GN coloured cable bet w e e n t h e i n s t r u m e n t panel 6 a n d the control unit 4

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

Both the no. plate lights are not working

Check t h e c o n d i t i o n o f t h e junction unit 4

Not OK

O v e r h a u l or replace junction unit 4

the

The left 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

Replace t h e b u l b

4A409N

Copyright by Fiat Auto

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 bulb holder

Not OK

O v e r h a u l or replace t h e b u l b holder

OK

Check f o r v o l t a g e at t h e GR c o l o u r e d cable, f o r t h e left no. plate light 1 4

OK

O v e r h a u l or replace t h e l i g h t cluster f o r t h e n o . plate 1 4

Not OK

Bridge t h e N c o l o u r e d cable at t h e left n o . plate l i g h t 1 4 w i t h an earth

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 n o . plate l i g h t 1 4 a n d t h e left rear earth 1 8

Not OK

Check f o r v o l t a g e at t h e GR c o l o u r e d cable, c o n n e c t o r E pin 1 0 o f t h e 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 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 and t h e left n o . plate l i g h t 1 4

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

Check 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, f o r t h e r i g h t no. plate light 1 5

OK

O v e r h a u l or replace t h e l i g h t cluster for t h e n o . p l a t e 1 5

Not OK

Bridge t h e N coloured cablet at t h e right n o . plate light 1 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 coloured cable between t h e right n o . p l a t e l i g h t 1 5 a n d t h e left rear e a r t h 1 8

Not OK

Check 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, c o n n e c t o r G pin 8 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 the GN coloured cable t w e e n the j u n c t i o n unit t h e right n o . p l a t e l i g h t

for be4 & 15

Not OK

Check t h e c o n d i t i o n o f t h e junction unit 4

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

Copyright by Fiat Auto

11

Fault diagnosis
Analytical charts

Bravo-Brava

55D.
Both the (lipped headlamps are not working when operaled by the steering column switch unit

Bridge HR & C B c o l o u r e d cables at c o n n e c t o r B f o r steering c o l . s w i t c h unit 7

OK

Overhaul or replace s t e e r i n g column s w i t c h unit 7

Not OK

Check f o r v o l t a g e at t h e H R c o l o u r e d cable, c o n n e c t o r F pin 1 of t h e j u n c t i o n unit 4

Not OK

Restore t h e c o n t i n u i t y o f t h e HR c o l o u r e d cable b e t w e e n the junction unit 4 & the steering c o l . s w i t c h u n i t 7

OK

Check t h e c o n d i t i o n of t h e junction unit 4

Not OK

O v e r h a u l or replace junction unit 4

the

Both the dipped headlamps are not working with the main beam headlamps on

Bridge t h e R a n d HR c o l o u r e d cables at t h e d i p p e d headlamps relay 5

OK

O v e r h a u l or replace t h e relay 5

Not O K

Bridge t h e R a n d LR c o l oured cables at relay 5

OK

O v e r h a u l o r replace t h e relay 5

Not OK

Bridge t h e N c o l o u r e d c a b l e at relay 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 coloured cable b e t w e e n t h e relay 5 a n d t h e earth o n dashboard 2 2

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

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 relay 5 a n d t h e u l t r a sound welding

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

Restore t h e c o n t i n u i t y of t h e LR c o l o u r e d c a b l e b e t w e e n t h e relay 5 a n d t h e c o n n e c t o r F of t h e j u n c t i o n u n i t 4 or overhaul t h e j u n c t i o n unit 4

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

Restore t h e c o n t i n u i t y o f t h e HR c o l o u r e d c a b l e b e t w e e n the junction unit 4 and the relay 5

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

O v e r h a u l or replace junction unit 4

the

The left dipped headlamp is not working

Check the condition of the fuse 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 replace t h e fuse 5

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

Copyright by Fiat Auto

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

Check f o r v o l t a g e at t h e H N c o l o u r e d cable f o r t h e left f r o n t l i g h t cluster 1

OK

O v e r h a u l or replace t h e left f r o n t l i g h t cluster 1

Not OK

Check for v o l t a g e at t h e H N coloured cable, connector C pin 5 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 H N c o l o u r e d cable b e t w e e n the junction unit 4 and the left f r o n t l i g h t cluster 1

Not OK

Check t h e c o n d i t i o n of t h e junction unit 4

Not OK

O v e r h a u l or replace junction unit 4

the

The right dipped headlamp is not working

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

Check 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 fuse 6

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

Print no. 506.670/02

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

Overhaul or replace t h e b u l b holder

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

Overhaul or replace t h e r i g h t f r o n t light c l u s t e r 2

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

Restore t h e c o n t i n u i t y f o r the H coloured cable between the j u n c t i o n unit 4 a n d the r i g h t f r o n t l i g h t 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

Overhaul o r replace junction unit 4

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

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 replace t h e fuse 7

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

O v e r h a u l o r replace junction unit 4

the

4A415N

Copyright by Fiat Auto

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

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 for t h e left front l i g h t cluster 1

OK

O v e r h a u l or replace t h e left f r o n t l i g h t cluster 1

Not O K

Check f o r v o l t a g e at t h e V N coloured cable connector C pin 6 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 f o r the V N c o l o u r e d c a b l e b e tween the junction unit 4 and t h e left f r o n t l i g h t c l u s ter 1

Not O K

Check t h e c o n d i t i o n o f t h e junction unit 4

Not OK

O v e r h a u l or replace junction unit 4

the

The right main beam headlamp is not working

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

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 6

4
16
Print no. 506.670/02

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
OK

Check the condition of the 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

Overhaul or replace t h e b u l b holder

OK

C h e c k f o r v o l t a g e at t h e V 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 light cluster 2

OK

Overhaul or replace t h e r i g h t f r o n t light cluster 2

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

Overhaul or replace junction unit 4

the

4A417N

Copyright by Fiat Auto

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

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 B pin 1 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 f o r t h e V N c o l o u r e d cable b e t w e e n t h e i n s t r u m e n t panel 6 and the junction unit 4

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 G in t h e i n s t r u m e n t panel 6 or c h e c k the c o n d i t i o n of t h e i n s t r 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 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

Copyright by Fiat Auto

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

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

Check for 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 fuse 7 2

OK

Bridge t h e R c o l o u r e d c a b l e at t h e electric w i n d o w s relay feed 91

OK

Overhaul or r e p l a c e t h e electric w i n d o w s relay 91

N o t OK

Bridge t h e R and RN c o l o u r e d cables ( p i n 3 0 ) at t h e relay 91

OK

Overhaul or r e p l a c e t h e electric w i n d o w s relay 9 1

Not OK

Bridge t h e N coloured cable at t h e electric w i n d o w s relay 91 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 s relay 91 a n d t h e earth o n d a s h board 2 2

N o t OK

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 ( p i n 3 0 ) f o r t h e electric w i n d o w s relay 91

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 relay 91 a n d t h e u l t r a s o u n d w e l d ing

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 e l e c tric w i n d o w s relay 91

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

Copyright by Fiat Auto

21

Fault diagnosis
Analytical charts

Bravo-Brava

55D.
OK

Check f o r v o l t a g e at o n e of the R cable for t h e electric w i n d o w s protective fuse 7 2

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 f u s e 7 2 a n d t h e electric w i n d o w s relay 9 1

OK

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 c o n nector 3 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 fuse 7 2 a n d t h e u l t r a sound welding towards the connectors 35 and 36

OK

A l t e r n a t e l y bridge t h e N c o l oured cables at control panels 7 5 a n d 7 3 w i t h an earth

OK

Restore c o n t i n u i t y f o r t h e N c o l o u r e d cables between t h e c o n t r o l panels 7 5 & 7 3 a n d t h e earth o n dash 2 2

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

O v e r h a u l or replace t h e left electric window control panel 7 3

Not OK

22

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 R c o l o u r e d cable f o r t h e left electric window control panel 7 3

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

B r i d g e t h e N c o l o u r e d cable at t h e left electric w i n d o w c o n t r o l panel 7 3 w i t h an earth

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

Check the condition of the left electric w i n d o w m o t o r 76

Not OK

Replace t h e left w i n d o w motor 76

electric

Copyright by Fiat Auto

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

Check t h e c o n d i t i o n of t h e right electric w i n d o w c o n trol panel 7 5

Not OK

O v e r h a u l or replace t h e r i g h t electric window control panel 7 5

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

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 at t h e electric w i n d o w c o n . panel 7 4

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 c o n t r o l panel 7 4 a n d c o n nector 3 6

OK

Check t h e c o n d i t i o n of t h e electric window control panel 7 4

Not OK

O v e r h a u l or replace t h e electric window control panel 7 4

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

Print no. 506.670/02

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

Restore t h e c o n t i n u i t y f o r t h e RV a n d C c o l o u r e d c a bles b e t w e e n t h e c o n t r o l panels 7 5 a n d 7 4

OK

Bridge the ZB 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 4 a n d t h e electric window motor 77

OK

Restore t h e c o n t i n u i t y f o r the Z B coloured cable b t w n the control panel 7 4 & t h e electric w i n d o w m o t o r 7 7

Not OK

B r i d g e t h e BR c o l o u r e d c a ble b e t w e e n electric w i n d o w control panel 7 4 & electric w i n d o w m o t o r 7 7

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 t w e e n the c o n t r o l panel 7 4 a n d t h e electric window motor 77

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

O v e r h a u l or replace t h e electric window control panel 7 5

Not OK

Copyright by Fiat Auto

25

Fault diagnosis
Analytical charts

Bravo-Brava

55D.

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 b o t h t h e R / C a n d R V / N c o l o u r e d cables

OK

O v e r h a u l or replace t h e c o n trol panel 7 5

Not O K

Extract t h e c o n n e c t o r f o r t h e electric window control panel 7 4 f r o m its h o u s i n g , bridge t h e R V / Z B a n d C / B R c o l o u r e d cables

OK

O v e r h a u l or replace t h e electric window control panel 7 4

Not OK

Extract t h e c o n n e c t o r f r o m the c o n t r o l panel 7 4 a n d bridge t h e R V / B R a n d C / Z B c o l o u r e d cables

OK

O v e r h a u l or replace electric w i n d o w control pan. 7 4

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

Copyright by Fiat Auto

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

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 fuse 7 2

OK

B r i d g e t h e N c o l o u r e d cable at t h e electric w i n d o w s c o n t r o l unit 71 w i t h a n earth

OK

Restore c o n . o f N c o l o u r e d cable b e t w e e n electric w i n d o w s c o n . u n i t 71 & e a r t h on dashboard 2 2

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

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 fuse 7 2 a n d t h e u l t r a sound welding

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

Copyright by Fiat Auto

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

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 t h e c o n t i n u i t y f o r the RN coloured cable bet w e e n t h e c o n t r o l u n i t 71 and the ultrasound w e l d i n g

OK

Bridge N c o l o u r e d cables at el. w i n d o w c o n t r o l panels 7 5 & 7 3 w i t h an earth

Not OK

O v e r h a u l or replace t h e electric window control panels 7 5 a n d 7 3

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

Check c o n d . of N c o l o u r e d cable b t w n c o n n e c t o r 3 5 & earth o n dash 2 2

Not OK

Restore c o n t i n u i t y of t h e N c o l o u r e d cable b e t w e e n t h e c o n n e c t o r & t h e earth 2 2

The left electric window is not working

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 for t h e e l e c tric w i n d o w c o n t r o l panel 73

N o t 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 t r o l panel 7 3 a n d t h e ultrasound welding

OK
4A430N

30

Print no. 506.670/02

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

Extract t h e c o n n e c t o r f o r t h e c o n t r o l panel 7 3 f r o m its housing, bridge the C B / R a n d N / C N c o l o u r e d cables

OK

O v e r h a u l or replace t h e electric w i n d o w s control panel 7 3

Not OK

Extract t h e c o n n e c t o r f o r t h e c o n t r o l panel 7 3 f r o m its housing, bridge the R / C N a n d N / C B c o l o u r e d cables

OK

Overhaul or r e p l a c e t h e electric w i n d o w s control panel 7 3

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

Restore c o n t . f o r B G / Z G c o l o u r e d cables b t w n m o t o r 76 & control unit 71

Copyright by Fiat Auto

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

Check t h e c o n d i t i o n of t h e right electric w i n d o w c o n trol panel 7 5

Not OK

O v e r h a u l or replace t h e r i g h t electric window control panel 7 5

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

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 at t h e electric w i d o w s c o u r t e s y l i g h t 74

Not OK

Restore c o n t i n u i t y of R coloured cable b t w n control panel 7 4 & c o n n e c t o r 3 6

4A432N

32

Print no. 506.670/02

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
OK

Check t h e c o n d i t i o n o f t h e electric window control panel 7 4

N o t OK

O v e r h a u l or replace t h e electric window control panel 7 4

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

Restore c o n t i n u i t y f o r RV & C c o l o u r e d cables b e t w e e n c o n t r o l panels 7 5 & 7 4

OK

Bridge Z B c o l o u r e d c a b l e b t w n electric w i n d o w c o n trol panel 7 4 & electric w i n d o w motor 77

OK

Restore t h e c o n t i n u i t y f o r ZB coloured cable between c o n t r o l panel 7 4 & electric w i n d o w motor 77

Not OK

Bridge BR c o l o u r e d c a b l e b e t w e e n electric window c o n t r o l panel 7 4 a n d electric w i n d o w motor 77

OK

Restore t h e c o n t i n u i t y f o r BR c o l o u r e d c a b l e b e t w e e n c o n t r o l panel 7 4 & e l e c t r i c w i n d o w motor 77

Copyright by Fiat Auto

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

Overhaul or replace t h e electric window control panel 7 5

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

Overhaul or replace t h e c o n t r o l panel 7 5

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

Overhaul or replace t h e electric window control panel 7 4

Not OK

Extract t h e c o n n e c t o r f o r c o n t r o l panel 7 4 f r o m its h o u s i n g & bridge R V / B R & C / Z B c o l o u r e d cables

OK

Overhaul or replace electric w i n d o w control pan. 7 4

Not OK

Check condition of right 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

34

Print no. 506.670/02

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

Copyright by Fiat Auto

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

C h e c k t h e c o n d i t i o n of t h e electric rear w i n d o w s p r o t e c t i v e fuse 8 1

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

C h e c k for v o l t a g e at t h e R c o l o u r e d cable f o r fuse 81

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 fuse 8 1 a n d t h e u l t r a sound welding

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

Restore c o n t i n u i t y f o r M c o l o u r e d c a b l e b t w n f u s e 81 & c o n n e c t o r 3 5 or o v e r h a u l f u s e holder 81

OK

C h e c k for v o l t a g e at t h e M c o l o u r e d cable at t h e electric rear w i n d o w s i n h i b i t o r button 80

Not OK

Restore c o n t i n u i t y f o r M coloured cable b t w n button 80 & connector 35

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

Copyright by Fiat Auto

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

Restore c o n t i n u i t y of N c o l o u r e d cable b t w n c o n nector 3 5 & c o n . panel 8 0

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

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 for t h e e l e c tric w i n d o w c o n t r o l panel 78

Not OK

Restore c o n t i n u i t y f o r R N c o l o u r e d cable b t w n panel 7 8 & electric w i n d o w s i n hibiting button 8 0

4
OK

Check t h e c o n d i t i o n of t h e electric window control panel 7 8

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

Print no. 506.670/02

Brava

Fault diagnosis
Analytical charts

55D.
The left rear electric window is not working when operated by the left rear panel

C h e c k f o r v o l t a g e at t h e R N coloured cable pin 15 of connector 3 5

Not OK

Restore c o n t i n u i t y f o r R N coloured cable b t w n c o n nector 3 5 & electric w i n d o w s inhibitor button 8 0

OK

C h e c k f o r v o l t a g e at t h e R N coloured cable pin 7 for connector 2 8 A

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 connector 2 8 A & connector 3 5

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

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 connector 86 & c o n nector 28 A

OK

C h e c k for 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 e l e c tric w i n d o w control panel 82

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 t w e e n panel 8 2 & c o n n e c t o r 86

OK

C h e c k t h e c o n d i t i o n of t h e electric window control panel 8 2

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

Copyright by Fiat Auto

39

Analytical charts

Fault diagnosis

Brava

55D.
The right rear electric window is not working when operted by the left front panel

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 f o r t h e electric w i n d o w c o n t r o l panel 79

N o t OK

Restore c o n t i n u i t y f o r t h e RN coloured cable between panel 7 9 & electric w i n d o w s inhibitor button 8 0

OK

Check t h e c o n d i t i o n o f t h e electric window control panel 7 9

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

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 p i n 1 2 f o r connector 35

N o t OK

Restore c o n t i n u i t y f o r R N c o l o u r e d cable b t w n c o n n e c t o r 3 5 & electric w i n d o w s inhibitor button 8 0

OK

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 p i n 1 4 f o r connector 2 8 A

N o t OK

Restore t h e c o n t i n u i t y f o r the RN coloured cable between connector 2 8 A & connector 35

OK

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 for c o n n e c tor 8 7

N o t OK

Restore t h e c o n t i n u i t y f o r the RN coloured cable between connector 87 & connector 2 8 A

OK

40

Print no. 506.670/02

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 R N c o l o u r e d cable at t h e electric w i n d o w c o n t r o l panel 83

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 t w e e n panel 8 3 & connector 87

OK

Check t h e condition of the electric window control panel 8 3

Not OK

O v e r h a u l or replace t h e p a n el 8 3

The left rear 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 t r o l panel 7 8 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 panel 7 8 & 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 f o r t h e panel 7 8 f r o m its h o u s i n g , bridge the R N / A N and A B / N 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 7 8

Not OK

Extract t h e c o n n e c t o r f o r t h e panel 7 8 f r o m it h o u s i n g , bridge the R N / A B and N / A N 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 7 8

Not OK

Copyright by Fiat Auto

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

Extract t h e c o n n e c t o r f o r panel 8 2 f r o m its h o u s i n g , bridge the RN/BV and Z G / A N 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

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

Restore t h e c o n t i n u i t y f o r the A N and A B coloured c a bles b t w n panels 7 8 & 8 2

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

Restore t h e c o n t i n u i t y f o r the ZG and BV coloured cables b e t w e e n m o t o r 8 4 & panel 8 2

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

Bridge t h e N coloured cable at t h e electric w i n d o w c o n t r o l p a n e l 7 9 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 panel 7 9 & 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 f o r panel 7 9 f r o m its h o u s i n g , bridge the R N / G N & N / G V 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 7 9

Not OK

Extract t h e c o n n e c t o r f o r panel 7 9 f r o m its h o u s i n g , bridge the R N / G V & N / G N 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 7 9

Not OK

Extract t h e c o n n e c t o r f o r panel 8 3 f r o m its h o u s i n g , bridge the R N / Z B & B R / G V 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 3

Not OK

Extract t h e c o n n e c t o r f o r panel 8 3 f r o m its h o u s i n g , bridge the R N / B R & Z B / G N 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 3

Copyright by Fiat Auto

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

Restore t h e c o n t i n u i t y f o r GN and GV coloured cables b e t w e e n panels 7 9 & 8 3

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

Restore t h e c o n t i n u i t y f o r BR & Z B c o l o u r e d c a b l e s between motor 8 5 and panel 8 3

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

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N.D.I"
r,
H

UHG

N.D. 108* 35
a
G G G H
1

N.D.
N N
1

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- : - H - T

ID 86 LT 22 113

- zn in 3 2

(e)

87

42 112

* N o n existent for t h e Bravo v e r s i o n ** 6 0 A fuse f o r DS v e r s i o n s

Copyright by Fiat Auto

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

Print no. 506.670/02

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
The central locking is not working

C h e c k t h e c o n d i t i o n of t h e fuse 1 1 3 p r o t e c t i n g t h e c e n tral l o c k i n g system

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 replace t h e fuse 113

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 for fuse 1 1 3

Not OK

Restore c o n t . o f R c o l o u r e d cable between fuse 1 1 3 & ultrasound w e l d i n g

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

Restore c o n t i n u i t y of R coloured cable between control unit 1 1 2 & fuse 1 1 3

OK

B r i d g e t h e N c o l o u r e d cable at t h e central d o o r l o c k i n g c o n t r o l unit w i t h a n earth

OK

Restore c o n t i n u i t y of N coloured cable between c o n t r o l u n i t 1 1 2 & earth o n dashboard 2 2

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

Copyright by Fiat Auto

47

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 central l o c k i n g c o n t r o l u n i t 112

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 is not locking the doois

Bridge t h e A c o l o u r e d c a b l e at t h e central l o c k i n g c o n t r o l unit 1 1 2 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 A c o l o u r e d cable b e t w e e n the control unit 112 a n d t h e ultrasound welding

Not O K

C h e c k - t h e c o n d i t i o n of t h e control locking control unit 112

Not OK

O v e r h a u l or replace t h e c o n trol unit 1 1 2

The cential locking does not lock the doors controlled by the left front lock

Bridge t h e N c o l o u r e d c a b l e at t h e left f r o n t central l o c k ing 1 1 0 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 c o l o u r e d cable b e t w e e n t h e central l o c k i n g 1 1 0 a n d t h e earth o n d a s h b o a r d 2 2

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

Restore c o n t . of A c o l o u r e d cable b e t w e e n c o n t r o l u n i t 112 and connector 35

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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between the connector 3 5 and the l o c k assembly 1 1 0

OK

Bridge the A / N coloured cables at t h e left f r o n t l o c k assembly 110

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

B r i d g e t h e N c o l o u r e d cable at t h e right f r o n t central l o c k i n g 111 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 central l o c k i n g 1 1 1 a n d t h e earth o n d a s h b o a r d 4 2

4
Not OK

Copyright by Fiat Auto

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

Restore c o n t i n u i t y of A coloured cable b t w n control unit 1 1 2 & c o n n e c t o r 3 6

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

Restore t h e c o n t i n u i t y o f t h e A 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 lock a s s e m b l y 111

OK

Bridge t h e A / N c o l o u r e d c a bles at t h e left f r o n t lock assembly 1 1 1

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

Check t h e c o n d i t i o n o f t h e left f r o n t l o c k assembly 1 1 1

Not OK

O v e r h a u l or replace t h e l o c k assembly 1 1 1

The central locking is not unlocking the doors

Bridge t h e B c o l o u r e d c a b l e at the central l o c k i n g c o n t r o l unit 1 1 2 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 B c o l o u r e d cable b e t w e e n the c o n t r o l u n i t 1 1 2 a n d t h e ultrasound welding

50

Print no. 506.670/02

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
Not OK

Check the condition of the central locking control unit 112

Not OK

Overhaul o r replace t h e c o n t r o l unit 1 1 2

The central locking does not unlock the doors controlled by the left front lock

Bridge the N coloured cable at t h e left f r o n t central l o c k i n g 1 1 0 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 central l o c k i n g 1 1 1 a n d t h e earth o n d a s h b o a r d 4 2

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

Restore c o n t . o f B c o l o u r e d cable b e t w e e n c o n t r o l u n i t 112 & connector 35

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

Restore t h e c o n t i n u i t y o f t h e B coloured cable between the connector 35 a n d the lock assembly 1 1 0

OK

Copyright by Fiat Auto

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

Check t h e c o n d i t i o n o f t h e left f r o n t l o c k assembly 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 unlock the doors operated by the right front lock

Bridge t h e N c o l o u r e d c a b l e at t h e r i g h t front c e n t r a l l o c k i n g 1 1 1 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 the central l o c k i n g 1 1 1 a n d the earth o n d a s h b o a r d 4 2

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

Restore c o n t i n u i t y of B c o l o u r e d cable b t w n c o n t r o l unit 1 1 2 and connector 3 6

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

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 the c o n n e c t o r 3 6 a n d t h e lock a s s e m b l y 1 1 1

52

Print no. 506.670/02

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
OK

Bridge t h e B / N coloured cables at t h e r i g h t f r o n t l o c k assembly 111

OK

Overhaul or replace t h e l o c k assembly 1 1 1

N o t OK

Check the condition of the r i g h t f r o n t l o c k assembly 111

Not OK

O v e r h a u l or replace t h e l o c k assembly 1 1 1

The left front central locking motor is not working

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

C h e c k t h e c o n d i t i o n of t h e left f r o n t central l o c k i n g m o tor 110

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

Copyright by Fiat Auto

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

Extract c o n n e c t o r s 3 6 a n d 111 f r o m their h o u s i n g s , bridge t h e H / G c o l o u r e d c a bles at c o n n e c t o r 3 6 a n d i n sert a n o h m m e t e r b e t w e e n the H / G c o l o u r e d c a b l e s at the l o c k assy c o n n e c t o r 1 1 1

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 connector 36 and t h e l o c k assembly 1 1 1

OK

Check t h e c o n d i t i o n of t h e right f r o n t central l o c k i n g motor 111

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

Print no. 506.670/02

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

Check t h e c o n d i t i o n of t h e left rear central l o c k i n g m o tor 108

Not OK

Overhaul or replace t h e c e n tral l o c k i n g m o t o r 1 0 8

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

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 a n d t h e c o n n e c t o r 8 7

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

C h e c k t h e c o n d i t i o n of t h e left rear central l o c k i n g m o tor 109

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

Copyright by Fiat Auto

55

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
The central locking is not working

Check t h e condition of the fuse 113 protecting the c e n tral l o c k i n g system

Not OK

Check f o r a s h o r t c i r c u i t in the system a n d r e p l a c e t h e fuse 1 1 3

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

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 f u s e 1 1 3 & ultrasound w e l d i n g

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 for 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

Restore c o n t . o f R c o l o u r e d cable b e t w e e n c o n t r o l u n i t 112 and fuse 1 1 3

OK

Bridge the N coloured cable at t h e central l o c k i n g c o n t r o l u n i t 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 coloured cable between the control unit 1 1 2 a n d t h e earth o n d a s h b o a r d 2 2

Not OK

Extract c o n n e c t o r s 3 5 & 1 1 2 f r o m their h o u s i n g s , b r i d g e H / G c o l o u r e d cables at c o n t r o l unit 1 1 2 & insert a n o h m m e t e r at H / G c o l o u r e d cables f o r c o n n e c t o r 3 5

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

Copyright by Fiat Auto

59

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
OK

Check t h e c o n d i t i o n o f t h e c o n t r o l l o c k i n g c o n t r o l unit 112

N o t OK

O v e r h a u l or replace t h e c o n trol unit 112

The central locking is not woiking operated by the remote control

Check t h e v o l t a g e o f t h e a c c u m u l a t o r inside t h e r e m o t e control

Not OK

Replace the accumulator

OK

Check t h e c o n d i t i o n o f t h e fuse 1 0 inside t h e j u n c t i o n unit 4

N o t 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 replace t h e fuse 1 0

OK

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 for receiver 107A

Not OK

Restore t h e c o n t i n u i t y f o r the RN coloured cable bet w e e n t h e receiver 1 0 7 A a n d t h e c o n n e c t o r G of t h e j u n c t i o n unit 4

OK

Bridge t h e N c o l o u r e d c a b l e at the central l o c k i n g r e m o t e c o n t r o l receiver 1 0 7 A w i t h an earth

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 receiver 1 0 7 A a n d t h e ultrasound welding

Not O K

60

Print no. 506.670/02

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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

C h e c k t h e c o n d i t i o n of t h e central locking remote c o n trol

Not OK

Overhaul or replace t h e r e mote control

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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between the connector 2 8 and the u l trasound w e l d i n g

OK

B r i d g e t h e A c o l o u r e d cable at t h e receiver 1 0 7 A w i t h an earth

Not OK

Restore c o n t i n u i t y of A coloured cable between receiver 1 0 7 A & c o n n e c t o r 2 8

OK

Check the c o n d i t i o n of the receiver 1 0 7 A

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

Restore t h e c o n t i n u i t y o f t h e B coloured cable between the connector 2 8 and the u l trasound w e l d i n g

OK

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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

Bridge M B c o l o u r e d c a b l e btwn connectors 28 & 70

OK

Restore t h e c o n t i n u i t y o f t h e M B c o l o u r e d cable b e t w e e n connectors 28 & 70

Not O K

Bridge t h e M B c o l o u r e d c a ble b e t w e e n t h e alarm c o n trol unit 1 0 0 c o n n e c t o r A pin 2 a n d t h e receiver 1 0 7 A

OK

Restore t h e c o n t i n u i t y o f t h e M B c o l o u r e d cable b e t w e e n t h e alarm c o n t r o l u n i t 1 0 0 a n d t h e receiver 1 0 7 A

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

O v e r h a u l or replace t h e c o n trol unit 1 0 0

4A463N

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Fault diagnosis
Analytical charts

5 5 D.
The doors ajar warning light is not working (For the versions with an alarm)

Bridge the V B coloured c a ble at c o n n e c t o r 7 0 w i t h an earth

OK

Restore t h e c o n t i n u i t y f o r the VB coloured cable ( N ) between connector 7 0 a n d t h e alarm c o n t r o l u n i t 1 0 0 connector B pin 14

Not OK

Bridge the V B coloured c a ble at t h e i n s t r u m e n t panel 6 c o n n e c t o r C p i n 1 w i t h an earth

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

Check the 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 the c o n d i t i o n of t h e instrument panel 6

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)

Bridge the V B coloured c a ble at the I n s t r u m e n t panel 6 connector C pin 1 w i t h an earth

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

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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

The central locking does not lock the doors

Bridge t h e A c o l o u r e d c a b l e at the c e n t r a l l o c k i n g c o n t r o l unit 1 1 2 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 A c o l o u r e d cable b e t w e e n the c o n t r o l unit 1 1 2 a n d t h e ultrasound welding

Not O K

Check t h e c o n d i t i o n o f t h e control l o c k i n g c o n t r o l u n i t 112

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

Bridge t h e N c o l o u r e d c a b l e at the left f r o n t central l o c k ing 1 1 0 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 the central locking 1 1 0 and the earth o n dashboard 2 2

Not O K

4A465N

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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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between the connector 3 5 a n d the l o c k assembly 1 1 0

OK

Bridge t h e A / 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 assembly 1 1 0

OK

Overhaul or replace t h e l o c k assembly 1 1 0

Not OK

Check t h e c o n d i t i o n o f t h e left f r o n t lock assembly 1 1 0

Not OK

Overhaul 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

Bridge t h e N c o l o u r e d c a b l e at t h e right f r o n t central l o c k i n g 111 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 the central l o c k i n g 1 1 1 a n d t h e earth o n d a s h b o a r d 4 2

Not OK

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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

Restore c o n t . o f A c o l o u r e d cable b e t w e e n c o n t r o l u n i t 112 & connector 36

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

Bridge t h e A / 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 assembly 1 1 1

OK

O v e r h a u l or replace t h e lock assembly 111

Not O K

Check t h e c o n d i t i o n o f t h e left f r o n t l o c k assembly 1 1 1

N o t OK

O v e r h a u l or replace t h e l o c k assembly 111

The central locking does not unlock the doors

Bridge t h e B c o l o u r e d cable at the c e n t r a l l o c k i n g c o n t r o l unit 1 1 2 w i t h an earth

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

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Fault diagnosis
Analytical charts

55D.
Not OK

Check the condition of the central l o c k i n g c o n t r o l unit 112

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

B r i d g e t h e N c o l o u r e d cable at t h e left f r o n t c e n t r a l l o c k ing 1 1 0 w i t h an earth

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 central l o c k i n g 1 1 1 a n d t h e earth o n d a s h b o a r d 4 2

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 c a b l e s 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 t w n A / B c o l o u r e d c a b l e s for connector 35

Not OK

Restore c o n t . o f B c o l o u r e d cable between control unit 112 & connector 35

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

Restore t h e c o n t i n u i t y of t h e B coloured cable between the connector 3 5 and the l o c k assembly 1 1 0

OK

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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

Check t h e c o n d i t i o n of t h e left f r o n t l o c k assembly 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 unlock the doors operated by the right front lock

Bridge t h e N c o l o u r e d cable at t h e r i g h t f r o n t central l o c k i n g 1 1 1 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 central l o c k i n g 1 1 1 a n d t h e earth o n d a s h b o a r d 4 2

Not OK

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 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 t w e e n A / B c o l o u r e d cables of c o n nector 3 6

Not OK

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 the control unit 112 and the connector 36

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

Restore t h e c o n t i n u i t y o f t h e B coloured cable between the connector 36 and the l o c k assembly 1 1 1

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Fault diagnosis
Analytical charts

55D.
OK

Bridge the B/N coloured cables at t h e r i g h t f r o n t lock a s s e m b l y 111

OK

Overhaul or replace t h e l o c k assembly 1 1 1

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

Overhaul or replace t h e l o c k assembly 1 1 1

The left 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 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

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 ultrasound w e l d i n g and t h e c o n n e c t o r 3 5

OK

Extract c o n n e c t o r s 3 5 a n d 1 1 0 f r o m their h o u s i n g s , 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 c a b l e s at t h e l o c k 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 c o l o u r e d cables b e t w e e n the c o n n e c t o r 3 5 a n d t h e lock a s s e m b l y 1 1 0

OK

Check the c o n d i t i o n of the left f r o n t central l o c k i n g m o tor 1 1 0

Not OK

Overhaul or replace t h e c e n tral l o c k i n g m o t o r 1 1 0

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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

Restore t h e c o n t i n u i t y f o r the H / G coloured cables between t h e ultrasound w e l d ing a n d t h e c o n n e c t o r 3 6

OK

Extract c o n n e c t o r s 3 6 a n d 111 f r o m t h e i r h o u s i n g s , bridge t h e H / G c o l o u r e d cables at c o n n e c t o r 3 6 a n d insert an o h m m e t e r b e t w e e n the H / G c o l o u r e d cables at the lock 1 1 1 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 H / G coloured cables between the connector 3 6 and the lock 111

OK

Check t h e c o n d i t i o n of t h e right f r o n t central l o c k i n g motor 1 1 1

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

Restore t h e c o n t i n u i t y f o r t h e H / G c o l o u r e d cables b e t w e e n t h e ultrasound w e l d ing and t h e connector 8 6

OK

4A471N

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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

C h e c k t h e c o n d i t i o n of t h e left rear central l o c k i n g m o tor 1 0 8

Not OK

Overhaul or replace t h e c e n tral l o c k i n g m o t o r 1 0 8

The righ 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 & 8 7 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 . c a b l e s at t h e central locking c / u n i t c o n n e c t o r 1 1 2 & insert a n o h m meter b t w n t h e H / G c o l . c a bles f o r c o n n e c t o r 8 7

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 ultrasound w e l d i n g and t h e c o n n e c t o r 8 7

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

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 87 and t h e lock a s s e m b l y 1 0 9

OK

C h e c k the c o n d i t i o n of t h e left rear central l o c k i n g m o tor 1 0 9

Not OK

Overhaul or replace t h e c e n tral l o c k i n g m o t o r 1 0 9

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71

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
The direction indicators/hazard warning lights are not woiking

Bridge A B / L B coloured cables at hazard w a r n i n g l i g h t s switch 23

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

Bridge LB c o l . cable b t w n s w i t c h 2 3 & steering c o l . switch unit 7 connector D

OK

Restore c o n t . f o r L B c o l . c a ble b t w n s w i t c h 2 3 & steering col. s w i t c h unit 7

Not OK

Bridge LB c o l . cable w i t h A N / A c o l o u r e d c a b l e s at steering c o l . s w i t c h u n i t 7

OK

O v e r h a u l or r e p l a c e d i r e c tion indicators/hazard w / lights intermittent device G in steering c o l . s w i t c h u n i t 7, or o v e r h a u l u n i t 7

The direction indicators are not working

B r i d g e t h e LR c o l o u r e d c a ble w i t h t h e A / A N c o l o u r e d cables at c o n n e c t o r C f o r steering c o l . s w i t c h u n i t 7

OK

O v e r h a u l or r e p l a c e t h e s w i t c h for direction indicat o r s H in s t e e r i n g c o l u m n s w i t c h u n i t 7 , or o v e r h a u l unit 7

Not OK

Bridge t h e A R / L B coloured cables at t h e hazard w a r n i n g lights c o n t r o l s w i t c h 2 3

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

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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

The hazard warning lights are not working

Bridge t h e A B / L B c o l o u r e d cables at c o n n e c t o r A for t h e hazard warning lights switch 23

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

Check f o r v o l t a g e at A B c o l . cable c o n n e c t o r A of hazard w a r n i n g lights s w i t c h 2 3

Not OK

Restore t h e c o n t i n u i t y o f t h e A B c o l o u r e d cable b e t w e e n switch 2 3 a n d the ultrasound welding

OK

Bridge L B / L R c o l . cables at steering c o l . s w i t c h u n i t 7

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

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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

B r i d g e LR c o l o u r e d c a b l e w i t h A / A N c o l o u r e d cables at c o n n e c t o r B of hazard w a r n i n g lights s w i t c h 2 3

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

C h e c k for v o l t a g e at t h e A N c o l o u r e d cable at c o n n e c t o r C , steering c o l u m n s w i t c h unit 7

OK

Restore c o n t i n u i t y o f A N c o l . cable b t w n s t e e r i n g c o l . switch unit 7 & ultrasound welding

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

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 at c o n n e c t o r C, steering c o l u m n s w i t c h unit 7

OK

Restore t h e c o n t i n u i t y o f t h e A coloured cable between steering c o l u m n s w i t c h u n i t 7 & the ultrasound w e l d i n g

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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

Bridge t h e L R / A N c o l o u r e d cables at c o n n e c t o r B o f t h e hazard warning lights switch 2 3

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

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 c a b l e at c o n n e c t o r B of t h e hazard w a r n i n g lights s w i t c h 2 3

OK

Restore t h e c o n t i n u i t y of t h e A N coloured cable between switch 23 & the ultrasound welding

The right branch of the direction indicators/hazard warning lights is not working operated by the hazard w/lights switch

Bridge t h e L R / A c o l o u r e d cables at c o n n e c t o r B o f t h e hazard warning lights switch 2 3

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

Check f o r v o l t a g e at t h e A c o l o u r e d cable at c o n n e c t o r B of t h e hazard w a r n i n g lights s w i t c h 2 3

OK

Restore t h e c o n t i n u i t y of t h e A coloured cable between switch 2 3 & the ultrasound welding

The left front and side direction indicators are not working

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 c o n n e c t o r I pin 4 of t h e j u n c t i o n u n i t 4

Not OK

Overhaul the j u n c t i o n unit 4

OK

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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

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 A pin 15 of the junction unit

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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between the junction unit 4 , c o n n e c tor A & c o n n e c t o r 1 3

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 cable of t h e r i g h t f r o n t l i g h t cluster 2

Not 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 r i g h t f r o n t l i g h t c l u s t e r 2 & connector 13

The left front direction indicator is not working

Check the condition of the bulb

Not OK

Replace t h e b u l b

OK

Copyright by Fiat Auto

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

The right front direction indicator is not woiking

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 holder

Not OK

O v e r h a u l or replace t h e b u l b holder

OK

Bridge t h e N c o l o u r e d cable at t h e r i g h t f r o n t l i g h t cluster 2 w i t h an earth

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 r i g h t f r o n t l i g h t cluster 2 & t h e right f r o n t earth 9

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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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between t h e light cluster 2 & t h e u l trasound w e l d i n g

The left front side direction repeater 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

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

Bridge the N coloured cable at t h e left f r o n t repeater 2 0 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 coloured cable between t h e repeater 2 0 & t h e left f r o n t earth 8

Not OK

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 at t h e left f r o n t repeater 2 0

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 repeater 2 0 & t h e u l t r a sound welding

The right front side direction repeater 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

4A482N

Copyright by Fiat Auto

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

Bridge t h e N c o l o u r e d cable at t h e r i g h t f r o n t repeater 21 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 coloured cable between t h e repeater 21 a n d t h e r i g h t f r o n t earth 9

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 cable at t h e r i g h t f r o n t repeater 2 1

Not OK

Restore t h e c o n t i n u i t y of t h e A coloured cable between t h e repeater 2 1 7 t h e u l t r a sound welding

The left rear direction indicator is not working

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

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 rear l i g h t cluster 1 6

OK

O v e r h a u l o r replace t h e l i g h t cluster 1 6

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4
Not OK

Fault diagnosis
Analytical charts

55D.

Check for voltage at the A N c o l o u r e d cable c o n n e c t o r E pin 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 o f t h e A N coloured cable b e t w e e n the junction unit 4 connect o r E and t h e l i g h t c l u s t e r 1 6

Not OK

Check the condition of the junction unit 4

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

The right rear direction indicator is not working

Check the condition of the 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

N o t OK

O v e r h a u l or replace t h e b u l b holder

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 t h e r i g h t rear l i g h t cluster 1 7

OK

O v e r h a u l or replace t h e l i g h t cluster 17

Not OK

4A484M

Copyright by Fiat Auto

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

Check 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 left direction indicators warning light is not working

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 at c o n n e c t o r B pin 10 of the instrument panel 6

OK

Replace t h e w a r n i n g l i g h t C in t h e i n t r u m e n t panel 6, or overhaul the instrument panel 6

Not O K

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 of c o n n e c t o r H pin 7 of the junction unit 4

OK

Restore t h e c o n t i n u i t y of t h e A N c o l o u r e d cable b e t w e e n the u n i t 4 c o n n e c t o r H & t h e i n s t r u m e n t panel 6 c o n n e c tor B

Not OK

Check 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 junction unit 4

The right direction indicators warning light is not working

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

Replace t h e w a r n i n g l i g h t D in t h e i n s t r u m e n t panel 6 , or overhaul the instrument panel 6

4A485N

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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

Restore t h e c o n t i n u i t y o f t h e A coloured cable between t h e unit 4 c o n n e c t o r H & t h e instrument panel 6 c o n n e c tor B

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

The hazard warning lights warning light is not working

B r i d g e t h e N c o l o u r e d cable at c o n n e c t o r A o f t h e hazard w a r n i n g lights s w i t c h 2 3

OK

Restore c o n t i n u i t y of N coloured cable between hazard w / l i g h t s s w i t c h 2 3 & earth on d a s h b o a r d 2 2

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 a r n i n g l i g h t s w / l i g h t A in t h e hazard w / lights switch 2 3

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

Copyright by Fiat Auto

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

Restore t h e c o n t i n u i t y f o r o n e of t h e A R / B N c o l o u r e d cables b e t w e e n c o n n e c t o r 5 5 & reversing s w i t c h 1 5 9 , or replace t h e reversing lights s w i t c h 1 5 9

Not O K

Bridge t h e A R / B c o l o u r e d cables b e t w e e n c o n n e c t o r s A pin 1 4 & B p i n 9 o f t h e junction unit 4

OK

Restore t h e c o n t i n u i t y f o r o n e of t h e A R / B c o l o u r e d cables b e t w e e n t h e j u n c t i o n unit 4 c o n n e c t o r s A & B & connector 55

Not OK

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 A p i n 1 4 o f the j u n c t i o n u n i t 4

Not OK

Overhaul the j u n c t i o n unit 4

OK

Using a c a b l e b r i d g e p i n 9 connector D w i t h pin 6 ( 7 ) c o n n e c t o r G of t h e j u n c t i o n unit 4

OK

Overhaul the j u n c t i o n unit 4

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

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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

C h e c k f o r v o l t a g e at t h e B c o l o u r e d cable for t h e left rear l i g h t cluster 1 6

OK

Overhaul or replace t h e l i g h t cluster 1 6

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

Restore t h e c o n t i n u i t y o f t h e B coloured cable b e t w e e n the junction unit 4 c o n n e c tor G & t h e l i g h t c l u s t e r 1 6

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

The right reversing light is not working

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

Overhaul or replace t h e b u l b holder

4A488N

Copyright by Fiat Auto

87

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
OK

Check f o r v o l t a g e a t t h e B c o l o u r e d cable f o r t h e r i g h t rear l i g h t cluster 1 7

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

Check f o r 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 pin 7 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 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

Check t h e c o n d i t i o n of t h e junction unit 4

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

The biake lights are not working

Bridge t h e A R / R N c o l o u r e d cables at t h e brake lights switch 4 0

OK

O v e r h a u l or switch 40

replace

the

Not O K

Bridge t h e A R / R N c o l o u r e d cables at c o n n e c t o r s D p i n 4 & A p i n 1 8 of t h e 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 f o r t h e A R / R N c o l o u r e d cables b e t w e e n t h e j u n c t i o n unit 4 , connectors D & A & the brake l i g h t s s w i t c h 4 0

Not O K

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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

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 for t h e left rear l i g h t cluster 1 6

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

Copyright by Fiat Auto

89

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
Not O K

Bridge t h e R N / R G c o l o u r e d cables at c o n n e c t o r E p i n 1 2 & 1 3 o f t h e j u n c t i o n unit 4

OK

Overhaul the junction unit 4

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

Check f o r v o l t a g e at t h e RN c o l o u r e d cable of t h e right rear l i g h t cluster 17

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

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 c o n n e c t o r E pin 1 3 o f t h e 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 f o r t h e R N c o l o u r e d cable b e t w e e n the j u n c t i o n unit 4 , connector E & the light cluster 1 7

Not O K

Bridge t h e R N / R G c o l o u r e d cables at c o n n e c t o r E p i n 1 2 & 13 o f t h e j u n c t i o n u n i t 4

OK

Overhaul the junction unit 4

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Fault diagnosis
Analytical charts

5 5 D.
The addition brake light is not working

Check the condition of the bulb

N o t OK

Replace t h e b u l b

OK

Check the condition of the 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

B r i d g e t h e N c o l o u r e d cable at t h e a d d i t i o n a l brake light 41 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 coloured cable between t h e a d d i t i o n a l brake l i g h t 4 1 a n d t h e right rear e a r t h 1 9

Not OK

C h e c k for 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 a d d i t i o n a l brake light 4 1

OK

Overhaul or replace t h e a d d i t i o n a l rear brake l i g h t u n i t 41

Not OK

Bridge the R / R N coloured cables at c o n n e c t o r E p i n 1 4 / 1 3 of 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

4A492N

Copyright by Fiat Auto

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

Bridge t h e N c o l o u r e d cable at t h e i n s t r u m e n t panel 6 c o n n e c t o r C p i n 1 5 w i t h an earth

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 i n s t r u m e n t panel 6 & t h e earth o n d a s h b o a r d 4 2

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

Restore t h e c o n t i n u i t y f o r t h e A R c o l o u r e d cable b e t 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 C & t h e ultra sound welding

OK

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 o f t h e i n s t r u ment panel 6 c o n n e c t o r C pin 3

Not OK

O v e r h a u l or replace t h e brake l i g h t s failure c o n t r o l 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 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

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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

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 o f t h e left rear l i g h t cluster 1 6

OK

Overhaul or replace t h e l i g h t cluster 1 6

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

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 junction unit 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

Not OK

Bridge pin 3 connector E & p i n 1 c o n n e c t o r J of t h e 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

C h e c k for v o l t a g e at t h e RG c o l o u r e d cable o f t h e i n s t r u m e n t panel 6 c o n n e c t o r C pin 2

Not 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 instrument panel 6 c o n nector C & t h e j u n c t i o n unit 4 connector J

OK

Copyright by Fiat Auto

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

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 c a b l e of t h e r i g h t rear light cluster 17

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

Check for v o l t a g e at t h e R N coloured cable connector E pin 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 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

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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

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 of t h e i n s t r u m e n t panel 6 c o n n e c t o r C pin 3

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 t w e e n the instrument panel 6 connector C & the junct i o n unit 4 c o n n e c t o r H

OK

C h e c k t h e c o n d i t i o n of t h e brake lights failure c i r c u i t

Not OK

Replace t h e brake l i g h t s f a i l ure circuit, o r o v e r h a u l t h e instrument panel 6

4A496N

Copyright by Fiat Auto

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

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 fuse 1 0

OK

Check f o r v o l t a g e at t h e junction unit 4 connector G p i n 11

Not OK

Overhaul t h e j u n c t i o n u n i t 4

OK

Bridge the N coloured cable at t h e f r o n t c o u r t e s y l i g h t 1 0 7 B 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 rear earth 1 8 & t h e ultrasound w e l d i n g

The fiont courtesy light is not working

Bridge t h e N coloured cable at t h e c o u r t e s y l i g h t 1 0 7 B 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 coloured cable between the courtesy light 1 0 7 B & 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 f o r t h e c o u r tesy light 1 0 7 B

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

Check the condition of t h e bulbs

Not OK

Replace t h e b u l b s

OK

Copyright by Fiat Auto

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

Bridge t h e BR c o l o u r e d c a ble at t h e left front p u s h b u t ton 6 0 w i t h an earth

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

Bridge t h e BR c o l o u r e d c a ble at t h e left front p u s h b u t ton 5 9 w i t h an earth

Not OK

Restore c o n t i n u i t y f o r BR c o l o u r e d cable b e t w e e n t h e left f r o n t push b u t t o n 5 9 & the ultrasound w e l d i n g

OK

Bridge t h e N c o l o u r e d cable at t h e left f r o n t push b u t t o n 59 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 p u s h b u t t o n 5 9 & the ultrasound w e l d i n g

100

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Fault diagnosis
Analytical charts

5 5 D.
The courtesy light does not work when the right fiont door is opened

Bridge the B R / N coloured c a b l e s at t h e r i g h t f r o n t c o u r t e s y light s w i t c h 6 0

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

B r i d g e t h e N c o l o u r e d cable at t h e right f r o n t p u s h b u t t o n 6 0 w i t h an earth

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)

Bridge the B R / N coloured c a b l e s at t h e left rear c o u r tesy l i g h t s w i t c h 6 1

OK

O v e r h a u l or replace t h e left rear push b u t t o n 6 1

Not OK

B r i d g e t h e BR c o l o u r e d c a ble at t h e left rear p u s h b u t t o n 61 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 left rear p u s h b u t t o n 6 1 & the ultrasound w e l d i n g

OK

B r i d g e t h e N c o l o u r e d cable at t h e left rear p u s h b u t t o n 61 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 coloured cable between t h e left rear p u s h b u t t o n 61 & the ultrasound w e l d i n g

Copyright by Fiat Auto

101

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
The courtesy light does not work when the right rear door is opened

Bridge t h e B R / N c o l o u r e d cables at t h e r i g h t rear c o u r tesy l i g h t s w i t c h 6 2

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

Bridge t h e BR c o l o u r e d c a ble at t h e right rear p u s h b u t t o n 6 2 w i t h an earth

Not OK

Restore c o n t i n u i t y f o r BR c o l o u r e d cable b e t w e e n t h e right rear p u s h b u t t o n 6 2 & the u l t r a s o u n d w e l d i n g

OK

Bridge t h e N c o l o u r e d c a b l e at t h e r i g h t rear push b u t t o n 6 2 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 c o l o u r e d cable b e t w e e n the r i g h t rear push b u t t o n 6 2 & the ultrasound w e l d i n g

The glove compartment light is not working

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

Bridge t h e N c o l o u r e d c a b l e at t h e g l o v e c o m p a r t m e n t light 6 4 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 the glove compartment light 6 4 a n d t h e dash earth

Not O K

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 at t h e g l o v e c o m p a r t m e n t light 6 4

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 light 6 4 & the j u n c t i o n unit 4 c o n n e c t o r J , or o v e r haul t h e j u n c t i o n u n i t 4

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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 glove compartment light assembly 64

Not OK

Overhaul t h e g l o v e c o m partment light assembly 6 4

The luggage compartment light is not working 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

Bridge the R / N coloured cables at t h e rear c o n t a c t board 27

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

Bridge the N coloured cable at t h e rear c o n t a c t b o a r d 2 7 w i t h an earth ( O n l y if t h e rearscreen w i p e r is also n o t working)

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

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 t h e rear c o n t a c t board 2 7

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

Copyright by Fiat Auto

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

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 replace t h e fuse 2

OK

Check f o r v o l t a g e at o n e o f the G N c o l o u r e d cables f o r the j u n c t i o n unit 4 c o n n e c tor J

N o t OK

Overhaul the j u n c t i o n unit 4

The ideogram lights in the instrument panel are not working

Check 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 for t h e j u n c tion u n i n t 4 c o n n e c t o r J p i n 12

Not OK

Overhaul the j u n c t i o n unit 4

OK

Bridge t h e cables G N / G R c o l o u r e d cables at t h e l i g h t dimmer 5 8 ( N o n existent f o r for t h e S / S X trim level)

OK

Replace t h e l i g h t d i m m e r 5 8

Not O K

Check 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 at t h e l i g h t dimmer 5 8 ( N o n existent f o r the S / S X t r i m level)

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.

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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

Check the condition of the i n s t r u m e n t panel 6

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

C h e c k f o r v o l t a g e at t h e G N coloured cable for t h e s w i t c h panel 3 4

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

The ideogram in the switch panel is not working

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 f o r v o l t a g e at t h e G N coloured cable for t h e s w i t c h panel 3 4

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

Copyright by Fiat Auto

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

The ideogram on the cigar lighter is not woiking

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

Check 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 f o r t h e cigar lighter 6 9

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 bet w e e n t h e cigar l i g h t e r 6 9 & the ultrasound w e l d i n g

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

The radio light is not working

Check 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 at t h e j u n c tion u n i t 4 c o n n e c t o r J p i n 10

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

Check 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 at c o n n e c t o r A for t h e radio 4 8

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

Overhaul the radio 4 8

4A507N

106

Print no.

506.670/02

2 5
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u U)

Bravo-Brava

Fault diagnosis
Analytical charts

55D.
The fuel level gauge is not working

Bridge t h e H R / N Z c o l o u r e d cables at t h e fuel level g a u g e 5 6 A so t h a t t h e pointer o n t h e i n s t r u m e n t panel 6 g a u g e K signals t h e e n d of scale - full t a n k

OK

Overhaul or replace t h e f u e l level g a u g e 5 6 A

N o t OK

Bridge t h e N Z c o l o u r e d c a ble at t h e fuei level g a u g e 5 6 A w i t h a n earth

OK

Restore t h e c o n t i n u i t y f o r t h e NZ c o l o u r e d c a b l e b e tween the assembly 5 6 A & t h e rear earth 1 9

N o t OK

Bridge t h e HR coloured c a ble at c o n n e c t o r 2 8 w i t h a n earth so t h a t 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 o f scale - f u l l tank

OK

Restore t h e c o n t i n u i t y o f t h e HR c o l o u r e d c a b l e b e t w e e n connector 2 8 & t h e fuel level gauge 5 6 A

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

Restore c o n t i n u i t y f o r t h e HR c o l o u r e d c a b l e b e t w e e n the instrument panel 6 c o n nector B & c o n n e c t o r 2 8

N o t OK

4AB11N

Copyright by Fiat Auto

109

Analytical charts

Fault diagnosis

Bravo-Brava

55D.

Check t h e c o n d i t i o n of t h e fuel level w a r n i n g l i g h t K in the f u e l level circuit J in t h e i n s t r u m e n t panel 6

N o t OK

O v e r h a u l or replace t h e w a r n i n g light K or t h e circuit J in t h e i n s t r u m e n t panel 6, 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 engine coolant temperature gauge is not working

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

Restore t h e c o n t i n u i t y of t h e HB coloured cable between connector 55 & temperature sensor 1 5 8

Not O K

4A512N

110

Print no. 506.670/02

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

The handbrake applied is not being signalled

Bridge the BN c o l o u r e d cable at t h e s w i t c h s i g n a l l i n g handbrake applied 9 0 w i t h an earth

OK

Replace t h e s w i t c h 9 0 or r e store the c o n n e c t i o n to earth

Copyright by Fiat Auto

111

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
Not O K

Bridge t h e B N c o l o u r e d c a ble at c o n n e c t o r 2 8 w i t h an earth

OK

Restore t h e c o n t i n u i t y f o r the B N c o l o u r e d cable b e tween connector 28 & switch 90

Not O K

Bridge t h e B N 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 5 w i t h an earth

OK

Restore c o n t i n u i t y f o r t h e B N c o l o u r e d cable b e t w e e n t h e i n s t r u m e n t panel 6 c o n nector B & c o n n e c t o r 2 8

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

The insufficient brake fluid level is not signalled

Bridge t h e B N / N c o l o u r e d cables at t h e s w i t c h s i g nalling insufficient brake f l u i d level 8 8

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

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 s w i t c h 8 8 & t h e left f r o n t earth 8 8

Not O K

Bridge t h e B N 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 A pin 2 w i t h an earth

OK

Restore t h e c o n t i n u i t y f o r t h e B N c o l o u r e d cable b e tween the instrument panel 6 connector A & switch 88

4A514N

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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

The insufficient engine oil pressure warning light is not working

Bridge the HG coloured c a ble at t h e i n s u f f i c i e n t e n g i n e oil pressure sensor 1 4 2 w i t h an earth

OK

Replace t h e i n s u f f i c i e n t e n g i n e oil pressure sensor 1 4 2

Not OK

Bridge the H G coloured c a ble at c o n n e c t o r 5 5 w i t h an earth

OK

Restore t h e c o n t i n u i t y f o r t h e HG c o l o u r e d c a b l e b e tween connector 55 & switch 142

Not OK

Bridge the HG coloured c a ble at t h e i n s t r u m e n t panel 6 connector A p i n 12 w i t h an earth

OK

Restore c o n t i n u i t y f o r t h e HG coloured cable b e t w e e n t h e i n s t r u m e n t panel 6 c o n nector A & connector 5 5

Not OK

Check the c o n d i t i o n of t h e insufficient e n g i n e o i l pressure w a r n i n g l i g h t B in t h e instrument panel 6

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

Copyright by Fiat Auto

113

Analytical charts

Fault diagnosis

Bravo-Brava

55D.
The left front brake pad wear warning light is not working

Bridge t h e BR c o l o u r e d c a ble at c o n n e c t o r 8 9 A w i t h an earth

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

Bridge t h e BR 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 c o n n e c t o r A p i n 8 w i t h an earth

OK

Restore 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 cable b e t w e e n the i n s t r u m e n t panel 6 c o n nector A & c o n n e c t o r 8 9 A

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)

Bridge t h e BR 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 A pin 8 w i t h an earth

OK

Restore cont. for BR c o l o u r e d 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 & the ultrasound w e l d i n g

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

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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)

Bridge t h e BR c o l o u r e d c a ble at c o n n e c t o r 8 9 A w i t h an earth

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

Bridge t h e BR 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 p a n e l 6 c o n n e c t o r A p i n 8 w i t h an 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)

Bridge t h e BR c o l o u r e d c a ble at c o n n e c t o r 1 8 2 A w i t h an earth

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

Bridge t h e BR c o l o u r e d c a ble at c o n n e c t o r 13 w i t h an 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 13 & c o n nector 1 8 2 A

N o t OK

Bridge t h e BR 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 p a n e l 6 c o n n e c t o r A p i n 8 w i t h an 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 13 & the ultrasound w e l d i n g

Copyright by Fiat Auto

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

The speedometer is not working

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

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 sensor 1 3 7 & t h e r i g h t f r o n t earth 9

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

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 c o n n e c tor 5 5

Not OK

Restore c o n t i n u i t y f o r t h e C N coloured cable between connector 55 & the instrum e n t panel 6 c o n n e c t o r A

116

Print no. 506.670/02

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

Copyright by Fiat Auto

117

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Bravo-Brava

TD

Electrical system
55.
page

Contents

- Wiring diagrams - Connector blocks -Key

1 31 36

Copyright Fiat Auto

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

Main beam headlamps

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

Turbo compressor pressure

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

Handbrake on and l o w brake f l u i d level Front f o g l a m p s

Right i n d i c a t o r

A.B.S.

(O)

Brake pad wear

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

A u t o transmission fluid temperature

Electric s u n r o o f

Handbrake on and l o w brake f l u i d

120 Km/h

S p e e d limits

Catalytic temperature

converter

Recharging

Fuel g a u g e

Resistor

Coolant temperature Engine oil pressure Diode

Copyright Fiat Auto

Wiring diagrams

Electrical system

Bravo-Brava

TD

55.
Electrical symbols

Trip computer control Warning light

Differential l o c k

Bulb

Electronic tion

fuel

injec-

A u t o transmission fluid temperature

Fuse

Engine o i l level

00'
level

Temperature

Switch open

BRAKE

Brake fluid ( J a p a n version)

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

Sport function trolled damping pension

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

A.B.S. (Japan version)

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

Publication no. 506.670/06

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

Analogue fuel gauge

Analogue coolant perature g a u g e

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

Copyright Fiat Auto

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
N.U.
AR
L

40
STOP

RN R H - - RN 1

96

RN
RU

m
1 2 3 4 5 6 7 8 31011121314

RU RNl

* 95

B
- RU

[D H

181

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20
]

CB

AR

N.D.
II - * 1 1
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AR*

N.D.

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CB

f N.D.
!

CB
mt/i its |

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4

f N.D.

176
AR
17

RU
13

NZ

NZ

44

N.D.

174

12 3
n
G

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03 H

CO) 178'
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

180 { J

Publication no. 506.670/06

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TD

Electrical system
Connector blocks

55.

CONNECTOR BLOCKS *

INTRODUCTION

page

I n t e r p r e t a t i o n o f t h e codes o n the c o n n e c t o r blocks Wiring colour code Connector blocks

58 58 59

* W i t h regard t o t h e 1 9 1 0 T u r b o D e n g i n e , t h e c o n n e c t o r b l o c k s have been a d d e d f r o m t h e p r e v i o u s p u b l i c a t i o n ; f o r aspects n o t c o v ered, refer t o t h e B r a v o - B r a v a p u b l i c a t i o n n o . 506.670/02.

4A57ZL

Copyright Fiat Auto

31

Electrical system
Connector blocks

Bravo-Brava

TD

55.
INTRODUCTION

Interpretation of the codes on the connector blocks

Connector block identification n u m b e r referring t o t h e w i r i n g d i a grams Cable c o l o u r i d e n t i f i c a t i o n c o d e

I d e n t i f i c a t i o n n u m b e r o f t h e cable's destination block

T h e a b b r e v i a t i o n n.d. identifies a n ultrasound-soldered joint taped into the wiring loom

Cable colour codes A B C G H L M N R S V Z AB AG AN AR AV


4A58ZL

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

Publication no. 506.670/06

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

Heated diesel filter control relay

R 127

NZ127

240

20A fuse protecting heated diesel filter control relay

242

u e

' ' j

e c t

' n control relay

Rn.d

N222

243

Engine advance adjustment solenoid

244

Fast idle adjustment solenoid

Copyright Fiat Auto

33

Electrical system
Connector blocks

Bravo-Brava

TD

55.
241 ^
u e

'P

electronic control unit

SB 244.

245

E.G.R. solenoid

246

Heated fuel filter

HV249 * HV241

Variant connections for 100 BHP version

247

Heated fuel filter thermal contact

248

Potentiometer on fuel pump

Gll.(t.*V241 * -

G249 V249

AR 241 * - A R 249

Variant connections for 100 BHP version

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

G 248 . VG 157 . B n.d.. . AR 248 . MG 55

r s ra ta
R n.d. BR 139 V 248 .

E I

la

BD

E I

T _

HV 245 N222 Cn.d.

251

Thermal switch for K.S.B.

252

Earth for K.S.B. device

C 251

253

R '

a v

f switching off compressor

HN 127 HG55

P4A612L01

Copyright Fiat Auto

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

Electrical s y m b o l s H o w t o read t h e w i r i n g d i a g r a m s Wiring diagrams Key t o w i r i n g d i a g r a m s

1 4 5 37

Copyright Fiat Auto

Bravo-Brava

Electrical system
55.

Wiring diagrams

Electrical symbols

S i d e lights

11 X

C h o k e (starter)
31)

'" 1 Switch discharge

15

ID

M a i n beam

Water i n fuel filter

to

Dipped headlamps

H e a t e d seat

Heater p l u g

Indicators flashing w i t h central d o o r l o c k ing

S e a t belts

Compressor turbo pressure

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

H a n d brake o n a n d l o w b r a k e f l u i d level Front f o g lamps Right 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

A u t o transmission fluid temperature

Electric s u n r o o f

Handbrake on and l o w brake f l u i d level

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

Engine c o o l a n t temperature gauge

Diode

Copyright Fiat Auto

Wiring diagrams

Electrical system

Bravo-Brava

55.
Electrical symbols

Trip computer control Warning light

Differential lock

Bulb

Electronic i n j e c t i o n

A u t o transmission fluid temperature

Fuse

Engine o i l level

00'

Temperature

Switch open

BRAKE

Brake f l u i d level (Japan version)

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

S p o r t f u n c t i o n o n electronic suspension system

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

A.B.S. (Japan version)

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

Publication no. 506.670/14

Bravo-Brava

Electrical system
55.

Wiring diagrams

Electrical symbols

388

D i g i t a l speedometer

limi") WIN I Digital rev c o u n t e r

Digital fuel gauge

IIIIIIIIIIIII

2l2

A n a l o g u e fuel g a u g e

Analogue coolant perature 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

Copyright Fiat Auto

Wiring diagrams

Electrical system

Bravo-Brava

55.
How to read the wiring diagrams

177
10
63

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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

DOOR LOCK D E V I C E R e m o v i n g - r e f i t t i n g central l o c k i n g ECU 91

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

11-98 - Supersedes previous version

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

E L E C T R I C A L L Y - O P E R A T E D DOOR MIRRORS R e m o v i n g - r e f i t t i n g d o o r mirror 111

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

C O P Y R I G H T Fiat A u t o S.p.A. T o t a l or partial r e p r o d u c t i o n o f t h e text or i l l u s t r a t i o n s is f o r b i d d e n . T h e i n f o r m a t i o n in t h i s p u b l i c a t i o n is i n t e n d e d as a g u i d e a n d c o u l d b e superseded as a result o f m o d i f i c a t i o n s a d o p t e d b y t h e M a n u f a c t u r e r at a n y t i m e d u e t o t e c h n i c a l a n d c o m m e r c i a l reasons a n d in a c c o r d a n c e w i t h local r e g u l a t i o n s .

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

134 134 134/1 134/2 134/2 134/2

Fiat Auto S.pA


D.M.C. - M.P.S. Servizi Post Vendita - Tefcnologie Assistenziali Largo Senatore G . Agnelli, 5 - 1 0 0 4 0 Volvera - T O (Italia) Print n o . 5 0 6 . 6 7 0 / 1 4 - Marzo 1 9 9 8 - 7 5 0 Printed by Satiz S.p.A. - Turin (Italy) n ordinazione * 6 0 4 . 4 5 . 8 3 2 *

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.

Copyright Fiat Auto

Electrical system
Instrument panel

Bravo-Brava

55.
INSTRUMENT PANEL FOR S , S X VERSIONS

888888 8888

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F r o n t o f c o n t r o l panel 1 . Fuel g a u g e 2. C o o l a n t t e m p e r a t u r e g a u g e 3. D i r e c t i o n indicators w a r n i n g l i g h t s 4 . A n a l o g u e s p e e d o m e t e r a n d d i g i t a l t r i p recorder 5. W a r n i n g lights (see page 1 3 ) 6. W a r n i n g l i g h t s (see page 1 3 )

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Publication no.

506.670/01

Bravo-Brava

Electrical system
Instrument panel

55.

Rear side (showing the connector sockets 10

n n nnnn n n nn n n n

+ + +

4-

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

Copyright Fiat Auto

Electrical system
Instrument panel

Bravo-Brava

55.
INSTRUMENT PANEL FOR EL, ELX VERSIONS

<y

IO

^ | 3 *c= '

t*

G (D (a s <& C)

Front 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 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

o o < s > @ o Rear side ( s h o w i n g the connector s o c k e t s 10

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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 BR VN
-

C
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
-

NZ

CN L HB
-

HR AR LG

Not connected
Anti-lock braking s y s t e m

RV
-

Not connected

Copyright Fiat Auto


/

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

INSTRUMENT PANEL FORG T VERSION

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.
w

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Wiring diagram

Copyright Fiat Auto

Electrical system
Instrument panel

Bravo-Brava

55

n n n (inn nil flu

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+ ++ +

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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 HN B,N LN

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

Circuit involved M a i n beam headlamps Panel s y m b o l l i g h t s Side lights Not connected


Emergency brake-brake fluid level

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

Brake pad wear

Fiat C o d e Plug preheating

AN A N

HG HN

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 Rev c o u n t e r s i g n a l


Coolant temperature

NZ

CN L HB

HR AR LG

RV

Not connected A n t i - l o c k braking system Water in fuel (diesel)

On t h e i n s t r u m e n t p a n e l f i t t e d t o t h e t u r b o diesel v e r s i o n s , t h e f u l l scale o n t h e s p e e d o m e t e r a n d rev counter are 2 2 0 k m / h a n d 6 0 0 0 r p m respectively.

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 )

Copyright Fiat Auto

Electrical system
Instrument panel

Bravo-Brava

55

10

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Wiring diagram

10

Publication no. 506.670/01

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

Connector B N pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 HR AR LG Wiring colours VN GR GN BN GR N AN A N NZ Circuit involved M a i n beam h e a d - l a m p s


Control panel symbol lights

Side lights Not connected


Emergency brake/brake fluid level

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
_

Copyright Fiat Auto

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 .

F u e l level gauge Setting test values Indicator position 4 / 4 (F) V a l u e in O h m s 16 6 140 12

1/2 Reserve b e g i n s 0(E)

240 5 292.5 1 5

HR
A .
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F u e l level g a u g e w i r i n g d i a g r a m

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+15

112

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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

Engine coolant temperature gauge

Gauge scale

Average resistance value (ohm)

Indicator o f f

2000 - 500

1 7 5 15

7 4 . 5 5.5

12

X-95 - Supersedes pruuous

version

Publication no. 506.670/04

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

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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

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1. 2. 3. 4. 5. 6. 7.

A i r Bag f a u l t w a r n i n g l i g h t 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 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 l i g h t S t o p lignts f a u l t w a r n i n g l i g h t

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

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1. 2. 3. 4. 5. 6.

Plug preheating w a r n i n g light 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 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 r e c h a r g i n g w a r n i n g l i g h t L o w e n g i n e o i l pressure 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

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

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 r e c h a r g i n g 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 l i g h t S i d e lignts w a r n i n g l i g h t H a n d b r a k e o n / l o w brake f l u i d level w a r n i n g light

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

Copyright Fiat Auto

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

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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

Copyright Fiat Auto

15

Electrical system
Fuse, relay and control units

Bravo-Brava

55.
List of f u s e s and main protected circuits

Fuse Amp. Symbol no.


1 15

Protected circuit

Fuse Amp. Symbol no.


6 10

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

Right main beam.

10

Left m a i n b e a m beam headlamps light. Rear f o g lamps.

- 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.

H e a t e d rear w i n d o w - Heated rear w i n d o w warning light - Mirror demisting (if present).

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

Right dipped beam - Headl a m p adjusters.

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.

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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

E 1 . I g n i t i o n s w i t c h d i s c h a r g e relay E2. H o r n relay E3. Heated rear w i n d o w relay

Copyright Fiat Auto

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

T o r e m o v e a n d refit t h e u n i t s s h o w n o n this p a g e , consult Section 33 (Braking system).


P4A018L02

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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 .

Copyright Fiat Auto

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.

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Electrical system
Lighting

55.

Disconnect the connection i n d i c a t e d and r e m o v e t h e rear l i g h t s cluster f r o m t h e car.

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.

Copyright Fiat Auto

25

Electrical system
Lighting

Bravo-Brava

55.

Removing-refitting (5-door version)

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

D.M.C. - M.P.S. - Servizi Post Tecnica

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

55.13.96 Fiat Brava 5540 A 461 AE LIGHT CLUSTER

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.

above for the trim on

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

Finish refitting the instructions

the parts by for tail light

reversing removal.

Copyright Fiat Auto

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

1. U n d o the screw indicated a n d remove t h e trim.

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 a n d w i t h d r a w t h e bulb holder unit f r o m the car.

3. Replace t h e b u l b s c o n c e r n e d .

Copyright Fiat Auto

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 .

2. U n d o t h e plastic n u t s s e c u r i n g t h e a d d i t i o n a l s t o p light t o t h e tailgate.


O P4A028L02

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.

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Bravo-Brava

Electrical system
Lighting

55.

P4A029L04

P4AO29L05

Copyright Fiat Auto

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

Carry o u t o p e r a t i o n s 1 , 2, 3 d e s c r i b e d o n t h e p r e v i o u s page. 1 . U n d o t h e c o v e r l o c a t e d at t h e rear o f t h e f r o n t f o g l a m p assembly. 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 i o n i n d i cated. 3 - 4 . T u r n t h e lever i n d i c a t e d w h i c h locks t h e b u l b in q u e s t i o n . 5. W i t h d r a w t h e b u l b f r o m t h e b u l b h o l d e r .

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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

Copyright Fiat Auto

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

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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.

3. Lift t h e w i n d s c r e e n w i p e r m o t o r p r o t e c tion and disconnect the connector indicated.

Copyright Fiat Auto

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

Replacing w i n d s c r e e n w i p e r blades 4 . T o replace t h e w i n d s c r e e n w i p e r blades, press t h e b u t t o n s h o w n in t h e f i g u r e , a n d w i t h d r a w in t h e d i r e c t i o n o f t h e a r r o w .

34

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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.

Copyright Fiat Auto

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

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Publication no.

506.670/01

Bravo-Brava

Electrical system
Various devices

55.

STALK UNIT Removing-refitting (for versions without NOTE Air Bag)

For versions with Air Bag, refer to the relevant sub-section.

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.

Copyright Fiat Auto

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 .

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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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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 ) .

These bolts assembly.

must

be renewed

during

4 . R e m o v e t h e s w i t c h f r o m t h e car. R e m o v i n g - r e f i t t i n g ignition s w i t c h c o n t a c t block 5. Carry o u t o p e r a t i o n 2 . D i s e n g a g e t h e b l o c k f r o m t h e car as s h o w n in t h e f i g u r e .

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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).

REVERSING LIGHTS SWITCH 3. 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 u n d o t h e g e a r b o x s w i t c h , t a k i n g care t o a v o i d leakage o f o i l .

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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

1-2. Fit t h e t o o l 1 8 6 0 8 9 3 0 0 0 o n t h e f u e l g a u g e sender unit a n d r e m o v e t h e a t tachment ring nut. 3. R e m o v e t h e f u e l g a u g e s e n d e r u n i t f r o m t h e car.

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

SOCKET FOR CONNECTOR A Pin no.


5 6 7 8 NOTE Service Lighting Supply: positive Supply: negative (earth) The pins not mentioned in the tables are not

SOCKET FOR CONNECTOR B Pin no.


3 4 5 6 connected. C o d e s relating t o the v a r i o u s w a v e b a n d s or ranges Code M L W a v e band a n d r a n g e Medium wave Long wave Frequency m o d u l a t i o n M a n u a l search f o r t r a n s m i t t i n g stations Frequency m o d u l a t i o n 1
=

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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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) (*)

(*)

The DOLBY noise reduction censing Corporation. DOLBY

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
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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.

p n m 10
s / >

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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;

ADJUSTING THE TONE

- 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

The "BASS"and "TREB"settings between - 6 and + 6.

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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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

The values "BAL L"and and 15.

which can be set for "BAL R"are between 0

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.

A D J U S T I N G T H E F A D E R (balance bet w e e n f r o n t a n d rear s p e a k e r s )

C O "7

n u

Press t h e " A U D I O " s w i t c h ( 2 0 ) briefly a n d r e p e a t e d l y u n t i l t h e w o r d " F A D " appears o n t h e d i s p l a y (Fader a d j u s t m e n t selection).

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- 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

the last station

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.

Automatic programming (AUTOSTORE)

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.

RDS

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55.

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 .

In certain countries there are radio transmit traffic information.

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 =

If n o level or a m i n i m u m level of 5 is pre-set, t h e n level 5 is a u t o m a t i c a l l y s e l e c t e d .

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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

- press s w i t c h ( 2 2 ) , t o o p e n t h e housing protective flap;

cassette

insert t h e cassette p r o p e r l y in t h e h o u s i n g , m a k i n g sure t h a t it is c o r r e c t l y in place; t h e r e p r o d u c t i o n w i l l start a n d t h e w o r d " T A P E " w i l l appear o n t h e d i s p l a y .

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 ;

- t o close t h e cassette h o u s i n g , press in a vertical d i r e c t i o n at t h e p o i n t s h o w n b y t h e s y m b o l a b o v e t h e h a n d in t h e d i a g r a m at the side ( 2 5 ) w i t h t h e f l a p c l o s e d u n t i l t h e r e t a i n i n g s p r i n g is heard t o c l i c k .

Changing cassette side

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.

L i s t e n i n g to t h e radio w h i l s t f a s t f o w a r d ing / r e w i n d i n g t h e t a p e 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 a t a p e , t h e last s t a t i o n t u n e d i n t o w i l l be heard.

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 .

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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.

Filling t h e C o m p a c t D i s c loader - Extract a s u p p o r t f o r each c o m p a c t disc t h a t y o u w i s h t o play;

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).

T o insert t h e loader in t h e c o m p a c t d i s c p l a y er, p r o c e e d as d e s c r i b e d b e l o w : - slide t h e f l a p A t o w a r d s t h e r i g h t , as i l l u s trated in t h e d i a g r a m , until it is n o t l o c k e d ; - c h e c k t h a t t h e s w i t c h B is in p o s i t i o n " 1 " ;

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insert t h e loader C in t h e c o m p a c t d i s c player w i t h t h e side w i t h t h e label (see arrow) upwards;

/T

<> 5
a

close t h e s l i d i n g flap A after h a v i n g inserted t h e loader t o prevent f o r e i g n b o d i e s a n d d u s t f r o m e n t e r i n g the player.

Eextracting player

loader

from

Compact

Disc

Proceed as illustrated b e l o w : - slide t h e f l a p A t o w a r d s t h e r i g h t , as i l l u s trated in t h e d i a g r a m , u n t i l it is n o t l o c k e d ; - act o n t h e eject b u t t o n ( s h o w n b y t h e arr o w ) o n t h e C o m p a c t D i s c player.

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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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 .

// the fast condition mentioned certain period of time.

above

occurs,

it is advisable

to switch

off the CD player

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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Scanning tracks (SCAN Function)

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.

- press t h e " T R K " s w i t c h ( 1 0 ) b r i e f l y ( t h e LED u n d e r t h e s w i t c h w i l l g o o u t ) t o exit from this mode.

Copyright by Fiat Auto

50/19

Electrical equipment
Radio equipment

Bravo-Brava

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.

- press t h e " R P T " s w i t c h ( 1 1 ) again ( t h e LED under t h e s w i t c h w i l l g o o u t ) t o e x i t f r o m this m o d e .

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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Radio equipment

55.
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.

Copyright by Fiat Auto

50/21

Electrical equipment
Radio equipment

Bravo-Brava

55.

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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Radio system

55.
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;

- press b u t t o n " 1 " t w i c e . T h e n u m b e r s h o u l d appear o n t h e d i s p l a y ;

"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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Electrical equipment
Radio system

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55.
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

Eliminating anti-theft protection It is p o s s i b l e t o e l i m i n a t e t h e a n t i - t h e f t p r o t e c t i o n b y d e - a c t i v a t i n g t h e radio c o d e : - s w i t c h o n t h e radio b y pressing t h e " O N " button ( 2 3 ) ;

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55.
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=
'I
2| 3| 4| 5| 6| 7| 8|

Musical power output Nominal power output Impedance

3|

sl 6|

7| 8|

,
Pin N
1 2 3 4 5 6 7 8

2D

4 Ohm

4|

CON. A HOUSING Connection


NC NC + Service + Controlled by ig. + Service + Lighting Supply + 30 Right dashboard earth

CON. B HOUSING Pin N


1 2 3 4 5 6 7 8

CON. C HOUSING Pin IM


13 14 15 16 17 18 19 20

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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Electrical equipment
Radio system

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55.
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.

Earth in Radio Speaker Speaker Speaker

right d a s h b o a r d in left d o o r o n left side o f d a s h b o a r d o n right side o f d a s h b o a r d

6. 7. 8. 9. 10. 11.

Speaker in r i g h t d o o r Battery s u p p l y ( + 3 0 ) Lighting supply Key s u p p l y ( + 1 5 ) Aerial Left rear speaker

1 2 . R i g h t rear speaker 13. Connection with compact disc

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Radio system

55.
R E M O V I N G R A D I O M O D E L A D 182 L

1 . T o o l 1 8 6 0 8 9 7 0 0 0 , w h i c h s h o u l d b e used t o remove t h e radio, is c o m p o s e d o f a r i g h t element a n d a left o n e , marked w i t h t h e letters R a n d L, respectively.

NOTE

The correct direction in which to use each element is shown by an arrow.

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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Electrical equipment
Radio equipment

Bravo-Brava

55.
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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55.
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 .

2. A t t h i s p o i n t press o n t h e radio c o w l i n g as illustrated in t h e d i a g r a m , until t h e r e t a i n ing s p r i n g s are heard t o c l i c k a v o i d i n g u s ing f o r c e o n t h e c o n t r o l s w i t c h e s .

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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REMOVING-REFITTING SPEAKERS S p e a k e r s in d a s h b o a r d 1 . R e m o v e t h e p r o t e c t i v e grille f r o m t h e d a s h b o a r d u s i n g 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 t h e arrow. 2. U n d o t h e b o l t s f i x i n g t h e speaker t o t h e dashboard. 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 remove t h e Speaker f r o m t h e v e h i c l e .

Rear speaker 4 . U n d o t h e b o l t s f i x i n g t h e speaker, a n d r e m o v e it f r o m t h e v e h i c l e after h a v i n g d i s c o n n e c t e d t h e electrical c o n n e c t i o n f o r t h e s u p p l y cables.

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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.

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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 .

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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 .

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1. 2. 3. 4.

C O D E w a r n i n g l i g h t o n i n s t r u m e n t panel I g n i t i o n s w i t c h w i t h aerial Fiat C O D E c o n t r o l u n i t Key w i t h t r a n s p o n d e r

5. E n g i n e c o n t r o l u n i t A . 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 ( p e t r o l ) or f u e l i n j e c t i o n p u m p c o n t r o l u n i t (diesel) B. Electrostop (diesel) 6. C O D E Card 7. F i a t / L a n c i a Tester

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.

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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 .

Under no circumstances may whether they are working.

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 ) .

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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

Electronic keys 1. 2. 3. 4. Master key ( m a r o o n c o l o u r ) M a i n key Key w i t h r e m o t e c o n t r o l Transponder

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 ) .

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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

of the car is advised

to CLOSELY

follow

the instructions car);

below:

- the MASTER - the MASTER

key must be stored key must be used

in a safe place only to memorize

(not in the new keys;

- 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 ) .

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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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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.

Insert t h e M A S T E R key ( m a r o o n ) in t h e i g n i t i o n s w i t c h , in t h e off ( S T O P ) p o s i t i o n .


P4A066L02

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 ( + 15) position; the CODE warning light c o mes o n f o r 0.7 s.


P4A064L02

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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 M A S T E R key f r o m t h e i g n i tion s w i t c h 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 a n d t u r n it t o t h e o n ( + 1 5 ) , p o s i t i o n ; t h e 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.


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W h e n the CODE w a r n i n g light goes out, turn t h e key ( 1 ) t o t h e i g n i t i o n off ( S T O P ) p o s i tion.

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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W h e n the C O D E w a r n i n g light goes out, turn t h e key ( 2 ) t o t h e i g n i t i o n o f f ( S T O P ) p o s i tion.

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.

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 off ( S T O P ) p o s i t i o n .

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 .

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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

CODE WARNING LIGHT POSITIVE RESULT

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

1,6 Hz 50% d.c.


ON

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.

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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.

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 at t h e i g n i t i o n off ( S T O P ) p o s i t i o n .

T u r n t h e M A S T E R key t o t h e o n p o s i t i o n ( + 1 5 ) ; the CODE warning light should come o n for 0.7 s.

W h e n the C O D E w a r n i n g light goes o u t , 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 .

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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.

W h e n the CODE warning light goes out, turn t h e key ( 1 ) t o t h e off ( S T O P ) p o s i t i o n .

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.

W h e n the CODE warning light goes out, turn t h e key ( 2 ) t o t h e i g n i t i o n o f f ( S T O P ) p o s i tion.


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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

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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

sure that the fuel injection unusable on

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.

Copyright Fiat Auto

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.

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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

Serial line not connected

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 ) .

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Electrical system
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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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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-

T h i s 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 o n l y o n c e , b u t it c a n be repeated a n u n l i m i t e d n u m ber o f t i m e s .

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

unit control units be exchanged between cars to check

Under no circumstances may engine whether they are working.

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

Replacing the Fiat CODE ing the "Key memorization

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-

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Electrical system
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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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- 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-

key is lost or its Transponder

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

with the car, as

Copyright Fiat Auto

11

Electrical system
Fiat CODE

Bravo-Brava

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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 )

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 Engine 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 .

M e c h a n i c a l breakage

The transponder from the broken M A S T E R k e y is inserted in t h e h a n d l e o f t h e M A S T E R k e y in the n e w set.

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 .

Spare key available or f o u n d by the customer

easily

yes-

no

C o d e Card available

yes

Set of 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 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.

The Fiat C o d e c o n t r o l u n i t a n d the engine c o n t r o l unit must be replaced a n d t h e e l e c t r o n i c keys memorized.

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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 )

Spare key available f o u n d by customer

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

Spare key available or f o u n d b y the c u s t o m e r no

easily

yes

T h e spare key is u s e d a n d possess i o n of t h e car is r e g a i n e d . F o l l o w 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 o reset t h e key set.

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 .

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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-

Set of keys w i t h o l d mechanical code available as spare no

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 .

Available spare key yes

no

yes-

Set of keys w i t h o l d mechanical code available as spare no

Code Card available yes

no

Set of keys w i t h o l d y e s - ^ mechanical c o d e available as spare

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

Set of keys w i t h o l d mechanical c o d e available as spare no

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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

O t h e r keys in t h e c u s t o m e r ' s p o s session are easily o b t a i n a b l e yes

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.

Key set w i t h o l d m e c h a n i c a l c o d e a v a i l a b l e as spare

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.

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55.
Aerial o n ignition s w i t c h faulty

Replace t h e aerial L o s s of C o d e C a r d yes

Code a v a i l a b l e ( t r a n s c r i b e d e l s e w h e r e ) ^no It is n o t possible t o have a d u p l i c a t e . It is i m possible t o activate t h e e m e r g e n c y p r o c e d u r e

It is n o t p o s s i b l e t o h a v e a d u p l i c a t e . If necessary, it is possible t o a c t i v a t e t h e e m e r g e n c y procedure

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

Fuel i n j e c t i o n fault 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 possible to activate the EMERGENCY p r o c e d u r e f r o m t h e accelerator p e d a l

Fiat C o d e c o n t r o l unit f a u l t y

Replace t h e Fiat C o d e c o n t r o l u n i t a n d carry out the R E M E M O R I Z A T I O N procedure, m e m o r i z i n g t h e keys a g a i n

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 )

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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.

*. Variant c o n n e c t i o n s f o r E L / E L X / H G T versions * . Variant c o n n e c t i o n s for 1 5 8 1 v e r s i o n

***. V a r i a n t c o n n e c t i o n s for 1 7 4 7 v e r s i o n * * * * . V a r i a n t c o n n e c t i o n s for 1 9 9 8 v e r s i o n

4. 6. 131. 139. 140.

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

unit unit unit

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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

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55.

P4A085L03

P4A085L04

Copyright Fiat Auto

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 )

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Diagram of hot-wire device

0 111111

* O n l y o n diesel versions
P4A087L01

3. 10. 11. 96. 119. 129. 143. 145. 201.

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

Copyright Fiat Auto

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

Publication no. 506.670/01

Bravo-Brava

Electrical system
Electric windows

55.

P4A089L04

Copyright Fiat Auto

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

3. 4. 10. 11. 12. 19. 22.

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

Publication no. 506.670/07

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.

Copyright Fiat Auto

91

Electrical equipment 55!

Bravo-Brava

92

11-98 - Supersedes previous version

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

Copyright Fiat Auto

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

II-98 - Supersedes previous version

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

Copyright Fiat Auto

It-SB Supersedes previoub version

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 .

P4A096L01

1. 2. 3. 4. 5.

Steering w h e e l Gas g e n e r a t o r Air bag installation plate Bag Bag c o v e r

96

Publication no.

506.670/74

Bravo-Brava

Electrical system
Air bag

55.

P4A097L01

1. 2. 3. 4.

A i r Bag m o d u l e Cushion I n f l a t i o n device Triggering device

5. Explosive c h a r g e ( s o d i u m n i t r i d e ) 6. Gas g e n e r a t o r m o u n t i n g plate 7 . T i l t i n g plate f o r h o r n

T h e i n n o v a t i o n o n t h i s s t e e r i n g w h e e l is t h e h o r n c o n t r o l , w h i c h is in a c e n t r a l p o s i t i o n a n d is of t h e t i l t ing type. T h e h o r n is h o u s e d in t h e c e n t r e a n d , by m e a n s of a t i l t i n g p l a t e s e c u r e d t o t h e b o t t o m of t h e A i r B a g p r o t e c t i o n , it permits o p e r a t i o n o f t h e d e v i c e . Four s p r i n g s l o c a t e d o n t h e e n d s p r o v i d e t h e e l e c t r i c a l contacts.

Copyright Fiat Auto

97

si

Electrical system
Air bag

Bravo-Brava

*5P A S S E N G E R ' S AIR BAG M O D U L E

P4A098LO1

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)

P4A098L02

98

Publication no.

506.670/01

Bravo-Brava

Electrical equipment
Air bag

55.
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

the modules resistances.

must be

discon-

Copyright Fiat Auto

II 08

Supersedes previous vi-ision

99

Electrical equipment
Air Bag

Bravo-Brava

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.

If t h e c o n t r o l u n i t is r e p l a c e d , r e m o v e t h e a d h e s i v e label f r o m t h e c o n t r o l u n i t a n d stick i n t h e a p p r o p r i a t e file as described a b o v e .

NOTE

After

working

on the system,

check

operation

by means

of a FIA TI LANCIA

TESTER.

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Action following an accident If any c o m p o n e n t o f t h e safety s y s t e m is d a m a g e d f o l l o w i n g an a c c i d e n t , it M U S T be r e p l a c e d . Never a t t e m p t t o repair t h e c o n t r o l u n i t , c l o c k s p r i n g or air b a g m o d u l e s .

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

to test the continuity resistances.

of system

components

unless

modules

have been

replaced

C Never repair A i r B a g m o d u l e s . S e n d all d e f e c t i v e m o d u l e s t o t h e supplier. D D o n o t heat t h e air b a g m o d u l e , e.g. b y w e l d i n g , p e r c u s i o n , d r i l l i n g , m a c h i n i n g etc.

- 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 .

Foreign markets Check c u r r e n t local l e g i s l a t i o n f o r f o r e i g n m a r k e t s a n d i n f o r m dealers.

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.

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i

105

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H5WIRING DIAGRAM

Fl

116
1 C 14 C

rI13

))J - 1 1 2 -

15A

115

o , o

B18 B l ? C4

133 213

-<CZD>-

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.

J u n c t i o n unit I n s t r u m e n t panel A i r bag control unit Passenger's air b a g Driver's air b a g

130. 133. 213. 231.

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

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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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1 . Remove t h e air b a g f r o m t h e s t e e r i n g wheel.

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

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Electrical equipment
Air bag

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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Electrical equipment
Air bag

Bravo-Brava

REFITTING CLOCK SPRING

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 .

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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.

Copyright Fiat Auto

110/3

Electrical equipment
Air bag
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 .

Thread fittings steering avoid

the horn lead through around the edge of wheel compartment fouling.

the the to

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Bravo-Brava

Electrical equipment
Air bag

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 .

Copyright Fiat Auto

110/5

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Air bag

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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 .

Check system panel warning

operation light goes

by off.

ensuring

NEVER UNTIL PLETE. NOTA

CONNECT THE BATTERY INSTALLATION IS COM-

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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Publication no.

506.670/14

Electrical system
Lighting

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

Copyright Fiat Auto

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Electrical system
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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 .

Location of components and wiring loom for electric headlamp adjuster

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

12. 13. 22. 42. 43. 44. 45.

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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Electrical system
Lighting

55.
HEADLAMP ALIGNMENT

A . S c r e w for h o r i z o n t a l h e a d l a m p b e a m a d justment B. S c r e w for vertical h e a d l a m p b e a m a d j u s t ment.

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 ) .

Copyright Fiat Auto

21

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Electrical equipment
Air bag

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 .

Copyright Fiat Auto

II-98 - Supersedes previous version

110/7

Electrical equipment
Air bag

Bravo-Brava

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

U n s c r e w t h e b o l t s f a s t e n i n g t h e air b a g t o the body. R e m o v e t h e air bag f r o m t h e car.

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.

NEVER UNTIL PLETE

CONNECT THE INSTALLATION

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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Bravo-Brava

Electrical equipment
Air bag

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-

Copyright Fiat Auto

11-98 - Supersedes previous version

110/9

Electrical equipment
Air bag

Bravo-Brava

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).

2. R e m o v e t h e t u n n e l t r i m f r o m t h e car as d e s c r i b e d o n p a g e 3 0 of S e c t i o n 7 0 - B o d y work, then disconnect the connection by t u r n i n g t h e r e t a i n i n g lever in t h e a r r o w e d direction.

3. D i s c o n n e c t t h e e l e c t r o n i c c o n t r o l u n i t b y u n d o i n g the three 5 m m hexagonal-headed socket screws.

A
110/10 11-98 - Supersedes previous version

Tighten the control unit retaining bo its to a torque of 0.8 daNm.

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Electrical equipment
Air bag

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

Copyright Fiat Auto

11-98 - Supersedes previous version

110/11

Bravo-Brava

Electrical system
Electrically-operated rearview mirrors

55.

REMOVING-REFITTING REARVIEW MIRROR

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.

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 r e a r v i e w mirror t o t h e d o o r a n d r e m o v e it. <


P4A107L03

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Recharging

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55.
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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Electrical equipment
Recharging

55.

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

0 +20 +40 +60

+10

+110
C

P4A113L06

Electronic regulator ambient temperature

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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55Checking diodes Checking exciter diodes

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)

R e m o v i n g - r e f i t t i n g (1580 Position t h e right wheel. 3. U n d o t h e 4 . Raise t h e arch liner bolts.

16V

version)

v e h i c l e o n a lift a n d r e m o v e t h e upper b o l t f i x i n g t h e alternator. vehicle a n d remove t h e w h e e l after h a v i n g u n d o n e t h e f i x i n g

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4. U n d o t h e b o l t s f i x i n g t h e e n g i n e s u p p o r t to the bodyshell. 5. L o w e r t h e h y d r a u l i c jack t o a l l o w t h e r e m o v a l o f t h e alternator.


P4A119L03

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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55.

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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Raise t h e v e h i c l e 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 alternator.

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.

3. L o w e r t h e v e h i c l e a n d r e m o v e t h e u p p e r b o l t f i x i n g t h e alternator, t h e n extract it f r o m the vehicle.

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Before carrying out the removal procedures, described in this chapter, disconnect the negative battery terminal.

M . M A R E L L I E80-0.9/12 S T A T E R M O T O R (versions with 1370 12V; 1580 16V engine)

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)

1 . Raise t h e v e h i c l e a n d m o v e aside t h e p r o t e c t i v e b o o t f o r t h e starter m o t o r s u p p l y contacts.

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 .

3. U n d o t h e 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 a n d remove it f r o m t h e v e hicle.

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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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5. U s i n g a screwdriver, r e m o v e a n d e x t r a c t the rotor/pinion engagement fork assemb l y f r o m t h e starter m o t o r f r o n t s u p p o r t .


P4A128L03

P4A128L04

P4A128L05

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R e m o v e a n d l o w e r the safety r i n g s h o w n . R e m o v e t h e c i r c l i p f r o m t h e r o t o r shaft. R e m o v e t h e free w h e e l w i t h p i n i o n f r o m t h e rotor.

When refitting, the operations moval.

reverse the order carried out for the

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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55.
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 .
P4A131L02

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MARELLI E 95 RL-2.2/1.2 M O T O R (versions with 1747 20V; 1910 TD engines) R e m o v i n g - r e f i t t i n g ^ d d S 20V

STARTER 16V; 1998 engine)

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

Each time placed.

the starter

motor; makes

noises

during

starting,

the pinion

I free wheel

must

be

re-

STARTER MOTOR OPERATIONAL FAULT DIAGNOSIS


\

1. T h e motor d o e s not rotate T h e cause may be: - t h e battery t e r m i n a l s are o x i d i z e d ;

\
/

- starter motor s u p p l y cable t e r m i n a l slack;

- 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.

2. T h e motor r o t a t e s very s l o w l y T h e cause may be: ' \

- 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

Location o f emergency key NOTE

Circuit s w i t c h w i t h

L o c a t i o n of e l e c t r o n i c c o n t r o l \ u n i t a n d a l a r m in left w h e e l a r c h after having removed the lower dashboard cov-

The emergency circuit er, driver's side. I

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 ) .

4A237L

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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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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

to carry out the operations,

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

key is in the OFF position L E D flashing

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

Country Italy Germany France Switzerland United Kingdoin

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-

1) - O p e n t h e b o n n e t l i d ; 2) - t u r n t h e i g n i t i o n key f r o m t h e O N p o s i t i o n to the OFF position; 3) - w i t h i n 1 5 s e c o n d s m o v e o n t o t h e n e x t o p eration;

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 .

Entering the p a s s w o r d - T h e m e t h o d f o r e n t e r i n g t h e p a s s w o r d (see l o w e r i n s e t ) is as f o l l o w s : 1 . Press t h e b u t t o n o n t h e receiver f o r a r o u n d 2 s e c o n d s : t h e LED s h o u l d f l a s h .

2. Release t h e b u t t o n : after a r o u n d 2 s e c o n d s t h e LED s h o u l d flash briefly i n d i c a t i n g t h a t it is possible t o enter t h e first f i g ure of t h e p a s s w o r d .


P4A23AL02

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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 .

4 . A b o u t 2 s e c o n d s after t h e last i m p u l s e ( t h e f i f t h in t h e e x a m p l e ) t h e LED w i l l e m i t a n o t h e r flash t o request t h e i n p u t of t h e next figure ( t h e 2 ) . 2 impulses

5. 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 t i m e s as i n d i c a t e d b y t h e s e c o n d d i g i t of t h e p a s s w o r d ( f o r e x a m ple: 2 t i m e s ) ; 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 b r i e f l y t o g i v e a v i sual c o n f i r m a t i o n .

A b o u t 2 s e c o n d s after t h e last i m p u l s e ( t h e s e c o n d in t h e e x a m p l e ) t h e LED w i l l e m i t another flash t o request t h e i n p u t o f t h e next f i g u r e ( t h e z e r o ) .

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^ ^ ^ ^
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.

8. After a b o u t 2 s e c o n d s t h e L E D w i l l e m i t a n o t h e r f l a s h t o request t h e i n p u t o f t h e last f i g u r e ( t h e 3 ) . 3 impulses

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

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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".

2. T h e operator, still k e e p i n g t h e receiver b u t t o n pressed, s h o u l d press a n d release t h e b u t t o n f o r o n e of t h e r e m o t e c o n t r o l s w h i c h c o m e w i t h t h e v e h i c l e ( k e e p i n g it about 40 cm away).

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.

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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

- The m e t h o d f o r entering t h e p a s s w o r d is as follows: 1 . Press t h e b u t t o n in the receiver f o r a r o u n d 2 s e c o n d s : t h e LED s h o u l d f l a s h .

2. Release t h e b u t t o n : after a b o u t 2 s e c o n d s the LED w i l l flash briefly i n d i c a t i n g t h a t it is p o s s i b l e t o i n t r o d u c e t h e first f i g u r e of the p a s s w o r d .

5 impulses

3. 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 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 e a c h i m p u l s e the LED w i l l c o m e o n b r i e f l y t o g i v e a v i sual c o n f i r m a t i o n .

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4 . A b o u t 2 s e c o n d s after t h e last i m p u l s e ( t h e f i f t h in t h e e x a m p l e ) t h e LED w i l l e m i t a n o t h e r flash t o request t h e i n p u t of t h e n e x t figure ( t h e 2 ) . 2 impulses

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 .

A b o u t 2 s e c o n d s after t h e last i m p u l s e ( t h e s e c o n d in t h e e x a m p l e ) t h e LED w i l l e m i t a n o t h e r f l a s h t o request t h e i n p u t of t h e next f i g u r e ( t h e z e r o ) . 0 impulses

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.

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8. A f t e r a b o u t 2 s e c o n d s t h e LED w i l l e m i t a n o t h e r flash t o request t h e i n p u t of t h e last f i g u r e ( t h e 3 ) . 3 impulses

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.

10. W h i l s t t h e LED is f l a s h i n g , press t h e b u t t o n in t h e c o u r t e s y l i g h t a n d k e e p it pressed; t h e LED s h o u l d c o n t i n u e t o flash.


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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.

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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

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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 .

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MAIN WIRING DIAGRAM

D D
21
o-y

c C

9 ~ V

+ 15

20
-o

o->

22

19
o->

Q.

A2 B13 B9 c(B15 B3 B16 Bl? B18


-TCJ

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

t ? V
o->

"_i
c

15
_

~1

f!

"I - I
r> r> A

EE

14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

13 12. 13. 14. 15. 16. 17. 18.

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

19. 20. 21. 22.

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

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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
#

* Signal c u r r e n t > 0,3 m A , < 1 0 m A . A l a r m c o n t r o l unit input a n d o u t p u t signals

P4A35AL01

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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

B2 A9 A6 Bl3 A? A4 A3 A2 Al u B6 D B14 = > B17 B18


nrr

+3 0
N.D.
-

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15/54

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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

Copyright by Fiat Auto

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

Print no. 506.670/01

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

1 . Fuel filter 2. Fuel o u t l e t 3. Fuel inlet PREHEATING E L E C T R O N I C C O N T R O L UNIT

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.

Copyright Fiat Auto

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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20 30 40 50

60 7o .

156

Publication no. 506.670/02

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

Wait-to-start warning light does n o t c o m e o n

Warning light bulb b l o w n C o n n e c t i n g cable b e t w e e n w a r n i n g light a n d p i n 5 of t h e c o n t r o l unit b r o k e n

Replace b u l b Clean c o r r o d e d cable e n d s or replace cable

The engine has d i f f i c u ly in starting The engine start does n o t

Faulty c o n t r o l unit g i v i n g p r e h e a t i n g times

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

C h e c k that p i n 1 o f t h e c o n trol u n i t is earthed

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

Copyright Fiat Auto

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

t BATT

T
60A

201 11
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5 43 2 i.

228

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1 1

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.D.

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1 5

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229 230

50 + 15/54

3. A. 6. 0. 9.

Power fusebox 6 0 A fuse p r o t e c t i n g fuel i n j e c t i o n system I n s t r u m e n t panel Heater p l u g s w a r n i n g l i g h t Front r i g h t earth

201. 228. 229. 230. N.D.

Preheating c o n t r o l u n i t G l o w plugs Engine c u t - o u t e l e c t r o s t o p (Fiat c o d e ) Earth f o r Fiat c o d e 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 loom

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

SEAT BELT PRETENSIONER


Introduction Operation Removal setting bracket Refitting seat belt w i t h pretensioner Safety rules for handling seat belt unit w i t h pretensioner - Removing-refitting 37 37 38 39 40 42 45 45 49 53 55 57

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

REPLACING BODY PANELS


Introduction Graphic index Symbols Front w i n g Replacing rear wing (3D) Replacing rear wing (5D) Replacing door sill rail Replacing vehicle roof panel Replacing rear beam trim (3D) Replacing rear beam trim (5D) Replacing tail-light cluster compartment (3D) 64 65 66 67 69 81 85 89 93 97 101

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

REPLACING STRUCTURAL PANELS


Graphic index Symbols Replacing front beam trim Replacing front side assembly Replacing front pillar Replacing central pillar (5D) Replacing door sill rail front reinforcement (3D) - Replacing door sill rail rear reinforcement (3D) - Replacing rear wheel arch 105 106 107 111 117 121 125 129 133

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

REPLACING STRUCTURAL PANELS


- Replacing partial front side - Replacing rear floor pan complete w i t h rails

- Specified dimensions

137 147 152

Copyright Fiat Auto

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

Copyright by Fiat Auto

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.

Print no. 506.670

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

Copyright by Fiat Auto

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

The arrows indicate the possible movements for the adjustment.

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

- Loosen 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 ; - w h e n t h e a d j u s t m e n t has been carried o u t , f u l l y t i g h t e n t h e striker f i x i n g bolts.

NOTE
P4A004M03

The arrows indicate the possible movements for the adjustment.

Print no. 506.670

Bravo-Brava

Bodywork
Front door

70.

P4A005M02

REMOVING-REFITTING DOOR AND P R O T E C T I V E LINING

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

Copyright by Fiat Auto

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

Print no. 506.670

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

Copyright by Fiat Auto

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

Print no. 506.670

Bravo-Brava

Bodywork
Front door

70.
2 ^ ^ ^ ^ ^ ^ ^ v

qM
Iff /

REMOVING-REFITTING EXTERNAL REAR VIEW MIRROR

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

Copyright by Fiat Auto

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

Print no. 506.670

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

Copyright by Fiat Auto

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

Print no. 506.670

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

Copyright by Fiat Auto

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

Print no. 506.670

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

Copyright by Fiat Auto

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

Print no. 506.670

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

Copyright by Fiat Auto

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.

REPLACING LOCK BARREL

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

Print no. 506.670

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

Copyright Fiat Auto

19

Bodywork
Seats

Bravo-Brava

70.
REMOVING-REFITTING SEAT FRONT

Operation sequence - M o v e t h e seat fully b a c k w a r d t o t h e e n d of its travel, t h e n u n s c r e w t h e bolts r e t a i n i n g t h e seat g u i d e s to t h e f l o o r p a n ;


P4A020M01

- m o v e t h e seat f u l l y f o r w a r d t o the e n d of its travel, t h e n u n s c r e w t h e b o l t s r e t a i n i n g t h e seat g u i d e t o t h e f l o o r p a n ;


P4A020M02

- 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

20

V - 9 8 - Supersedes previous version;

Publication no.

506.670/15

Bravo-Brava

Bodywork
Seats

70.
DISMANTLING-FITTING COVERS FRONT SEAT

Operation sequence R e m o v e t h e seat assembly f r o m t h e car, t h e n p r o c e e d as f o l l o w s : 1 . R e m o v e c a p A and s q u a b a d j u s t m e n t k n o b B. U n s c r e w bolts C r e t a i n i n g e x t e r i o r t r i m D, t h e n remove.

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

Copyright Fiat Auto

V - 9 8 - Supersedes previous version

21

Bodywork
Seats

Bravo-Brava

70.

1 . Use c u t t i n g pliers t o r e m o v e r e t a i n i n g h o o k s A s e c u r i n g the c o v e r t o t h e padding.


P4A022M06

2. F o l d back the cover a n d r e m o v e r e t a i n i n g hooks B positioned around the u p h o l stered edges.

Remove any remaining parts of the hooks connected to the padding to prevent damage to the new cover.

3. R e m o v e the e d g e of t h e s q u a b cover f r o m its fasteners. 4. D i s c o n n e c t the seat tensioners.


P4A022M07

P4A022M08

P4A022M09

22

V - 9 8 - Supersedes previous version

Publication no.

506.670/15

Bravo-Brava

Bodywork
Seats

70.

1 . Release t h e s q u a b r e c l i n e h a n d l e . U n s c r e w b o l t A , remove h a n d l e B a n d u n s c r e w b o l t s C. R e m o v e panel D ( o n l y f o r BRAVO version).


P4A023M06

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

Copyright Fiat Auto

V - 9 8 - Supersedes previous version

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.

M o v e t h e g u i d e s b a c k using t h e release control b o w . Unscrew front bolts C retaini n g t h e g u i d e s o n t h e inside a n d o u t s i d e .


P4A024M07

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.

Reverse removal Tighten retaining 2.4 daNm.

instructions to refit. bolts to a torque of

24

V - 9 8 a Supersedes previous version

Publication no.

506.670/15

Bravo-Brava

Bodywork
Seats

70.
REMOVING-REFITTING SEAT RAISE DEVICE

The seat need the car.

not be removed

from

1. Position t h e seat f u l l y f o r w a r d a n d f u l l y raised. U n s c r e w s c r e w s r e t a i n i n g outer trim A . T u r n t r i m B u p w a r d .


P4A024M09

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

Copyright Fiat Auto

V - 9 8 - Update

24/1

Bodywork
Seats

Bravo-Brava

70.
REMOVING-REFITTING REAR SEAT

U n s c r e w t h e bolts f a s t e n i n g the c u s h i o n t o the b o d y , t h e n take o u t of the car.


P4A024M13

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

1. R e m o v e the c u s h i o n f r o m t h e car (see p r e v i o u s p a g e ) . Release plastic m o u l d i n g A as s h o w n in t h e f i g u r e . R e m o v e u p h o l stered c u s h i o n .


P4A024M17

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

Use tool 1878077000 to fasten the cushion

when hooks

refitting

Use new

hooks.

DISMANTLING-FITTING REAR SQUAB

ONE-PIECE

F o l d d o w n t h e s q u a b . U n s c r e w b o l t s A ret a i n i n g t h e s q u a b t o t h e bracket, t h e n rem o v e t h e s q u a b f r o m t h e car.


P4A024M19

Copyright Fiat Auto

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

Fold back t h e cover a n d c u t h o o k s C r e t a i n i n g the cover t o t h e p a d d i n g a r o u n d the e d g e of the u p h o l s t e r y .

Remove attached damage

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

Copyright by Fiat Auto

25

Bodywork
Interior fittings

Bravo-Brava
5 P.

70-

P4A026M01

ROOF LINING Removing

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

Print no. 506.670

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

Copyright by Fiat Auto

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).

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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^

,-:. . :^7 ';.v.


;

: ;

475

P4A029M03 4A029M

Copyright Fiat Auto

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

Detail of roof panel trim


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506.670/12

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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

odywr terior trim

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

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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

Copyright by Fiat Auto

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.

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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.

Copyright by Fiat Auto

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

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Bodywork
Interior fittings

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70.

REMOVING-REFITTING REAR SEAT BELTS

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.

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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.

Diagram s h o w i n g operation of pre-tensioner

Copyright by Fiat Auto

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
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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

Copyright Fiat Auto

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

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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.

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Seat belt pre-tensioner

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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).

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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

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Seat belt pre-tensioner

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.

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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.

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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.

Supply pin Knife b o d y Temperature adjustment knob C o m p r e s s e d air t a p On s w i t c h P r o t e c t i v e fuse

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

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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 .

T o prevent t h e shears f r o m o v e r h e a t i n g it is useful t o a d j u s t t h e a d v a n c e a n d t h e n u m b e r of o s c i l l a t i o n s a c c o r d i n g t o t h e u s a g e c o n d i tions. Detail A s h o w s t h e scraper t o be f i t t e d t o t h e v i b r a t i n g shears t o level t h e r e s i d u e s o f sealant.

Do not use lubricants during ting. The blades should always be ened.

cutsharp-

T h e d i a g r a m s at t h e side a n d u n d e r n e a t h i l lustrate c e r t a i n s i t u a t i o n s w h i c h r e c u r w h e n cutting bonded w i n d o w s w i t h the appropriate t y p e o f blade.

P4A047M03

Copyright by Fiat Auto

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Window glasses

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70.
r-ti
nr.-=i-'

Y
ui-

Wire The t o o l illustrated in t h e d i a g r a m must b e used t o c u t t h e bead o f sealant w i t h t h e w i r e .

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.

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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

8. 9. 10. 11. 12. 13.

D o o r seal Spacers W i n d s c r e e n w i p e r blades Lower w i n d o w trim W i n d o w perimeter t r i m Retaining mountings

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.

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Window glasses

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Preparing t h e w i n d s c r e e n housing 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 sealant f o r t h e w i n d s c r e e n h o u s i n g , l e a v i n g a thickness of between 0.25 and 1 m m w i t h o u t r e a c h i n g t h e p a i n t a n d s c r a t c h i n g it.

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.

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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.

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- 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.

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- 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.

- Refit t h e elements r e m o v e d p r e v i o u s l y a n d clean t h e w i n d o w . The v e h i c l e s h o u l d n o t be h a n d e d b a c k f o r at least 1 5 hours after t h e w i n d s c r e e n has been s t u c k .

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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 .

1 . Rearscreen w i p e r b l a d 2. T a i l g a t e interior c e n t r e l i n i n g 3. T a i l g a t e interior r i g h t side l i n i n g

4 . T a i l g a t e interior left side l i n i n g 5. T a i l g a t e interior l i n i n g 6. W i n d s c r e e n w i p e r m o t o r

- 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

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Window glasses

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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 .

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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

1 . Rearscreen w i p e r blade 2. T a i l g a t e interior l i n i n g 3. T a i l g a t e interior t r i m

4. Windscreen wiper motor 5. Tailgate side t r i m s 6. L o w e r w i n d o w t r i m

- 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

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Bodywork
Window glasses

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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

Extrude a b e a d of sealant, a l o n g t h e p e r i m e t e r of t h e rearscreen scrupulously f o l l o w i n g the figures given in t h e diagrams.


P4A056M02

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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

5. Fixed glass 6. T h r e a d e d reference p i n s 7. R e t a i n i n g c l i p s

NOTE

from inside

the vehicle

using

an appropriate

blade

to

cutting

the

sealant.

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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 .

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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

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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.

S u n visors C o u r t e s y light G r a b handles W i n d s c r e e n pillar covers C e n t r e pillar covers

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).

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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

The centre brackets must be completely

(6) are connected to the roof rib (7); disconnected (see detail A)

to remove

the sun roof

frame

they

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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

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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

4 . A t t h e edges of t h e spoiler ( 5 ) t h e r e are t w o o p e n i n g s w i t h slots ( s h o w n b y t h e arr o w s ) for f i x i n g a n d a l i g n m e n t w i t h t h e v e h i c l e profile.

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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 .

W h e n carried o u t correctly t h e o p e r a t i o n w i l l i n v o l v e a n excess o f several c e n t i m e t r e s b e t w e e n t h e t w o c u t t i n g lines in order t o d i s t r i b u t e t h e p o i n t s created b y w e l d i n g (see f i g u r e 2 ) .

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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

Replacing b o d y panels page 6 7 3 door version: page 69

P4A065MO2

Rear w i n g 5 P

U n d e r d o o r side m e m b e r l i n i n g Replacing b o d y panels 5 door version: page 81 3 door version: page 85

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

Rear cross member c o v e r 5 P

Rear l i g h t cluster h o u s i n g 3 P Replacing b o d y panels

A.'^r!

nnfa|\rjD.

\v

-TT

fangs~-k

5 door version: page 97 3 door version: page 101

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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

CLEANING WITH ROTARY B R U S H

MIG WELDING

REMOVING SPOT WELDS WITH CHAMFERING MACHINE

WELDING WITH LENE C A N I S T E R

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

APPLYING ANTI-OXIDANT PROTECTIVES

(gig}

f\
APPLYING SEALANTS

APPLYING HIGH THICKNESS ELECTRO-WELDABLE PROTECTIVES

APPLYING PROTECTIVES

UNDERBODY

CENTERING

COMPONENTS

. <

APPLYING

PAINTS

MEASURING

APPLYING W A X BASED PROTECTIVES

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

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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

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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.

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REPLACING REAR W I N G (7090A 5 4 ) *

(*)

This number indicates the code given in the Fiat rate

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 e d in t h e d i a g r a m at t h e side. PRELIMINARY PROCEDURES


P 4 A 0 6 9 M 0 1

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.
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Protective gloves

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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.

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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

R e m o v e t h e rear w i n g t a k i n g care n o t t o d i s t o r t t h e inner frames.

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.

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70.

- Using a hammer and dolly block straighten t h e edges o f t h e v e h i c l e .

- R e m o v e t h e excess parts f r o m t h e r e p l a c e m e n t part s o that t h e r e p l a c e m e n t pillars are a b o u t 5 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 v e h i c l e .

- 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

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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

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73

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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 .

Offer u p 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 , 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 a n d c h e c k that it is p e r f e c t l y a l i g n e d w i t h t h e c o m p o n e n t s t o be w e l d e d edge t o e d g e .

1
P4A074M02

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Start t h e w e l d i n g o p e r a t i o n s 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 a n d t a c k t h e corners o f t h e pillars and t h e underdoor panel.

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

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70

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 , w e l d t h e pillars a n d t h e u n d e r d o o r p a n e l , p r o c e e d i n g in c h a i n - s t i t c h f a s h i o n in order n o t t o distort t h e panels.

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.

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U s i n g a disc grinder, level t h e w e l d beads m a d e w i t h 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 o n t h e pillars a n d u n d e r d o o r panel.

P4A077M01

Level at t h e p o i n t s w h e r e t h e f i l l i n g w e l d i n g ( r i v e t i n g ) has been carried o u t .

P4A077M02

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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.

PREPARATION AND PAINTING P R O C E D U R E

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 ) .

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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 .

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REPLACING REAR W I N G (7090A 5 4 ) *

(*)

This number indicates the code given in the Flat rate

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 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. PRELIMINARY PROCEDURES


P 4 A 0 8 1 M 0 1

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.

Copyright by Fiat Auto

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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 .

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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

Welding the spare part

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 .

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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 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 .

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REPLACING UNDERDOOR S I D E M E M B E R (7090G 6 2 ) *

(*)

This number indicates the code given in the Flat rate

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 the d i a g r a m at t h e side.


P4A085M01

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.

Copyright by Fiat Auto

85

Bodywork
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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

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Replacing body panels

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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

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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 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)"

(*)

This number indicates the code given in the Flat rate

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.


P4A089M01

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.

Copyright by Fiat Auto

89

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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 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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Bodywork
Replacing 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 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

Copyright by Fiat Auto

91

Bodywork
Replacing body panels

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

92

Print no.

506.670/01

Bravo

Bodywork
Replacing body panels

70.
REPLACING REAR CROSS M E M B E R L I N I N G (7090G 7 6 ) *

(*)

This number indicates the code given in the Flat rate

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.

Copyright by Fiat Auto

93

Bodywork
Replacing body panels

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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Bodywork
Replacing 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 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

Copyright by Fiat Auto

95

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 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

96

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Brava

Bodywork
Replacing body panels

70.
REPLACING REAR CROSS M E M B E R LINING (7090A46)*

(*)

This number indicates the code given in the Flat rate

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.

Copyright by Fiat Auto

97

Bodywork
Replacing body panels
10.
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

98

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Brava

Replacing body panels

Bodywork 70.

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

Copyright by Fiat Auto

99

Replacing body panels

Bodywork

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 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

Print no.

506.670/01

Bravo

Bodywork
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 ) '

(*)

This number indicates the code given in the Flat rate

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

Protective and gloves

101

Bodywork
Replacing body panels

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 .

102

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Bodywork
Replacing 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 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

W e l d i n g t h e s p a r e part 1 . 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 as s h o w n in t h e d i a g r a m . 2. Using 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 i n t h e r e p l a c e m e n t part.

P4A100M08

Copyright by Fiat Auto

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.

P4A100M03

104

Print no.

506.670/01

Bravo-Brava

Bodywork
Replacing structural body panels

70
GRAPHIC INDEX

Replacement operation

R e f e r e n c e in Manual

Front cross m e m b e r cover Replacing b o d y panels Structural page 1 0 7

C o m p l e t f r o n t panel

Front pillar Replacing b o d y panels Structural page 111

page 1 1 7
P4A101MO2 P4A101M03

Centre pillar 5 P

Underdoor front reinforcement 3 P Replacing b o d y panels Structural page 121

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

Rear w h e e l arch 5 P Replacing b o d y panels Structural page 1 2 9

page 1 3 3
P4A101MO6

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SYMBOLS CUTTING WITH HACK SAWING MACHINE CHECKING G A P S AND ALIGNMENTS

CUTTING W I T H C I R C U L A R BLADE SAW

SPOT W E L D I N G

CLEANING WITH ROTARY B R U S H

MIG WELDING

R E M O V I N G SPOT W E L D S WITH CHAMFERING MACHINE

WELDING WITH LENE CANISTER

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 ANTI-OXIDANT PROTECTIVES

APPLYING SEALANTS

A P P L I C A T I O N OF HIGH THICKNESS ELECTROW E L D A B L E PROTECTIVES

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

FIXING THREADED RIVETS

<

A P P L Y I N G W A X BASED PROTECTIVES
_

APPLYING FOAM PRODUCTS

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

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REPLACING FRONT CROSS M E M B E R L I N I N G (7090G 0 7 ) *

(*)

This number indicates the code given in the Flat rate

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 i n t h e d i a g r a m at t h e side.


P4A103M01

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.

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107

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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 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 .

P4A104M01

Preparing t h e r e p l a c e m e n t p a r t s 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 o f t h e r e p l a c e m e n t part using a d i s c grinder. 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 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 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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109

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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.

P4A106M01

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 e m e n t parts 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 a c r y l i c sealant o r 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 COMPLETE F R O N T S I D E P A N E L (7090G 10)*

(*)

This number indicates the code given in the Flat rate

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


P4A107M01

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.

Copyright by Fiat Auto

111

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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

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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 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

W e l d i n g t h e r e p l a c e m e n t internal panel 1 . Carry o u t s p o t w e l d i n g b y t h e floor. 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 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 . 3. Carry o u t s p o t w e l d i n g o n t h e f r o n t cross member.

P4A109M02

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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 .

P o s i t i o n i n g the r e p l a c e m e n t o u t e r panel 1. C o r r e c t l y p o s i t i o n t h e o u t e r p a n e l . 2. C h e c k that t h e o u t e r panel is perfectly p o s i t i o n e d . 3. Fix t h e replacement part t o t h e b o d y s h e l l u s i n g t h e s p e c i a l s e l f - l o c k i n g c l a m p s .

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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 .

Proceed w i t h f i t t i n g 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 Panels - R e p l a c i n g Front P i l l a r " ) .

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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

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 e m e n t parts 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 a c r y l i c 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 . 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 FRONT P I L L A R (7090G 3 0 ) *

(*)

This number indicates the code given in the Flat rate

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 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 the d i a g r a m at t h e side.


P4A113M01

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.

Copyright by Fiat Auto

117

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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 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

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119

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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.

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 ) *

(*)

This number indicates the code given in the Flat rate

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.


P4A117M01

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.

Copyright by Fiat Auto

121

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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.

Copyright by Fiat Auto

123

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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 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)*

(*)

This number indicates the code given in the Flat rate

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.

Copyright by Fiat Auto

125

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Replacing structural body panels

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 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 .

P4A122M01

Preparing t h e s p a r e p a r t 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 p e r i m e t e r o f the 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 panel u s i n g a disc grinder. 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 .

P4A122M02

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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

W e l d i n g t h e s p a r e part 1 . Carry o u t s p o t w e l d i n g b y t h e f r o n t pillar frame a n d t h e upper edges. 2. U s i n g t h e 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 b o d y s h e l l .

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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70.
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)

This number indicates the code given in the Flat rate

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.

Copyright by Fiat Auto

129

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Replacing structural body panels

Bravo

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 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 .

P4A1Z7M01

Welding the spare part 1 . Carry o u t s p o t w e l d i n g b y t h e u p p e r edge. 2. U s i n g t h e 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 b o d y s h e l l .

P4A127M02

Proceed w i t h f i t i n g 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 rear w i n g (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 U n d e r d o o r side m e m b e r " a n d - R e p l a c i n g rear w i n g " ) .

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131

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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.

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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70.
REPLACING REAR W H E E L A R C H (7090G 7 2 ) *

(*)

This number indicates the code given in the Flat rate

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.

Copyright by Fiat Auto

133

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Brava

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 .

P4A130M01

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 h o l e s in t h e u p p e r e d g e of 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 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 d i s c 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 p r e v i o u s l y t r e a t e d .

P4A130M02

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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 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.

W e l d i n g t h e s p a r e part 1 . Carry o u t s p o t w e l d i n g b y t h e l o w e r e d g e . 2. U s i n g t h e 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.

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Bodywork
Replacing structural 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 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

Proceed w i t h f i t t i n g t h e rear w i n g (see: " R e p l a c i n g b o d y panels - Replacing Rear w i n g " ) .

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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Bodyshell

70.
TYPICAL MEASUREMENTS

M e a s u r i n g w i n d s c r e e n h o u s i n g a n d engine c o m p a r t m e n t d i m e n s i o n s T h e f i g u r e s f o r t h e h o u s i n g s , g i v e n b e l o w , are t a k e n f r o m t h e t e c h n i c a l d e s i g n s and are s u b j e c t t o t o l e r ances of a r o u n d 2 m m .

P4A133M01

F i g u r e s for c h e c k i n g w i n d s c r e e n h o u s i n g , e n g i n e c o m p a r t m e n t a n d d i s t a n c e f o r f r o n t s h o c k a b sorber attachment turrets

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Bodywork
Bodyshell

Bravo-Brava

70.
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 )

'1518 : Centre pillar " 1 4 7 5 , 5 : Rear pillar

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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Bodyshell

707
Measuring door housing dimensions

P4A135M02

P4A135M03

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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Bodywork
Bodyshell

Bravo-Brava

70.
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 )

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 pillars f o r d o o r s m e a s u r e d by the s e a t b e l t a t t a c h ment n u t s and b e t w e e n the l o c k s t r i k e r s (3 d o o r 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

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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

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 (3 door v e r s i o n )

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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

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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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70.
PARTIAL R E P L A C E M E N T OF FRONT PANEL

The component for w h i c h the 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 a t t h e s i d e .


P4A146M01

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

- R e m o v e t h e f r o n t c r o s s 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 f r o n t cross m e m b e r )

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 .

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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.

Preparing t h e s p a r e 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 .

P4A148M02

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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 ) .

2 . R e m o v e t h e part p r e v i o u s l y m a r k e d w i t h t h e c u t t i n g line ( 1 ) f r o m t h e b o d y s h e l l , t a k i n g care n o t t o d a m a g e t h e internal reinforcement. 3. R e m o v e t h e s e c t i o n o f t h e r e i n f o r c e m e n t m a r k e d p r e v i o u s l y w i t h t h e c u t t i n g line ( 2 ) f r o m t h e r e p l a c e m e n t part.

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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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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).

the same line and

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

P r o c e e d w i t h f i t t i n g t h e f r o n t cross m e m b e r (see: " R e p l a c i n g f r o n t cross m e m b e r " ) Protections Refer t o w h a t has b e e n d e s c r i b e d p r e v i o u s l y f o r t h e o t h e r c o m p o n e n t s .

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Replacing structural body panels

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70.
PARTIAL REPLACEMENT O F REAR FLOOR

The c o m p o n e n t for w h i c h the 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 s i d e .


P4A146M02

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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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

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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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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

2. Carry o u t t h e w e l d i n g f o r f i l l i n g . 3. R e m o v e a n d level t h e w e l d residues, u s i n g a n abrasive g r i n d e r .

P4A155M02

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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

Positioning the replacement part 1 . C o r r e c t l y p o s i t i o n t h e s i d e m e m b e r u s i n g t h e t e m p l a t e s , s u p e r i m p o s e it, l o c k it a n d trace t h e o u t l i n e . 2. T r i m it r e m o v i n g t h e excess parts. 3. 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 .

P4A156M02

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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.

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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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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.

P r o c e e d w i t h r e f i t t i n g t h e rear cross m e m b e r (see: " R e p l a c i n g rear cross m e m b e r " )

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 .

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