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Panda 4x4 - FC Connect

1. gb Fiat Grande Punto OK 169 532 2004 Fiat Auto S p A All rights reserved Every time the rotor passes in front of the sensor the output voltage from the sensor is varied due to the Hall effect this variation takes place during all the time when the rotor passes in front of the sensor then the signal returns to the initial value 5V N B If the sensor is faulty the control unit will make use of internal emergency mapping which will allow the engine to be started in any case Boosting pressure sensor The boosting pressure sensor is fitted to the inlet manifold and makes it possible to measure a suction pressure up to 1 5 bar corresponding with 2 5 absolute bar The sensitive element consists of a piezoresistive element the signal of which is amplified by an electronic circuit built into the sensor The sensor is directly powered by the electronic control unit with 5 V and provides the output voltage directly proportional to the boosting pressure Ro men cm mn n Nessi ee E Pe R R R K KRE R eR e A gb Fiat Grande Punto OK 170 532 O 2004 Fiat Auto S p A All rights reserved Overpressure sensor pin out Type of Pin Name signal 1 Power supply Input 5 V 2 Ground Ground Analog 3 Sensor output output Reference Fressure Signal 1 iis Rn mi gb Fiat Grande Punto OK 171 532 2004 Fiat Auto S p A All rights reserved In the 90 HP engine ver
2. 3 10 3 Injected fuel amount check The control unit carries out the following operations depending on the signals from the sensors and on the measured values controls the pressure regulator varies the pilot injection time over the entire revs range varies the main injection time 3 10 4 Idling speed check The control unit processes the signals from the various sensors engine revs engine temperature vehicle speed and adjusts the amount of injected fuel it controls the pressure regulator DRV2 it varies the injection time of electric injectors CR1MI2 2 Within some thresholds the speed allows for the battery voltage 3 mn gb Fiat Grande Punto OK 148 532 2004 Fiat Auto S p A All rights reserved 3 10 5 Fuel cut off during the release phase cut off The control unit performs during the accelerator pedal release phase the following logics it sets the injection time to zero it partially varies the electric injector injection time before the idling speed is reached controls the fuel pressure regulator gb Fiat Grande Punto OK 149 532 2004 Fiat Auto S p A All rights reserved 3 10 6 Idling cylinder balancing check The control unit checks depending on the signals from the various sensors engine revs vehicle speed phase sensor that the torque is correct until the idling speed is reached it varies the amount of injec
3. play recovery device a FIAT PUNTO 41 532 2004 Fiat Auto S p A All rights reserved 2 6 Gearbox 1 3 Multijet 16V 90 1 3 Multijet 16V 1 4 8V 1 2 8V HP 1 9 Multijet 8V 75 90 HP 120 HP 2 cascade shafts 2 cascade shafts supported on ball 3 shafts supported on Configuration supported on ball l l l bearings output ball bearings bearings shaft rear amp front Total length from the engine na 382 5 on main flywheel mm axle 45 dry 46 5 with oil o 35 5 dry 37 3 Weight kg 33 dry 34 5 with oil 47 dry 48 5 with with oil oil Synchronizers 1 2 3 4 5 R 1 2 3 4 5 R 1 2 3 4 5 6 R HCR High Contact HCR High Contact HCR High Contact Ratio toothing Ratio toothing Ratio toothing Gear ratio 1 3 909 3 818 3 818 Gear ratio 3 1 480 1 302 1 302 Gear ratio 5 0 921 0 744 0 744 Gear ratio REV 3 818 3 909 3 545 FIAT PUNTO 42 532 2004 Fiat Auto S p A All rights reserved 2 Braking system 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP Hydraulic Hydraulic Hydraulic Hydraulic baei Type servo assisted servo assisted servo assisted servo assisted servo baei Power brake cylinder O O 0 0 0 diameter Anti lock Bosch 8 0 Bosch 8 0 Bosch 8 0 Bosch 8 0 Bosch 8 0 system 2 7 1 Front brakes 1 3 Multijet 1 3 Multijet 1 9 Multijet 8V 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 120 H
4. gt gb Fiat Grande Punto OK 363 532 2005 Fiat Auto S p A All rights reserved Control unit The control unit processes the input signals received by the sensors and also drives the electric motor by delivering the current required to obtain the desired interlocking torque Moreover it manages the communication on the C CAN network and performs continuous self diagnosis of the system to ensure correct operation of the latter The alternator and vehicle speed values are read on the C CAN line The position and torque signals from the sensors represent the base values by means of which the microprocessor processes the output data in terms of current delivered to the engine The drive interlocking management control unit is secured onto the electric drive body 1 Power supply from the battery 30 EPS EPS ground 1 Body computer SC 2 C CAN H C CAN H out CLAN L aut 3 C CAN L C CAN L ln 7 C CAN H 8 C CAN L gb Fiat Grande Punto OK 364 532 2005 Fiat Auto S p A All rights reserved 7 3 Drive housing It features two drive rations Technical features for petrol engines reduction ratio 51 mm rev steering wheel angle wheel angle ratio 15 7 steering wheel degrees wheel degrees steering wheel turns 2 8 with kerb to kerb steering diameter of 10 1 m Technical features for diesel engines reduction ratio 60 44 mm rev steering wheel angle wheel angle ratio 13 4 steering wheel degrees w
5. REST POSITION coil 4 is de energized and shutter 6 is in the closing position and does not allow fuel to be let into cylinder Fc gt Fa Fc due to the line pressure that acts on control area of rod 1 Fa due to the line pressure that acts on feed volume 8 START OF INJECTION coil 4 is energized and causes shutter 6 to be raised The control volume fuel 9 flows out toward return manifold 10 thus causing a pressure drop on control area 7 At the same time the line pressure through feed duct 12 exerts a force Fa gt Fc in feed volume 8 thus causing pin 2 to be lifted with resulting fuel flow into the cylinders through holes 3 such holes amount to 6 in the CR1 MI 2 2 injector they feature a diameter of 0 121 mm and a flow rate of 280 cm3 30 s at 100 bar FIAT PUNTO 114 532 2004 Fiat Auto S p A All rights reserved END OF INJECTION coil 4 is de energized and causes shutter 6 to go back to its closing position which gives rise to such a force balance that pin 2 is made to go back to its closing position and injection is terminated accordingly IMA classification Injector classification according to the IMA method aims at improving the engine performance and emission levels by properly matching the construction features of every single injector with the software control strategies within the engine management control unit Thus the production tolerances can be recovered e
6. indicator emergency light ticking sound button pressure roger beep The acoustic signals may differ in loudness and frequency depending on the signalled function The alarm signal volume can be set down to 0 acoustic signal OFF except for the robotized gearbox parking sensor SBR and indicator emergency ticking signals for which a volume other than zero is provided The access priority among the various signals is managed by a priority table in the vehicle panel LED diagnosis LED diagnosis is provided for the warning lights listed below the vehicle panels memorize and transmit through the CAN network the warning light status ON OFF and the presence of possible failure handbrake ON low brake fluid level EBD failure ABS system failure ESP system actuation failure AIRBAG system failure passenger s AIRBAG deactivation safety belts not fastened SBR electric drive failure Signalling safety belts not fastened It may be of 3 types in automatic operation A First warning cycle signalling by means of the warning light The safety belt warning light informs that the safety belt has not been fastened both on the driver s and passenger s sides by coming on steadily since the key ON gb Fiat Grande Punto OK 429 532 2005 Fiat Auto S p A All rights reserved B Warning cycle signalling by means of the warning light and the acoustic signal The warning light on the boar
7. gb Fiat Grande Punto OK 388 532 2005 Fiat Auto S p A All rights reserved C CAN MTA C514 amp ESP ECM C CAH H i E CAH L Y 110 4 0 G CAN L auk A 110 B 5 D CAN H auk Y T10 0 5 C GAN L im H T11 G4 5 E CAN H in Y 111 6 5 C CAN L 1 in H T24 0 5 3 C CAN L 2 suk M 111B 5 Y RE CAN H 1 in 139 lt G 5 4 C CAN H 2 aut T41 B 5 5 C G4N H auk T C GAR L de H H EE Lin H T24 9 5 s R M L A Hi Y TZJ 0 5 1 gb Fiat Grande Punto OK 389 532 2005 Fiat Auto S p A All rights reserved LIN line i 52 0 39 LUN bue Ret LIN H 35 9 1 7 Remote control switch Fuse holder unit The Nuova Punto features various types of power distribution units realized by means of 3 different technologies power PCB sheared circuit wired with sheared circuit In particular HAHHAA Body Computer node control unit BCM Body Computer Module realized with Power PCB Engine compartment control unit FDU Front Distribution Unit realized by means of a sheared circuit Fuse control unit on the battery positive pole BDU Battery Distribution Unit realized by means of a sheared circuit mi gb Fiat Grande Punto OK 390 532 2005 Fiat Auto S p A All rights reserved Optional fuse control unit on the battery positive pole BDU S Battery Distribution Unit supplementary r
8. 208 ET ina ii ir 43 526 Riina 43 e Rina 44 2 8 II E E E io tada 44 29 PRONTSUSPENSIO Saia a aaa 45 SEENEN 47 2 11 SUSPENSION CHARACTERISTIC ANGLES AND TRIM aeres Teena ege eege nea ei arar it 49 2 11 1 AAA E AE E E A E E II II II E E S 50 KE F TTT 32 2 12 BATTERY EE ee 54 2 13 IEEE SPT BRN C 54 2 14 VERE EE E E E N E S6 2 14 1 EE 56 2 14 2 EE 37 2 14 3 EE 37 2 14 4 L 58 2 14 5 LO IZ 58 2 14 6 KTT 58 2 14 7 TIONS pressure DAT A 59 I3MULILILJETT6V 75 AND 90 HP ENGINES E 61 3 1 GENERAL RI eege 61 3 2 COMPONENT EE 63 SE E O TTT 63 A EE 65 IE EZ E 66 E AONO RT 68 ENEE 70 e EE 71 i Lilla 71 E nest nena enter ner eee eer nten ee ee neers ee ee eter 72 A A A E ee eis en ores A E 73 3 2 10 EDE 74 32 11 CS Een 76 3 212 EE GE 3 2 13 Distributing shafts in the upper head nono non nono nono nono non nn nana n anna n nn nana nana nro G 3 2 14 EE 78 3 2 15 Spark plug preheating control unit 3 2 16 E EE 80 3 2 17 VII O PRO ROERO 84 3 2 18 MOUSE DOS IONI O RIA 84 3 2 19 ROOT SOI RA 85 3 3 CATA CONVERTER E 85 331 EXNAUST eas recirculation CE GA E 86 3 3 2 Engine base vapour gas recirculating SS Midis 89 SEO E IE 90 3 3 4 Hear exchanger and oil E E 9 K EO Eege 91 St LO ln 93 KES e an A 94 3 4 ENGINE COODINE PARED TAN pacta 94 St Maler pump and iii 94 3 4 2 Water temperature control devices ccccccccccccccccccceececeeeeeeee cece cece ee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeees
9. Considering that a vehicles line is the main appeal as regards the reasons for purchasing Nuova Punto means to become the leader within its own market segment by relying on a modern fascinating line launching out to the young world thanks to its nimbleness and versatility that distinguish it from ordinary two box cars 1 2 The vehicle 1 2 1 Style Nuova Punto features a design style and lines that are deeply rooted in the most authentic and renowned tradition of Italian car making with a surprising unexpected shapes that make it go against the current compared with the trends followed by nearly all of the European car manufacturers A real automobile line which originally and nicely combines style sporting character elegance and beauty while following the modern customer s tastes Si FIAT PUNTO 14 53 2004 Fiat Auto S p A All rights reserved 1 2 2 Dimensions Outer dimensions Nuova Punto s outer dimensions are a consequence of market expectations and the resulting choices made in terms of style However outer dimensions have also been influenced by the progress made by the law regulations with regard to occupant safety which has conditioned the choice of peculiar layouts The final outcome as far as some dimensions are concerned sets Nuova Punto at the top of its market segment see table below Competitor car comparing table E Bei OPEI gt T IESTA RE JLT NIS IT CITROEN ba a
10. E gb Fiat Grande Punto OK 261 532 2004 Fiat Auto S p A All rights reserved Operation The air temperature sensor is made up of a NTC Negative Temperature Coefficient thermistor The resistance exhibited by the sensor decreases as the temperature increases The control unit input circuit distributes the 5 V reference voltage between the sensor resistance and a fixed reference value thus obtaining a voltage proportional to the resistance and therefore to the temperature The pressure sensor sensitive element is made up of a Wheatstone bridge silk screen printed on a ceramic membrane The absolute reference vacuum is found on one face of the membrane the vacuum found in the inlet manifold acts on the opposite face The signal of a piezoresistive nature resulting from the distortion suffered by the membrane is amplified by an electronic circuit contained in the support that houses the ceramic membrane and is then conveyed to the engine management control unit The diaphragm bends with the engine off depending on the atmospheric pressure value thus the exact altitude information is obtained with the key inserted During the engine operation the effect of the vacuum causes a mechanic action on the sensor membrane the latter bends thus making the resistance value to change Since the power supply is strictly kept constant 5 V by the control unit the resistance value variation causes the output voltage value
11. Ka Cep sa gb Fiat Grande Punto OK 282 532 2004 Fiat Auto S p A All rights reserved 4 5 5 Cold operation Under these conditions the mixture becomes lean due to poor turbulence of fuel particles at low temperatures less evaporation and heavy condensation on the inlet manifold inner walls All of this is enhanced by the greater viscosity of the lubricating oil which as everyone knows increases at low temperatures the rolling resistance of the engine s mechanic members The electronic control unit recognizes this condition based on the cooling fluid temperature signal and increases the injection base time 4 5 6 Fully loaded operation The fully loaded condition is detected by the control unit by means of the values provided by the throttle position and absolute pressure sensors Under fully loaded conditions the injection base time has to be increased in order to obtain the maximum power delivered by the engine 4 5 7 Operation during deceleration Two strategies overlap during this engine utilization phase atransient strategy to keep the fuel amount supplied to the engine stoichiometric less pollution this phase is recognized by the control unit when the throttle potentiometer signal shifts from a high voltage value to a lower one e a strategy for soft escorting to a lower engine speed in order to implement the variation of delivered torque reduced exhaust brake 4 5 8 Atmosph
12. Wiping control lever Windscreen wiper control the windscreen wiper is controlled by a ring with 3 stable positions located at the lever end which is actuated by rotation along the lever axis Three different speeds can be chosen intermittent automatic operation continuous speed 1 continuous speed 2 Window washer control the bi directional pump for front window washing is actuated by pulling the lever towards the steering wheel crown This actuation is unstable therefore the lever shall return to its rest position when it is released thus opening the contact again Rear window wiper control the rear window wiper is controlled by turning a ring with 2 Stable positions located in the middle of the lever Rear window washing control the bi directional pump for rear window washing is actuated by pushing the lever towards the dashboard This actuation is unstable therefore the lever shall return to its rest position when it is released thus opening the contact again Trip function button by pressing the unstable button located at the lever end the Trip function will be commanded to the vehicle panel gb Fiat Grande Punto OK 436 532 2005 Fiat Auto S p A All rights reserved Cruise Control control lever This system is managed by the engine control unit and makes it possible to easily maintain the set vehicle speed regardless of the varying running conditions Steering column st
13. gb Fiat Grande Punto OK 157 532 2004 Fiat Auto S p A All rights reserved 3 10 14 Auxiliary fuel electric pump check Regardless of the revs number the control unit powers the auxiliary fuel pump with the key turned to MAR cuts the auxiliary pump power supply off if the engine is not started within a few seconds 3 10 15 Cylinder position check The control unit recognizes during every single engine rev the cylinder in the bursting stroke through the phase sensor and controls the injection sequence to the proper cylinder S gb Fiat Grande Punto OK 159 532 2004 Fiat Auto S p A All rights reserved 3 10 16 Main injection and pilot injection advance check Depending on the signals from the various sensors engine temperature engine revs camshaft sensor air mass meter including the absolute pressure sensor built into the control unit itself the control unit determines according to internal mapping the optimum injection point based on the driving comfort and also the emission limits laid down by the EURO 3 4 standards lt gb Fiat Grande Punto OK 160 532 2004 Fiat Auto S p A All rights reserved 3 10 17 Injection pressure closed cycle check Depending on the engine load as determined by processing the signals from the various sensors i e engine revs engine temperature RDS4 rail pressure sensor fuel temperature the control unit dri
14. Connect the phase sensor electric connection Connect the front engine junction Connect the electric connection of the oxygen sensor upstream the catalyst Connect the injection control unit ground cable Connect the injection control unit electric connections si P gb Fiat Grande Punto OK 323 532 O 2004 Fiat Auto S p A All rights reserved List of tools Type Item code Function Template 2000004500 Drive shaft timing Template 2000004400 Camshaft timing Tool 2000004300 Tappet cover centring gb Fiat Grande Punto OK 324 532 2004 Fiat Auto S p A All rights reserved 5 M20 gearbox 5 1 Features The M20 6 gearbox belongs to a new family of three axle transmission units aimed at improving driveability and characterized by enhanced compact design compared with traditional two axle gearbox units This type of gearbox can sustain and transmit very high torque values 230 Nm for this reason it has been fitted to the most performing diesel engine versions 1 3 Multijet 16V 90 HP Below are the main features of this gearbox very good gear shift control optimum synchronization very high transmissible torque small dimensions The gearbox configuration is of the transverse type with 3 shafts and a differential HCR High Contact Ratio toothing is provided for all the gears Precision finishing after the thermal treatment is provided for all the gears and the final reduction in ord
15. N B The blinking frequency of the external lights and the LED if any on the emergency button will not change Brake lights When the brake pedal is pressed the two brake lights and the third brake light will come on The diagnosis will be carried out for every single brake light bulb and the third brake light bulb as well If an anomaly is found the failure signalling will be actuated on the instrument board gb Fiat Grande Punto OK 481 532 2005 Fiat Auto S p A All rights reserved Headlamps The newly designed transparent glass front light clusters contain the bulbs for dimmers A W 5 W bulb low beam high beam headlights B H4 55 60 W bulb and indicator lights C PY 21 W bulb Headlamp trim is controlled by electric motors Lamp replacement the low beam high beam headlight and dimmer bulbs can be replaced by removing the rubber cap A force fitted at the light cluster rear Release H4 bulb B and take it out As regards dimmer W5W bulbs C take it out of seat B without taking the light cluster off the vehicle The light indicator bulbs can be removed by steering the front right or left wheels outwards to gain access to the lid on the wheelbox which will be released by turning the locking device counterclockwise Now the bulb holder cover can be removed by being rotated counterclockwise gb Fiat Grande Punto OK 482 532 2005 Fiat Auto S p A All rights reserved Protection fuse repla
16. The left control board ELC consists of a module that incorporates the controls on the steering wheel outer side and is interfaced to the Body Computer node BCM and the instrument panel node IPC through the dashboard cable harness The left control board ELC receives the power supply for ideograph lighting and includes the following controls fog lights rear fog lights headlamp trim corrector mode mode mode control used to control different functions depending on the instrument _ FIAT W gb Fiat Grande Punto OK 458 532 2005 Fiat Auto S p A All rights reserved Control mask on the front ceiling light fixture The control mask on the front ceiling light fixture includes the roof opening closing controls which are interfaced with the electric sunroof management control unit through a dedicated bridle as well as the Convergence nod controls which are connected through the front body cable harness 9 2 16 TPMS tyre pressure control system The TPMS tyre management system monitors two tyre pressure control thresholds corresponding to the low tyre pressure and tyre puncture conditions If any of these thresholds is exceeded the respective warning light signalling icon available with the Comfort panel only and the respective message on the display will be actuated In case of tyre puncture the panel will also emit an acoustic signal Moreover a TPMS failure signal warning light ico
17. Tir i F _ j f 1 Ca e y 1 f i f D Ap C F aTi im d Zi Fi d gt il L i E Si if Yi iT al E EA A 14 d 1 Ee e I 3 an A ob pb e e e ex t f T L nl U cdi r d a Fae a F d 4 e 4 KH al AL ET ECH L S rg r a C ai 4 i ta E r 4 ke km Ti Lag U l K A f E mm f f 1 i i i l UH VHH AH KA Lk EE HH dd poros d HEI 5 i 1 1 H NPL PASS ALL A Pu EAKA J L mi Sal ea d J d Sch 1 ta a F i d KP 5 L lor A i d dch KAL REL Le I I i 1 r D L i i i La Ze H k ve gt N d h i 4 hi k L L L i L SC a GE eem a ig d A i LE J L HAE i As E EE ni Ae i n LL t U gb Fiat Grande Punto OK 225 532 2004 Fiat Auto S p A All rights reserved 4 3 7 Pistons al gb Fiat Grande Punto OK 226 532 2004 Fiat Auto S p A All rights reserved 4 3 8 Inlet manifold Newer inlet manifold Es gb Fiat Grande Punto OK 227 1532 2004 Fiat Auto S p A All rights reserved 4 3 9 CVCP continuous phase variator The Fire 1 4 8V engine is equipped with a continuous phase variator Continuos Variable Cam Phaser i e a device capable of continuously modifying during operation the position of the camshaft with respect to the drive shaft thus obtaining an engine timing variation Thus the engine will at any instant be operating with optimum ti
18. 1 3 Multijet 1 4 8V 16V 90 HP Dual tube size 22 x 32 x 46 5 diameters 22 x 32 x 46 5 diameters stem piston stem piston ext tube ext tube Traditional Traditional mechanic stop mechanic stop Open length start of plugging mm Close length at abutting end mm Travel mm 176 different calibration Front stabilizer bar 1 3 Multijet 16V 1 4 8V 90 HP Bar diameter 18 19 mm Si Dual tube size FIAT _ Dual tube size 22 x 32 x 46 5 diameters stem piston ext tube Traditional mechanic stop 1 2 8V Dual tube size 22 x 32 x 46 5 diameters stem piston ext tube Traditional mechanic stop 1 3 Multijet 16V 75 HP 1 3 Multijet 1 9 Multijet 1 2 8V 16V 75 HP 8V 120 HP Dual tube size 22 x 32 x 46 5 diameters stem piston ext tube Traditional mechanic stop 1 9 Multijet 8V 120 HP FIAT PUNTO 46 532 2004 Fiat Auto S p A All rights reserved 2 10 Rear suspensions Helical springs 1 3 Multijet 1 3 Multijet 16V 1 9 Multijet 8V rn wem me msn Edge diameter el JEE No of active coils Free spring height FR x 291 5 mm Spring height under theoretic project load Pack sprin E D I 58 height mm FIAT PUNTO 47 1532 2004 Fiat Auto S p A All rights reserved Shock absorbers AE Y emm mm 16V 90 HP 16V 75 HP 8V 120 HP Dual tube Dual tube Du
19. 13 5 V on H mann aaa A maes i SN LL e OA pedal potentiometer 1 Sig_GND ECU ground Not conecte ss connected I management system remote Main relay 6 4 A 13 5V control switch Engine management system remote Main relay 6 4 A 13 5V control switch pa Accelerator Kee potentiometer 1 0 01 mA 5V signal HN E Brake pedal switch warning light 10 mA 13 5 V gb Fiat Grande Punto OK 199 532 2004 Fiat Auto S p A All rights reserved gt gt A ss A Fuel pump remote control switch 500 mA 13 5 V Engine revs sensor for MTA 40 mA O 13 5 V SE cooling electric fan 2 remote 300 mA 13 5 V control switch Not connected 62 JO A C compressor remote control switch 200 mA 13 5 V Pin lOS Supply source Function Max content Coil 3 control 3 control 9A 9A IV 22 V Power supply from the main relay for a 1 gt e A 77 Engine ground A Phase sensor air temperature sensor sig GND ECU l atmospheric pressure sensor ground neea TOMAS Phase sensor air temperature sensor 5V ECU atmospheric pressure sensor power 100 mA 5 V Not connected gb Fiat Grande Punto OK 200 532 2004 Fiat Auto S p A All rights reserved 5V ECU Throttled body sensor power supply 100 MA 5V ee ee AAA E mi LC I mn arem ger mi mem mn P rem Fenn z f rem foem OOOO EI N I O IL Phase sensor 2MA SV 26 Not connected rp O Pin O S Supply source Function Max co
20. E G R solenoid valve negative Cylinder 1 injector negative Cylinder 2 injector positive Not connected Not connected Not connected Phase sensor negative Not connected Sucked air temperature and boosting pressure sensor positive Sucked air temperature and boosting sensor negative Phase sensor positive Not connected Air flow meter negative Not connected Engine coolant temperature sensor ground Not connected Cylinder 3 injector negative Not connected Not connected Fuel pressure regulator negative Not connected Not connected Not connected FIAT PUNTO 132 532 2004 Fiat Auto S p A All rights reserved Fuel pressure sensor signal Not connected Air flow meter positive Booster pressure signal Not connected Engine revs sensor positive Not connected Not connected Cylinder 4 injector negative Cylinder 1 injector negative Cylinder 3 injector negative Cylinder 2 injector negative Not connected Not connected Not connected Not connected Engine coolant temperature sensor signal Not connected Phase sensor signal Not connected Not connected Revs sensor negative Not connected Connector B Control unit power ground Control unit power ground Control unit power ground Control unit power supply 12 V Control unit power supply 12 V FIAT PUNTO 133 532 2004 Fiat Auto S p A All rights reserved Control unit power supply 12 V Electric fan 1 control E
21. FIAT PUNTO TRAINING OUTLINE a After Sales Training 8 VALVE 1 4 ENGINE Position on the vehicle do Y Sch Saa TREN Ce l Atmospheric pressure sensor position gb Fiat Grande Punto OK 217 532 2004 Fiat Auto S p A All rights reserved Pin out Component Component connector pin Atmospheric pressure sensor Recovery Receiving item pin Power supply from the ECU 13 ECM connector B Ground from the ECU 7 ECM connector B Atmospheric pressure sensor 61 ECM connector B signal In case of sensor failure the value found in the inlet manifold upon key ON or in fully loaded conditions throttle fully open will be considered as the atmospheric pressure value FIAT dy i a Eeer gb Fiat Grande Punto OK 278 1 532 2004 Fiat Auto S p A All rights reserved 4 5 Operation logic 4 5 1 System self adaptation The control unit features self adaptive functions that recognize the changes occurring in the engine following time adjustment processes and component or engine ageing These changes are stored into the memory as basic mapping modifications their purpose is to adapt the system operation to the progressive engine and component alterations compared with as new features This self adapting feature also makes it possible to compensate for the unavoidable differences due to production tolerances of replaced components if any The control unit modif
22. Fiat Punto alal AA FIAT PUNTO 1 532 2004 Fiat Auto S p A All rights reserved DOCUMENTATION MODIFICATIONS UPDATES Date Referent File name Description of modification 2004 Fiat Auto S p A All rights reserved No part of this publication may be reproduced or disclosed in any form or by any means Processing the material below may not involve specific responsibilities for unintentional errors or omissions The information given in this publication are liable to continuous updates Fiat Auto S p A undertake no responsibility for the consequences resulting from the use of outdated information This publication is issued for training purposes only As regards the technical information complete and updated for servicing purposes please refer to the service manual and any other service information for the vehicle model concerned Index 1 A nn o 11 1 1 CENERI 11 P Ilia 11 DL Mo rile 12 1 2 KE E 14 P T ann 14 A e O EL o GE OOO 15 2 DIVI 16 FE Z LIO 18 A E 19 EE 19 EL All 20 AOL ILL 20 gt O ui ZZ 1 2 10 Ee 23 1 2 11 CO 24 1 2 12 Tnierior com ort E 24 1 2 13 UREA P 26 1 2 14 PP e eo OO ze 28 1 2 15 UMM 28 1 3 ACCESSORI E 30 od PONE 30 52 Cioe ea 30 io Sluc AI 31 2 TECHNICAL SFECIFICATIONS oasis ate 33 2 1 ENCON E 33 Sit A GE 33 Sege A A iaa 34 22 TIMING ANGEES Re RR RZ EE 35 2 3 ENGINE OHA RAO TRUS TO CURVES rino aio 37 2 4 KL CR 41 Zid CUR E 41 26 RTE E 42
23. 3041 Tunnel ground Rear window wiper motor gb Fiat Grande Punto OK Headlamp washing When front washing is requested through the steering column stalk with the high beam headlamps ON headlamp washing will be actuated for 1 2 seconds Cruise Control function operation the system operates in the following modes speed memorization achieved discrete and continuous speed increase set speed memorization achieved discrete and continuous speed decrease set memorized speed recall resume A warning light on the board actuated by the engine management control unit indicates the system s operating status To actuate the system turn the ON OFF ring to the ON ignition position then bring the vehicle to the desired speed the vehicle speed shall in any case be higher than 40 k p h and act on the sett or set controls now the accelerator can be released and the Cruise Control may be allowed to operate automatically This system may function over the entire range of revs permitted by the engine and may manage vehicles equipped both with manual and robotized gearbox units However the system control does not come into action in the following cases neutral reverse gear 1 speed mechanic gearbox vehicle speed lower than 40 k p h The Cruise Control can be deactivated by simply actuating either the brake or the clutch pressing the RES resume button will subsequently ma
24. if the glass is opened for more than 4 mm from the gasket edge when an obstacle is found on the rear side of the glass panel it reverses the glass motion until the compass opening position is reached In both cases the load that causes motion inversion is less than 100 N as laid down by the EC Directive 2000 4 Possible pinching from the vehicle interior in the panel side zones is avoided by making use of side guards that prevent the hazard zones from being reached gb Fiat Grande Punto OK 530 532 2005 Fiat Auto S p A All rights reserved 11 4 Emergency actuation The front glass panel can be opened or closed manually in an emergency or if maintenance operations are carried out when the power supply is not available by following the procedure below remove the protection cap located on the inner covering between the two due window shades procure the Allen wrench supplied with the tool kit located in the luggage compartment put the wrench into seat A then rotate it clockwise to open the sunroof counterclockwise to close it 11 5 Initialization In case of battery disconnection or manual emergency glass handling the sunroof shall be initialized Follow the procedure below keep button A depressed in the closing position keep the button depressed so that the sunroof jolts along to be fully closed wait after the sunroof has fully closed for the electric motor to come to a halt gb Fiat Grand
25. low pressure means that the load imposed to the air conditioner is such that it does not require very high fluid flow rate high pressure means that a very high load is imposed to the air conditioner and the required amount of cooling fluid is great Operation The pulley motion is transmitted continuously to the compressor shaft by means of jumpers referred to as limiters 3 which are interrupted in case of seizure due to a compressor fault thus preventing the pulley from getting stuck and therefore the auxiliary member belt from being broken In order to reduce the torque fluctuations that generate noise special dampers referred to as dumpers 4 and an inertia ground 5 directly secured to the shaft are also used Since the motion is always transmitted to the compressor shaft the compressor switch on off function is entrusted to the ON OFF valve 6 gb Fiat Grande Punto OK 517 1 532 2005 Fiat Auto S p A All rights reserved u a ta jo al e H E proa H wt P la F Sectional view of the compressor Technical features The 5SL 12 compressor flow rate may vary depending on the load variations requested from the system as well as changing external temperature and or humidity conditions and sudden engine load changes Below are the main technical features of the compressor direction of rotation clockwise max number of continuous re
26. set up menu When the limit expiry value 0 km miles has been reached the Servicing expired message will be displayed gb Fiat Grande Punto OK 421 532 2005 Fiat Auto S p A All rights reserved Displaying after the 9 slips have been carried out After the nine servicing slips have been completed no message will be displayed automatically any longer and the respective item from the set up menu cannot be selected any more i e it cannot be actuated Reset by the servicing dealership Upon every scheduled expiry the following operations shall be carried out the km or mile counter shall be reset to the starting values through the diagnosis instrument the execution of the preventive maintenance servicing slip operation shall be stored in the memory therefore the latest slip carried out shall be traceable through such indications as the date of servicing number of the slip and the total distance covered kilometres These stored data are kept even if the battery is disconnected from the vehicle Vehicle panel replacement In case of vehicle panel replacement the following operations shall be carried out resume the covered kilometres or miles as indicated by the odometer check the number of servicing slips carried out and write them down on the new vehicle panel check the counter that calculates the kilometres or miles left before the vehicle is to be serviced again then
27. the central knob makes it possible to control the fan speed four different speeds can be selected the right knob allows the user to control air distribution five positions shown in the area around the knob During the designing of the special knob and control shape ergonomics has taken priority over style thus obtaining intuitive easy to reach controls Inside the mask are also the buttons for recirculation control rear heated window actuation and compressor switch on versions with air conditioner only gb Fiat Grande Punto OK 513 532 2005 Fiat Auto S p A All rights reserved N 109 Ri st LO 10 1 2 Air flows Air flow and vent diagrams 10 2 Components 10 2 1 ECC Electronic Climate Control control unit As we have said above the automatic air conditioner is available in the two zone configuration only this version is the only one that makes use of the ECC ECC pin out Re pe pre CANL CAN H N C N C PWM output Spreading sensor power supply Temperature sensor 1 signal Spreading sensor signal N C Temperature sensor 4 signal Temperature sensor 3 signal Spreading sensor signal Temperature sensor 2 signal Z Z OLO N C C z z OL o Z O Z O j LI Mep KA KEE K KEE H Left mixing motor position signal gb Fiat Grande Punto OK 515 532 2005 Fiat Auto S p A All rights reserved EUR sr a sr po sant 28 Left distri
28. the following procedure shall be followed put the starting key into latch B turn the device from position 2 to position 1 then close the leaf After the device has been switched on the rear doors can be opened by acting on the vehicle s inner handles Child safety device 5 door versions This device prevents the rear doors from being opened from the inside and comes useful especially when children are carried on the vehicle The device can be actuated only when the doors are open Position 1 device ON door locked Wal DI gb Fiat Grande Punto OK 471 532 2005 Fiat Auto S p A All rights reserved Position 2 device OFF the door can be opened from inside the vehicle The device will remain ON even if the doors are unlocked electrically NOTE Do not actuate the rear door locking emergency device simultaneously with the child safety device 9 4 Electric window regulators 9 4 1 General remarks The electric window regulator controls for both the front doors all the range versions and the rear doors where available are managed on the driver s side front door The other window regulators are controlled directly from their respective doors Controls and operation front window regulators only Versions not equipped with the automatic device The front electric window regulators can be operated only manually the window start and stop are controlled manually by the user by pres
29. 4 8V 1 2 8V 16V 90 HP 16V 75 HP 120 HP Type code 350A1000 199A3000 199A4000 199A2000 939A1000 Location on Front Front Front Front Front the vehicle No of 4 4 4 4 4 cylinders Position of cylinders No of valves 2 A 2 4 2 per cylinder 1ACT with l 2ACT 1ACT 2ACT 1ACT phase variator Finger rocker Finger rocker Timing With mechanic arm with With mechanic arm with With mechanic tappets hydraulic tappets hydraulic tappets tappet tappet m e e LL e L MultiJet direct MultiJet direct injection of the MultiJet direct injection of the MPI Common Rail injection of the Common Rail MPI electronic l electronic type with l Common Rail type with Fuel feed sequential sequential variable l type with variable timed timed geometry turboblower geometry turboblower and intercooler turboblower and and intercooler intercooler FIAT PUNTO 33 532 2004 Fiat Auto S p A All rights reserved 2 1 2 Engine data RE a a aee 16V 90 HP 16V 75 HP 8V T HP Bore Bore mm Dn 708 8 Set Stroke mm ae 86 a l 4 Total Ba A 1368 1248 1242 1248 1910 cm Compression ratio ratio ALE MO 1 TH 47 TB 1 A rating EC HP Max rating 56 48 55 88 EC KW Max power speed 5750 4000 5500 4000 4000 r p m Max torque 114 200 102 2 190 280 EC Nm Max torque 11 6 20 4 10 4 19 4 28 5 EC kgm Max torque speed 3000 1750 3000 1750 2000 r p m Idlin
30. Description The throttled body is secured to the inlet manifold and controls the amount of air sucked by the engine The injection control unit controls depending on the signal from the accelerator pedal potentiometer the opening of the throttle by means of a direct current motor integrated into the throttled body Operation The opening of the throttle takes place from 0 to 82 thus including the idling speed control The throttled body is equipped with two integrated potentiometers so that the injection control unit Knows when either of them is broken In the event that both potentiometers are broken or if the power supply is missing the control unit will depending on the accelerator pedal position perform a recovery strategy with resulting degraded operation which will be perceived by the driver and disables EOBD diagnosis The replacement of the throttled body or injection control unit or air intake manifold does not ask for the execution of the self learning procedure Position on the vehicle ee gb Fiat Grande Punto OK 21 6 53 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A 8 VALVE 1 4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training Throttle Potentiometers Motor gb Fiat Grande Punto OK 21 7 532 2004 Fiat Auto S p A All rights reserved Electric features 1 5 SE 15 d4 20 35 el el Ssss a of lol olo El Fl Sigg 2 1 ECM 2 Throttle a
31. Engine oil cooling water oil heat exchanger Nozzle timing chain lubrication Engine oil pressure warning light switch Turboblower lubrication pipes Engine oil level dipstick Engine oil level maintaining and scraper ring bulkhead Timing chain cover FIAT PUNTO 90 532 2004 Fiat Auto S p A All rights reserved 3 3 4 Heat exchanger and oil filter assembly This assembly includes both the filter element and the heat exchanger the latter features the oil filling cap on its side 1 Oil filling cap 2 Filter element cover 3 Water oil heat exchanger 3 3 9 Engine oil pump The engine oil is sucked by the sump through the vacuum generated by the rotation of the gears force fitted onto the drive shaft The vacuum is found starting from the gear partition bulkhead 1 up to the oil sump plummet Conversely the pressure develops starting from the partition bulkhead 1 in all the engine oil supply ducts 2 FIAT PUNTO 91 532 2004 Fiat Auto S p A All rights reserved When pressure exceeds 5 bar the thrust applied on relief valve 6 overcomes the reaction of the spring underneath and moves the valve until the connecting duct 8 between pressure chamber 7 and low pressure chamber 5 is opened 1 Partition bulkhead 2 Oil supply duct 3 Driven gear 4 Driving gear 5 Low pressure chamber 6 Relief valve Pressure chamber 8 Connecting duct between high and low pressure FIAT P
32. In case of collision the column folds back by causing controlled energy absorption All of this reduces to a large extent the load suffered by the occupant s thorax during the collision gb Fiat Grande Punto OK 366 532 2005 Fiat Auto S p A All rights reserved 8 Suspensions 8 1 Description The suspensions fitted to the Nuova Punto have been completely re designed compared with the previous model The main differences with respect to the known models are as follows wider wheel tracks and greater tyre dimensions compared with the current Punto 15 to 17 inches wheel rims with 175 65 15 to 205 45 17 tyres compared with 14 and 15 inches rims and the 165 70 14 to 185 55 15 tyres of the current Punto Front suspension geometry with right angled triangle lower arms realized in order to decouple to a larger extent the effect of the braking loads from the effect of the cornering loads thus ensuring optimum balance under any running condition The new front geometry has also made it possible to reduce the vehicle steering diameter to values similar to the current model despite the use of wider wheels with a higher wheelbase Torsional axle rear suspension designed in order to increase both structural rigidity and loaded suspension flexibility obtained by optimizing the bushing that connects the rear axle with the body The development of the new suspension has also concerned the plugging configuration in order to imp
33. L1 out 16 Front left ABS sensor ABS control unit pin out power supply Hood D H DH H OD D D DH DH HD H D DH od U 17 Rear left ABS sensor signal 18 Body Computer node 19 Rear right ABS sensor signal 20 Brake lights 21 ASR button input 22 ASR button LED 23 VSO output 24 N C 25 C CAN H1 26 C CAN H gb Fiat Grande Punto OK 352 532 2005 Fiat Auto S p A All rights reserved 6 4 2 ABS hydraulic unit The ABS electro hydraulic control unit 1 is connected to the brake pump and calipers through the braking system pipes and makes up together with the electronic control unit 2 the electro hydraulic driving unit This unit is fitted in a vertical position and incorporates 4 couplings 3 on its side two front pipe couplings and two rear pipe couplings Moreover two pipes from the master cylinder are found on the upper part 4 G WAT 4 DA TAa FIDA Y Ca 38 ABS hydraulic unit e gb Fiat Grande Punto OK 353 53 2005 Fiat Auto S p A All rights reserved 6 5 E S P The E S P Electronic Stability Program is an active safety system for controlling the vehicle during dynamic manoeuvres It comes into operation in emergency situations and has been designed to correct the path of the vehicle in case of sudden manoeuvres which are often unintentional thus enhancing active safety especially on slippery road surfaces In fact the E S P promptly re
34. Lack Unlock key cyl inder Dead lack Driver s side front door locking actuator gb Fiat Grande Punto OK 469 532 2005 Fiat Auto S p A All rights reserved Device actuation and deactivation The device is automatically actuated on all the doors if the button on the key equipped with the remote control is pressed twice quickly Remote control antenna CNVd TIOS RF antenna CB angl conxiel cable AE Gee caren ase RF antennae GHO coomiol cable e N 66H1 6 35 M BCHi 8 35 Body Computer node BCM The device actuation is signalled by 3 blinks of the indicator lights and the blinking of the LED located on the button placed between the controls on the dashboard The device cannot be switched on if one or several doors are not closed correctly this prevents anybody from getting on the vehicle through the open door and then getting stuck inside the passenger compartment after the door has been closed The device will be automatically deactivated on all the doors when the mechanic starting key is turned to the opening position in the driver s side door the doors are unlocked by means of the remote control the starting key is turned to position gb Fiat Grande Punto OK 470 532 2005 Fiat Auto S p A All rights reserved Rear door locking emergency device The rear doors feature a device that makes it possible to lock the doors when the current is missing In this case
35. OK 211 53 2004 Fiat Auto S p A All rights reserved Pin out Component Component connector Power supply from the main relay Cylinder 1 ignition control Cylinder 2 ignition control Cylinder 3 ignition control Cylinder 4 ignition control d 1 FIAT a a pt Receiving item pin The wires reaches 1 JUNCTION FDU until gb Fiat Grande Punto OK 212 532 2004 Fiat Auto S p A All rights reserved 4 3 3 Petrol vapour recovery solenoid valve canister Electric features Engine management system remote control switch 2 3 1 12 E AN 1 00 7 5 3 1 ECM 2 FDU engine management remote control switch 3 Junction 4 Canister solenoid valve d i 1 L k mi FIRT D MN 0 75 1 gb Fiat Grande Punto OK 213 532 2004 Fiat Auto S p A All rights reserved Position of components on the vehicle Canister FIAT gb Fiat Grande Punto OK 214 532 O 2004 Fiat Auto S p A All rights reserved Pin out Component Petrol vapour recovery solenoid valve Component connector pin W s le _ Function Power supply from the battery Canister valve control ni gb Fiat Grande Punto OK 215 532 2004 Fiat Auto S p A All rights reserved Receiving item pin 7 junction 51 ECM connector B Remarks The wire reaches FDU until pin D3 4 3 4 Throttled body
36. RDS 4 4567 CR1 MI 2 2 INJECTOR FEED 8 FEED FROM HIGH PRESSURE CP1 CP1H 9 RETURN OVER FLOW Two types of single fuel manifold pipes rail are available one standard forged rail FR for the 75 HP engine version one standard laser welded rail LWR for the 90 HP engine versions fitted to the cylinder head on the intake side With a volume of approximately 20 crm it dampens the fuel pressure oscillations due to the pressure pump operation the opening of the electric injectors The difference between the two rails lies with the manufacturing procedure one is forged FR whereas the other is made with laser welds LWR that ensure more accurate manufacture and higher resistance to high pressures 1 600 bar FIAT PUNTO 119 532 2004 Fiat Auto S p A All rights reserved The fuel pressure sensor RDS 4 is fitted to one side of the RAIL delivery manifold whereas the pressure regulator RDS 4 is connected to the other side The hydraulic high pressure connections between the pump manifold and the electric injectors manifold are made by means of steel pipes with inner diameter of 2 mm and outer diameter of 6 mm With regard to these pipes special wrenches shall be used for disassembling and assembling and a torque wrench shall be used when tightening to less than 20 Nm Standard Forged Rail FR Standard Laser Welded Rail LWR FIAT PUNTO 120 532 2004 Fiat Auto S p A All rights reserved 3
37. a pressure of at least 0 7 bar therefore the fuel feed system is equipped with an auxiliary electric pump immersed into the tank The maximum discharge pressure reaches 1 400 bar The pressure pump is lubricated and cooled by the fuel itself through special channelling FIAT PUNTO 105 532 2004 Fiat Auto S p A All rights reserved Pump section View of the three plungers FIAT PUNTO 106 532 2004 Fiat Auto S p A All rights reserved CP1 pump diagram and section CP1 pump section a Shut off valve High pressure active High pressure off b Lubrication hole holeazione FIAT PUNTO 107 532 2004 Fiat Auto S p A All rights reserved 3 6 3 Bosch CP1H high pressure pump 90 HP Return High pressure flow outlet Low pressure inlet KUEV valve Features The 90 HP engine features a Bosch CP1H high pressure pump which is a step forward compared with the CP1 pump Now the high pressure pump makes a system pressure of up to 1 600 bar available in the rail This has been achieved by reinforced drive modified valve units and measures taken to increase the body sturdiness To ensure a sufficient amount of fuel the high pressure pump has been set to reach a total flow rate of 160 I h The required flow rate is adjusted continuously by means of the M PROP solenoid valve found on the high pressure pump This valve adjusts the fuel amount let into the r
38. and rear pillars 1 side acceleration and yaw sensor incorporated into one single device fitted onto the central tunnel 1 electro hydraulic unit fitted onto the special support in the engine compartment 1 switch on the brake pedal gb Fiat Grande Punto OK 354 532 2005 Fiat Auto S p A All rights reserved 1 ON OFF button available on the dashboard to switch the A S R off 1 steering angle sensor built into the steering column 1 longitudinal acceleration sensor YRS built into the yaw sensor available only with the Hill Holder option In addition to the above mentioned sensors and of course the control unit the system is interfaced with the items below high speed CAN line ABS data exchange with the engine control unit automatic transmission control unit power assembly specific brake pump power driven throttled body petrol versions data exchange with the ASR instrument board warning lights of the active type steering angle sensor fitted to the steering column yaw sensor located on the central floor in the central cabinet area to detect the vehicle s side acceleration and inclination special control unit fitted to the engine compartment The E S P is automatically switched on when the vehicle is started and cannot be switched off a FA gb Fiat Grande Punto OK 355 532 2005 Fiat Auto S p A All rights reserved 6 5 1 ESP wiring diagram ASR button on the d
39. as well as the functions below passenger compartment interior lighting external lighting sidelights brake lights low high beam headlamps indicator lights reversing lights wiper operation rear heated window door and boot lock unlock fuel level fuel pump key status management and acquisition gateway between the B CAN and C CAN networks and between the LIN and B CAN The immobilizer and remote control RF antenna interfaces are provided on the BCM N i Wi DI gb Fiat Grande Punto OK 401 532 2005 Fiat Auto S p A All rights reserved Pin out Connector LA Description KI 15 relay control T6 Switch lighting Fog light relay control KL 15a relay control T30 VSO output 2 Headlamp washing pump sensor signal Driver s door ajar signal to the MTA n our indicator LED control I orn relay control igh beam headlamp relay control omfort closing WLW O Rear defrosting LED control KL 15a relay control T5 Not connected Not connected Low beam headlamp relay control Boot opening switch signal Four indicator switch signal Light switch signal normally closed EN ear defrosting switch signal Brake oil level signal n ront wiper parking contact signal eserve input ront wiper contact signal Clutch switch signal After sales anti theft system signal Front brake pad wear sensor signal Brake light switch signal normally open Front driver s door key cyl
40. bar Inflating pressure with average front load Version 1 3 Multijet 16V 90 HP 185 65 R 15 88T 195 55 R 16 87H 205 45 R 17 88V Inflating pressure with average front load Inflating Inflating pressure with pressure with average rear full front load load Inflating l l Inflating pressure with pressure with average rear full front load load Kr FIAT PUNTO 59 532 2004 Fiat Auto S p A All rights reserved Inflating pressure with full rear load Inflating pressure with full rear load Version 1 2 8V Inflating pressure with average front load 175 65 R 15 84T Version 1 3 Multijet 16V 75 HP Inflating pressure with average front load 185 65 R 15 88T Version 1 9 Multijet 8V 120 HP Inflating pressure with average front load 185 65 R15 88H Inflating Inflating pressure with pressure with average rear full front load load Inflating Inflating pressure with pressure with average rear full front load load Inflating Inflating pressure with pressure with average rear full front load load Inflating pressure with full rear load Inflating pressure with full rear load Inflating pressure with full rear load 205 45 R 17 BBV FIAT PUNTO 60 532 2004 Fiat Auto S p A All rights reserved 3 1 3 Multijet 16V 75 and 90 HP engines 3 1 General remarks Turbo diesel direct injection engine with no
41. cable harness Body Computer node NBC Convergence node NCV 38 Low veel CU Iremn ee Dak A For Fab AH LA For Opal inbarrally aonmgabed Lo 018 Ga GA lou ei CAN ramzer SCAN A For Fe SULE For Jul internally connpetod to DS Z Low apaa CEN Lenger CAN A For Fink SW LE For opel inberrally armeobad to 499 014 b Lom bae CAN Lann inn DIL H For Fink kU LE For Opel mam lu greska lo I Radio receiver node NRR BA Blo enden BAU Aan pe Light apn Instrument board node NQS B CAN FOR ORIGINAL SYSTEM RADIO Ln U U mmm Airbag node di LE WX H BUR ssl ug sa I BARA 2005 Fiat Auto S p A All rights reserved 434 532 gb Fiat Grande Punto OK General remarks CRUISE CONTROL LEVER Light control lever Below are the controls associated with this lever light selector flashing light steady high beam headlamp switch indicator and lane change lights The controls are actuated by acting on the levers as follows movement on the steering wheel plane in both directions with double click the former is unstable the latter is stable pulling movement towards the driver with double click unstable ring rotation by 3 or 4 clicks gb Fiat Grande Punto OK 435 532 2005 Fiat Auto S p A All rights reserved Light selector it consists of a ring with 3 stable positions located at the lever end which is actuated by rotation along the lever axis
42. closed cpelescheck suine 161 de Fleece balance Che iaia 161 SA E E 162 3 10 20 Cruise Control system check where available i 163 3 11 PP E oo e E 165 3 12 AIR FLOW METER WITH BUILT IN AIR TEMPERATURE SENSOR HEM oi 175 3 13 iE RE REST RI ARR RSA 184 4 eV ALY BEA A AI a 187 4 1 TEEN RAT INK TH 187 4 2 IAW SSF INJECTION IGNITION CONTROL UNIT NEE 191 C leva 19 A Milian 196 4 3 COMPONENTS eege 203 55 PA 203 A PPP A E E EA A E N E SEAE EE ES EEE TES EA EAE A 208 4 3 3 Petrol vapour recovery solenoid valve canister iiiiii 213 4 3 4 Throttled body n FIAT PUNTO 6 532 2004 Fiat Auto S p A All rights reserved 4 3 5 nn E E E 223 i EE 226 E Wide 227 EI 228 4 4 SENSOR titi 241 e AI A ee ee eee 241 Sd L02400 TTT 245 c LCOS ona 248 EE 253 445 Engine coolant temperature Sensor iii 247 4 4 6 Sucked air pressure and temperature SenHSOr EERE EERE EEE 261 4 4 7 Accelerator pedal potentioanmieter rina 266 440 EE 269 4 5 OPERATION TO I ila 219 CS E NEE 279 495 2 Wel QIAQTIOSIS and CONO rin ia 280 4 5 3 Cylinder position recognition sse eee 281 4 5 4 Oxygen sensor combustion check 281 535 cr 283 450 PFullydoaded MAA 284 43 7 Operalion EE 285 EE 285 SE EE 287 4 5 10 ee 288 4 5 11 EE EE 289 4 5 12 Lae ee RAE AA io o A 290 4 5 13 MOR 291 4 5 14 RANGO CICCIO JAN CONT drill 292 4 5 15 ENLNEIdINSCOMFOLMMALMEN siii 293 4 5 16 Optimization of thermal operating co
43. constant value every time the lever is slightly moved towards the sign and subsequently released thus causing the speed to increase by steps of equal size When the lever is released the system will maintain and memorize the new speed reached by the vehicle Decelerate function this function makes it possible to decrease the vehicle speed previously set in the Cruise Control so as to generate as long as the lever is kept operating in the direction a steady slope deceleration ramp When the lever is released the system will maintain and memorize the new speed reached by the vehicle The system may only reduce the set speed not the actual speed if the engine is already pulled e g vehicle running downhill and high gear Tip down function this function makes it possible to decrease the vehicle speed previously set in the Cruise Control by a constant value every time the lever is slightly moved towards the sign and subsequently released thus causing the speed to decrease by steps of equal size When the lever is released the system will maintain and memorize the new speed reached by the vehicle gb Fiat Grande Punto OK 445 532 2005 Fiat Auto S p A All rights reserved Resume function this function makes it possible to resume by pressing the RES button the latest vehicle speed value stored by the Cruise Control if the latter has not been switched off due to partic
44. ear ln Sh FIAT PUNTO 19 532 2004 Fiat Auto S p A All rights reserved 1 2 7 Active safety Active safety is meant as the whole of the technical solutions that help avoid road accidents Nuova Punto features the mechanic and electronic safety systems below ABS all versions feature an integrated anti lock system that controls the braking action so as to prevent the wheels from being locked EBD electronic braking distributor between the front and rear wheels ESP an active safety system which comes into operation in emergency situations for controlling the vehicle during dynamic on road manoeuvres The ESP system comes as a standard item on the Sporting version only The entire range is equipped with ABS system with EBD and ventilated brake discs on the front wheels except for the 1 2 8V engine version which is equipped with non ventilated discs 1 2 8 Passive safety Passive safety is meant as the whole of the technical and product solutions that protect the driver and the passengers in case of accident The technical solutions adopted aim at protecting the driver and the passengers in case of head on side and rear collisions With Nuova Punto FIAT has made important progress as far as safety is concerned Innovative design and construction solutions have been adopted on Nuova Punto so as to obtain the best results in terms of occupant protection FIAT PUNTO 20 532 2004 Fiat Auto S
45. from the central board by means of button C Button geb actuates the remote opening of the boot gb Fiat Grande Punto OK 464 532 2005 Fiat Auto S p A All rights reserved AA IL IL IL ee SE 22 Oo eS If the doors are locked the LED will light up for approximately 3 seconds and then will start blinking deterrent function If the boot or one or several doors are not closed correctly the LED will blink quickly together with the indicator lights Vw N gb Fiat Grande Punto OK 465 532 2005 Fiat Auto S p A All rights reserved Control dashboard 430 Jun GEN BEL H H BL B JY GE He 0N UNO 351 Body Computer node NBC GE p JY SE H H SE He h LL ue up apre UBU pay EE prou Baymuo BP HLH 260 SEQ REH 99 Ppiopuupg A yeuwe qui Li p un GD quubia 2005 Fiat Auto S p A All rights reserved 466 532 gb Fiat Grande Punto OK Boot lock actuator Automatic central locking with the vehicle running Autoclose This function makes it possible when actuated ON to automatically lock the doors when a speed of 20 k p h is exceeded The function can be actuated ON or deactivated OFF as follows briefly press the MENU ESC button the display will show a submenu briefly press the MENU ESC button the display will show ON or OFF in the blinking mode depending on what has been previously set select by pre
46. gas is best used to actuate the turboblower exhaust gas turbine the latter actuates the compressor which compresses the sucked air by heating it Then the air is cooled again in the intercooler Operation At low speeds the turboblower s distributor blades are actuated electrically and positioned i by vacuum in such a way that the exhaust gas flow hits the outer edge of the turbine blades This causes the exhaust gas flow to be restricted and involves increasing exhaust gas flow speed and boosting pressure According to the principle of the lever all of this involves a higher torque at low speeds If the engine revs number increases the exhaust gas inlet section will be increased by displacing the distributor blades 11 Now the gas particles will not preferably hit the outer edge of the distributor blades any longer they will be found along the entire length of the blades The turboblower will operate less efficiently which will however be compensated for by the greater exhaust gas volume at high engine speeds If however the engine s maximum power is required e g when overtaking the electro pneumatically operated blades will be displaced to the low speed position which will significantly enhance the turbine performance and as a result the boosting pressure thus making the engine s maximum power available FIAT PUNTO 82 532 2004 Fiat Auto S p A All rights reserved Turboblower view LO014202 1 Lo
47. give up by pressing the or buttons press the MENU ESC button for a short time a selection confirmation message will be shown and the menu screen will be resumed alternately press the button for a long time to go back to the standard screen without storing in the memory gb Fiat Grande Punto OK 504 532 2005 Fiat Auto S p A All rights reserved Display Multifu Bas Pass OFF EE 630 MENU ESC MENU ESC MENU ESC o Passeasero Bas Passessero cio CD RI 8 30 disinserito ab 830 gb Fiat Grande Punto OK 505 532 2005 Fiat Auto S p A All rights reserved 9 7 4 Diagnosis and recovery Airbag warning light SDM side Based on the airbag status signal on the B CAN the SDM communicates the following conditions to the IPC airbag system failure the airbag warning light comes on through the signal from the SDM test not completed the airbag warning light blinks through a signal from the SDM check upon key ON the airbag warning light comes on through an automatic combination set by the IPC for 4 seconds the signal comes from the SDM From the other side the IPC sends the SDM through the B CAN line the airbag warning light signal and informs the SDM for the warning light status diagnosis Upon key ON the warning message will be shown for 20 seconds if the light is still ON after the typical time AB 15 s since the key ON if after the
48. icy road surfaces loss of grip on wet roads A S R switch on off The ASR is switched on automatically every time the engine is started The ASR can be switched off and then on again when the vehicle is running by pressing the special switch located among the controls on the instrument board gb Fiat Grande Punto OK 358 532 2005 Fiat Auto S p A All rights reserved When travelling on snow covered roads with the snow chains fitted to the wheels the ASR can be switched off under these conditions the driving wheel slip during the pick up phase makes it possible to achieve better traction To ensure correct operation of the ASR system all the tyres should be of the same type on all the wheels moreover they should be in perfect conditions and above all of the prescribed type make and dimensions 6 5 4 M S R This function is an integral part to the ASR and comes into operation in case of a sudden shift down by delivering torque to the engine again Thus excessive driving wheel drag is avoided which may cause the vehicle s loss of grip especially in poor grip conditions 6 5 5 Hill Holder The Hill holder function combined with the ESP system assists the driver in starting the vehicle uphill This function combines the information gained through special sensors from the pedal unit gearbox and engine management control unit so as to automatically deliver the FIAT gb Fiat Grande Punto O
49. in 10 of all head on collisions For this reason airbags with dual actuation stage have been designed When a medium seriousness collision takes place the electronic control unit will only drive the first airbag actuation stage avoiding the development of unnecessary energy for the occupant s protection Conversely in case of very serious collisions the control unit will drive both stages so as to absorb the occupant s greatest kinetic energy before the occupant hits against the steering wheel or the dashboard Driver s side front airbag it consists of an instantly inflating cushion held in a special compartment located in the middle of the steering wheel i A Wal DI gb Fiat Grande Punto OK 499 532 2005 Fiat Auto S p A All rights reserved Passenger s side front airbag where available It consists of an instantly inflating cushion held in a special compartment located in the instrument board the cushion volume is greater than the driver s side cushion Safety belts with pretensioner and load limiter the sensors that control the airbags also control the actuation of the safety belt pretensioners Their function is to recover the belt tape play if any and hold the occupant tight to the vehicle form the very first instants of the collision thus reducing the overall displacement of the occupant inside the passenger compartment The belts also feature load limiters that reduce the force transmitte
50. in the rear passenger foot zone Air flow and vent diagram o nani FIAT PUNTO 26 532 2004 Fiat Auto S p A All rights reserved G l 865 Automatic two zone air conditioner Air conditioning control layout FIAT PUNTO 27 1532 2004 Fiat Auto S p A All rights reserved 1 2 14 Sunroof The Nuova Punto sunroof includes a special wide glass system called Skydome made up of two glass panels one front sliding panel and one rear fixed panel The glass surface is so large that it takes the place of approximately 70 of the roof panel During the opening phase the front moving panel slides out of the roof panel spoiler position The wide roof glass surface lets a lot of sunshine into the vehicle interior This helps increasing the feeling of much interior space available to the occupants The Skydome sunroof is equipped with sliding curtains that allow less sunshine into the passenger compartment 1 2 15 Audio system The sound sources available depending on the versions are a radio tuner and a CD MP3 player The sound system found on the vehicle may be of two different kinds standard hi fi sound system Ve_ N Gi hi _ E i FIAT PUNTO 28 532 2004 Fiat Auto S p A All rights reserved Standard system This system is made up of 6 loudspeakers as follows mid woofer loudspeakers 40 W diameter 160 mm located on the front
51. makes it possible to easily accommodate two passengers on the rear seat of the 3 door vehicle yet approval for five passenger seating can be asked for by fitting the third rear safety belt too The vehicle layout setting has been guided by the most advanced state of the art criteria for defining the basic ergonomic functions consistently with the style and safety prerequisites Interior space and volume Interior comfort and room Easy access into the vehicle Visibility Luggage compartment Utilization capabilities These functions are related to parameters that measure the vehicle s capability of meeting with the interior comfort requirements FIAT PUNTO 25 532 2004 Fiat Auto S p A All rights reserved 1 2 13 Air conditioning Psychophysical wellbeing of the vehicle occupants is guaranteed by an air conditioning system that creates the optimum conditions for travelling The range offer makes three different systems available heater air conditioner automatic two zone air conditioner with provision for obtaining different air temperatures and distribution patterns both for the driver and the passenger These systems make it possible to choke and direct the air flow in many ways so as to create the desired effect which is always homogeneous in the entire passenger compartment In addition the windscreen demisting function comes as a useful tool The versions equipped with air conditioner feature air ducts
52. of the scale if the temperature is included between 50 C and 80 C the pointer will move linearly in the temperature is included between 80 and 15 C normal operation the pointer will remain stable in the middle of the scale if the temperature is included between 115 and 124 C uphill and between 120 and 115 C downhill the pointer will move linearly gb Fiat Grande Punto OK 411 532 2005 Fiat Auto S p A All rights reserved If the temperature is 124 C uphill the pointer will remain at the start of the red hazard sector of the scale 124 C 130 C if the temperature equal to or higher than 124 C the max engine coolant temperature warning light will come on at the same time the pointer will position itself at the bottom of the scale MODE panel COMFORT panel Max interpixel dimensions Power supply 4 7V gb Fiat Grande Punto OK 41 2 532 2005 Fiat Auto S p A All rights reserved MATRIX panel R Position The IPC is located in the driver s side dashboard Visible area 67 x 35 mm Max interpixel dimensions 0 02 mm on the vehicle Instrument board pin in pin out OO al 0 08347 07 E003 PA Ger FIAT gb Fiat Grande Punto OK 41 3 532 2005 Fiat Auto S p A All rights reserved PIN FUNCTION ml mme O o Irene mm 30 IPC OR K 18 MIL warning light control form the ECM IPC functi
53. precombustion chamber with 4 in line cylinders total displacement 1 248 c c 4 valves per cylinder with hydraulic tappets two overhead camshafts with motion gear drive air boosting by means of a turboblower and an intercooler no load weight 137 kg 75 HP and 139 kg 90 HP Magneti Marelli MJD 6F3 Common Rail electronic injection system These engines make use of a Magneti Marelli Common Rail high pressure electronic injection system for fast diesel engines which is fully controlled by a Multijet MJD6F3 control unit FIAT PUNTO 61 532 2004 Fiat Auto S p A All rights reserved The engines feature the performance levels below max rating 55 kW 75 HP EC at 4 000 r p m 66 KW 90 HP EC at 4 000 r p m max torque 190 Nm 19 4 kgm EC at 1 750 r p m 200 Nm 20 4 kgm at 1 750 r p m To reduce polluting emissions these engines are equipped with exhaust system with oxidizing catalytic converter exhaust gas recirculation E G R system modified for the 90 HP version with heat exchanger engine base vapour gas recirculation system UEGO oxygen sensor temperature sensors for DPF available as options for 90 HP versions only new DRV 2 pressure regulator new RDS 4 air pressure sensor The unit consists of a system made up of the engine and all the systems required for its operation fuel feed system air boosting system engine cooling system exhaust system with catalyt
54. preheating control unit Features This device is interfaced and controlled by the engine control system according to the EOBD protocol It has been designed to perform all the functions for driving and monitoring the operating condition of every single spark plug during the diesel engine preheating phase The control unit includes a protection device against high current and overvoltage and also features an electronic self resetting logic Considering the thermal and weather resistance features the device can be fitted directly to the engine compartment The control unit is protected against any possible electric connections with battery polarity reversal on all of its terminals and has been designed so as to withstand all the stress found in the vehicle aed FIAT PUNTO 791532 2004 Fiat Auto S p A All rights reserved Terminal Name Direct connection to the battery positive Vbat for spark 30 plug power supply G1 G2 63 G4 Spark plug connection output 86 Power supply from the engine control unit 31 Ground connection GND ST Input for control start from the engine control unit K Input for control start from the engine control unit DI Output for direct diagnosis toward the engine control unit 3 2 16 Turboblower The turboblower 1 is connected to the exhaust manifold it is used to enhance the engine s volumetric efficiency It is essentially made up of two impellers force fitted to one single shaft
55. setting for the alarms faults warnings button pressing 0 mute to 7 max volume with the Buzz writing in place of the odometer Setting the unit of measurement distance Unit writing in place of the odometer Comfort and Matrix panels Speed speed limit threshold selection and setting Twilight sensor sensitivity level control where the twilight sensor if available Trip B actuation deactivation Clock and time format 12 24 h setting Date setting Audio information repeat actuation deactivation Actuation deactivation of automatic door boot locking above 20 k p h Setting the units of measurement distance consumption temperature gb Fiat Grande Punto OK 4171532 2005 Fiat Auto S p A All rights reserved Language setting Italian English German Portuguese Spanish French Dutch Polish Alarm fault warning buzzer volume setting Button pressing buzzer volume setting roger beep Seat belt reminder re actuation Servicing slip expiry displaying km miles Passenger s airbag actuation deactivation Initial setting Instrument initialization The table below shows the factory made instrument settings for the vehicle COMFORT MATRIX PANELS MODE PANEL Speed limit ON OFF Speed limit 130 k p h 130 k p h threshold Twilight sensor oe 1 enen ae went pep with speed gt 20 k p h 01 01 aaaa Vyyy year of release SW d ES G km if the k
56. that rotates on floating bearings lubricated through a branch 3 of the engine lubricating circuit FIAT PUNTO 80 532 2004 Fiat Auto S p A All rights reserved 1 Turboblower 2 Waste gate 3 Lubricating circuit branch 4 Pneumatic actuator The oil used eliminates part of the large amount of heat yielded by the exhaust gas to the turbine The turboblower incorporates a WASTE GATE valve 2 controlled by a pneumatic actuator 4 which makes it possible to choke the exhaust gas flow to the turbine depending on the pressure reached at the compressor outlet BORG WARNER VNT 90 HP turboblower The 1 3 MJTD 90 HP engine features a new generation of turboblowers the VNT Variable Nozzle Turbines turboblower The distributor blades are actuated electro pneumatically This technology makes it possible to achieve optimum turboblower with all engine speeds i T i J d WI es FIAT PUNTO 81 532 2004 Fiat Auto S p A All rights reserved Purpose of a turboblower The purpose of a turboblower is to achieve very high torque values and therefore greater engine performance All of this can be obtained by compressing the sucked air Thanks to the greater density at every intake phase a greater amount of oxygen can be let into the engine s combustion chamber The greater oxygen content improves combustion and as a result increases power The thermal and kinetic energy of the engine s exhaust
57. the one required to actuate the direction change gb Fiat Grande Punto OK 437 532 2005 Fiat Auto S p A All rights reserved Light actuation diagram Steering column stalk USM Reference Ground Body Computer node NBC Auto Park ing Rear Right headlamp Rear Left headlamp Manual wiping mode by moving the ring of the steering column stalk lever located on the driver s right to any of the three position below intermittent operation continuous speed 1 continuous speed 2 the windscreen wiper motor will be actuated as described below Intermittent operation the windscreen wiper is controlled at speed 1 yet with a pause between two subsequent strokes that varies depending on the vehicle speed in accordance with the diagram below iw a gb Fiat Grande Punto OK 438 532 2005 Fiat Auto S p A All rights reserved Pause time 4 s I A D Bee i i 1 1s G e I I I I l Vehicle speed 40 k p h 90 k p h 110 k p h Continuous speed 1 the windscreen wiper is driven at speed 1 45 strokes per minute Continuous speed 2 the windscreen wiper is driven at speed 2 65 strokes per minute Automatic wiping mode rain sensor The rain sensor is actuated by turning the ring of the steering column stalk right hand lever to the intermittent automatic operation position Thu
58. this structural layout are as follows two shell swinging arms made of stamped sheet metal instead of cast iron as with the current Punto with a significant weight reduction use of bushings with larger rubber volume than the bushings fitted to the current Punto to improve comfort to dampen minor roughness and at the same time ensure optimum road holding and stability when cornering gb Fiat Grande Punto OK 368 532 2005 Fiat Auto S p A All rights reserved front suspension crossbar with high structural rigidity with transverse connecting strap next to the arm front mounts except for the 1 2 8V model reinforced pillars to ensure better road holding when cornering dome dowels of the double type dual path layout to reduce to a large extent the effect of the vibrations generated by the road surface without affecting the structural rigidity to the detriment of driving accuracy stabilizer bar with rods for anchoring to the shock absorbers instead of the swinging arm which makes it possible to achieve greater stabilizing efficiency and prompt dynamic response when cornering offset helical springs for thrust axis optimization in order to reduce the tangential forces on the shock absorber stem and therefore the internal friction with resulting better damping of minor road roughness Hydraulic telescopic dual effect shock absorbers with stem diameter of 22 mm on all the versions fo
59. through the cigar lighter socket The kit is even easier to use The procedure to repair a punctured tyre is essentially as follows Connect the electric cable to the cigar lighter socket connect the silicone tube to the tyre valve then switch the compressor on the sealant will be automatically injected into the tyre mixed with air The repair will be completed when the tyre pressure reaches the prescribed value The Fix amp Go kit may also be used to check and restore the tyre pressure by connecting the special tube equipped with the quick coupling Ger EN FIRAT FIAT PUNTO 23 532 2004 Fiat Auto S p A All rights reserved 1 2 11 Comfort Ergonomics and comfort are among the most outstanding features of Nuova Punto easy access visibility pedal position steering wheel alignment adequate position of the armrest plane adequate position of the footrest plane very good gearshift knob controllability full visibility of instruments and main drive controls excellently profiled snug seats which comfortably constrain the driver s body even in the most dynamic driving situations In order to make Nuova Punto a landmark car within its own category great care has been specially devoted to the following passenger compartment soundproofing interior noise rolling noise and vibration filtering acoustic sensitivity to the excitation transmitted through solid pathways vehicle compactn
60. to high seriousness side collision Curtain airbags they are actuated together with the side airbags where available and interpose themselves between the occupant and the vehicle exterior thus preventing the occupant s head from hitting highly intruding objects The curtain airbags protect both the front and rear passengers since they range from the front pillar to the luggage compartment Side head protection airbags window bags where available They consist of two curtain cushions housed in the side roof panel coverings and coated with special trimmings They are used to protect the front and rear occupants heads in case of side collisions thanks to the wide deployment surface of the cushions gb Fiat Grande Punto OK 501 532 2005 Fiat Auto S p A All rights reserved Connections The airbag node SDM is connected to the B CAN line B CAN NETWORK A B CAN NETWORK B BS 35 E NS 6 354 12 PAM HS BS B CAM A HENG B CAN B Se SE D CAN A cas I TPMS B CAN E 53 Low Speed CAN transceiver CTM 3 Low Speed CAN Eranzca iver 1 B CAN A BCM 20 Low Speed CAN transceiver S Low Speed CAN transceiver e gb Fiat Grande Punto OK 502 532 2005 Fiat Auto S p A All rights reserved 9 7 3 Airbag node SDM It constitutes the core of the occupant restraint system and is located on the front tunnel It simultaneously controls a
61. to vary too gb Fiat Grande Punto OK 262 532 O 2004 Fiat Auto S p A All rights reserved Electric features The figure below illustrates the sensor s electric features 49 933 26 628 15 701 3 539 AA AA BERESEE SSL EEREEE gb Fiat Grande Punto OK 263 532 2004 Fiat Auto S p A All rights reserved gb Fiat Grande Punto OK T 12 31 ES Sl SG BS z 5 El S gl a amp ol ol o Di OI Aa gt DI Ql i 1 ECM 2 Sucked air pressure and temperature sensor Sn 264 532 2004 Fiat Auto S p A All rights reserved Pin out Component Sucked air pressure amp temperature sensor Recovery If the error is found upon vehicle starting Component connector pin e a value of 50 C is assumed e the mixture ratio self adaptivity is cut out If the error is found in the other conditions Receiving item pin Ground from the ECU 7 ECM connector B Temperature sensor signal 63 ECM connector B Power supply from the ECU 13 ECM connector B Pressure sensor signal 31 ECM connector B the latest valid value is stored which is updated depending on the coolant temperature IW P el 4 FIAT a gb Fiat Grande Punto OK 265 532 2004 Fiat Auto S p A All rights reserved 4 4 7 Accelerator pedal potentiometer Description The accelerator pedal features two built in potentiometers one main potentiome
62. typical time tAB 15 s the signal comes from the SDM while the message is being displayed then the message will further remain ON for a maximum of 5 seconds Switch off 30 Signal not available Key controlled Signal CrashOutputSts available The function is cut off during the first 4 power supply 15 seconds after key ON Ignition OFF Signal not available MA Cut off upon Signal CrashOutputSts available The function is cut off during the first 4 starting seconds after key ON The function is ensured by an internal power reserve during engine starting or any other condition in which voltage is missing The node will turn off below 6 V When the voltage goes up again the gb Fiat Grande Punto OK 506 532 2005 Fiat Auto S p A All rights reserved node will exhibit the same behaviour as the preceding step Key controlled power supply 15 Cut off with run Signal CrashOutputSts available The function is ensured by an internal down battery power reserve for a maximum time of 150 msec In case of collision the SDM will transmit through the B CAN line a proper collision signal STATUS SDM CrashOutputSts this signal will inform the network about the type of collision and the time when It occurred The airbag node will perform its functions as shown in the table below Driver s Passen Y X Actuation side ger s i Internal Internal Safety threshold i side accelerom accelerom function p
63. up menu Warning danger signalling Ice Available with the Comfort and Matrix panels In order to warn the driver that icy patches may be found on the road surface when the measured external temperature is equal to or less than 3 C the Comfort panel display shows the warning message the blinking external temperature for the duration of the message gb Fiat Grande Punto OK 430 532 2005 Fiat Auto S p A All rights reserved the respective icon snow symbol Matrix panel only The warning cycle is carried out only once after an external temperature equal to or lower than 3 C has been recognized it can be repeated only if the temperature reaches a value of more than 6 C and then is again equal to or lower than 3 C Warning danger signalling Doors boot open In order to warn the driver that one or several doors or the boot are open the corresponding message will be shown on the display as soon as a door or the boot opens The warning light icon will remain ON until all the doors and the boot of the vehicle are perfectly closed Moreover an acoustic signal is actuated when the doors are open while the vehicle is running Tyre pressure control OPT TPMS Available only with the Comfort and Matrix panels The TPMS system monitors two tyre pressure control thresholds corresponding to the low pressure and tyre puncture conditions In the event that each of these thresholds is exceeded the resp
64. vent windows bumper protection rubber kit side buffer bands interior rubber or carpeted mat covers tailored seat linings miscellaneous object restraint grids dog restraint partition net which can be combined with a semi rigid polypropylene receptacle for easier luggage compartment cleaning Finally an aluminium sill board is available which must be positioned on the vehicle s internal sill As far as leisure time is concerned the ACCESSORY LINE includes transverse bars used to carry various items such as SKIS BICYCLES and SURFING BOARDS Two different types of towing hooks of the removable ball type are available for towing purposes FIAT PUNTO 30 532 2004 Fiat Auto S p A All rights reserved Those who own I Pod Applemay choose a dedicated set that allows the former to be used by controlling its content through the factory installed radio system 1 3 3 Safety The vehicle active and passive safety is ensured by a special range of alarms and the parking sensor kit to be positioned on the license plate sides The traditional anti theft system provided in a modular make up with door opening closing actuation remote control exchanges data through the CAN network with the vehicle s electronic control unit Any break in is signalled by a siren located in the engine compartment The CLEAR BOX or GPS GSM locator is the best device that current technology may offer in the field of automotive satellite cel
65. 0 Z Q 40 115 O E 35 110 30 105 25 100 20 95 15 90 10 85 5 80 0 75 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 Speed r p m Engine 1 4 8V Max torque 114 Nm at 3 000 r p m Max rating 56 KW at 5 750 r p m Engine 1 2 8V Rating kW AAA AAA TAH TTT Max torque 102 2 Nm at 3 000 r p m Max rating 49 5 KW at 5 500 r p m Torque Nm 38 532 2004 Fiat Auto S p A All rights reserved LA el TTT LL L o 6 SS o s Ss D G D D R B di fa Si i 8 1750 Engine 1 9 Multijet 8V 120 HP Max torque 280 Nm at 2 000 r p m Max rating 88 Kw at 4 000 r p m FIAT PUNTO 39 532 2004 Fiat Auto S p A All rights reserved 100 y TO Engine 1 3 Multijet 16V 90 HP Max torque 200 Nm at 1 750 r p m Max rating 66 Kw at 4 000 r p m FIAT PUNTO 40 532 2004 Fiat Auto S p A All rights reserved 2 4 Transmission 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120HP 2 5 Clutch 1 3 Multijet 16V 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 90 HP 16V 75 HP 8V 120 HP Push type Push type Push type Push type Push type EE Hydraulic Hydraulic with e Hydraulic Hydraulic Hydraulic with Control external with external with external external actuator actuator and actuator actuator actuator with external Disc spring load
66. 0 532 2005 Fiat Auto S p A All rights reserved Speedometer The instrument board provides a speed reading slightly higher than the actual speed due to safety reasons This increase is calculated by the panel Upon key ON the indicator reaches 0 zero k p h or m p h and the instrument board displays the vehicle speed information Revs counter Upon key ON the indicator reaches 0 zero r p m and the instrument board displays the engine revs information Moreover a revs counter anti oscillation logic is available in the engine idle running conditions Fuel level indicator Two seconds after the key ON the indicator displays the fuel level information The indication corresponding to the start of the fuel reserve is red and the relevant warning light is made of an amber LED positioned among the indicator s graphic elements The indicator calibration ensures greatest accuracy at the start of the red sector Engine coolant temperature indicator Two seconds after the key ON the indicator displays the engine coolant temperature information The indication corresponding to the start of the hazard area is red and the relevant warning light is made of a red LED positioned among the indicator s graphic elements The indicator calibration ensures greatest accuracy at the start of the red sector Pointer behaviour if the temperature is lt 50 C the pointer will position itself on the first mark grade
67. 01 532 2004 Fiat Auto S p A All rights reserved Press the clips then remove the coil air inlet sleeve Air inlet sleeve gb Fiat Grande Punto OK 302 532 2004 Fiat Auto S p A All rights reserved Unscrew the air filter fastening screws Lift the air filter Loosen the strap then disconnect the engine oil vapour pipe from the air filter and remove it ALV REST Te Fiat Auto S p A ai FIAT PUNTO TRAINING OUTLINE i ENGINE _ After Sales Training Air filter fastening SCrews gb Fiat Grande Punto OK 304 532 2004 Fiat Auto S p A All rights reserved Engine oil Vapour pipe 1 Unscrew the timing belt protection upper cover fastening screws S gb Fiat Grande Punto OK 305 532 2004 Fiat Auto S p A All rights reserved Timing belt upper and lower protection Disconnect the electric connections from the injection control unit Disconnect the ground cable Disconnect the electric connection of the oxygen sensor upstream the catalyst Disconnect the front engine junction FIAT y iW N gb Fiat Grande Punto OK 306 532 2004 Fiat Auto S p A All rights reserved Oxygen sensor upstream the catalyst with its respective connection FIAT N gb Fiat Grande Punto OK 307 53 2004 Fiat Auto S p A All rights reserved Disconnect the phase variator control electromagnet electr
68. 01 998 J98Z 9 84070 y 0143314814 KS 1804 11191 1J98Z 9 OPUBUOI Z OIOOON 1IZYH A 19443 11 H comino A RECH y YSO3 ANIA S ONIN XIVA N CINONYYH NAONA H FIT y OIITI9 A3II H Errr A D a metal a i HER EEE BEE maana Xava 1 RRE sp 4800 1110351 87 Opueuog side ia ia COONYIA ILIHM a y 04aNZZY gt 3M18 COLINYAY 329NY 30 3901094807109 oO 17918 WANOSO 0 gt un Wl YN 0 Ka LE O pam lt l lt a We O lt 2 LL LO CN 6 Le XS 1504 Y Ld H k 2 K i INDAJ 014009 DAYI 2 i D B N BER J A Aala SEH E m s WW Be H H mesas A cece rt sl K SE D t949k BEB REE TO x Bu 001 Dal sia 8 d is T77 S ch Ki N af i E 3 S A ZU 1S0d Y130d TETE 3 st aooaa 1N08Y4 OL 4008 0449 9 RANA D XD 1500 1119351 499219 24010 470174008 OA O ur e se gt 129202620 SRRSE OT NY Y1I0d GAD GINE DUBA BU BJU J L k poor z Kao1 9 Eday Ska yA 9 09 r a Ex e 5 NH 079 GUOJEUDUO ns Bessey Di UP BAJOS IPUPUOD 9700P d gb Fiat Grande Punto OK Anti pinch safety device The versions equipped with four electric window regulators front and rear feature a safety system capable of detecting the presence of an obstacle during the window upward closing movement When such an obstacle is detected the system will interrupt the window travel and depending on the window position will also rever
69. 1 SENSOR GROUND 2 TEMPERATURE SIGNAL analog output toward the ECM 3 POWER SUPPLY 12 V from the ECM 4 GROUND FIAT PUNTO 128 532 2004 Fiat Auto S p A All rights reserved 3 Engine air feed circuit 1 Air filter complete with resonator 2 Digital air flow meter 3 Sleeve for connection with the turboblower 4 Turboblower with waste gate 75 HP VNT with VGT valve 90 HP 5 Air air heat exchanger intercooler 6 Intercooler air inlet manifold connecting sleeve 7 Air intake manifold FIAT PUNTO 129 532 2004 Fiat Auto S p A All rights reserved 3 8 MJD 6F3 diesel engine management control unit 3 8 1 Features The Magneti Marelli MJD 6F3 common rail is a high pressure 1 400 bar 75 HP 1 600 bar 90 HP electronic injection system with the possibility of modulating these pressures from 150 bar up to the maximum working value of 1 400 1 600 bar regardless of the rotation speed and the engine load operation at high engine speeds up to 5 000 r p m in full loaded conditions injection control accuracy advance and injection duration less consumption lower emission levels The main functions of the system are essentially as follows fuel temperature control engine coolant temperature control injected fuel amount control idling speed control fuel cut off during the release phase cut off idling cylinder balancing control engine jerk prevent check accelerati
70. 17 6 1 FIAT PUNTO 68 532 2004 Fiat Auto S p A All rights reserved Inlet ducts 70 PS Bowl CR 184 00 PS Bowl CR 17 601 Nozzle features w Type KS microsac Holes number 5 6 Nominal hole diam mm 0 13 0 12 Flow rate cm7 30s 270 280 lsoentropic rea Cyl Capacity Swirl Number 69 532 2004 Fiat Auto S p A All rights reserved 3 2 5 Base sump and covers The engine base oil sump is a structural part of the engine with mechanic functions which is used to hold the engine lubricating oil It is made of stamped sheet metal and includes the threaded hole with cap for engine oil drain Sealing with the engine base is achieved by means of a bead of silicone sealant A bulkhead is put between the engine base and the oil sump which prevents the engine oil from being shaken off due to the vehicle and drive shaft motion and also ensures that the level remains constant FIAT PUNTO 701 532 2004 Fiat Auto S p A All rights reserved 3 2 6 Oil seals on the drive shaft Front drive shaft sealing is achieved by means of an oil seal fitted onto the valve gear cover Rear drive shaft sealing is achieved by means of an oil seal fitted directly into the housing obtained between the engine base and the underbase 3 2 7 Engine flywheel The engine flywheel is made of cast iron with set steel ring gear The flywheel is secured to the drive shaft through a f
71. 2 2004 Fiat Auto S p A All rights reserved 4 5 9 Operation during acceleration During this phase the control unit adequately increases the fuel amount required by the engine to achieve maximum torque depending on the signals from the following components e throttle potentiometer e T D C and revs sensor The base injection time is multiplied by a coefficient depending on the engine coolant temperature the accelerator throttle opening rate and the pressure increase in the inlet manifold If the sudden change of the injection time is calculated when the injector is already closed the control unit will open the injector extra pulse again to be able to compensate for the ratio as quick as possible conversely the following injections will be increased according to the above mentioned coefficients gb Fiat Grande Punto OK 287 532 2004 Fiat Auto S p A All rights reserved 4 5 10 Out of revs protection When the engine rotation speed exceeds the value of 6 530 r p m set by the manufacturer the engine itself will be operating in critical conditions When the electronic control unit recognizes that the aforesaid speed has been exceeded it will disable electric injector driving When the revs number falls again into a non critical value 6 500 r p m the driving will be restored 4 5 11 Fuel electric pump control The fuel electric pump is driven by the engine management c
72. 451 532 2005 Fiat Auto S p A All rights reserved A continuous signal indicates that the distance from the obstacle is smaller than 30 cm If several obstacles are found the nearest obstacle will be signalled on approaching The acoustic signal will immediately cease if the obstacle distance increases The sound cycle remains constant if the distance measured by the central sensors does not change conversely if this situation occurs with the side sensors the signal will be interrupted after 3 seconds in order to avoid for instance signals in case of manoeuvres along walls parallel to the vehicle axis If a trailer is coupled with the vehicle rear obstacles will not be signalled The system covers the vehicle s rear side and median areas If the obstacle is positioned in the median rear area the obstacle will be detected at a distance of less than 1 50 m If the obstacle is positioned in a side area the obstacle will be detected at a distance of less than 0 6 m Work conditions Ignition OFF 30 Ignition ON 15 Parking assist The system is active with the following management conditions key ON and reverse gear engaged Diagnosis Upon starting the control unit carries out a self diagnosis and sensor test Sensors are continuously diagnosed during the system s operation Failure to even one single sensor will disable the operation of the entire system in this case the system will cut itself off a
73. 6 6 Fuel tank and components Submergible pump assembly complete with level gauge control The fuel electric pump is fitted into one single assembly into the level gauge and the fuel filter therefore the components cannot be replaced as individual items The function of the fuel electric pump is to feed the high pressure pump It is fully immersed into the fuel inside the tank The pump unit is realized so as to obtain the maximum fuel level in the suction area This function is implemented by means of a Venturi pipe placed on the suction return pipe with respect to the one of the tank The pumping unit is of the roller type and makes it possible to achieve a flow rate of 160 litres h FIAT PUNTO 121 532 2004 Fiat Auto S p A All rights reserved Pump tray P max 8 5 bar Venturi pipe Electric pump Pre filter The fuel electric pump includes a permanent magnet electric motor 1 that controls the pump impeller 2 and an end support cover 3 that contains the electric and hydraulic connections The electric pump stage is of the single peripheral flow type with high performance in low voltage and temperature conditions The advantages compared with the electric pumps operating according to the volumetric principle are as follows less weight small dimensions FIAT PUNTO 122 532 2004 Fiat Auto S p A All rights reserved Power supply Current absorption Pressure Flow rate F
74. 6 gearbox features the upgraded synchromesh unit previously fitted to the F40 manual gearbox The synchronization springs and pins used so far have been replaced by push dowels Accurate synchromeshes are used with the single gears too Two or three cone synchromeshes are used Below are some illustrations that show the synchromeshes used with every single gear 1 2 gears The three cone synchromesh is used with the 1 and 2 gears 1 Inner synchromesh ring 2 Intermediate ring 3 Outer synchromesh ring 4 Engaging sleeve 5 Synchromesh hub 6 Push dowels gb Fiat Grande Punto OK 326 532 2004 Fiat Auto S p A All rights reserved 3 14 gears The two cone synchromesh is used with the 3 and 4 gears 1 Intermediate ring 2 Synchromesh ring 3 Engaging sleeve 4 Synchromesh hub 2004 Fiat Auto S p A All rights reserved 327 532 gb Fiat Grande Punto OK Sue gears The single cone synchromesh is used with the 5 and 6 gears 1 Synchromesh ring Intermediate ring 2 Engaging sleeve 3 Synchromesh hub Reverse gear The reverse gear features a single cone synchromesh just like the 5 and 6 gears gb Fiat Grande Punto OK 328 532 2004 Fiat Auto S p A All rights reserved 5 2 2 Drive L0009679 The M20 6 manual gearbox features a tie rod drive Every single gear is selected by means of a central control unit gb Fiat Grande
75. A ml ae JL ei O ee M Y A S pai I H a yA a e SE le _ al 9 a 16 14 d d M d A3 nota Bar Both compressor actuation enable and electric fan speed control depending on the pressure variation take place within this pressure range Below and above these values the compressor will be turned off as a safety condition to avoid damaging the system itself The supply voltage may undergo a variation of 10 Whereas the sensors utilization temperature is included between 5 C and 80 C Electric features 1 Ground 2 Supply voltage 3 Output signal E N E gb Fiat Grande Punto OK 2721532 2004 Fiat Auto S p A All rights reserved CL 011 15 DIA 1 FDU 2 ECM 3 A C linear pressure sensor gb Fiat Grande Punto OK 273 532 2004 Fiat Auto S p A All rights reserved Pin out Component Component Receiving item pin connector pin Ground from the ECU 15 ECM connector A A C linear Power supply from the 3 ECM connector A sensor ECU A C sensor signal 5 ECM connector A Atmospheric pressure sensor Atmospheric pressure sensor gb Fiat Grande Punto OK 275 532 2004 Fiat Auto S p A All rights reserved Electric features MB 050 BO 0 50 n ME 0 50 MB 0 50 1 ECM 2 Atmospheric pressure sensor gb Fiat Grande Punto OK 276 53 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A
76. A All rights reserved 9 6 Audio system Two audio sources are available radio tuner and audio CD MP3 player The sound system fitted to the vehicle may be of two standard types e standard e hi fi sound system General features of the standard system The system consists of 6 loudspeakers fitted to the vehicle as follows e mid woofer loudspeakers 40 W diameter 160 mm located in the front doors and designed to reproduce middle low frequencies The technology used for these components of the water resistant type allows the latter to stand water jets if any from inside the door without being damaged e tweeter loudspeakers 30 W located on the door opening handle designed to reproduce the highest frequencies e full range loudspeakers 40 W diameter 130 mm located on the rear side frames which can reproduce the entire range of the sound frequencies These components feature the water resistant technology General features of the hi fi sound system This system consists of 6 loudspeakers and a sub woofer box containing a single channel power amplifier Below are the main features of the components e mid woofer loudspeakers 40 W diameter 160 mm located on the front doors designed to best reproduce the low middle frequencies the water resistant technology is used with these components e tweeter loudspeakers 40 W located on the door opening handle designed to reproduce the highest freque
77. AT PUNTO 63 532 2004 Fiat Auto S p A All rights reserved 3 Reaction tie rod FIAT PUNTO 64 532 2004 Fiat Auto S p A All rights reserved Right axle shaft support for 1 3 Multijet 90 HP version 3 2 2 Engine base The engine base is made of ductile cast iron The cylinders are obtained directly into the base and are classified into three dimensional classes plus one oversize class Class A Class B Class C Plus one oversize The drive shaft is rested by means of five main bearings 1 Special channels obtained in the base walls allow the cooling fluid and the lubricating oil to flow through A nozzle 2 is fitted into the lower part of each cylinder through which oil is sprayed on the piston crown in order to cool the piston and ensure pin lubrication through falling FIAT PUNTO 65 532 2004 Fiat Auto S p A All rights reserved 3 2 3 Lower engine base The lower engine base is made of die cast aluminium alloy with cast iron main caps The main bearing and cap finishing operations are carried out by joining with the upper engine base Joining with the upper base is carried out by means of screws and dowel bolts that ensure assembling accuracy A bead of sealant is put between the two engine bases to avoid engine oil leaks The figure below illustrates the upper engine base 1 and the lower base 2 FIAT PUNTO 66 532 2004 Fiat Auto S p A All rights reser
78. Auto S p A All rights reserved Pin out Component l Component Function connector pin Knock sensor signal Knock sensor Ground from the ECU Recovery Receiving item pin 41 ECM connector B 48 ECM connector B In case of sensor failure the engine management control unit actuates more conservative ignition advance maps in order to protect the engine gb Fiat Grande Punto OK 244 532 2004 Fiat Auto S p A All rights reserved 4 4 2 Oxygen sensor Description Two oxygen sensors are available one upstream and one downstream the catalyst The oxygen sensor upstream the catalyst is used to check the combustion result The control unit analyzes its signal and corrects the stoichiometric ratio so as to always keep combustion within the limits necessary for emissions The oxygen sensor downstream the catalyst is used to check the actual efficiency of the catalyst the control unit analyzes its signal and informs you of catalyst deterioration through the MIL warning light i gb Fiat Grande Punto OK 245 532 2004 Fiat Auto S p A All rights reserved Position on the vehicle 1 oxygen sensor upstream the catalyst 2 oxygen sensor downstream the catalyst gb Fiat Grande Punto OK 246 532 2004 Fiat Auto S p A All rights reserved Electric features 1 FDU engine Engine management management remote system remote control switch contr
79. B CAN E PAM e s em E 0 33 H5 B CAN B DLC d B CAN B B GAN A El sous f TPMS E CAN A 53 Low Speed CAN transceiver 3 Low Speed CAN tranzcaiwar CTM Term Sch BCM Bs 35 20 Low Speed CAN transceiver x SCAN A SSS l i I a E gb Fiat Grande Punto OK 385 532 2005 Fiat Auto S p A All rights reserved JE LE C1 NR BE cl HIS L 29 HAN Ah Ca UH NYJ 2005 Fiat Auto S p A All rights reserved HI aaa B D BEA u H WTI 5 U PELA 108 1 Hd B U HC lN 100 H Ng 1 7 nn B H O lch Sdi KM Ked oo 386 532 yo a H eo MI L HMI Y a d 1 WILD zB UI L 1 Ny 0 0 ec 9 1 6 C CAN high speed line BASE C CAN Ock VIN U 3548 NYJ Y gb Fiat Grande Punto OK C CAN with MTA without ESP CAN L 1 in CHAN L auk CLAN H 1 in G GAN H Z auk C CAN H aut Y T29 0 5 2 C CAN L ut DEE EGP C CAN H ine 5 7 C CAN L nn g EA LACAN L um H Ted 5 CIM _ _ H in Ted 0 2 gb Fiat Grande Punto OK 387 532 2005 Fiat Auto S p A All rights reserved C CAN with ESP without MTA V T B 5 Me T 6 5 CLEAN L 1 in CAN L auk C CAN H 1 in tn can H 2 aut C CANL 1 in T29 0 5 4 C CAN L 2 ouk M 111 0 5 NRS e CAN HI in 139 5 4 C CAN H 2 gut T41 B 5 5 C CAN H aut Y T29 0 5 a C CANL dini ESP C CAN H in S 1 C CAN Lime G 5 g NL ing HIE 8 E e CTM LAN H P Ted 5 1
80. C and 150 C with a resulting duty cycle value in the range of 10 to 90 gb Fiat Grande Punto OK 177 1532 2004 Fiat Auto S p A All rights reserved 1 533 N i ee a 1 665 1 733 5 115 e 1 066 amp i TEF The resistive value variation is converted from analog into logic thanks to a digital analog converter 3 The data item obtained is stored in a data memory 2 Data are sent to the engine management control unit through a function generator 1 mi gb Fiat Grande Punto OK 178 532 2004 Fiat Auto S p A All rights reserved Air flow rate signal trend In the digital air flow meter the signal sent to the engine management control unit features an amplitude of 5 V and is frequency variable 1 4 kHz and 12 kHz An increase in inlet air flow rate is matched by an increase in the frequency of the output signal from the meter and as a result a decrease in the period value 50 Eg h 600 Egh Air flow rate Frequency output Digital air flow meter AIR FLOW RATE signal To measure and check the signal amplitude voltage 5 V a graphic voltmeter is needed To measure the frequency value you will just need to use a multimeter with selection of the frequency measurement and the respective prods connected as follows one to the air flow meter ground pin one to the air flow rate signal pin gb Fiat Grande Punto OK 179 532 2004 Fiat Auto S p A All rights
81. Fiat Auto S p A All rights reserved 1 2 9 Tyres and wheels To optimize the vehicle performance especially with regard to road holding safety and driving comfort the following tyres have been fitted to Nuova Punto 175 65 R15 Active Dynamic 185 65 R15 Active option Dynamic option Elegance Sport option tyres can be fitted with snow chains 195 55 R16 Dynamic option Elegance option 205 45 R17 Elegance option Sport As far as alloy rims are concerned Nuova Punto comes with a full range that stands out for style dimensions and paint colours ALLOY RIMS 5 dual rungs colour silver standard ALLOY RIM 10 rungs of which 5 dual rungs colour aluminium ALLOY RIM NON CATENABILE 205 45 R17 tyres 15 flat surface rungs colour silver standard ALLOY RIM NON CATENABILE 205 45 R17 tyres 15 flat surface rungs colour chrome shadow ALLOY RIM NON CATENABILE 205 45 R17 tyres 3 dual rungs spider type colour chrome shadow i E FIAT PUNTO 22 53 2004 Fiat Auto S p A All rights reserved 1 2 10 Tyre repair kit Nuova Punto is equipped with the new version of the Fix amp Go kit to repair punctured tyres max puncture diameter 4 mm The new kit includes one single component made up of a compressor a sealant bottle a silicone tube for tyre repair a tube equipped with a spout for tyre check and inflation and an electric cable for power supplying
82. GINE VERSIONS TYRES STD O MN 2mm 1mm 1 88 mm 1mm e S Tit 1 3 MJet 70 CV 1 88 mm 1mm 175 65 R15 84T 1 2 8V 2mm 1mm 1 88 mm 1mm 1 3 MJet 70 CV 1 88 mm 1mm 1 4 8V 2 mm 1 mm 1 88 mm 1mm 1 3 MJet 90 CV 2 mm 1 mm 1 88 mm 1mm 1 3 MJet 90 CV 1 88 mm 1mm 1 9 MJet 2 mm 1 mm 1 88 mm 1mm 185 65 R15 88T 1 9 MJet 195 55 R16 87h 1 87 mm 1mm Represented by mm d2 d1 see figure above Only toe in can be adjusted in the traditional way by acting on the steering connecting rod nuts gb Fiat Grande Punto OK 372 532 2005 Fiat Auto S p A All rights reserved 8 3 Rear suspensions 8 3 1 General remarks The Nuova Punto has introduced a suspension layout whereby the wheels are interconnected by a torsional axle made up of a tube bent sheet metal with an open central section The wider body attachments and the optimization of the torsional contour have made it possible to achieve greater structural rigidity despite the weight reduction The peculiar configuration of the torsional contour with different thicknesses depending on the versions has made it possible to obtain optimum roll stabilizing rigidity even if an antiroll bar has not been added therefore the antiroll bar shall not fitted to any of the Nuova Punto models The vertical arrangement of the shock absorbers with the body attachment inside the wheel
83. Ground signal BCM eee ene rr oo o ou o JO LL al al Right dome light control er i i IV OOO Mi W O oO D al DI O 7 Ka M L K K K LD e L K K K K ka a bai KA gb Fiat Grande Punto OK 406 532 2005 Fiat Auto S p A All rights reserved 19 Central door locking unlocking control power supply Brake module power supply Comfort function enable power supply Brake switch power supply ASR button power supply EPS power supply 25 Front ceiling light fixture power supply Rear ceiling light fixture power supply Luggage compartment light power supply EOBD connector power supply 300 Boot lock power supply Driver s door unlocking control ER Front wiper low speed power supply mei s i rane sant O 2 sengen O kg gb Fiat Grande Punto OK 407 532 2005 Fiat Auto S p A All rights reserved Connector LG AR ae asa ooo 3 Radio power supply G T IPC 15 Display power supply Glove compartment chest light power supply OIL ELC light power supply ei o Raa ooo se o gb Fiat Grande Punto OK 408 532 2005 Fiat Auto S p A All rights reserved 9 2 4 Instrument board node IPC Features The design of the 199 instruments has been realized by establishing a family feeling with the other FIAT vehicles of its generation such as Stilo Punto Face Lifting and Panda all of which feature orange background i
84. IAT PUNTO 13 V 4 6A 2 to 4 bar 160 litres h 123 532 Mit 2004 Fiat Auto S p A All rights reserved 3 6 7 Inertia switch The inertia switch is fitted to the right side under the dashboard on the passenger side In case of vehicle collision the switch cuts off the ground connection of the fuel electric pump and as a result the fuel supply to the injection system N C A steel ball 1 fitted into a tapered housing 2 is normally kept secured through the attraction force of an adjacent magnet FIAT PUNTO 124 532 2004 Fiat Auto S p A All rights reserved Under specific acceleration loads the ball is released from the magnetic retainer and gradually comes out of the tapered support with an upward movement according to the cone angle Above the ball is a quick connect mechanism 3 that makes up the normally closed N C electric circuit The mechanism changes position when it is hit by the ball from N C circuit to normally open N A circuit thus cutting off the fuel electric pump ground circuit The switch can be restored by pushing a button protected by a flexible cover 4 NOTE Following any collision even a slight one the switch shall not be actuated again if fuel smell is smelt or leaks are found from the fuel feed system The fault shall be located and remedied to avoid the risk of fire Otherwise if no leak is noticed and the vehicle can be started press the
85. Jet 195 55 R16 87h 1 3 mm 2 mm 1 5 mm 2mm N B The wheels of the previous Punto models cannot be fitted to the Nuova Punto since the dimensions e g the centre line between the bolts have changed trying to do so would affect the integrity of the wheel hub components and above all the driving safety 9 Electric system 9 1 General description of the system The technology used for the electric system of the Nuova Punto is based on the complex architecture called Famiglia1 first used on a FIAT model Modular system To obtain the minimum number of wiring families each circuit connected to a sectioning joint holds the same position inside the joint regardless of the trim level also the position and type of the joint on the vehicle does not depend on the body version level To safeguard the modular arrangement of the cable harnesses the inputs outputs of each control unit shall not differ for the various body engine versions in the connector positions and the cable terminal connector interface 9 1 1 General features ECM 1 3 diesel engine ECM Fire engine 1 9 diesel engine MTA C514 gear gb Fiat Grande Punto OK 377 532 2005 Fiat Auto S p A All rights reserved Description Description EH RRM Radio Receiver Module E A es ek BSM Brake System Module Braking node EFs ea Poner Siew Seres RET SP rt Hees prints eremm ng taent O LL IL 9 1 2 Seri
86. K 359 532 2005 Fiat Auto S p A All rights reserved braking torque required to keep the vehicle stationary until when the driver releases the clutch pedal and the deflecting torque is enough to set the vehicle moving gb Fiat Grande Punto OK 360 532 2005 Fiat Auto S p A All rights reserved 7 Electric drive 7 1 Description All the Nuova Punto versions are equipped with electric power steering E P S The Nuova Punto steering control has been designed to minimize the driver s effort on the steering wheel during the parking manoeuvres combined with accuracy and safety during high speed driving 2 8 steering wheel turns are required for full stop to stop steering and the kerb to kerb steering diameter is 10 1 m vehicles equipped with long travel rack and 175 tyres or 10 76 m vehicles equipped with short travel rack and any other type of tyre The electric power steering is actuated by an electric motor that is more compact and lightweight compared with the previous systems It is made up of a steering column with integrated electric drive system and a special management control unit gb Fiat Grande Punto OK 361 532 2005 Fiat Auto S p A All rights reserved 7 2 Electric Power Steering EPS The electric power steering comes as a standard item on all versions Power steering is ensured by an electric motor located in the dashboard area which transfers the generat
87. OSCH premises The production plants of the POWERTRAIN engine have to receive and interpret the IMA codes for every single electric injector reading by means of a camera in order to match the same with the corresponding cylinder to which the injector is fitted and also produce a label that is put onto the timing belt cover The FIAT bodywork plants match the engine management control units with the respective software control strategies by means of special in line test equipment which reads the data shown on the label and then carries out the operation with the diagnosis services described below The new spare control units and the ones supplied at the FIAT plant are delivered with a standard default IMA code with a 00 hex value the vehicles fitted with control units that have pi Y FIAT i Se i FIAT PUNTO 116 532 2004 Fiat Auto S p A All rights reserved NOT yet been classified can be handled even before the operation has been carried out by means of suitable diagnosis equipment Under these conditions and prior to performing IMA classification the MIL failure warning light upon every Power On key turned to MARCIA engine stopped or rotating will be managed in the Blink blinking mode and an error with P1301 code and current status will be found in the error memory until classification has been completed After classification has ended the P1301 error will be automatically invalidated and w
88. P Self Non Type of disc Self ventilated Self ventilated Self ventilated ventilated ventilated Disc diameter 257 284 257 257 284 mm Rated thickness mm Type of caliper Bosch ZOH Bosch ZOH Bosch ZOH Bosch ZOH Bosch BoschZOH Caliper piston diameter mm FIAT PUNTO 43 532 2004 Fiat Auto S p A All rights reserved 2 2 Rear brakes ee 16V 90 HP 16V 75 HP 8V 120 HP ii E AC N RL E mme na na nd a ooo mear mm Jm nm Fam 2 8 Steering jae 1 3 Multijet 1 3 Multijet 1 9 Multijet 16V 90 HP 16V 75 HP 8V 120 HP Type Electric Electric EPS Electric EPS Electric EPS Electric EPS Electric EPS een diameter m ae 1 10 76 0000 76 AS 1 10 4000 1 No Bant I Steering wheel turns for full steering Steering box ratio 51 60 44 51 60 44 60 44 mm turn Steering wheel angle wheel angle ratio Rack travel travel ici FI on the steering wheel from stationary 2 5 mod city 2 5 mod city 2 5 mod city 2 5 mod city 2 5 mod city position Nm FIAT PUNTO 44 532 2004 Fiat Auto S p A All rights reserved Helical springs Edge diameter mm No of active coils Helix direction Free spring height mm Pack spring height Spring height under control load mm 2 9 Front suspensions 4 3 Multijet 4 3 Multijet 4 9 Multijet 16V 90 HP 16V 75 HP 8V 120 HP rr o A T T 17 5 5 Shock absorbers
89. Punto OK 329 532 O 2004 Fiat Auto S p A All rights reserved 5 2 3 Shafts Assembly drawing Axle shaft seal Differential case guide bushing Differential case Axle shaft seal ring sealing flange Axle shaft seal ring sealing flange Axle shaft sealing Differential Differential unit O O N OO bh W N A Transmission case gb Fiat Grande Punto OK 330 532 2004 Fiat Auto S p A All rights reserved 10 11 12 13 14 15 16 17 18 19 20 gb Fiat Grande Punto OK 331 532 O 2004 Fiat Auto S p A All rights reserved Assembly drawing Upper output shaft assembly Top gear shaft assembly Lower output shaft assembly Clutch vent coupling Fastening bushing Reverse gear headlamp switch Central disengagement Pressure pipe Clutch housing Gearbox control assembly Magnet CON OO A OO N gt wech eke ze ek ch or WwW N a O 0 gb Fiat Grande Punto OK 332 I 532 12 4 5 6 7 0 8 1011 12 13 14 15 16 fr Nes DI DI A pos 29 26 27 c ed 23 fe el Bick Position of the upper output shaft components Oil recovery pipe Upper output shaft Upper output shaft roller bearing Safety ring Reverse gear roller bearing Reverse speed gear driven Reverse gear engaging sleeve Reverse gear synchromesh ring Push dowel Synchromesh hub Spacer bushing Safety ring 3 speed gear driven 3 speed gear roller bearing Int
90. UNTO 92 532 2004 Fiat Auto S p A All rights reserved 3 3 6 Engine cooling Engine cooling system Water pump Engine coolant temperature sensor Thermostat Radiator Electric fan Feed tank Engine oil heat exchanger Vehicle interior heating radiator E G R exhaust gas heat exchanger Water recirculation pipe FIAT PUNTO 93 532 2004 Fiat Auto S p A All rights reserved 3 3 Engine cooling tank and radiator 3 4 Engine cooling feed tank In addition to feeding the circuit the tank absorbs the cooling fluid volume variations as the engine temperature changes By means of a special calibrated valve included in the pressurized cap the following will be obtained air flows out of the circuit which is collected by the pipe from the thermostat air flows in when the circuit is in vacuum condition due to engine cooling Engine cooling radiator It is made up of a core and two side trays for coolant inlet and outlet The core pipes and fins are made of aluminium whereas the tanks are made of plastic 3 4 1 Water pump and thermostat FIAT PUNTO 94 532 2004 Fiat Auto S p A All rights reserved The water pump is of the centrifugal vane type with pump body and impeller made of phenol resin and arbor made of steel It is secured to the engine base and driven directly through the service belt Thermostat 1 EGR valve output 2 temperature sensor 3 oil filter out
91. Us 5P 02 C B MI Y C3 02 ee 2427 2373 2460 Width S 1680 1640 1660 1660 7 72 ma oes no 7 659 586 cos 524 H100 Vehicte height 1467 1418 1525 1516 P Current Fiat Punto N Nuova Punto FIAT PUNTO 15 532 2004 Fiat Auto S p A All rights reserved To sum up Nuova Punto is longer than the competing cars of its market segment by approximately 20 cm whereas it is perfectly in line as far as width and height are concerned 1 2 3 Body versions Nuova Punto comes with four body versions characterized by specific interior trim and features that customize the dashboard panels and seats Active Dynamic Elegance Sporting The ACTIVE version features the following standard items ABS Electric power steering Electric window regulators Dual airbag The DYNAMIC version features the following standard items ACTIVE contents Remote control Height adjustable driver s seat Rear split seat 5 door version Height adjustable steering wheel Rear headrests The ELEGANCE version features the following standard items DYNAMIC contents Leather covered steering wheel and gear shift lever cap Car radio CD player Air conditioner tall FIAT PUNTO 16 53 2004 Fiat Auto S p A All rights reserved Alloy wheel rims The SPORTING version features the following standard items DYNAMIC contents Vehicle Dynamic Control ESP Fog lights Alloy wheel rims and
92. above one of the holes on the solenoid valve is made to communicate with the A FIAT gb Fiat Grande Punto OK 237 1 532 2004 Fiat Auto S p A All rights reserved drain by the solenoid valve itself Thus the rotor and therefore the camshaft is made to rotate in one given direction advance or delay If the oil flows into both openings alternately and continuously for an equal time period dynamic pressure balance will be achieved at the two rotor sides as a result the rotor will be stationary The advance position corresponds to the rest position in fact the spring that acts as a flexible coupling i e prevents the camshaft play from occurring especially when the vehicle is started due to poor oil pressure is loaded to the advance position Spring gb Fiat Grande Punto OK 238 532 O 2004 Fiat Auto S p A All rights reserved Stator Rotor S gb Fiat Grande Punto OK 239 532 2004 Fiat Auto S p A All rights reserved Blades on the rotor Effects of delay timing variation gb Fiat Grande Punto OK 240 53 2004 Fiat Auto S p A All rights reserved 4 4 Sensors 4 4 1 Knock sensor Description The piezoelectric knock sensor is fitted to the engine base and measures the intensity of the vibrations caused by the knock in the combustion chamber The knocks generate a mechanic rebound on a piezoelectric crystal that sends a signal to the contr
93. ach injector is tested at 7 characteristic operation points associated with special control time and fuel pressure conditions which reproduce the engine s typical operation points idling fully loaded etc The characteristic points are termed as follows e Main at full load e Main at emission Pilot at emission Pilot at full load Pilot at idle Combi at 800 Bar e Combi at 300 Bar FIAT PUNTO 115 532 2004 Fiat Auto S p A All rights reserved D NBE nar Sa IER 6 IH ee Bn 16621 n 206 A me ee gt E 1 A 46 BE ELO Be dirt SS I AN e O p ee e h i d S Pn j d Ah E z q r F 7 z F T Rp lt SW rs T 7 Sr a R P 2 D S ex a r 7 x gt P n qe P TS a E 7 i H i d di F 8 F AS L Mara Fall load 13 iha ro d h P i j i D E d A 4 I e Cumin ar 800 lu Man Bain Cosh lo 300 har Pilot Tole ku ra LT bel The chart illustrates the characteristic curves of 4 injectors based on the control time ET for various rail pressure levels The axis of ordinates shows the amount of fuel delivered at every injection instance mm ciclo the highlighted points are those where the measurements for IMA classification are made The features of each electric injector are identified by a set of 9 alphanumeric characters factory printed on the electric injector body at the B
94. ack elapsed time file name printed audio or data CD CD R and CD RW playing Sound features bass treble balance fader loudness 7 band equalization Preset default Rock Jazz Classic User provision for customization Blaupunkt CD changer audio input gb Fiat Grande Punto OK 493 532 2005 Fiat Auto S p A All rights reserved Blaupunkt CD changer 10 disc features power driven eject loading CD and track selection UP amp DOWN pause FF F REW Scan function Track Repeat and CD Repeat functions Mix CD magazine function TPM Track Program Memory function CD Naming 8 characters for 30 CDs Telephone section features telephone mute ON OFF function telephone volume function telephone volume control through the volume knob Steering wheel radio controls The car radio system features remote controls on the steering wheel see figures below Actuates MUTE voice radio Radio volume control Radio sound source search 9 7 Airbag system 9 7 1 General remarks The safety performance ensured by Nuova Punto result from accurate combination between the structural components and the high number of special devices that make up the occupant s protection system head on collision back collision side collision overturning All of this results in better performance levels than the prescribed ones with virtua
95. ail to the system requirement Such flow rate adjustment makes it possible to reduce both the high pressure pump power absorption and the maximum fuel temperature The feed pressure required for the high pressure pump is made available by an electrically operated fuel feed FIAT PUNTO 108 532 2004 Fiat Auto S p A All rights reserved pump found in the tank module The high pressure pump volume flow rate is distributed as follows approximately 22 is injected by the injectors and burnt in the cylinder approximately 28 is used to lubricate the high pressure pump and is recovered through the KUEV valve approximately 50 corresponds to the excess fuel recovered through the pressure accumulator and the injectors KUEV valve The purpose of this mechanic valve is to keep the pressure inside the pump constant it discharges any overpressure to prevent pressure peaks from damaging the pump and also control the fuel flow needed to cool and lubricate the eccentric shaft and the plungers of the CP1 H FIAT PUNTO 109 532 2004 Fiat Auto S p A All rights reserved M PROP valve This electronically controlled valve is used to modulate the feed rate from the low pressure circuit to the high pressure pump by rotating a flap inside the valve directly controlled by the ECM 1 0 amp max flow rate even if disconnected 1 2 5 amp zero flow rate H J ee o FIAT PUNTO 110 532 2004 Fia
96. ain FIAT PUNTO 76 532 2004 Fiat Auto S p A All rights reserved 3 2 12 Camshaft drive idlers iS The timing chain is stretched by an automatic oil pressure operated stretching device which O minimizes maintenance operations fitted inside the valve gear on the block which acts on the moving shoe 3 2 13 Distributing shafts in the upper head These are two camshafts made of cast iron with induction hardened cams FIAT PUNTO 771532 2004 Fiat Auto S p A All rights reserved The distributing shaft on the exhaust side is directly driven by the chain and transmits the motion to the distributing shaft on the intake side by means of a pair or straight toothed gears The distributing shaft on the exhaust side also drives the high pressure pump whereas the one on the intake side drives the vacuum pump 3 2 14 Tappets A hydraulic tappet is used for every single valve which is actuated by a rocker arm that is in turn driven by the cam axle The rocker arms are made in such a way as to avoid serious damage to the other engine members in case of timing chain breaking or stepping In fact they are able thanks to a pre established fracture section to get deformed so as to absorb the stress caused by the contact between the valves and the pistons Intake exhaust valve diameter 21 47 mm FIAT PUNTO 78 532 2004 Fiat Auto S p A All rights reserved 3 2 15 Spark plug
97. al lines and networks The Famiglia 1 architecture especially designed for the Nuova Punto controls the vehicle s electric system As regards the system s optimization the architecture follows the topological local approach each control unit either electronic or electro mechanic is placed in a barycentric position with respect to the functions managed This makes it possible to minimize the power and signal distributing system even by making extensive use of the serial communication lines thus making it possible to solve the dimension reliability weight and cost problems A node is meant as an electric control unit equipped with a CAN interface gb Fiat Grande Punto OK 378 532 2005 Fiat Auto S p A All rights reserved The most complete structure is made up of two CAN communication lines that connect nodes belonging to two different areas dynamic vehicle control and bodywork function on board information and also an additional LIN bus serial line first used on a FIAT model of this segment C CAN ECM MTA WD gear B CAN PAM HTA YRS EFS CTM DI w l OE Antenna GPS Antenna GSM EES gea gateway BCM wei Toi To bada Ce DI Antenne AN ZEN IMMO CODE RLS Antenna GPS The developed architecture is compatible with various user interfacing solutions control arrangement information display modes and assignment The electric protections fuses and the remote control switches
98. al module for GSM telephone and GPS navigation management gb Fiat Grande Punto OK 447 1 532 2005 Fiat Auto S p A All rights reserved 9 2 Rear parking sensor node PAM General remarks The parking assist system provides the driver during the reversing operation and information on the distance when approaching obstacles placed behind the vehicle This device helps you park the vehicle in safer conditions since it makes it possible to locate any obstacle found out of the driver s field of vision The obstacle presence distance information is transmitted to the driver through acoustic pulse signals the frequency of which varies with the vehicle s distance from the obstacle By combining the visual information with the acoustic information generated by the system the driver will be able to avoid collisions The parking sensor node PAM is an electronic component connected to the B CAN network and the body to front cable harness which assists driving during the manoeuvres with the reverse gear engaged thus recognizing any obstacle at the rear The interfaces for the sensors on the rear bumpers the trailer control unit and a buzzer placed into the IPC instrument board node are provided on the PAM parking sensor node The parking assist system of FIAT Nuova Punto is made up of the following components ultrasound sensors on the rear bumper one dedicated electronic control unit Un Fs ai Ir e Activ
99. al tube Dual tube size Dual tube size size 14 2 x size 14 2 x 27 size 14 2 x 14 2x 27 x 38 14 2 x 27 x 38 27 x 38 x 38 27 x 38 diameters diameters stem diameters diameters diameters stem piston piston ext stem piston stem piston stem piston ext tube tube ext tube ext tube ext tube Traditional Traditional Traditional Traditional Traditional mechanic stop mechanic stop mechanic mechanic stop mechanic stop stop Open length start of plugging mm Close length at abutting end mm The stabilizer bar is not available and has been replaced by a twisting link of adequate thickness 1 3 Multijet 1 3 Multijet 1 9 Multijet 8V 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 120 HP Medium link 5 9 5 9 5 9 5 9 5 9 mm FIAT PUNTO 48 532 2004 Fiat Auto S p A All rights reserved Crossbar en Ee Ed 90 HP 16V 75 HP 8V 120 HP Soft link IN O A ea Medium link 5 9 5 9 mm Hard link 7 1 7 1 mm 2 11 Suspension characteristic angles and trim Standard A vehicle unloaded incl spare wheel tools accessories fuel and fluid filling Standard 0 vehicle unloaded incl spare wheel tools accessories fluid filling with 5 litres fuel N B Only front wheel toe in can be adjusted at a workshop FIAT PUNTO 49 532 2004 Fiat Auto S p A All rights reserved 2 11 1 Front Engine versions Tyres Sta
100. alk functions Flashing light steady high beam headlamp switch the flashing light control is obtained by pulling the lever from the rest position towards the steering wheel crown while preventing the lever from going past the first click flashing light contact This actuation in UNSTABLE therefore the lever shall return to its rest position when it is released thus opening the flashing light contact again The steady high beam headlamp control is obtained by pulling the lever the same way as the flashing light control in this case however the lever shall be allowed to travel a longer stroke up to the second click high beam headlamps contact Here too the actuation is UNSTABLE the lever shall return to its rest position thus opening the high beam headlamp and flashing light contacts The high beam headlamps can be turned off by pulling the lever again up to the high beam headlamp position the same way as during ignition Indicator and lane change light control this control is obtained by making the lever to move along the steering wheel plane in both directions upwards and downwards The translatory motion of the lever in each direction of rotation involves two different ways to actuate the electric contact itself an UNSTABLE one referred to lane change and a STABLE one referred to as direction change The lane change function is actuated through a smaller angular travel than
101. an electric winding 2 The magnetic flux created by the magnet 3 undergoes due to the passage of the phonic wheel teeth oscillations resulting from the gap variation These oscillations induce an electromotive force in the winding 2 an alternately positive tooth facing the sensor and negative slot facing the sensor voltage is found at the winding ends i FIAT f 1 p i d Fa d E F We Salle i 1 i gb Fiat Grande Punto OK 249 532 2004 Fiat Auto S p A All rights reserved v LA MIN DM gutt Wm ei 1 Sensor 2 Output signal 3 Signal corresponding to the two missing teeth 4 Drive shaft pulley with phonic wheel The sensor output voltage peak value depends other factors being equal on the distance between the sensor and the tooth gap Sixty teeth are obtained on the phonic wheel two of these teeth are removed so as to make a reference the wheelbase will therefore correspond to an angle of 6 360 divided by 60 teeth The synchronism point is recognized at the end of the first tooth following the space of two missing teeth when the latter passes below sensor the engine s piston pair 1 4 will be found at 114 before the T D C Electric features resistance 1134 1386 Q at 20 C The distance gap required to obtain correct signals between the sensor end and the phonic wheel shall be in the range of 0 5 to 1 5 mm gb Fiat Gra
102. are grouped in the power distribution control units positioned in the engine compartment and in the dashboard These control units also act as interconnections for the various wirings and as electric distributors gb Fiat Grande Punto OK 379 53 2005 Fiat Auto S p A All rights reserved 9 1 3 Network architecture The most complete structure is made up of two CAN communication networks connected through a gateway for common information transfer DESCRIPTION CAN low speed twin wire 50 Kbit s CAN high speed twin wire 500 Kbit s Serial data bus single wire 9 6 Kbit s B CAN network for data communication bodywork standard function management C CAN network for dynamic vehicle control The gateway for the communication between C CAN and B CAN is located in the Body Computer node A LIN serial communication line is also available between the Body Computer control unit and the control unit on the rain sensor in this case the Body Computer node performs the gateway function between the LIN serial line and the CAN networks The node diagnosis in the B CAN and C CAN is performed for the first time on a FIAT model through the CAN line by using a protocol on the CAN network ISO 14229 Mex numer of odes trat can be comi e meme 5 gb Fiat Grande Punto OK 380 532 2005 Fiat Auto S p A All rights reserved Full optional network architecture Parking sensors Y L Private
103. arning light OFF after the engine has been started no fault is found on the components that affect the system safety Warning light ON when the engine is running a fault is present 3 9 2 FAULT SIGNALLING DURING VEHICLE OPERATION Warning light ON a fault is present Warning light OFF no fault is found on the components that affect the system safety RECOVERY The control unit defines each time the type of recovery depending on the broken components The recovery parameters are managed by the components in good working order 3 9 3 FIAT CODE recognition The control unit exchanges at the instant when it receives the key turned to MAR signal data with the body computer through the CODE function to obtain start enable Engine control unit Immobilizer gb Fiat Grande Punto OK 144 532 2004 Fiat Auto S p A All rights reserved 3 10 Checks 3 10 1 Fuel temperature check When the fuel temperature is 80 C as measured by the sensor in the diesel fuel filter the ECM controls the pressure regulator in order to reduce the line pressure if this is not enough it will also reduce the amount of injected fuel 3 10 2 Engine coolant temperature check When the engine coolant temperature is higher than 105 C the ECM reduces the amount of injected fuel i e reduces the engine power controls the cooling electric fans causes the cooling fluid temperature warning light to come on
104. ashboard o el i LI HE i I I HH El I Wi o BSM Brake node Ground gb Fiat Grande Punto OK 3 2005 Fiat Auto S p A All rights reserved 6 5 2 YRS Yaw Rate Sensor The YRS must be assembled with the arrow stamped on the sheet facing the direction of running and the connector facing the vehicle rear part 1 Power supply 2 C Can L1 3 C Can L2 4 C Can H1 5 C Can H1 This node incorporates the yaw longitudinal acceleration and transverse acceleration sensors into one single component gb Fiat Grande Punto OK 357 1 532 2005 Fiat Auto S p A All rights reserved 6 5 3 A S R Anti Slip Regulator This is a vehicle drive control function that comes into operation automatically when one or both of the driving wheels skid This function is available only with the ESP Two different control systems are actuated depending on the slip conditions if both the driving wheels slip the ASR comes into operation by reducing the power delivered by the engine if only one driving wheel slips the ASR comes into operation by automatically braking the slipping wheel The ASR system is very useful especially if the following conditions occur inner wheel slip when cornering due to dynamic load variations or excessive acceleration excessive power transmitted to the wheels even depending on the road surface conditions vehicle acceleration on slippery snow covered or
105. at runs through it the necessary flow is supplied by the low pressure pump The latter feeds the pump with a fuel amount that is always larger than the engine needs so as to make the fuel circulate back to the tank by doing so pump lubrication and cooling will be achieved the former taking priority over the latter Piston motion is obtained through a cam integral to the pump shaft the latter actuates a polygonal ring that acts on the piston foot Each pumping unit is equipped with a gate intake valve and a ball delivery valve The pump features a valve referred to as shutoff valve which makes it possible to protect the pump in case of low flow rate from the low pressure delivery thus allowing the pumping units and the eccentric mechanism to be lubricated DECH Si H AZ o 1 Pressure pump 2 Oldham coupling for camshaft connection FIAT PUNTO 104 532 2004 Fiat Auto S p A All rights reserved Hydraulic pump efficiency 500 bar 750 bar 1000 bar 4200 bar 1300 bar Efficiency 0 KIT 600 900 1200 1500 1300 2100 2400 Pump revs r p m Pump efficiency increases as revs do decreases as pressure does Construction Each pumping unit is made up of the following items three pistons 5 actuated by a cam 2 integral to the pump shaft 6 one gate intake valve for each piston 3 one ball delivery valve for each piston 4 The pressure pump must be fed with
106. atalytic converter is made up of a ceramic honeycomb monolith 1 the cells of which are soaked with platinum 2 a catalyzing substance of oxidation reactions Operation The exhaust gas flowing through the cells heats the catalyst thus triggering the conversion of polluting substances into inert compounds The chemical reaction for CO HC and particulate oxidation is efficient at temperatures ranging between 200 C and 350 C Beyond 350 C the sulphur contained in the diesel fuel starts oxidizing thus giving rise to sulphur dioxide and sulphur trioxide SN A i T i J d WI es FIAT PUNTO 85 532 2004 Fiat Auto S p A All rights reserved 3 3 1 Exhaust gas recirculation E G R system This system makes it possible under certain operating conditions to convey a portion 5 15 of the exhaust gas to the intake Thus the temperature peak is lowered in the combustion chamber thus reducing the formation of nitric oxides NOx The function of the E G R solenoid valve 1 controlled by the injection control unit 2 is to let a portion of the exhaust gas drawn by exhaust manifold 4 again into the engine intake A heat exchanger 3 makes it possible to partially cool the exhaust gas by further lowering the combustion chamber temperature FIAT PUNTO 86 532 2004 Fiat Auto S p A All rights reserved E G R solenoid valve Injection control unit Heat exchanger Exh
107. aust manifold Air inlet manifold Operation The injection control unit drives with coolant temperature of more than 20 C and engine speed ranging between 800 and 3 000 r p m the E G R solenoid valve through a square wave signal Variation of this signal allows the E G R coil to displace a shutter thus controlling the flow of burnt gas from the exhaust manifold to the inlet manifold Two results will thus be obtained less air Is let in the combustion temperature is lowered due to the presence of inert gas thus reducing the formation of NOx nitric oxides The injection control unit is constantly informed about the amount of recirculated gas by the data from the air flow meter In fact if a certain amount of air Qam is to be sucked with a given engine speed and the value provided by the air flow meter Qar is smaller the difference Qgr will be the value of the recirculated gas amount Qam Qar Qgr Qam Stored theoretic air amount Qar Actual air amount Qgr Recirculated gas amount The atmospheric pressure signal is used when driving the E G R solenoid valve to recognize the high altitude driving condition so as to reduce the amount of recirculated gas and avoid engine smokiness FIAT PUNTO 87 1532 2004 Fiat Auto S p A All rights reserved E G R solenoid valve The purpose of the Pierburg E G R solenoid valve fitted to the cylinder head is to modulate the exhaust gas flow to t
108. b Fiat Grande Punto OK 1 89 53 1 4 8v 1 368 cm 72mm 84 mm N D N D 2004 Fiat Auto S p A All rights reserved Max power engine speed Max power engine speed Max torque engine speed Compression ratio Engine management control unit Anti pollution regulatory standard Torque curve and power curve 57 KW 6 000 r p m 75 HP 6 000 r p m 115 Nm 3 000 r p m 11 1 Marelli 5SF3 Euro 4 60 55 50 D Wu 120 Rating kW S 115 35 110 Torque Nm 30 105 25 100 20 95 15 90 10 85 80 0 15 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 gb Fiat Grande Punto OK Speed r p m 190 53 2004 Fiat Auto S p A All rights reserved Engine identification codes ENGINE 1 4 8V TYPE CODE 350A1000 4 2 IAW 5SF injection ignition control unit 4 2 1 Injection system architecture The Marelli IAW 5SF systems falls into the category of the integrated systems for digital electronic ignition with inductive discharge static distribution electronic injection of the phased sequential type 1 3 4 2 The figure below provides an overall view of the system TAI W Ey HA OI J ZE L KL U eh I i Fuel tan
109. belt 1b gb Fiat Grande Punto OK 314 532 2004 Fiat Auto S p A All rights reserved An l aN vi Tad ee 2 0 A dt oat Ka o lt d Moving belt stretcher Fit template 2000004400 onto the distributing shaft rear shank m kai gb Fiat Grande Punto OK 315 532 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A 8 VALVE 1 4 FIAT PUNTO TRAINING OUTLINE S ENGINE After Sales CH gb Fiat Grande Punto OK 316 532 2004 Fiat Auto S p A All rights reserved Fit the template securing the pulley to the camshaft gb Fiat Grande Punto OK 317 532 2004 Fiat Auto S p A All rights reserved Fit drive shaft timing template 2000004500 onto the driving pulley FI AT N De gf gb Fiat Grande Punto OK 318 53 2004 Fiat Auto S p A All rights reserved Proceed as shown in the figure to bring the automatic stretcher reference fork to the abutting end W gb Fiat Grande Punto OK 319 532 2004 Fiat Auto S p A All rights reserved Remove the templates previously fitted then make the engine turn twice to settle the engine timing belt Loosen the belt stretcher fastening nut then act on the front fork until the latter coincides with the rear fork Tighten the belt stretcher fastening nut to the specified torque 2 5 3 0 daNm Fit the templates previously removed in order to check engine timing gb Fiat G
110. box has made it possible to dampen the road surface roughness to optimum levels to the advantage of the acoustic comfort inside the passenger compartment Neither toe in nor the camber angle can be adjusted the correct values shall therefore be guaranteed during the assembling phase gb Fiat Grande Punto OK 3731532 2005 Fiat Auto S p A All rights reserved 8 3 2 Characteristic angles Camber angle Loading conditions ENGINE VERSIONS TYRES STD O 1 2 MN 1 ER 20 1 7194 20 20 aa 4 8V LE 1 lia dl 20 1 Se 20 1 3 MJet 70 CV 1 20 1 20 1 5 65 R15 84T 1 2 8V 1 20 1 20 1 3 MJet 70 CV 1 20 1 20 1 4 8V 1 20 1 20 1 2 JTD 90 CV 1 20 1 20 1 2 JTD 90 CV 185 65 R15 88T 1 9 JTD 1 4 20 1 20 1 9 JTD 195 55 R16 87H 1 20 1 20 gb Fiat Grande Punto OK 374 532 2005 Fiat Auto S p A All rights reserved Toe in Loading conditions ENGINE VERSIONS 1 2 8V 1 3mm 2mm 1 5 mm 2mm 1 4 8V 1 3mm 2mm 1 5 mm 2mm 1 3 MJet 70 CV 1 3 mm 2 mm 1 5 mm 2mm 175 65 R15 84T 1 28V 1 3 mm 2 mm 1 5 mm 2mm 1 3 MJet 70 CV 1 3 mm 2 mm 1 5 mm 2mm 1 4 8V 1 3 mm 2 mm 1 5 mm 2mm 1 3 MJet 90 CV 1 3 mm tt 2 mm 1 5 mm 2mm 1 3 MJet 90 CV 185 65 R15 88T 1 3 mm 2 mm 1 5 mm 2mm 1 9 MJet 1 3 mm 2 mm 1 5 mm 2mm 1 9 M
111. bulb holder Third brake lamp This lamp located outside and positioned above the rear heated window incorporates the wiping function detergent outlet nozzle and the lighting function by means of 8 bulbs L FI DI gb Fiat Grande Punto OK 485 532 2005 Fiat Auto S p A All rights reserved Bulb replacement open the rear hatch remove rubber caps A press on elements B and take transparent glass C out disconnect the connector act on fins D in an opposing way to remove the bulb holder then take out the force fitted bulbs and replace the same NOTE Take care of the wiping nozzle tube Rear fog lights reversing lights These lights are housed onto the rear bumper Left hand rear fog light P21W bulb A right hand reversing light P21W bulb A for left hand drive versions Reverse arrangement for right hand drive versions Built in reflector Bulb replacement disconnect from under the bumper the connector then take the bulb holder off The lights shall not be removed from the bumper License plate lights Two lights with W5W bulbs housed onto the rear bumper Optimum homogeneity of light distribution which allows the license plate to be clearly seen gb Fiat Grande Punto OK 486 532 2005 Fiat Auto S p A All rights reserved Bulb replacement act to tabs A to release the transparent glasses from the bumper then replace the bulbs by taking the bulb holder off the transparent
112. bus d d f i i if i i FIAT Qn K E A Te gb Fiat Grande Punto OK 381 532 2005 Fiat Auto S p A All rights reserved Diagnostic architecture The situation of the diagnostic architecture both as regards the control units integrated to the CAN network nodes and the ones not equipped with a CAN interface is summarized in the table below Audio amplifier Rain sensor control unit Sunroof control unit Convergence node B CAN B C CAN Instrument board node B CAN Parking sensor node Auxiliary heater node B CAN Engine control node C CAN Robotized gearbox node C CAN YES Braking node C CAN Electric drive node C CAN YES YES YES YES YES B CAN B C CAN B CAN B CAN B C CAN B CAN Ko YES YES YES YES B CAN C CAN C CAN C CAN C CAN Some control units and nodes are indicated as diagnosis free despite their featuring self diagnosis functions e g rain sensor control unit in fact they do not feature any implemented diagnostic protocol and their errors if any are detected through the diagnosis of other control units e g BCM gb Fiat Grande Punto OK 382 532 2005 Fiat Auto S p A All rights reserved 9 1 4 Diagnosis instrument adapter The diagnosis of Fiat Punto which makes use of a serial network of the CAN HIGH SPEED type can be performed by means of the new A16HS high speed cable Moreover release 6 30 or any other subsequent
113. buting motor position signal 29 Fan input a Rees EE E AN e A AA AS 35 O 10 2 2 Actuators and sensors The air conditioning system is made up of the following items A controls knobs buttons and displays B sensors passenger compartment temperature sensor external temperature sensor left right dashboard mixed air temperature sensor left right foot area temperature sensor solar sensor C actuators left right mixing actuator recirculation actuator DEF SX dashboard foot area air distribution actuator DEF DX dashboard foot area air distribution actuator fan speed actuator compressor disable actuator gb Fiat Grande Punto OK 516 532 2005 Fiat Auto S p A All rights reserved MAX DEF function actuator rear heated window actuator D connecting lines with Body Computer CAN network 10 2 3 Compressor Nuova Punto is equipped with the variable displacement magnetic clutch free Denso 5SL12 compressor It makes it possible to gradually vary the flow rate of the cooling fluid reaching the evaporator as a result the anti frost sensor would be redundant and has therefore not been fitted to the system Control is based on the intake pressure value according to the following logic low pressure the compressor displacement tends to the minimum value high pressure the displacement is increased This operating logic refers to the following actual conditions
114. button to actuate the electric pump again FIAT PUNTO 125 532 2004 Fiat Auto S p A All rights reserved 3 6 8 Fuel filters Description of components The fuel filter GREEN FILTER is fitted to the engine compartment on the right side It is made up of a plastic shell that incorporates a filtering cartridge made of synthetic material which is highly efficient in terms of performance service life and water separation Diesel fuel inlet Filtering cartridge sealing O ring supplied Temperature sensor Diesel fuel outlet from the injection system Diesel fuel outlet from the control valve toward the tank Regulating valve inside the outlet Water drain actuating screw Water escape zone Water presence sensor electric connection O DAN OT FP W N O Diesel fuel heater FIAT PUNTO 126 532 2004 Fiat Auto S p A All rights reserved Water sensor 3 6 9 Fuel temperature sensor and heating device The fuel filter is equipped with a fuel preheating device and a fuel temperature sensor through a NTC thermistor fitted inside the cover The heater is controlled by the injection control unit depending on the signal of the fuel temperature sensor Refer to the fuel temperature sensor for specifications FIAT A FIAT PUNTO 127 532 2004 Fiat Auto S p A All rights reserved HEATER WIRING DIAGRAM NTC WIRING DIAGRAM gt 1 1 Relays 4 Pin DUT PIN OUT
115. can be opened only by means of a special control In the event that the battery does not deliver enough power for the electric door lock handle function the boot can in any case be unlocked and opened by actuating a special lever that can be reached by removing a mask located on the luggage board No latch is found on the boot The boot can also be opened from the inside in case of electric system malfunction by means of a mechanic safety device that can be actuated through a mask located in the upper portion of the luggage board gb Fiat Grande Punto OK 463 532 2005 Fiat Auto S p A All rights reserved 9 3 1 System functions Door locking unlocking The door locking system makes it possible to control the locks of the various doors from the vehicle The door locks can be unlocked from the outside by putting the mechanic key into the latch driver s door and turning the same The vehicle s doors cannot be locked if one or several doors are not fully closed In this case a light signal informs you that the doors have not been locked In the event that the boot is open the doors can be locked yet an acoustic signal will inform you that an anomaly is found If the vehicle is locked from the outside the door s central locking unlocking buttons will be disabled and will be enabled again the next time the doors are unlocked Locking unlocking actuation The boot and door locking unlocking can be actuated
116. capable of coming up to the expectations of the targeted customer groups active dynamic elegance and sport 1 1 2 Market and customers Today the segment to which Nuova Punto belongs accounts for 26 of the West European car market that is to say the market core with approximately 3 750 000 units sold annually In Italy this segment accounts for as much as 37 of the market which is made up of petrol engines 56 and diesel engines 44 FIAT has always been a key player in the small average car segment Despite the crisis of the past few years Fiat Punto has been the best selling car in Italy and the third best seller in West Europe Today Nuova Punto aims at being a market leader again not only in Italy but also all around Europe How can this goal be achieved By taking advantage of Nuova Punto s dynamic and determined style expressed through the typical Italian car design and simple clever solutions FIAT PUNTO 12 532 2004 Fiat Auto S p A All rights reserved This step will allow the FIAT brand to make a comeback which has somehow started with Nuova Panda and currently in progress with Idea and Croma The main goal of Nuova Punto is to win back the young customers thanks to its dynamic and sporting character through a typically Italian style the symbol of personality and elegance Therefore Nuova Punto is a car for the young at heart people who wish to express their personality
117. cement the protection fuses are found inside the engine compartment control unit CVM left low beam headlight fuse F14 right low beam headlight F15 left high beam headlight fuse F16 right high beam headlight fuse F17 Fog headlamps The are built where available into the bumper and are equipped with a H1 bulb Bulb replacement to replace the lamp unscrew the cap release the retaining clip and take the bulb out the headlamp shall not be taken off the bumper Fuse replacement the F31 protection fuse is located inside the engine compartment control unit FDU Sgp a la al d FS gb Fiat Grande Punto OK 483 532 2005 Fiat Auto S p A All rights reserved Side repeater They feature an oblong shape and are fitted onto the front bumper WY5W bulb D Bulb replacement move transparent glass A forward so as to press clip B then take the unit off Rotate connector C then take bulb D off Fixed rear headlamps These rear headlamps are fitted to the red rear pillar with function distribution dual position with ROW bulbs C brake light dimmer P21 5W bulb D and indicator light P21W bulb B arranged vertically Screws A are used to remove the headlamps from the pillar and replace the bulbs S gb Fiat Grande Punto OK 484 532 2005 Fiat Auto S p A All rights reserved Bulb replacement after the headlamp has been removed from the pillar undo screw E to release the
118. conditions may occur Error memory reading DTC P 0016 76 DTC P 0016 76 No DTC No DTC Possible problem Engine timing does not fall within the permitted tolerances The enable conditions are not met upon execution of the procedure Engine timing falls within the permitted tolerances The enable conditions are not met upon execution of the procedure Solution The engine must be disassembled and the current timing shall be checked Repeat the procedure None If this condition occurs immediately after reprogramming repeat the procedure Otherwise no remedying action is required In the event that a vehicle is allowed to travel in the traffic with engine timing out of the permitted tolerances the engine itself may be broken FIAT a gb Fiat Grande Punto OK 299 532 2004 Fiat Auto S p A All rights reserved 4 6 2 Timing detachment reattachment camshaft drive Act on the moving idler 1a with a wrench in the counterclockwise direction then remove the single engine member drive belt 1b Unscrew screws 2a then remove the drive shaft pulley 2b gb Fiat Grande Punto OK 300 532 2004 Fiat Auto S p A All rights reserved ENET EE Re Fiat Auto S p A 8 VALVE 1 4 FIAT PUNTO TRAINING OUTLINE Sia ENGINE After Sales Training Moving idler 1a gb Fiat Grande Punto OK 3
119. ct features 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP Front constant velocity Tutela Tutela MRM Tutela MRM Tutela Star universal joint Tutela Star 325 MRM Zero Zero 325 differential side Zero Front constant velocity Tutela Star Tutela Tutela Star Tutela Star universal joint wheel Tutela Star 500 500 Star 500 500 500 side Wheel hubs steering Lr ove meme T Underbody member CHE Brake circuit component ee ee ee n Lubricant capacity Oil amounts 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP Engine oil amount for regular replenishment 2 6 3 2 2 6 3 2 4 18 sump and filter litres Gearbox oil front 1 5 2 08 1 5 1 8 2 08 differential kg FIAT PUNTO 55 532 2004 Fiat Auto S p A All rights reserved 2 14 Vehicle features 2 14 1 Dimensions 1 3 Multijet 1 3 Multijet 1 9 Multijet 8V 16V 90 HP 16V 75 HP 120 HP o pa pa om Jm om mme me Im Im 1 473 1 473 1 473 1 473 1 473 1 687 1 687 1 687 1 687 1 687 er I J U Em K FIAT FIAT PUNTO 56 532 2004 Fiat Auto S p A All rights reserved 2 14 2 Performance 1 3 Multijet 16V 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 90 HP 16V 75 HP 8V 120 HP Top sped ben mm Acceleration sec 0 to 100 k p h 2 persons 12 12 14 3 14 5 20 kg sporting body version 2 14 3 Fuelling and
120. ctuator gb Fiat Grande Punto OK 21 8 53 2004 Fiat Auto S p A All rights reserved Pin out Component Component connector pin Potentiometer 1 position Power supply from the ECU Throttle motor positive Throttled body Potentiometer 2 position Throttle motor negative Receiving item pin 44 ECM connector B 15 ECM connector B 57 ECM connector B 30 ECM connector B 52 ECM connector B es Ground from the ECU 35 ECM connector B Recovery In case of failure a value is set which is calculated starting from the values read by the absolute pressure sensor if the latter is broken a fixed value equal to 50 throttle opening will be set The dash pot and mixture ratio idling speed self adapting strategies will be blocked i L L FIAT A ef gb Fiat Grande Punto OK 219 532 2004 Fiat Auto S p A All rights reserved 4 3 5 Hydraulic valve for camshaft phase control E la Electric features 1 1 Camshaft phase control valve 2 ECM Position on the vehicle Phase control valve K N gb Fiat Grande Punto OK 221 532 2004 Fiat Auto S p A All rights reserved Pin out Component oe Component Function Receiving item pin connector pin Power supply form the main 4 ECM connector B relay Ground from the ECU 2 ECM connector B Recovery In the event that the phase variator has got stuck
121. cv 1 3mm 2mm 1 5mm 2mm FIAT PUNTO 52 532 2004 Fiat Auto S p A All rights reserved Camber angle Engine versions Tyres Standard 0 Standard A 1 20 1 20 1 20 1 20 175 65 R15 84T 1 2 8V 1 20 1 20 1 20 1 20 1 3 Multijet 16V 90 cv 1 9 Multijet 8V 120 cv 1 4 16V 1 20 1 20 195 55 R16 87H 1 20 1 20 2 12 Battery and alternator Vehicle models without air conditioner 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP gek AN ASD Sf vale Vehicle models with air conditioner 1 3 Multijet 1 3 Multijet 1 9 Multijet 8V 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 120 HP 50 50 50 60 Battery capacity Ah 50 rt o o e In Im 2 13 Fluids and lubricants Oils and fluids Recommended product features 1 3 Multijet 1 9 1 3 Multijet 1 4 8V 1 2 8V 16V 75 Multijet 8V 16V 90 HP HP 120 HP Selenia Engmeot Selene K Selenia WR seenak K Selenia WR differential kaci Car Tutela car kad Car Tutela car Tutela car Technyx Matryx Technyx Technyx Matryx Brake Brake fluid Tutela Tutela Top4 4 Tutela Tutela Top4 4 Tutela Top 4 Tutela Top 4 Tutela Tutela Top 4 4 E ae Up Mar up Paraflu up Paraflu up Mae up Radiator fluid 50 50 50 50 50 FIAT PUNTO 54 532 2004 Fiat Auto S p A All rights reserved Grease Recommended produ
122. d by the belts to the thorax The load limiters combine in the front seats with the airbags to better restrain the occupants Passenger detecting sensor This sensor makes it possible to detect the presence of a passenger and if necessary warn the driver that the safety belts have to be fastened by emitting a visual and sound signal through the vehicle panel Auxiliary central head on collision sensor The auxiliary deceleration sensor located on the vehicle s front structure ECS Early Crash Sensor helps the main electronic control unit to advance airbag actuation compared with traditional systems by nullifying the risk of minor injuries resulting from the airbag actuation phase this phase shall therefore be completed before the occupant starts moving forward towards the steering wheel or the dashboard gb Fiat Grande Punto OK 500 532 2005 Fiat Auto S p A All rights reserved Side protection system Front side airbags they are of the thorax pelvis type and ensure together with the door panels the protection of critical body parts such as the ribs abdomen and pelvis They are fitted to the seat so as to always ensure the maximum efficiency depending on the seat position Front side thorax pelvis airbags side bags where available They consist of two types of instantly inflating cushions housed in the seat backs which are used to protect the occupant s thorax and pelvis in case of medium
123. d starts blinking and the acoustic signal sounds intermittently for 90 seconds if any of the following conditions occurs elapsed time of 60 sec and vehicle speed higher than 10 k p h vehicle speed higher than 25 k p h covered distance longer than 500 m If the belts are fastened during the cycle the warning cycle will be automatically interrupted and will be repeated only when the unfastened belt condition occurs again Warning cycle switch off mode the driver may switch the warning cycle off temporarily before the key ON by fastening the front safety belt s by keeping the same for at least 20 seconds with the key ON and then releasing it or permanently by asking for the assistance of the Technical Service personnel The warning cycle is actuated again upon every key ON with the temporary switch off mode Warning cycle re actuation mode the driver may actuate the warning cycle again it the latter has been switched off permanently by either asking for the assistance of the Technical Service personnel Mode panel or through a special item of the set up menu Comfort and Matrix panels This item will disappear when the warning cycle is actuated again External temperature displaying Available with the Comfort and Matrix panels The external temperature indication is ensured if the external temperature sensor is available in standard screen conditions The desired unit of measurement C or F can be selected from the set
124. doors designed to reproduce low middle frequencies The technology used for these components of the water resistant type allows the latter to stand water jets if any from inside the door without being damaged tweeter loudspeakers 30 W located on the door opening handle designed to reproduce the highest frequencies full range loudspeakers 40 W diameter 130 mm located on the rear side frames which can reproduce the entire range of the sound frequencies These components feature the water resistant technology Hi fi sound system This system is made up of 6 loudspeakers and a sub woofer box containing a single channel power amplifier Below are the main features of the components mid woofer loudspeakers 40 W diameter 160 mm located on the front doors designed to best reproduce the low middle frequencies the water resistant technology is used with these components tweeter loudspeakers 40 W located on the door opening handle designed to reproduce the highest frequencies full range loudspeakers 40 W diameter 130 mm located on the rear side frames which can reproduce the entire range of the sound frequencies These components feature the water resistant technology sub woofer box of the bass reflex type 6 5 7 volume including a loudspeaker 100 W diameter 130 mm to reproduce the lowest frequencies This box is fitted into the luggage compartment on the right wheelbox side sing
125. e the Cruise Control will remain ON without having to press the resume RES button to resume the previous conditions once acceleration has ended gb Fiat Grande Punto OK 446 532 2005 Fiat Auto S p A All rights reserved Automatic switch off The Cruise Control is temporarily disabled in case of ABS or VDC actuation longer than a permitted maximum time the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button The Cruise Control can be deactivated automatically in case of unintentional or wrong actuation of the lever buttons and acceleration higher than a pre established limit value in this case the function can be resumed by acting on the main switch ON OFF during switch off and switch on and then starting over with the desired speed setting operations In the event that a fault is found in the Cruise Control or the engine control system the Cruise Control will be disabled until key OFF In this case the Technical Service centre shall be contacted CSM Steering column stalk BCM gt Body Computer node o ES K ID KL KD ld KS LJ CSM Reference Ground 9 2 6 Radio receiver node RRM The radio receiver node RRM is an electronic component connected to the B CAN network and the dashboard cable harness Interfacing with an external audio amplifier is provided on the radio receiver node RRM with a CD changer and an extern
126. e B CAN line the request to the IPC to actuate the obstacle detection acoustic signal Acquiring on the B CAN line the request for obstacle presence acoustic signal actuation Acquiring on the B CAN line the parking sensor correct operation System failure indication Actuating the obstacle detection acoustic signal Functional diagram F404 I F192 i FU ZU S1 S2 S3 S4 Ultrasound sensors 1 4 Electric wire connection AS Towing hook available Electric wire connection 6 Output signals see PAM B CAN line Reverse gear actuation status B CAN line External temperature acquisition B CAN line WA Buzzer actuation oo actuation Internal connection connection A Vehicle a operation B _ line cl Failure warning light Internal connection System actuation and deactivation When the vehicle is started ignition key turned to MAR a self diagnosis test is carried out by the control unit and the sensors the system will be actuated when the reverse gear is engaged and will be deactivated when the reverse gear is disengaged The acoustic signal emitted by the system warns the driver that the vehicle is drawing near an obstacle It consists of pulse sound signals the signal duration is constant whereas the pause between the signals is directly proportional to the obstacle distance pulses in a quick sequence indicate the presence of a very near object gb Fiat Grande Punto OK
127. e Punto OK 531 532 2005 Fiat Auto S p A All rights reserved
128. e circuit 90 HP FIAT PUNTO 101 532 2004 Fiat Auto S p A All rights reserved High pressure circuit It is made up of the following items pressure pump CP1 75 HP CP1H 90 HP single fuel manifold pipe with built in pressure regulator and pressure sensor electric injectors CR1MI2 2 connecting pipes ei wi ee OS Sa High pressure line Injectors 75 HP amp 90 HP CR1MI2 2 FIAT PUNTO 102 532 2004 Fiat Auto S p A All rights reserved Assembly drawing 1 Fuel tank 2 Fuel filling pipe 3 Backflow pipe 4 Fuel filter 5 Fuel filter water sensor 6 Pressure pump 7 High pressure pipes 8 Single fuel manifold pipe rail 9 Electric injectors CR1MI2 2 10 Pipe from electric injectors to fuel return manifold pipe 11 Fuel return manifold pipe 12 Pressure regulator DRV 2 13 Fuel pressure sensor RDS 4 14 Fuel temperature sensor 15 Fuel heater FIAT PUNTO 103 532 2004 Fiat Auto S p A All rights reserved 3 6 2 Bosch CP1 high pressure pump 75 HP Features The high pressure pump is of the CP1 Compact type with three radial pistons radialjet The pump features a capacity of 567 mm3 rev and a rotation speed equal to half the rotation speed of the drive shaft step down ratio 2 1 owing to the pump being fitted onto the camshaft through an Oldham coupling The pump needs no timing moreover it is lubricated and cooled by the fuel flow th
129. e crash tests and also of the injection fuel feed system has made FIAT AUTO aware of the need to define from the start the bodywork construction design principles and the layout of the various systems fitted to motorcars For this reason the whole of Fiat Punto from the body to every single component has been designed so as to comply with the strictest latest FIAT in house fire prevention regulations Fire Prevention System FPS All the petrol and diesel engine versions feature the FPS Fire Prevention System inertia switch which causes the engine to be switched off immediately a few milliseconds after a collision The plastic tank conforming to the forthcoming directives is located in an area protected in case of collision It can withstand distortion if any with no risk of fuel escape moreover it poses no explosion hazard if the vehicle is set on fire due to its being made of plastic gb Fiat Grande Punto OK 511 532 2005 Fiat Auto S p A All rights reserved Engine compartment electric system The main sectioning of the positive high power cables is carried out directly on the battery s positive pole through a box complete with fuses This solution is advantageous since no cable sections are found which are not protected by a fuse and therefore subjected to casual short circuits All the cables are electrically insulated and placed inside corrugated coverings for mechanic protection against the possibl
130. e fuel consumption constantly updated It helps the driver be aware of the consumption differences according to the driving behaviour The unit of measurement k p l cannot be selected in the Mode panel Average speed k p h or m p h it is calculated starting from the start of the missions Driving time hh mm it indicates the time 00 00 to 99 59 elapsed since the start of the mission with resolution and updating of 1 minute When the maximum value is reached the count will be reset automatically gb Fiat Grande Punto OK 416 532 2005 Fiat Auto S p A All rights reserved Set up menu The set up menu functions can be actuated only when the vehicle is stopped except for the speed limit function speed limit threshold and speed limit actuation deactivation selection Pressing the Menu Esc and buttons will allow you to select adjust and set the displayed values If no operation is carried out for some time the standard screen will be resumed Mode panel Speed speed limit threshold selection and setting the SPEED writing appears in place of the odometer k p h or mph writing depending on the set unit of measurement OFF or ON writing and speed limit in place of the clock with a range of 30 to 250 k p h 20 155 m p h anda step equal to 5 k p h 5 m p h Clock setting the Hour writing appears in place of the odometer Buzzer setting one single
131. e of this engine enhance the elasticity features of Fiat Punto ensuring smooth driving and quick pick up without having to shift down with very good consumption levels The introduction of the continuous phase variator and a new concept of variable turbulence combustion chamber have made it possible to significantly reduce fuel consumption and exhaust emission especially when driving in the city traffic and out of town The new combustion chamber with a compression ratio of 11 0 combined with the new intake and exhaust pipes the new inlet manifold and optimized valve gear timing ensure bright performance low fuel consumption and emission levels The 1 4 engine complies with the Euro 4 regulatory standard Below are the main features of this new engine 8 valve 4 cylinder in line OHC engine gb Fiat Grande Punto OK 187 1 532 2004 Fiat Auto S p A All rights reserved aluminium alloy head valve control by means of a camshaft and mechanic tappets of the bucket and adjust type electronically controlled hydraulic continuous phase variator cast iron engine block variable turbulence combustion chamber fluid cooling with forced circulation by means of a centrifugal pump secured to the engine base and sealed circuit radiator and auxiliary expansion tank engine timing by means of a timing belt flexible flywheel with resulting reduction of the power unit vibrations transmitted inside the passenger compartment p
132. e risk of rubbing The electric insulation of the battery starting motor power cable is made of a material which features high resistance against the abrasions and cuts Moreover the cable routing has been optimized and special fasteners have been used Electric system inside the passenger compartment All the cables are protected by fuses located in the interconnecting control units located in the engine compartment FDU front left side passenger compartment BCM left side under the dashboard or luggage compartment RDU wired on the vehicle cable and positioned in the rear left headlamp area The cable routing is properly arranged to avoid cable pinching when the trimmings are fitted gb Fiat Grande Punto OK 512 532 2005 Fiat Auto S p A All rights reserved 10 Air conditioner 10 1 General remarks 10 1 1 System configurations The range offered makes three different system available heater air conditioner automatic two zone air conditioner with provision for obtaining different air temperatures and distribution patterns both for the driver and the passenger The versions equipped with air conditioning an optional item on the heated versions feature pipes for air distribution to the rear passenger foot area The heater and air conditioner controls feature the same layout characterized by 3 knobs the left knob allows the user to control the temperature of the air let into the passenger compartment
133. e ultrasound sensor Electronic control unit drawing gb Fiat Grande Punto OK 448 53 2005 Fiat Auto S p A All rights reserved The electronic control unit actuates and controls the sensor functioning processes the signals received from the sensors and actuates the acoustic device The sensors are ultrasound technology based electronic components which act as smart transmitters receivers with ultrasound technology according to a triangulation method it allows better measurement in critical situations or when small obstacles are found The emitted pulses are reflected by the obstacles if any found in the ray path thus the transducer receives an echo that is converted into a digital signal and sent to the electronic control unit The acoustic device is located inside the instrument board moreover it signals the system actuation when the reverse gear is engaged and the fault if any System coverage area PAM parking node functions Acquiring the signals from the rear ultrasound sensors Acquiring the towing hook presence when the towing hook is available the system shall be switched off Acquiring the external temperature signal for the diagnosis strategy see diagnosis specification Parking sensor management Transmitting on the B CAN line parking sensor correct operation N gb Fiat Grande Punto OK 449 53 2005 Fiat Auto S p A All rights reserved Transmitting on th
134. e up of a infrared LED sensor fitted to the vehicle s front window and is capable of detecting the presence of rain and as a result managing the wiping operation depending on the amount of water found on the glass 9 2 11 Brake pedal switch This switch is located on the brake pedal and is connected to the body to front cable harness Its function is to indicate the brake pedal status in order to report the latter to the control units that request so Wal AT gb Fiat Grande Punto OK 454 532 2005 Fiat Auto S p A All rights reserved It is a control with two contacts NO N C with separate power supply and the same interface on the cable harness side Below are the control units that request the indication of the brake pedal status Body Computer control unit engine management control unit braking system control unit for both versions ABS and ESP robotized gearbox 9 2 12 Control board on the driver s side front door DDC The control board on the driver s side front door DDC is a module that integrates the different controls located on the driver s side front door and is interfaced with the driver s side front door cable harness The DDC control board receives the power supply for ideograph lighting and correct control operation It may feature the following controls depending on the body version level front electric window regulator control rear electric window regulator if availab
135. each time the type of recovery depending on the broken components The recovery parameters are managed by the unbroken components gb Fiat Grande Punto OK 280 532 2004 Fiat Auto S p A All rights reserved 4 5 3 Cylinder position recognition The engine phase signal together with the top dead centre T D C and engine revs signal allows the engine control unit to recognize the cylinder sequence to implement the timed injection This signal is generated by a Hall effect sensor positioned on the tappet cover just next to the phonic wheel obtained on the distributing shaft pulley 4 5 4 Oxygen sensor combustion check In EOBD systems two oxygen sensors which are of the same type but cannot be exchanged with one another are available one before the catalyst system pre catalyst and one after the same post catalyst The pre catalyst sensor determines the loop 1 mixture ratio control pre catalyst sensor closed loop The post catalyst sensor is used to diagnose the catalyst and finely modulate the loop 1 control parameters To this regard the purpose of loop 2 adaptivity is to recover both the production dispersions and the slow drift that the pre catalyst sensor response may exhibit due to ageing and contamination Geff HE i d gb Fiat Grande Punto OK 281 532 2004 Fiat Auto S p A All rights reserved This control is referred to as loop 2 control post catalyst sensor closed loop
136. ealized by means of a sheared circuit Luggage compartment control unit RDU Rear Distribution Unit wired with a sheared circuit BCM fuses A DESCRIPTION OF COMPONENT FUNCTION mir be Brake pedal switch normally open clutch switch IPC ns BSM SAS brake pedal switch normally closed cable stretcher EPB YRS ASR deactivation switch Bidirectional window washing pump 10 IPC diagnosis connector DLC display DAB F51 HB TM or radio CTM or mobile phone connector PA Front dome light rear dome light glove compartment light sun visor light front door mudguard light boot light F58 f0 Airbag module SDM weight sensor Rain twilight sensor parking assist module CTM or mobile phone connector CSS control illumination LED ELC control illumination LED SWC control illumination LED TPMS sunroof motor sto Kee fuel lid and door closing F85 15 Reserve output gb Fiat Grande Punto OK 391 532 2005 Fiat Auto S p A All rights reserved FDU fuses Component identif code Identif code F12 F14 47 F20 F70 F85 F86 gb Fiat Grande Punto OK Description Engine BSM Valve BSM Engine cooling fan low middle speed or single speed Engine cooling fan high speed Left low beam headlamp Right low beam headlamp Left high beam headlamp Right high beam headlamp Passenger s glove compartment ECM MTA and gearshift lever HVAC ACC driver s door control side
137. ective signalling warning light icon will be actuated and the respective message will be shown on the display In case of tyre puncture the panel will also generate an acoustic signal Moreover a TPMS failure signalling warning light icon message is available Operating conditions The following functional degrading is permitted during the thermal motor starting phase no display back lighting softer panel back lighting graphic elements and pointers After the transient is over all the functions will be restored However the maintenance and subsequent use of the data relative to the functions below shall be ensured during this phase even following a reset if any during the cranking phase clock date trip computer A and B trip odometer included in the trip computer gb Fiat Grande Punto OK 431 532 2005 Fiat Auto S p A All rights reserved Moreover the loss of the following data parameter is not permitted odometer displaying and calculation logic parameter e g revs counter anti oscillation thresholds check time recovery time delay time etc EOL Proxi and DTC data brightness softening and CAF levels dimming set up menu setting parameters memorized by the user Following a reset during the cranking phase the panel shall also carry out a consistency check of the stored data not found in the EEPROM and restore valid data restart the check phase upon key ON as described bel
138. ed torque directly onto a toothed wheel coaxial and integral to the column The torque delivered at the input by the driver is detected by a sliding contact potentiometer sensor The electric steering column fitted to the Nuova Punto incorporates the steering angle sensor too this signal is also used by the ESP control unit if available In case of service procedures the steering angle sensor shall be reset by means of a suitable diagnosis instrument The driver can choose from two drive programs City and Normal which can be selected by means of a button available on the dashboard Wal DI gb Fiat Grande Punto OK 362 532 2005 Fiat Auto S p A All rights reserved City button The City program maximizes comfort during the parking manoeuvres with record breaking effort on the steering wheel 2 5 Nm compared with 4 6 Nm of traditional power steering systems The Normal program ensures average performance during the parking manoeuvres while ensuring a gradual optimum effort on the steering wheel even at low speeds especially in poor road grip conditions In any case both programs provide varying interlocking depending on the vehicle speed gradual power assistance therefore with no compromise between the performance during the parking manoeuvres and the steering control quality when the vehicle is running A special calibration for both programs is provided for every single body engine versions
139. eeeeseeeeeenas 96 CAT 96 3 5 SERVICE CONTRO cinica ai etanolo 96 3 6 PUED TED ESTE acini ariani iaia cia 99 000 Iii 99 3 6 2 Bosch CPI high pressure pump 75 HP 104 3 6 3 Bosch CPIH high pressure pump HUH 108 304 Lee A E E rE E 113 gt gt SERE 119 300 AM 121 gt Wlan 124 SCIE RR TN NT TNT N E O 126 3 6 9 Fuel temperature sensor and heating device ccccccccccccccccccccccce cece cece cece cece cece eee keke EEE EEE E ELLE ELLE EEE E ELLE EEE E ELLE EEE EEE EEE 127 3 7 eE EE E IDETE E 129 3 8 MJD 6F3 DIESEL ENGINE MANAGEMENT CONTROL UNITA 130 SI Paini 130 52 7 6 5 r iaia 131 K VD CSI CON EE 137 K E EE 138 3 8 5 Control unit ingoing outgoing information diagram oooooonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninens 14 3 9 SELF DIAGNOSIS 3 9 1 N G FIAT PUNTO 51532 2004 Fiat Auto S p A All rights reserved 3 10 1 E EE 145 3 10 2 BIRRA CECI T 146 3 10 3 ZAINI AT RE 147 3 10 4 CASI AREE 148 3 10 5 Fuel cut off during the release phase cut off aria 149 3 10 6 ddiine E 150 3 10 7 ADORA 134 3 10 8 Checking the exhaust smoke level during acceleration sse 152 3 10 9 Melia 153 KiTHE a on 154 3 10 11 EE EE EE EE 55 0 2 E paik PUE ina 156 3 10 13 Air conditioning system actuation check 137 3 10 14 Auxiliary fuel electric pump check 158 3 10 15 Cylinder postion CN Kt rar rl 159 3 10 16 Main injection and pilot injection advance check 160 3 10 17 TInjection pressure
140. elves into their respective seats obtained in the inlet manifold pipes whereas the fluoridated rubber O rings 1 and 2 ensure the sealing on the intake manifold and the fuel manifold Fuel is fed from the upper part 3 of the electric injector the body of which includes the winding 4 connected to the terminals 5 of electric connector 6 Fuel manifold Intake manifold The fuel jet comes at the absolute pressure of 3 5 bar out of the injector and is immediately atomized Operation The injector control logic is of the phased sequential type i e the four injectors are controlled according to the intake phases of every single cylinder Geff NM d gb Fiat Grande Punto OK 203 532 2004 Fiat Auto S p A All rights reserved Electric features Engine management system remote control switch A 075 IM 7 3 ars N v NR 0 75 SES WW 0 E LN 0 75 UG O IL ji 075 N J75 1 2 3 4 Electric injectors 5 6 Junction ECM 8 FDU Engine management remote control switch gb Fiat Grande Punto OK 204 532 2004 Fiat Auto S p A All rights reserved Position of injectors on the vehicle Injector housing on the intake pipe L FI DI gb Fiat Grande Punto OK 205 532 2004 Fiat Auto S p A All rights reserved Pin out Component Receiving Receiving Receiving Component O S Function connector p
141. epending on the logic described below Manual mode The window can be started and stopped manually by the user by pressing the control button briefly 50 to 300 ms When this button is released the motor will stop Automatic mode the window is started manually by the user by pressing the control button for a long time longer than 300 ms The window regulator will not be actuated when the control buttons are pressed for less than 50 ms The window regulator operation will be interrupted when automatic operation is under way and the window lifting or lowering control is pressed again The window regulating function can be actuated on all the windows only when the key is inserted except for window central closing opening by means of the remote control and during the timed period during which the key is not inserted as described below Following the key OFF the front windows can only be actuated manually over a period of 3 minutes After this time has elapsed the system will not be acquiring new commands any more In the event that during the timing door opening is detected new commands will no longer be acquired only the commands if any received prior to the door opening will be completed If upon key OFF any of the doors is open the commands if any received prior to the door opening will be completed The driver s side window actuation is managed by the local controls The passenger s side window actuation is managed both by
142. er compartment and therefore lower limb injury In case of disconnection the pedal shall be replaced gb Fiat Grande Punto OK 348 532 2005 Fiat Auto S p A All rights reserved The pedal unit system is made up of the following components plastic pedal support plastic accelerator pedal with a potentiometer metal brake pedal plastic clutch pedal Ke Dee gb Fiat Grande Punto OK 349 532 2005 Fiat Auto S p A All rights reserved 6 4 ABS system All the Nuova Punto versions are equipped with the Bosch 8 0 ABS antilock system with built in EBD Electronic Brake force Distribution which controls the braking action so as to prevent rear wheels from being locked thus ensuring correct distribution of the braking action to the axles under any condition The Bosch 8 0 ABS system is one of the most advanced systems currently available on the market The system is made up of the components below one hydraulic control unit with 12 solenoid valves 4 active sensors and 4 channels with braking corrector distributor The system s peculiarities as far as active safety is concerned are as follows it ensures that every wheel about to be locked is braked as efficiently as possible compatibly with the road grip conditions available it ensures full vehicle control under extreme conditions when the wheels are about to get locked it ensures prompt control response it is capable of adjust
143. er to ensure total toothing accuracy and therefore noiseless operation Both the wheelcase and the clutch housing have been optimized for lightweight and soundproofing features by means of a F E M Finite Element Method structural analysis method The synchromesh for all the forwards gears and the reverse gear is of the free loop brass type Borg Warner type and is placed on the countershafts upper shaft for the 3 4 gears and the reverse gear lower shaft for the 1 2 5 and 6 gears gb Fiat Grande Punto OK 325 532 O 2004 Fiat Auto S p A All rights reserved The synchromesh features a triple cone design on the 1 and 2 gears i e the gears most frequently used and subjected to stress and a double cone design on the 3 and 4 gears to ensure significantly lower engaging effort compared with a traditional single cone synchromesh of equal dimensions The new internal gear control system which provides for 4 selection levels with central bearing gear positioner gives the advantage of low hysteresis and therefore smaller gear selection loads The wheels and kinematic mechanisms inside the gearbox are lubricated dynamically through channelled oil flow paths through holes on the cases and shafts This ensures better torque transmission performance and higher efficiency in terms of wear and manoeuvrability even at low temperatures thanks to the use of multigrade oil 5 2 Component 5 2 1 Synchromesh The M32
144. eric correction The atmospheric pressure varies depending on the altitude this causes such a volumetric efficiency variation that requires a correction of the base ratio injection time The injection time correction will depend on the altitude variation and will be automatically updated by the electronic control unit every time the engine is switched off and also under certain throttle position and revs number conditions typically with low engine speed and throttle opened to a large extent dynamic atmospheric correction adjustment Cut off operation The cut off fuel cut off strategy is implemented when the control unit recognizes the accelerator pedal released position pedal percent value 0 and engine speed of more than approximately 1 350 r p m this value is approximate and varies depending on a few parameters the most significant of which are essentially the temperature and the running condition The recognition of the accelerator pedal non released condition and engine speed of less than 1 270 r p m approximate value varying according to the various models enables engine feed again gb Fiat Grande Punto OK 285 532 O 2004 Fiat Auto S p A All rights reserved In case of very high engine speeds the cut off strategy is implemented also when the throttle valve is not fully closed but when the pressure in the inlet manifold is significantly low partial cut off gb Fiat Grande Punto OK 286 53
145. ermediate ring AAA 7 8 9 2004 Fiat Auto S p A All rights reserved 16 17 18 19 20 21 22 23 24 25 26 21 28 29 Synchromesh ring 34 speed engaging sleeve Push dowel Synchromesh hub Safety ring Differential Output shaft roller bearing 4 speed gear roller bearing 4 speed gear Intermediate ring Synchromesh ring 34 speed engaging fork Gearshift lever pin Reverse gear engaging fork gb Fiat Grande Punto OK 2005 Fiat Auto S p A All rights reserved CON O Oo A W N gt 1 2 3 4 5 7 9 1011 12 13 14 34 33 32 Ka 31 30 29 28 27 26 25 24 23 Position of the lower output shaft components Push dowel Safety ring 15 2 speed engaging sleeve Outer synchromesh ring Outer synchromesh ring Inner synchromesh ring 2 speed gear driven 200 gear roller bearing Closing ring Thrust washer 11 12 13 Push dowel 15 5 speed gear driven 2 speed gear roller bearing Synchromesh ring Synchromesh hub 15 16 1 18 19 20 21 gb Fiat Grande Punto OK 334 532 2005 Fiat Auto S p A All rights reserved 16 17 18 19 20 21 22 23 24 25 26 21 28 29 30 31 32 33 34 35 5 6 speed engaging sleeve Safety ring Synchromesh ring 6 speed gear driven 6 gear roller bearing Output shaft roller bearing Differential 5 6 speed engaging fork Gearshift lever pi
146. ernator Selespeed pump T relay Selespeed In line connection r Front wiring body L gb Fiat Grande Punto OK 394 532 2005 Fiat Auto S p A All rights reserved Table 3 Bodywork Pedal MTA C514 DLC switch Cockpit wiring P BCM EPS Front bodywork wiring L D O x _ E 3 3 E SDM O 5 E YRS O O E 3 e Front seat Front seat 5 a G036 Preset G033 A RDU LL O N E O Rear bumper a 8 3 3 C041 wiring X s A Reversing light Rear fog Rear left light ig License ple Rear right light liaht Parking sensor wiring gb Fiat Grande Punto OK 395 532 2005 Fiat Auto S p A All rights reserved 9 1 9 Electronic components The Famiglia1 architecture is made up of the elements listed in the table below TPMS Tyre pressure measuring control unit Derived from Nuova Croma PAM Parking sensor node New Audio hi fi amplifier Derived from Punto BCM Body Computer node New CTM Convergence node RLS Rain sensor control unit New SDM Airbag node New AHM Auxiliary heater node The derived components differ in the HW SW implementation from the components used on the reference models e g Nuova Croma gb Fiat Grande Punto OK 396 532 2005 Fiat Auto S p A All rights reserved Use control module The Nuova Punto Famiglia1 architecture provides for integration of the user c
147. es are implemented in a gradual way whereas the decreases are implemented immediately During acceleration the strategy will make use of a higher threshold to allow for increased engine noise under this condition Moreover this strategy features a self adapting function that memorizes in a non permanent fashion the advance reductions that might occur continuously so as to adapt the advance to the different conditions suffered by the engine e g when fuel with a low octane number has been used The strategy is capable of resuming the advance to the threshold value stored in the memory when the conditions that caused reduction to occur are not present any more 4 5 14 Radiator electric fan control The control unit directly controls the radiator electric fan operation depending on the engine coolant temperature and the air conditioning system actuation The electric fan is switched off when the temperature exceeds 95 C 1 speed or 105 C 2 speed The switch off takes place with hysteresis 3 C lower than the actuation threshold approximate values varying according to the various models and based on experimental tests The high and low speed functions are managed by the actuation of special remote control switches placed in the air conditioning system management control unit and driven by the injection control unit 4 5 15 Engine idling control management The control unit recognizes the idling condition throu
148. eserved Example The panel also displays the information sent by Convergence module through a dynamic multi message The number of frames that can be received depends on the number of characters sent by the Convergence module Examples Displaying form the Convergence module Matrix panel Telephone displaying The Convergence status and the information sent by the Convergence module will be displayed on one single screen Navigator displaying The following information is displayed Navigation pictograph Distance to the next turn Unit of measurement Name of the street or road Logistic mode This function can be actuated deactivated only through the diagnostic network and makes it possible to cut down consumption current absorbed so as to prevent the battery from running down gb Fiat Grande Punto OK 426 532 2005 Fiat Auto S p A All rights reserved In particular the vehicle board disables the following displaying upon key OFF and key ON clock odometer even when the front doors are opened or closed Warnings and messages Message displaying Comfort and Matrix panels The messages on the display are divided into four different classes high priority anomalies low priority anomalies warning messages e g doors boot open feedback e g ASR ON OFF When a fault occurs on the vehicle the following will be displayed the warning light and or the icon on the Matrix display cor
149. ess on rough road surfaces dynamic systems engine intake and exhaust 1 2 12 Interior comfort and room When evaluating a passenger compartment customers seem to base their assessment of the vehicle interior comfort mainly on the drivers seat comfort o nani FIAT PUNTO 24 53 2004 Fiat Auto S p A All rights reserved The area around the driver s seat is together with the components included in it the passenger compartment portion that bears the greatest significance when the customer has to make a final judgement of the driving comfort that the whole of the vehicle passenger compartment can offer The designing of Nuova Punto has focussed on ergonomics Optimum balance has been achieved between the style prerogatives and the customer s unavoidable needs in terms of interior comfort easy access into the vehicle inner visibility all controls are easily visible and within reach and outer visibility thanks to the large dimensions of side rear view mirrors Nuova Punto can accommodate occupants of all builds this has been achieved without affecting the dimensions of the boot which features a minimum holding capacity of 263 litres with the standard running trim Feeling good on board means having a lot of space available and such space should be available just where it is needed for Nuova Punto features living space volume cubic volume values at the top of its category The passenger compartment profile
150. essing the button again Manual opening by pressing the button briefly for 60 to 300 ms the front glass panel fully closed will move to open proportionally to the time T during which the button is pressed and will stop when the button is released By pressing the button again and again on the same side still within the time range of 60 to 300 ms the panel will jolt along until it reaches the maximum opening position This function allows the user to position the front panel at intermediate positions with respect to the maximum opening position gb Fiat Grande Punto OK 528 532 O 2005 Fiat Auto S p A All rights reserved 11 2 2 Sunroof closing Similarly with the opening operation the front glass panel can be closed in two different ways by pressing the respective button on the closing side upon key ON automatic closing by pressing the button on the opening side for more than 300 ms the front glass panel fully opened will reach the spoiler opening position By pressing the button again on the panel will reach the closing position Following the initial opening control the glass panel may be stopped at intermediate positions by pressing the button again Manual opening by pressing the button briefly for 60 to 300 ms the front glass panel fully opened will move to close proportionally to the time T during which the button is pressed 60 to 300 ms and will stop when the button is released By
151. f new Fiat Punto tailored by Giugiaro has a tremendous pull on those who wish to own a car for the young comfortable and carefully planned to the last detail In fact Nuova Punto is targeted mainly at the young and the young at heart thanks to its trim engine driving pleasure and comfort Nuova Punto stands out from its main competing cars for the following STYLE meant as the capability of coming up to the expectations of the end customer thanks to designs and versions that appeal to the customer and make the latter eager to own a Nuova Punto DRIVING PLEASURE meant as the capability of accommodating all the passengers into a comfortable nice car and also pointing up those aspects which come up to the customer s expectations in terms of safety comfort and quality as well as the technical features of the vehicle ensuring driving behaviour that stands out from the competing models BRIGHTNESS meant as the capability of combining low operating costs and the vehicle s performance FIAT PUNTO 11 532 2004 Fiat Auto S p A All rights reserved The launch product offer envisages two petrol engine versions and three diesel engine versions the main features of which are as follows Petrol engines 1 2 8v 65 HP 1 4 8v 75 HP Diesel engines 1 3 Multijet 16V 75 HP 1 3 Multijet 16V 90 HP 1 9 Multijet 16V 120 HP with four different body versions that stand out for their contents and engine models
152. features music sound power 4 x 30 W graphic 7 band equalizer digital tuner built in large sized alphanumeric display 20 characters per RDS functions control icons easily controlled menu to adjust the settings for the radio and any external interface CH changer telephone Mute function actuated by pressing the volume knob for a brief time Soft mute function during the source radio channel changing operations volume control depending on the vehicle speed can be selected through the menu car radio switch off timing control immediate switch off or 20 minutes after key OFF antenna power supply remote control form the steering wheel provision for interfacing with external Blaupuntk CD changer through a private BUS line provision for connection with a mobile phone hand free set active control of the hi fi system where available Radio features radio CD player and radio CD MP3 player high selectivity digital tuner digital selection with dynamically varying bandwidth multi search FM provision for selecting the HICUT High cut i e dynamic high sound reduction depending on the RF signal function e autostore function automatic memorization of the radio channels with the best signal gb Fiat Grande Punto OK 491 532 2005 Fiat Auto S p A All rights reserved RDS Radio Data System with EON AF alternative frequencies TA TP PTY and REG function can be selected by
153. fect sensor fitted to the overhead just next to the distributing shaft on the exhaust side A tooth is obtained on the overhead which allows the phase sensor to signal the engine timing position The injection control unit uses the phase sensor signal to know the top dead centres at the end of the compression phase and also synchronize during the starting phase the injections with respect to the position of the pistons Phase sensor i gb Fiat Grande Punto OK 168 53 2004 Fiat Auto S p A All rights reserved Operation A semiconductor layer through which current flows immersed into a standard magnetic field lines of force perpendicular to the direction of the current generates a potential difference known as Hall voltage at its ends If the current intensity remains constant the generated voltage will depend only on the magnetic field intensity Therefore it is enough for the magnetic field intensity to vary periodically in order to obtain a modulated electric signal the frequency of which is proportional to the speed by which the magnetic field changes To obtain this change the sensor is periodically moved near by a tooth obtained on the inner side of the pulley PIN OUT Type of Pin Name i signal 1 Ground Ground Frequency 2 Phase signal output 3 Power supply Input 12 V In the specific case of the phase sensor this is powered by the engine management control unit with 5 V
154. fi system iii 453 DE DD lla 453 9 2 10 ROOT OI ie a AI REI 454 9 211 A E O E E E AEA EA 454 9 2 12 Control board on the driver s side front door ODC 455 9 2 13 e de EE 457 9 2 14 COMI PR 1 457 9 2 15 ET E WE 458 9 2 16 TP MS Dre pressure E 459 9 3 EE 460 Soi Gnor al EE 460 E NEE 464 9 4 ECECIRIC WINDOW E 472 G e AU 472 9 5 Rap O e K N ees E E E E E E T 479 9 6 ADOS T C 489 N G FIAT PUNTO 9 532 2004 Fiat Auto S p A All rights reserved 9 7 A 495 Si E 495 0 Is A A ne eT 499 LL a A ee ene Ria 503 UFA DIRO acre a I 306 9 8 PIREPROTBCHO eege 511 i AR CONDE ON Rara ii 513 10 1 E Eege 513 10 1 1 KEE 513 10 1 2 Ere TTT 514 10 2 COMPONEN E 515 10 2 1 ECC Electronic Climate Control control unit i 515 10 2 2 AMANI L did did 516 10 2 3 CO nale 517 10 2 4 Fillers dnd CONG CIS CF rire 520 10 2 5 EEN 521 10 2 6 ees 522 10 3 OPERA TON TTT 522 E A e y y E ila iaia 524 it SUN ROO iia 525 11 1 DESRRION loi 525 11 2 A A ECO E EEE 528 11 2 1 EI TILL 528 11 2 2 Oil 529 11 2 3 Ee 530 11 3 SUNROOF CLOSING AN EIEPINCH PEAT ORE TT 530 RN EER 531 11 5 are WON rN KL WE 531 1 Briefing 1 1 General features 1 1 1 Introduction Nuova Punto a new dynamic and exciting car capable of blending style and sporting features into an irresistible mix Nuova Punto stands out to reaffirm the excellent Italian car design tradition and FIAT s calling for youth appealing sportscars The determined line o
155. filling 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP Fuel reserve l 5 7 5 7 5 7 5 7 5 7 FIAT PUNTO 57 1532 2004 Fiat Auto S p A All rights reserved 2 14 4 Consumption EC Directive 199 100 CE litres per 100 km 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V sa HP 16V TE HP 8V hie HP 75076 a bed e SEN sporting body version 2 14 5 Emissions 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP coat gm ze sporting body version All engines complying with the Euro 4 emission level requirements Standard 175 65 R15 84T items 185 65 R15 88T 175 65 R15 84T 185 65 R15 88T 2 14 6 Tyres 185 65 R15 88T 195 55 R16 87H 205 45 R17 88V 185 65 R15 88T 195 55 R16 87H 175 65 R15 84T 185 65 R15 88T 175 65 R15 84T 185 65 R15 88T 1 3 Multijet au 1 3 Multijet 1 9 Multijet 8V 16V 90 HP 16V 75 HP 120 HP 185 65 R15 88T 195 55 R16 87H 205 45 R17 88V 185 65 R15 88T 195 55 R16 87H 1 5 65 R15 84T 185 65 R15 88T 1 5 65 R15 84T 185 65 R15 88T Spare 175 65 R15 84T 185 65 R15 88T 175 65 R15 84T 175 65 R15 84T 185 65 R15 88T wheel 185 65 R15 88T 185 65 R15 88T 185 65 R15 88T FIAT PUNTO 98 532 O 2004 Fiat Auto S p A All rights reserved Version 1 4 8V 175 65 R 15 84T 185 65 R 15 88T 2 14 7 Inflating pressure
156. fitted to Nuova Punto consists of a special wide glass system referred to as Skydome made up of two glass panels one fixed rear panel and one front sliding pane and a front fin which acts as an air baffle The glass extends to such an extent that it takes the place of over 70 of the sheet metal roof panel surface The glass allows when closed the external light to be let into the vehicle while allowing the occupants inside the passenger compartment to have a very good vision of the outside The glass allows when opened the roof compartment to be opened to approximately half its surface area During the opening phase the front mobile panel slides out of the roof panel spoiler function In particular the sunroof consists of the following gb Fiat Grande Punto OK 525 532 2005 Fiat Auto S p A All rights reserved Side view a sheet metal frame on which the other components are secured D a system right and left of mechanisms secured to the chassis for front glass panel handling which are driven by an electric motor by means of a metal spiral cable E two tempered glass panels thickness 4 mm with low energy and light transmission values a moving front panel A which can also act as a spoiler and a fixed rear panel B secured to the chassis a front fin C which acts as an air baffle it lifts when the roof is opened two polyester roller type window shades front and rear w
157. flows into the valve through a filter 2 i gb Fiat Grande Punto OK 234 532 2004 Fiat Auto S p A All rights reserved The box solenoid valve makes the rotor advance or delay openings to communicate with the oil channels in the engine head through two holes 1 2 A hole conveys the pressure oil to set the rotor blade moving whereas the other is made to communicate with the drain 3 by the solenoid valve Therefore each of holes 1 and 2 1 2 will always act an in inlet in the direction of the variator and an outlet in the direction of the head respectively depending on whether the phase is to be delayed or advanced by the engine control unit 2 1 The following figures a b c d illustrate the section that makes the solenoid valve and the phase variator to communicate with each other gb Fiat Grande Punto OK 236 532 O 2004 Fiat Auto S p A All rights reserved As we have said above the phase variator is made up of a rotor and a stator The rotor is equipped with blades and moves due to the effect of the engine oil pressure in the blades themselves Two openings advance and delay openings are obtained at the sides of each of the blades the engine oil may flow into either opening The pressure of the oil flowing into an opening pushes the blade on one side whereas the oil found in the other opening is drained into the engine head through the solenoid valve as we have said
158. g speed 750 50 750 50 r p m FIAT PUNTO 34 532 2004 Fiat Auto S p A All rights reserved 2 2 Timing angles Valve play 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 cv 16V 75 cv 8V 120 cv Cold operation valve pla E ES 0 3 0 3 Intake mm Cold operation valve pla E SES 0 4 0 4 Exhaust mm Intake 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP Opening before T D C 7 n d E n d n d Exhaust 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP ER A A A ARANA AA FIAT PUNTO 35 532 2004 Fiat Auto S p A All rights reserved Injection 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP l l l l Bosh Type Marelli 5SF3 Marelli 6F3 Marelli 5SF3 Marelli 6F3 EDC16C9 Injection sequence 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 Ignition 1 3 Multijet 1 3 Multijet 1 9 Multijet 1 4 8V 1 2 8V 16V 90 HP 16V 75 HP 8V 120 HP F M BAE F M BAE Coils 940A 940A S San E ZKR7A ark plugs a ZKR7A 10 Preheating drive Bitron control unit Preheating spark Beru 4101192 plugs Ignition sequence 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 FIAT PUNTO 36 532 2004 Fiat Auto S p A All rights reserved 2 3 Engine characteristic curves 60 55 D 50 c D D 45 12
159. gb Fiat Grande Punto OK 461 532 2005 Fiat Auto S p A All rights reserved System components Mechanic key The mechanic key is used to get on the vehicle and lock unlock the driver s and passenger s doors It features a coded mechanic insert matched with the driver s and passenger s front lock latches This insert can be removed from the key head upon utilization The latch on the driver s door fitted onto the handle allows you to unlock all the doors by means of the mechanic key whereas the latch on the passenger s door fitted onto the handle allows you to unlock the single passenger s door The key s metal part A is fixed Key equipped with remote control This key consists of a fold away metal insert A and a handle enclosing the same The metal insert can be removed by pressing the special button B on the handle and can be fitted back into place by keeping the same button depressed and rotate the metal insert in the handle until the locking click which indicates correct locking is heard The key actuates the starting device and the front door locks gb Fiat Grande Punto OK 462 532 2005 Fiat Auto S p A All rights reserved Boot If the independent driver s door unlocking option is active the boot will not be unlocked the customer has requested that the vehicle can be accessed only through the driver s door The boot is always independent with respect to the door status and
160. ge diesel fuel pressure accelerator pedal position diesel fuel temperature FIAT PUNTO 140 532 2004 Fiat Auto S p A All rights reserved 3 8 5 Control unit ingoing outgoing information diagram 1 Auxiliary fuel electric pump 2 Diesel fuel water presence sensor 3 Conditioner compressor where available 4 E G R solenoid valve 5 Revs counter 6 Electric fans 7 Spark plug preheating control unit 8 Dual trace accelerator pedal potentiometer 9 Dual brake pedal switch clutch pedal switch 10 Fuel pressure sensor 11 Air flow meter 12 Cooling fluid temperature sensor 13 Fuel temperature sensor 14 Cruise Control where available FIAT PUNTO 141 532 2004 Fiat Auto S p A All rights reserved 15 Overpressure sensor 16 Phase sensor 17 Revs sensor 18 Speedometer 19 Battery 20 FIAT CODE body computer 21 Diagnosis connector 22 Pressure regulator 23 Electric injectors 24 Preheating spark plugs 25 Spark plug preheating warning light 26 Injection warning light 2 Max water temperature warning light 28 Fuel water presence warning light FIAT PUNTO 142 532 2004 Fiat Auto S p A All rights reserved 3 9 Self diagnosis The control unit self diagnosis system checks the signals from the sensors and compares them with the permitted limit data 3 9 1 FAULT SIGNALLING UPON VEHICLE START Warning light ON until the engine has been started test phase W
161. gh the accelerator pedal release position The control unit drives in order to control the idling speed depending on the devices turned off and the brake clutch pedal signals the power driven throttle position The idling speed envisaged for hot operation is 750 50 r p m 4 5 16 Optimization of thermal operating conditions The revs number is corrected above all depending on the engine coolant temperature When the optimum temperature is reached the idling soeed management will only depend on the signal from the engine revs sensor when external loads are applied the control unit drives the throttle control actuator to adjust the engine revs to the conditions that have occurred and also manage the engine load by sustaining the idling speed 4 5 17 Fuel vapour recirculation control This strategy controls the vapour cut off solenoid valve position as follows during the starting phase the solenoid valve remains closed thus preventing the fuel vapour from excessively enriching the mixture this condition persists until the engine coolant temperature reaches 65 C e with the engine is thermal condition the electronic control unit sends the solenoid valve a square wave signal duty cycle that modulates its opening Thus the control unit checks the amount of fuel vapour sent to the intake thus avoiding significant variations of the mixture ratio gb Fiat Grande Punto OK 293 532 2004 Fiat Auto S p A All right
162. ght parking light Front left parking light 9 Front right indicator light 10 Right side indicator light 11 Rear right indicator light enee ee A License plate light 15 Right brake light e AAA Rear left dimmer 19 Left side indicator light Rear left indicator light Bus LIN B CAN B C CAN H El JI E A AA K EM AAA H Light switch module 10 Four indicator button LED E Ar 19 Rear window button LED a Parking assist deactivation LED gb Fiat Grande Punto OK 404 532 2005 Fiat Auto S p A All rights reserved 14 Spare 15 Immobilizer coil power supply A3 Immobilizer antenna AN H 17 C ee pare 19 Ground Ad E Power steering control 29 Four indicator button control 24 Rear window regulator switch 28 Boot button actuation control 3 Spare 28 City button control 29 Windscreen wiper control 30 Fog light control WELL I nem a eni e oo y Rees O Reference ground C CAN L 28 Spare Blinking control S oka GIL I aeaaaee RIN x AS ese alpen Sahra L gb Fiat Grande Punto OK 405 532 2005 Fiat Auto S p A All rights reserved 48 Ignition key power supply Ground Steering wheel control 2 Indicator light control Steering wheel controls 3 59 Steering wheel horn controls KA Wiper controls speeds 1 and 2 automatic intermediate Front rear window washing control ae 57
163. ghts reserved Alternator Belt stretcher Water pump Drive shaft pulley Engine member drive belt FIAT PUNTO 97 532 2004 Fiat Auto S p A All rights reserved Versions with air conditioner FIAT PUNTO 98 532 2004 Fiat Auto S p A All rights reserved 3 6 Fuel feed system 3 6 1 Features This fuel injection system makes use of electronically controlled high injection pressure and fuel supply obtained by means of one main injection and one or several pilot injections according to the engine s operating conditions which are electronically controlled by the injection control unit through electric injector CR1MI2 2 This system is capable of carrying out up to five cycle injections depending on the engine s operating conditions The pressure value represents one of the main parameters in order to optimize fuel consumption and exhaust smoke levels The engine control by means of several pilot injections makes preheating possible in the combustion chamber so as to avoid the pressure peak caused by quick combustion thus ensuring smoother operation and also allows emissions to be further reduced The injection pressure can be controlled thanks to the construction features of the system which is equipped with a pressure pump pressure regulator pressure sensor and separate electric injectors all of which are managed by a control unit Thus the injection pressure is independent from the engi
164. glass DL Functions The diagnosis is carried out by the trip computer with the actuation control ON as follows Anomaly recognition Failure to one bulb Rear Failure to at least two bulbs When a bulb anomaly is found the trip computer signals upon key ON the dimmer failure Indication Headlamp trim control it operates with the starting key turned to MAR and the low beam headlights ON The vehicle slopes backwards when it is loaded thus causing the light beam to be raised In this case the headlamps shall be orientated correctly again The trim can be controlled by pressing the buttons indicated by the arrows and located on the control mask The instrument board display provides a visual indication of the control positions position 0 one or two persons sitting on the front seats position 1 five persons travelling on the vehicle position 2 five persons travelling on the vehicle and luggage compartment loaded position 3 driver plus maximum permitted load stored in the luggage compartment gb Fiat Grande Punto OK 487 1 532 2005 Fiat Auto S p A All rights reserved Follow me home this function makes it possible to achieve timed switch on of the dimmers except for the licence plate lights and the low beam headlights immediately after the vehicle has been switched off The function can be deactivated only within 2 minutes from the key OFF through the flashing light control by means of
165. he headlamp trim corrector When the low beam headlamps are not active any longer handling will be disabled and the current position of the headlamp reflectors will be maintained Upon key ON and when the low beam headlamp ON control is available both the headlamp trim corrector symbol and the number for the current position will light up on the instrument board display When the low beam headlamps are switched off both the symbol and the respective number will go out and the function will be disabled gb Fiat Grande Punto OK 423 532 2005 Fiat Auto S p A All rights reserved Speed limit function A speed limit can be set within a range of 30 to 250 k p h and steps of 5 k p h i e 20 to 155 m p h and steps of 5 m p h which actuates when the limit is exceeded the following driver warning procedure the relevant speed limit exceeded message will be displayed As regards the Mode panel the fixed Speed writing in place of the odometer k p h or m p h writing will appear depending on the set unit of measurement or a fixed writing indicating the speed limit exceeded together with the unit of measurement km miles in place of the clock Acoustic buzzer signal The message will disappear after the warning cycle has been completed and or when the vehicle speed falls below 5 k p h or the equivalent m p h value with respect to the set limit value Follow me home functi
166. he engine management control unit ECM which Identifies the camshaft position through the phase sensor modifies this position based on the engine operation point according to a calibrated map keeps the camshaft position under control gb Fiat Grande Punto OK 229 532 2004 Fiat Auto S p A All rights reserved The CVCP is made up of a rotor integral to the camshaft that can rotate with respect to the pulley stator set moving by the drive shaft Stator Rotor gb Fiat Grande Punto OK 230 532 2004 Fiat Auto S p A All rights reserved a box solenoid valve that allows oil to flow into the openings by making the advance or delay openings to be connected with the oil channels in the engine head Position on the vehicle Operation Check Engine oil inlet from the head sees OCV control Oil drain into E valve the head L J WUE ai d Vall NG YE y A ripe you GGT ESS WLLL ost wan a i a AAA gb Fiat Grande Punto OK 232 532 O 2004 Fiat Auto S p A All rights reserved The engine oil flows into the tappet cover at point 1 and then into the channel to the right 2 Geff NM d gb Fiat Grande Punto OK 233 532 2004 Fiat Auto S p A All rights reserved The engine oil reaches the box valve seat through a hole flywheel side in the tappet cover 1 The oil
167. he intake depending on the control of the injection control unit Modulation takes place by means of the inner solenoid PWM controlled by the control unit which actuates the control rod of the inner valve that conveys after it has opened the gas into the inlet manifold E G R valve body Gas inlet from the exhaust manifold Gas outlet to the inlet manifold Solenoid positive Solenoid negative FIAT PUNTO 88 532 2004 Fiat Auto S p A All rights reserved 3 3 2 Engine base vapour gas recirculating system The oil vapour emissions are controlled by means of an oil separator 1 that collects the vapour from the engine base and the valve gear cover through pipe 2 Condensed vapour returns to the sump through pipe 3 whereas non condensed vapour is conveyed through pipe 4 to the turboblower air inlet sleeve L a i A Tr nate x l I G z a E L A PEE EE e e le PER L d L L i I oh A SCT e 3 LA L S d lj mi C z L 3 ec i vd LA L GK Sa y be Fh w d ele bw Kl L co ZA 1 Oil separator 2 Oil vapour outlet from the cover 3 Condensed vapour return to the sump 4 Pipe for sending the vapour to the intake FIAT PUNTO 89 532 2004 Fiat Auto S p A All rights reserved 3 3 3 Engine oil lubricating circuit Below is a representation of the engine lubricating system Plummet with filter strainer Oil pump Oil filter with replacement cartridge
168. heel degrees in the middle and 18 2 steering wheel degrees wheel degrees at the end of travel steering wheel turns 2 8 with kerb to kerb steering diameter of 10 76 m 7 4 Steering column The steering column consists of two coaxial stubs It contributes to a significant extent to avoiding dangerous steering wheel penetration into the passenger compartment in case of head on collisions The lower portion consists of a metal tube that slides to keep the steering wheel position fixed in case of collision The max sliding load is 8 kg and is obtained by means of an injected plastic insert The upper portion manufactured in such a way as to ensure steering wheel position adjustment is sliding to allow for axial adjustments when requested or previously provided for by the body version and pivoting to allow for vertical adjustment when requested or previously provided for by the body version The steering column is borne by a support which is in turn bound to a bracket both of these items are made of steel These components contribute to a significant extent thanks to their very high rigidity to reduce the steering wheel vibrations All of this makes it possible to achieve important results in terms of vehicle passive safety driving comfort The vehicle s safety performance is further enhanced by the collapsible steering column The device is based on magnesium capsules of the wafer type with plastic injection
169. iagnosis instrument the drive unit shall command airbag warning light blinking indefinitely until the correct command is received from the external diagnosis equipment Acquiring data from the various side and front sensors Actuating the various airbags and pretensioners gb Fiat Grande Punto OK 503 532 2005 Fiat Auto S p A All rights reserved Passenger s side front airbag deactivation Fuel supply cut off Passenger s airbag disable the vehicle panel set up menu allows the user to deactivate the passenger s bag so that a child seat facing against the direction of running can be fitted with no risk at all Airbag deactivation is signalled by the lighting of the respective warning light on the instrument panel Actuation deactivation of passenger s side front and side thorax pelvis protection airbags side bags where available BAG P This function makes it possible to actuate deactivate the passenger s side airbags without deactivating the side head protection airbag window bag where available Proceed as follows press the MENU ESC button then after displaying the BAG P OFF or Bag Pass OFF message to deactivate or the BAG P ON or Bag Pass ON message to actuate on the display by pressing the or buttons press the MENU ESC button once again the confirmation request message will be shown on the display select YES to confirm actuation deactivation or NO to
170. ic connection Disconnect the electric connection from the ignition coil module Unscrew screws 3a then remove the ignition coil module 3b Remove the electric connection from the phase sensor Ignition coil module x N y e Phase variator control electromagnet with its respective connection Wa DI gb Fiat Grande Punto OK 309 532 2004 Fiat Auto S p A All rights reserved Unscrew the screw then remove the phase sensor Unscrew the screws then remove the injection control unit support Phase sensor gb Fiat Grande Punto OK 310 532 2004 Fiat Auto S p A All rights reserved 1 Unscrew screws 1a then remove tappet cover 1b and timing belt upper cover 1c Timing belt upper cover FIAT y gb Fiat Grande Punto OK 311 532 O 2004 Fiat Auto S p A All rights reserved Unscrew the screws then remove the timing belt lower cover Disconnect the revs sensor electric connection Disconnect the minimum oil pressure switch connection Timing belt lower cover gb Fiat Grande Punto OK 312 532 2004 Fiat Auto S p A All rights reserved Disconnect the intermediate junction of the degassing pipe Position an arm lifting device below the engine oil sump Unscrew fasteners 2a then remove the power unit cover on the valve gear side 2b Power unit Support valve gear side Act on belt stretcher 1a to remove timing
171. ic converter oil vapour recirculation system exhaust gas recirculation E G R system with heat exchanger The operation of these systems can be optimized by means of an electronic control system managed by a control unit Understanding the control unit operation logic allows you to get an overall picture of the entire system i p A FIAT FIAT PUNTO 62 532 2004 Fiat Auto S p A All rights reserved 3 2 Components 3 2 1 Power unit supports The function of the power unit supports is to ensure structural connection between the power unit and the body These supports are dimensioned so as to bear the weight of the power unit and also withstand the loads resulting from the torque transmitted by the engine They have been modified in the 90 HP versions in order to withstand greater weight and torque values 200 Nm Each support features a metal rubber dowel used to dampen the vibrations generated by the engine thus reducing to a significant extent the vibrations transmitted to the body The power unit support is of the barycentre type it is made up of two dowels and a reaction link which acts as a tie rod where the new supports are aligned to an axis passing through the engine barycentre so as to obtain reaction forces with nil arm Moreover the 90 HP version features one further support for the right hand axle shaft 1 Support on the valve gear side 2 Support on the gearbox side FI
172. icle will not cause the fog light control to be reset License plate lights The two external license plate lights are switched on when the driver requests that either the dimmers or the parking lights are switched on The diagnosis is also carried out for every single license plate light with the actuating control ON followed by the license plate light failure indication if any on the instrument board with the key ON Rear fog lights The rear fog light can be switched on by pressing the rear fog light button only if either the low beam headlights or the fog lights with only the dimmers ON have already been switched on It can be switched off by pressing the same button again or if the low beam headlights or the fog lights with only the dimmers ON are switched off If the rear fog light has been switched off through the low beam headlights or the fog lights switching the low beam headlights or fog lights on again will not involve switching the rear fog light on again They can be switched on again by pressing the button When the rear fog light is switched on the respective indication will appear on the panel Turning the vehicle off key OFF with the rear fog light ON will cause the latter to be switched on Upon the following key ON the rear fog lights will remain OFF gb Fiat Grande Punto OK 480 532 2005 Fiat Auto S p A All rights reserved The trip computer will diagnose the rear fog light if a
173. ies through the exhaust gas analysis the basic mapping with respect to the as new features of the engine The self adaptive parameters will not be cleared when the battery is disconnected Gay i K A gb Fiat Grande Punto OK 279 1 532 O 2004 Fiat Auto S p A All rights reserved 4 5 2 Self diagnosis and recovery The control unit self diagnosis system checks correct operation of the system and signals any anomaly by means of a warning light MIL on the instrument board the colour and ideograph of which comply with the European normalization standards This warning light signals both the engine management faults and the anomalies found by the EOBD diagnosis strategies The MIL warning light operation logic is as follows with both the key and the instrument board ON the warning light illuminates and remains ON until the engine has been started the control unit self diagnosis system checks the signals from the sensors and compares them with the permitted limit data Fault signalling upon engine starting the warning light s failure to go out after the engine has been started indicates the presence of an error stored in the control unit Fault signalling during operation the blinking warning light comes on to indicate possible catalyst damage due to misfire the warning lights illuminates and remains ON steadily to indicate the presence of engine management faults or EOBD diagnosis faults The control unit defines
174. ight status or switch are not clear either of them is faulty or out of time message the warning light will be actuated immediately and the passenger s airbag will be promptly deactivated gb Fiat Grande Punto OK 508 532 2005 Fiat Auto S p A All rights reserved DTC B0108 B0108 B0109 B0109 B0109 B010 B0110 B0110 B0110 B0110 B0110 B0111 B0111 B0112 B0112 B0113 B0113 B0113 B0113 B0114 B0114 B0114 B0114 B0115 B0115 B0115 B0115 B0116 B0116 B0116 B0116 B0117 B0117 B0118 B0119 B0120 B0121 B0122 UO001 UO001 U1 00 U1 00 1 03 U1 03 Front Driver Side Bag Value too low see page 122 Front Driver Side Bag Value too high see page 122 Front Passenger Side Bag see page 123 Front Passenger Side Bag see page 123 Front Passenger Side Bag see page 123 Front Passenger Side Bag see page 123 Front Passenger Airbag Disable Switch Short to Battery see page 123 Front Passenger Airbag Disable Switch Value too low see page 123 Front Passenger Airbag Disable Switch Value too high see page 124 Front Passenger airbag Disable Switch Defective Signal see page 124 Front Passenger Airbag Disable Switch Plausibility see page 124 Front Driver Side Satellite Defective Signal see page 124 Front Driver Side Satellite Internal Error see page 124 Front Passenger Side Satellite Defective Signal see page 125 Front Passenger Side Satellite Internal Error see page 125 Front Driver Airbag nd S
175. ill become intermittent until Key OFF To cause the DTC to be automatically cleared off the error memory a key OFF key ON operation shall be carried out complete with power latch after classifying the four injectors The DTC can no longer appear over the entire control unit life cycle after it has been cleared off the error memory the CCM cannot after the operation has been carried out be brought back to the virgin state when classification has to be performed Classification shall ALWAYS be carried out at the FIAT production plant and at the Service Centre every time the CCM control unit injector needs be replaced Classification will not be completed until even one of the cylinders injectors is worth 0x00 the operation shall be necessarily carried out with the key turned to RUNNING and ENGINE STOPPED FIAT PUNTO 117 532 2004 Fiat Auto S p A All rights reserved Below is the electric injector drawing Anchor Ring Anchor pin Shell Shim Anchor guide Anchor spring Co moulding Ball High pressure ring Shim Body Spring Reference dowel Sprin Retaining nut egen WI Valve ball Full valve Valve body Adapter Connector S Guide Pin Washer Bar filter IMA CODE FIAT PUNTO 118 532 2004 Fiat Auto S p A All rights reserved 3 6 5 Single fuel manifold pipe 1 COMMON RAIL FR LWR 2 QUANTITY CONTROL VALVE DRV 2 3 PRESSURE SENSOR
176. in a distinctive way by making choices with a heavy emotional component To better meet the customer s needs Nuova Punto comes with four body building levels ACTIVE it is mainly for the young aged between 25 and 30 who are sensitive and open to the most noticeable expressions of performance related values dynamic open minded people full of energy DYNAMIC for the young to middle aged people between 30 and 45 resourceful people hovering between emotional impulse and rationality youthful enthusiasm and adult control ELEGANCE for mature people who make firm choices and count on high quality outfit and optimum comfort people sensitive to design proposals that are meant to enrich the automobile world with new drives and enthusiasm SPORTING mainly intended for dynamic sporting young people both men and women who are looking for highly distinctive style features and performance elements Style emotion comfort safety low cost what people are really looking for in a car Style emotion comfort safety low cost this is what people are really looking for in a car FIAT PUNTO 13 532 2004 Fiat Auto S p A All rights reserved Nuova Punto will offer to you Distinctive Italian style More space 50 mm longer than the current Punto Safety levels comparable with the best competing cars Sturdiness Diesel engines standing out in their categories 1 3 75 amp 90 HP and 1 9 120 HP
177. in a position max advance max delay or an intermediate position due to a mechanic fault to the variator or short circuit to the variator drive solenoid valve the solenoid valve will not be controlled by the ECM any longer In the event that the variator is slow the ECM will control the solenoid valve so as to hold the variator in a max advance position rest position gb Fiat Grande Punto OK 222 532 2004 Fiat Auto S p A All rights reserved 4 3 6 Head The aluminium head is characterized by a peculiar shape see Figure A that makes it possible to obtain a variable turbulence combustion chamber This feature combined with the new intake and exhaust pipes and optimized valve gear timing ensure bright performance low fuel consumption and emission levels Moreover this system makes it possible to recirculate a considerable amount approximately 25 of the exhaust gas in the combustion chamber Figure A Exhaust gas masking A a A v 1 i L EI S Ka E gb Fiat Grande Punto OK 223 532 2004 Fiat Auto S p A All rights reserved Intake whirl Exhaust gas whirl Intake tangent to the opening Variable turbulence system A gb Fiat Grande Punto OK 224 532 2004 Fiat Auto S p A All rights reserved Technical drawing Li i F me ui i i f Fal i a J J i gt 1 I y M A Ka IA d PA IL ro L 4 al F a UE 4 H B
178. in item pin item pin item pin Power supply 3 junction 1 junction D1 FDU Electric injector from the battery 1 Electric injector 1 l l 50 ECM 2 1 junction control connector B Component l Receiving item Receiving item Receiving Component Function connector pin pin item pin Power supply l l l l 3 junction 1 junction D1 FDU o from the battery Electric injector 2 Electric injector 2 34 ECM 2 junction control connector B Component Receiving item Receiving Receiving Component O S Function connector pin pin Item pin Item pin Power supply l l l l 3 junction 1 junction from the battery Electric injector 3 Electric injector l l 49 ECM 4 junction 3 control connector B gb Fiat Grande Punto OK 206 532 2004 Fiat Auto S p A All rights reserved Component l Receiving Receiving Receiving Component Function connector pin item pin item pin item pin Power supply l l l l 3 junction 1 junction D1 FDU from the battery Electric injector Electric injector 4 33 ECM 5 junction control connector B Ra eg gb Fiat Grande Punto OK 207 1 532 2004 Fiat Auto S p A All rights reserved 4 3 2 Ignition coils Description The coils are integrated into one single body secured to the engine head They are of the magnetic closed circuit type i e made up of a plate pack the core of which made of silicon steel interrupted by a small gap ca
179. in order to diagnose any assembling anomalies The procedure must be carried out again in the following cases phonic wheel actuation replacement revs sensor actuation replacement gb Fiat Grande Punto OK 297 1 532 2004 Fiat Auto S p A All rights reserved phase sensor actuation replacement camshaft actuation replacement drive shaft actuation replacement phase variator actuation replacement cylinder head disassembling timing belt actuation replacement ECM replacement reprogramming NOTE In the event that the ECM is moved from one vehicle to another the procedure shall be carried out again Which tools should be used Examiner diagnosis tool Operations required to carry out the procedure The self learning procedure is fully automatic It starts with the cranking phase and finishes after 30 seconds at most provided that the following enable conditions are met Enable conditions upon execution of the procedure The engine coolant temperature shall exceed i 20 C During the starting phase the accelerator pedal needs be fully released i e the engine rotation speed should be in the range of 650 to 1 300 r p m After 30 seconds have elapsed from starting switch the key contact to the OFF position then wait for data item recording in the permanent memory gb Fiat Grande Punto OK 298 532 O 2004 Fiat Auto S p A All rights reserved Upon completion of the procedure the following
180. inder switch lock unlock Front passenger s door key cylinder switch lock unlock Reserve output Antenna RF GND coaxial cable n gb Fiat Grande Punto OK 402 532 2005 Fiat Auto S p A All rights reserved 33 Quick signal 1 unlock Quick signal 3 unlock Roof LIN Front high speed CAN L to ACC LHL HS Powertrain Chassis CAN L to the diagnosis connector HS Powertrain Chassis CAN L to wiring L LL ____ Fuel level sensor ground ar Rear left door closing switch signal Boot closing switch signal normally closed Handbrake sensor or damaged cable signal Right door rear glass detection switch Fuel level sensor signal Rear window defrosting relay control 47 Antenna RF Signal coaxial cable Quick signal 2 lock even e Raa 50 Serial line ASM Front HS CAN H to ACC LHL ER HS Powertrain Chassis CAN H to the a diagnosis connector HS Powertrain Chassis CAN H on wiring L oe S 54 LS CAN B on wiring L Rear right door closing switch signal 56 Front passenger s door closing switch signal 57 Front driver s door closing switch signal 58 Left door rear glass detection switch ER External temperature sensor ground External temperature sensor signal Connector LC Description T Front right indicator light gb Fiat Grande Punto OK 403 532 2005 Fiat Auto S p A All rights reserved Front right light control Ceiling light control 2 a Leem ILL O i LE ront ri
181. ing itself automatically to a wide range of operating conditions the control unit is lightweight The function of the active sensors is to measure the wheel speed The main peculiarity of active sensors is that the signal is processed directly by the sensor The active sensors enhance the accuracy of the vehicle s control systems thanks to the capability of detecting very low speeds 2 7 k p h Moreover the information gained by the ABS active sensors are used to update by means of the GPS Global Position System satellite detection system the position of the vehicle on the maps included in the memory Therefore continuous information is essential even at low speeds about the road along which the vehicle is driven to calculate the exact position of the vehicle gb Fiat Grande Punto OK 350 532 2005 Fiat Auto S p A All rights reserved 6 4 1 ABS wiring diagram Rear left ABS sensor Rear right ABS sensor Front left ABS sensor N Front right ABS sensor E mh och Ground BSM Brake node gb Fiat Grande Punto OK 2005 Fiat Auto S p A All rights reserved 1 Pump ground 2 Pump 30 3 Solenoid valve 30 4 Solenoid valve ground 5 Front left ABS sensor signal 6 Rear left ABS sensor power supply T N C 8 Rear right ABS sensor power 9 Front right ABS sensor power supply 10 Front right ABS sensor signal 11 K line 12 N C 13 N C 14 C CAN L1 in 15 C CAN
182. iod in case of full failure to both potentiometers it cuts throttle opening out gb Fiat Grande Punto OK 268 532 2004 Fiat Auto S p A All rights reserved 4 4 8 A C linear sensor Description The A C linear sensor checks correct system operation by taking over the task carried out by the quadrinary pressure switch The sensor continuously analyzes the air conditioning system circuit pressure and provides the engine control unit with real time data of pressure variations thus making the actuation threshold management more flexible Position on the vehicle gt Z i 1 A C linear pressure sensor placed on the high pressure duct alal K A gb Fiat Grande Punto OK 269 532 O 2004 Fiat Auto S p A All rights reserved 4 L SE Ki Bai el A D Pa Een V ni K L lt 1 High pressure duct 2 Low pressure duct Operation Every single pressure variation is matched by a voltage signal used by the engine control unit to actuate the electric fan speeds and turn the compressor off if the pressure goes above or below the permitted limits safety function The linear sensor operating range goes from 3 018 bar to 29 508 bar according to the following characteristic curve for pressure bar output voltage percentage Vcc FIAT gb Fiat Grande Punto OK 270 532 O 2004 Fiat Auto S p A All rights reserved 106 E CR Kee DS
183. ion frequency 500 Hz Electric resistance 15 4 0 7 Q at 20 C TYPE OF CONTROL PWM V 12V MEASURING MEANS UEGO oxygen sensor gb Fiat Grande Punto OK SMA Oscilloscope or analog instrument Examiner with 1 84 532 2004 Fiat Auto S p A All rights reserved Hexagon Protection Tube guaina Rcomp Connector gb Fiat Grande Punto OK 185 532 2004 Fiat Auto S p A All rights reserved Vs Vs Ip Vpt H H Rcomp UEGO Sensor Universal Exhaust Gas Oxygen Sensor Ip O to be measured i o Vs Ip Septum Detection chamber O reference o Vs 4 8 valve 1 4 engine 4 1 General remarks The development of the 8 valve 1 4 engine has caused the Fire 8V engine to be shifted to the segment B vehicles and light commercial vehicles This engine can be compared with the Fire 1 2 16V MPI as far as performance is concerned with better consumption levels and cost efficiency The development of the 8 valve 1 4 engine has made it possible to cut down fuel consumption by 6 NED through two actions the modification made to the valve train with smaller valve weight and the introduction of low load valve springs both of these improvements have reduced fuel consumption by 2 NEDC the use of the CVCP continuous phase variator on the 8V engines which helped cutting down fuel consumption by 4 The power and above all the low speed torqu
184. is pulled upwards for more than 0 5 seconds the windscreen wiper will be automatically made to operate at continuous speed 1 When the control is released the washing will be turned off and three further windscreen wiping strokes will occur followed by one further wiping every 6 seconds to remove dripping In the event that the windscreen wiper has already been actuated prior to actuating the washing control through the lever the smart washing logic will only be performed to actuate the same in the intermittent mode gb Fiat Grande Punto OK 441 532 2005 Fiat Auto S p A All rights reserved Manual rear window wiper operation mode by turning the ring of the steering column stalk rear window wiper lever located on the driver s right to ON the windscreen wiper will be actuated as described below intermittent operation a pause of 2 7 seconds between two subsequent strokes interlocking to the windscreen wiper in case of simultaneous request synchronous operation at a frequency equal to half the windscreen wiper continuous operation with the reverse gear engaged Smart rear washing by moving the steering column stalk right hand lever rear washing will be actuated By keeping the lever pushed for more than 0 5 seconds the rear window wiper will be automatically actuated at continuous speed When the control is released the washing will be turned off and three further rear window wiping strokes will occur followed b
185. ith manual two position control open closed gb Fiat Grande Punto OK 526 532 2005 Fiat Auto S p A All rights reserved The sunroof is controlled by means of the components below control push button panel 1 Key ON 15 2 Speed signal from the brake node Battery suppu mu OU signal Key supply 3 Power supply 30 2 5 N C gb Fiat Grande Punto OK 2005 Fiat Auto S p A All rights reserved 11 2 Operation Control mask The Skydome sunroof is operated by pressing the opening A and closing B buttons located in the mask close to the front central ceiling light fixture The operation logic described below is implemented through actuation of an electric motor managed by an electronic control unit The sunroof movements obtained by the control button are permitted only with the panel ON key ON 11 2 1 Sunroof opening The front glass panel can be opened in two different ways by pressing the respective button on the opening side upon key ON automatic opening by pressing the button on the opening side for more than 300 ms the front glass panel fully closed will open to the spoiler opening position so as to ensure very low drag noise By pressing the button again on the same side the front glass panel will reach the maximum opening position Following the initial opening control the glass panel may be stopped at intermediate positions by pr
186. k Fuel electric pump Multi purpose valve Safety valve Fuel delivery pipe Injection ignition electronic control unit Battery Ignition switch Inertia switch ia AS gb Fiat Grande Punto OK 192 532 2004 Fiat Auto S p A All rights reserved Air conditioning unit Fuel vapour cut off solenoid valve Injection phase sensor Active carbon filter Body computer diagnosis connector and Fiat CODE signal Temperature and absolute pressure sensor T D C and revs sensor Spark plugs Coolant temperature sensor Electric injectors Throttle control actuator and throttle position sensor Accelerator pedal potentiometer Fuel feed manifold Air filter Ignition coils Oxygen sensor upstream System failure optical indicator Revs counter Catalyst Oxygen sensor downstream Atmospheric pressure sensor Phase variator drive solenoid valve Control unit ingoing outgoing information diagram Control unit ingoing outgoing information diagram gb Fiat Grande Punto OK 193 532 2004 Fiat Auto S p A All rights reserved Electronic control unit Phase variator drive solenoid valve Body computer with built in Fiat CODE control unit Throttle control actuator and throttle position sensor Electric injectors Fuel vapour solenoid valve Diagnosis connector Spark plugs Ignition coils High engine coolant temperature warning light Injection failure warning light Air conditioning system Engine co
187. ke it possible to resume the speed conditions previously set in the memory If the Cruise Control is ON it will not be disabled by an acceleration request by the driver e g when overtaking yet it will automatically resume the vehicle s set speed as soon as the accelerator pedal is released The main ring switch off action will turn the system off and clear any speed previously set The ASR wheel antiskid function takes priority over the Cruise Control for safety reasons After the ASR system has stopped operating the Cruise Control function is automatically resumed to the latest speed value stored in the memory gb Fiat Grande Punto OK 444 532 2005 Fiat Auto S p A All rights reserved Set function this function actuated through discrete action of the lever towards the or sign makes it possible to set and maintain in the Cruise Control the vehicle speed to the value corresponding to the instant when the lever is actuated Accelerate function this function makes it possible to increase the vehicle speed previously set in the Cruise Control so as to generate as long as the lever is kept operating in the direction a steady slope acceleration ramp When the lever is released the system will maintain and memorize the new speed reached by the vehicle Tip up function this function makes it possible to increase the vehicle speed previously set in the Cruise Control by a
188. l four window regulators including the anti pinch protection Moreover this model features a control used to disable the window regulator controls placed on the rear doors complete with its respective signalling LED Window regulator control on the passenger s side front door CDC The window regulator control on the passenger s side front door is connected through the passenger s side front door cable harness to provide the respective window regulator motor with the control It receives the power supply for ideograph lighting and correct operation of the control itself Two passenger s side front window regulator control models are available depending on the body version The window regulator control of the base model directly drives the electric motor on the passenger s side front door with no electronic control of the motor itself The window regulator control of the second model is acquired by an electronic module located inside the electric motor on the passenger s side front door This model features automatic functioning both during the up and down movement with anti pinch protection gb Fiat Grande Punto OK 456 532 2005 Fiat Auto S p A All rights reserved Electric window regulator control on the rear doors RDC The control on the rear door left side and right side RDC is connected through the cable harness on the rear door It is acquired by an electronic module located inside the window regula
189. lange with bolts a phonic wheel for the revs sensor is secured toward the engine side 1 Engine flywheel 2 Set ring gear 3 Phonic wheel for revs number FIAT PUNTO 71 532 2004 Fiat Auto S p A All rights reserved Operation The engine flywheel is a member that makes engine rotation uniform by accumulating energy during the active phases expansion and giving the same back during the passive phases The flywheel is dimensioned so as to allow the engine to idle without coming to a halt and overcoming the friction work developed by the same during no load operation 3 2 8 Drive shaft It is made of forged steel and rests on five main bearings Its axial play is controlled by two half rings housed in the central main bearing Accurate balancing of the rotating masses is ensured by eight counterweights A number of channels run through the drive shaft for lubrication of journals and crankpins FIAT PUNTO 721532 2004 Fiat Auto S p A All rights reserved 3 2 9 Pistons The pistons are made of silicium based aluminium alloy with antifriction inserts They are divided into three dimensional classes Class A 69 520 69 530 75 HP nd 90 HP Class B 69 530 69 540 75 HP nd 90 HP Class C 69 540 69 550 75 HP nd 90 HP The OMEGA combustion chamber is obtained on the piston crown to improve combustion efficiency see Cylinder head A channel is obtained inside the pin
190. le controls rear electric window regulator where available cut off controls with respective LED electric side mirror selector electric side mirror control joystick Three window regulator control module models are available depending on the vehicle s body version which feature three different types of window regulator motor controls The electric window regulator controls of the base model directly drive the motors of the driver s and passenger s side front window regulators only with no electronic control on the motors themselves This model does not feature rear electric window regulator control The second model incorporates an electronic module for controlling the up and down movement of the driver s side front electric window regulator only in automatic mode gb Fiat Grande Punto OK 455 532 2005 Fiat Auto S p A All rights reserved Conversely the passenger s side front electric window regulator control directly drives the passenger s side window regulator motor with no electronic control of the motor itself Similarly with the first model rear electric window regulator control is not available The third model features control of both the front electric window regulators and the rear electric window regulators in this case the controls are acquired by an electronic module located inside the window regulator motor This model features a function with an automatic device both for the up and down movement on al
191. le channel sound power amplifier located inside the sub woofer box and used for sub woofer drive FIAT PUNTO 29 1 532 2004 Fiat Auto S p A All rights reserved 1 3 Accessory line The Nuova Punto accessories have been designed with the specific intent to provide the customer with options suited to satisfy the customer s need to customize their own car in an emotional functional way The accessory designing activity has been supported by the FIAT Style Centre and has been guided by the search for exclusive products consistent with the vehicle identity integrated into the vehicle s essential lines and of high practical value The accessory offer can be divided in the following areas 1 3 1 Sporting character In order to satisfy the need to enjoy your own car in a more emotional way a kit has been designed which includes side skirts a spoiler on the rear hatch streamlined attachments on the front bumper These items give the vehicle a modern aggressive look Moreover two kits are available which include a 16 and a 17 alloy wheel rims to be used with 195 55R16 and 205 45R17 tyres respectively The tailored sporting accessories also include leather steering wheel and gearshift lever knob and aluminium pedal covers with rubber inserts for safer comfortable driving 1 3 2 Comfort utility leisure time Optimum driving comfort is ensured by a range of accessories such as modern anti whirl
192. lectric fan 2 control Not connected Conditioner compressor linear sensor negative Not connected Not connected Fuel temperature sensor ground Not connected Race 2 positive on the accelerator pedal potentiometer Not connected Not connected Not connected Not connected Not connected Not connected Not connected Key controlled power supply Not connected Not connected Not connected Not connected Request for air conditioner actuation from the control button Engine revs number signal for robotized gearbox Not connected Not connected Accelerator potentiometer race 2 negative Not connected Not connected FIAT PUNTO 134 532 O 2004 Fiat Auto S p A All rights reserved Accelerator potentiometer race 1 negative Not connected Conditioner compressor linear sensor positive Not connected Not connected High speed CAN 1 line Accelerator potentiometer race 2 signal Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Direct power supply from the battery Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Fuel temperature sensor signal Not connected Not connected High speed H CAN 1 line FIAT PUNTO 135 532 2004 Fiat Auto S p A All rights reserved Accelerator potentiometer race 1 signal Communicati
193. ll rights reserved L DU D D DU D U DU D D D D U DU O C L U D U U D U U U U D D U U O U L U D U U D U U U U D D U U O U L U D U U D U U U U D D U U O U Connector vehicle side Connector engine side L U U DU U U U DU U U U U DU U U U L D D D D D D D D D D D D O D U 0 U DU DU D D U U D U O U U D U U 0 U DU DU D D U U D U O U U D U U Connector A vehicle side Tyco 3 284272 0 TB o Battery 30 Battery output voltage 6 4 A 13 5V Accelerator pedal potentiometer 1 100 mA 5 V power supply Linear pressure sensor AC and accelerator pedal potentiometer 2 power supply Not connected Linear pressure sensor AC 0 01 mA 5V Not connected Not connected Not connected Not connected Not connected Not connected Not connected Linear pressure sensor AC and accelerator pedal potentiometer 2 ground Remote control switch key 5mA O 16V Engine management system remote 400 mA 13 5 V control switch erea 1 area area 1 area 1 ret gb Fiat Grande Punto OK 198 532 2004 Fiat Auto S p A All rights reserved Not connected eret CITE af mee IS E ml LO LI emeng Pin I O S Supply source Function Max content 30 Not connected RR _0OS L 32 Clutch pedal switch 10 mA O 13 5 V Raman Raen aaeeea RR sp eana mg E Accelerator pedal potentiometer 2 0 01 mA 5V signal Oil temperature sensor 3 mA 05 V Starting motor remote control switch 500 mA
194. ll the restraint system actuation and detection devices by processing signals from the various sensors found on the vehicle It decides on the specific protection devices are to be actuated in case of accident and when the same have to be actuated through the signals from the sensors it incorporates Moreover it prevents the aforesaid devices from being actuated when a minor collision takes place A capacitor which acts as a power reserve ensures full operation of the front bags in the event that no power is supplied by the electric system i e when a collision causes the battery or the power cables to be broken The algorithm used for the head on collision situations is in the operators and experts jargon referred to as Crash Severity Algorithm since it can tell whether a collision is serious so as to properly actuate the dual stage airbags SDM functions System fault acquisition Transmitting the airbag status signal ON OFF Flash on the B CAN line Acquiring the airbag warning light status ON OFF Fail from the B CAN line through the warning light itself Performing real time memorization of the airbag warning light status ON OFF Fail the permanent memory for the collisions already occurred is also available If an airbag warning light failure occurs the SDM shall set the passenger s airbag deactivation warning light to the ON condition for 4 seconds If the test phase is not completed through the external d
195. llumination The instrument board node IPC is an electronic component connected to the B CAN network and the dashboard cable harness it acquires some user controls and manages the vehicle menu and the headlamp trim control The connector provides for discrete interfacing with other vehicle systems engine control and is available in two versions with three type of display Version with black graphic elements Gioved 71 8 fm LR BT TRP Nn 23D 483 E in i MZ DI 123456 22 wraa 230 053 Mode display Comfort display Matrix display FIAT k K A i gb Fiat Grande Punto OK 409 532 2005 Fiat Auto S p A All rights reserved Version with white graphic elements TT 50 sa JP ___ 123456 22 laa ay 105 Mode display Comfort display Matrix display Vehicle panel with re configurable matrix display connected to the B CAN network and standardized for the right hand and left hand drive versions with various indicators The electronic architecture of the indicators is realized by means of a microprocessor and stepping motors ensuring accuracy and continuity no tripping or crawling over the entire reading scale under the operating limit conditions It is equipped with a maximum of 30 28 and 23 LED light up warning lights Mode Comfort and Matrix respectively with negative contrast 2 warning light presettings that can be actuated through the CAN network gb Fiat Grande Punto OK 41
196. lly zero occupant injury risk Head on collision Two types of vehicle head on collisions are taken into consideration one head on collision at a speed of 64 k p h against a deformable barrier typical of a head on collision between two vehicles one head on collision at a speed of 56 k p h against a fixed rigid barrier typical of a collision against a fixed rigid obstacle Nuova Punto is capable in case of head on collision of retaining the load located in the luggage compartment which may hit the passengers seriously if not properly secured Side collision Nuova Punto ensures front and rear passenger safety during high speed side collisions by means of two main types of test a crash that simulates a collision between two vehicles at a speed of 50 k p h and a crash against fixed obstacles of small side dimensions such as trees or posts which represents the most dangerous type of collision to a vehicle s driver or passengers Thanks to the sturdy structural construction and the use of energy absorption highly efficient materials the intrusion levels for this type of test have proved to be very low on gb Fiat Grande Punto OK 495 532 2005 Fiat Auto S p A All rights reserved Nuova Punto and make it possible to avoid significant inertial stress on the occupants in any case inertial stress is absorbed perfectly thanks to the side airbag system Back collision Attention is during the back collision tes
197. lometres or miles left before the vehicle is to be serviced will be automatically display upon key ON after the initial check procedure The displaying information can also shown on the display at the user s request by selecting a special item in the set up menu regardless of the set expiry the display will show the kilometres or miles left before the vehicle is to be serviced In this case the Wrench icon will not appear The preventive maintenance schedule provides for 9 servicing slips organized in such a way that each of them is carried out not later than 30 000 km or 18 000 miles from the preceding one Automatic displaying The first expiry message will be automatically displayed only once upon key ON if the kilometres or miles left before the vehicle is to be serviced are equal to or less than lt 2 000 km 1 240 miles Next the message will be displayed only once upon key ON with the following threshold values 1 800 1 600 1 400 1 200 1 000 800 600 400 200 100 50 km 1 240 1 116 992 868 744 620 496 372 248 124 62 31 miles will no longer be displayed during the time period in between When the limit expiry value 0 km miles has been reached the Servicing expired message will be displayed The driver can interrupt this message by pressing the Menu Esc button Displaying at request The expiry value can be displayed at request at any time by means of a specific item of the
198. lular protection The ACCESSORY LINE module matched with the traditional anti theft system allows you to always keep your vehicle under control by clearly identifying its position and also receive any break in message The ultrasound parking sensor is actuated when the reverse gear is engaged and gives out an acoustic signal to warn you of the obstacles that cannot be seen by means of the rear view mirrors Moreover the Bluetooth MetaBlue hand free set system makes it possible to easily speak on the mobile phone without handling the same with no connecting cable The calls are managed by means of one single control button and you can listen to the person you are talking to directly through the vehicle s audio system both is the radio has been factory installed and if the unit is owned by the customer and even if only the loudspeaker preset is available All of this means safe comfortable driving in compliance with the rules of the Highway Code FIAT PUNTO 31 532 2004 Fiat Auto S p A All rights reserved Children safety The ISOFIX UNIVERSALE child seat is available with the vehicles equipped with specific mounts for children weighing 9 to 18 kg The range is made complete by traditional seats such as CRADLE for children weighing up to 10 kg KIDDY LIFE seat for children weighing 9 to 36 kg 2 Technical specifications 2 1 Engine 2 1 1 Type of engine 1 3 Multijet 1 3 Multijet 1 9 Multijet 8V 1
199. m if the speedometer scale is speedometer scale is Distance unit of represented by the represented by the measurement kilometre mi if the YES kilometre mi if the km miles speedometer scale is speedometer scale is Date setting dd mm yyyy Audio information repeat ON OFF Door boot locking represented by the represented by the mile mile 100 km if the speedometer scale is represented by the kilometre m p g if NO the speedometer scale is represented by the mile Consumption unit of measurement k p 1 100 km m p g gb Fiat Grande Punto OK 419 532 2005 Fiat Auto S p A All rights reserved Temperature unit of YES C NO measurement C F Language italian English German Italian Portuguese Spanish French Dutch e Buzzer volume 0 7 Sigs eeoa lx AA ee d km if the speedometer scale is represented by the Service km or miles YES kilometre mi if the NO speedometer scale is represented by the mile Depending on the signals from the Passenger s airbag enn actuation deactivation Confirmation always NO gb Fiat Grande Punto OK 420 532 2005 Fiat Auto S p A All rights reserved Preventive maintenance signalling Comfort and Matrix panels When the term of the preventive maintenance the so called servicing slip is about to expire the Service message and the Wrench icon followed by the number of ki
200. magnet 3 Plastic sensor body 4 Coil winding 5 Polar core 6 Ring gear or phonic wheel 7 Coaxial two wire cable or electric connection PIN OUT Pin Name Type of signal Phonic wheel signal Frequency A output S Phonic wheel signal Frequency B output Technical features Winding resistance 790 Q 20 Winding resistance 680 mH 20 f 1KHz The distance gap required between the sensor end and the phonic wheel to obtain correct signals shall be included in the range of 0 8 to 1 5 mm This distance cannot be adjusted therefore if an out of tolerance gap value is found verify that the sensor and the phonic wheel are intact The diagram shows the sensor output signal in connection with the horizontal development of the phonic wheel 1 Toothed wheel contour 2 Revs sensor signal 3 Reference tooth 4 Measuring point for T D C recognition KC gb Fiat Grande Punto OK 167 53 2004 Fiat Auto S p A All rights reserved Operation The shift from the full to the empty condition due to the presence or absence of the tooth causes a variation of the magnetic flux which is enough to generate an induced alternating voltage resulting from the count of the teeth placed onto one ring or phonic wheel The frequency and amplitude of the voltage sent to the electronic control unit provide the latter with the measurement of the drive shaft angular speed Cam or phase angle sensor This is a Hall ef
201. mation 100 15971 9620 5975 3816 2502 2044 1679 1152 807 576 418 309 231 176 Electric features 1 ECM 2 Engine water temperature sensor Pin out Component Component connector Receiving item pin pin Engine temperature signal 45 ECM connector B Engine water temperature sensor Ground from the ECU 36 ECM connector B Recovery Coolant temperature sensor In case of failure the ECU cuts out the idling mixture ratio self adaptation It sets the latest measured temperature value in the event that it does not correspond with the running speed one the ECU will increase it gradually depending on the time since the engine start until a temperature of 80 C is reached The radiator cooling fan is actuated gb Fiat Grande Punto OK 260 532 2004 Fiat Auto S p A All rights reserved 4 4 6 Sucked air pressure and temperature sensor Description The sucked air pressure and temperature sensor is an integrated component used to measure the pressure and temperature of the air inside the inlet manifold Both of the above pieces of information are used by the injection control unit to define the amount of air sucked by the engine the latter piece of information is subsequently used to calculate the injection time and the ignition point The sensor is fitted to the inlet manifold Position on the vehicle Sucked air pressure and temperature sensor FIAT N
202. ming in terms of fuel consumption An approximate 5 reduction of consumption over the NEDC cycle is achieved The phase variator modifies the engine timing in the delay direction By delaying the intake valve opening and the exhaust valve closing a portion of the intake stroke the greater the phase variator stepping the greater such portion will take place with the intake valve closed and the exhaust valve still open whereby a portion of the burnt gas will be sucked by the exhaust EGR Such gas will take the place of a portion of the cylinder volume less displacement In order to let the same amount of fresh air in and achieve the same engine performance i e the same torque power at that operation point the throttle will have to be opened further The engine operation performance being equal with the throttle opened to a larger extent will reduce the pumping loss that occurs during the charge replacement phase exhaust intake phases thus consumption will be reduced significantly gb Fiat Grande Punto OK 228 532 2004 Fiat Auto S p A All rights reserved Exhaust valve timing EGR Intake I Intake valve delay shift 1 timing delay shift st vee __ dt ERREA f i H DG LION EST AS et Pye yS N SSAA IRMA TIA HI A Ane Apr CO ANA 40 00 120 160 200 240 260 3420 400 440 450520 560 600 640 660 PMI PMS PMI Crank angle Valve lift mm Description The CVCP is fully managed by t
203. mirrors reversing light MTA C514 LHM RHM Oxygen sensor heater heating EGR canister etc secondary loads Ignition coils injectors or ECM 2 power supply primary loads Power supply ECM Fuel pump Fog lights Headlamp washing pump Horn A C compressor Starter relay Valves Bi power Fuel filter heater Robotized gearbox pump 30 A C control panel ECC 30 Selespeed or MTA or TCM ECM Cigar lighter or 12 V output Fuel water sensor reversing light flow meter hot film Rear heated window Side mirror defrosting Front right window regulating motor Front left window regulating motor Spare Spare 392 532 2005 Fiat Auto S p A All rights reserved 9 1 8 Wiring Table 1 Engine compartment Left headlamp G009 Front wiring R Rear B001 Engine washing cooling fans pipe Washing pump Power supply with FDU G005 BSM G001 Plastic inserts Right headlamp A C pressure sensor Rubber lun Y Wiring HVAC K ECC BCM G031 G021 Front bodywork wiring L Intrument panel wiring P gb Fiat Grande Punto OK 393 532 2005 Fiat Auto S p A All rights reserved Table 2 Engine power supply Wiring Battery M A C compressor B001 Reversing switch G006 r Engine Engine wiring E FDU sensors ECM r r Wiring Battery B Alternator C a wiring J 3 5 30L Selespeed l 0 0 pump Starting motor Alt
204. mperature in the driver s side and passenger s side parts to the temperature requested in automatic mode The air flow rate air distribution compressor deactivation recirculation state and the MAX DEF function which turns the rear heated window on automatically can be selected manually Moreover the system can by means of the MONO button be set to operate in a single zone mode i e the air temperature and distribution in the passenger compartment as requested by the passenger can be adapted to the one requested by the driver The operation logic is based on the equivalent temperature 10 4 Diagnosis Control unit proxy procedure The control unit is capable by means of special sensor control logic and setting logic with actuator self learning to record and store in the memory a number of anomalies and faults that may affect the system These stored errors can be read by getting connected to the Body Computer diagnosis connector This operation makes the system learn the end of travel position of the air conditioning control unit electric actuators The established procedure can be carried out by means of the computer assisted diagnosis equipment This operation shall be repeated after at least one actuator has been replaced The procedure shall be started again in case of interruption gb Fiat Grande Punto OK 524 532 2005 Fiat Auto S p A All rights reserved 11 Sunroof 11 1 Description The sunroof
205. n message is available 9 3 Central locking 9 3 1 General remarks The keys are supplied in duplicate together with the vehicle They are accompanied by the CODE Card A electronic code B mechanic code of the key to be notified to the FIAT Dealership if a key duplicate is requested It is recommended that you always bring the electronic code with yourself WARNING To ensure optimum efficiency of the electronic devices fitted inside the key the latter should not be exposed to the sunshine Below is a summary of the main functions that can be actuated by the key with and without the remote control where Lock locking from available Lock Windows Windows Type of key Lock unlocking _ the outside actuation unlocking down up Key turned counter Key turned clockwise clockwise Mechanic key driver s side driver s side Key turned counter clockwise clockwise driver s side driver s side Button Button Button pressed fir pressed for Key equipped with remote Button pressed Button pressed Button pressed control briefly briefly twice pressed a long time a long time Indicator light blinking only with key equipped with remote control 2 blinks 1 blink 2 blinks 2 blinks 1 blink ON steadily for Deterrent blinking Switch off blinking approximately 3 Blinks twice Deterrent seconds then then deterrent LED Switch off deterrent blinking blinking
206. n 1 2 speed engaging fork Synchromesh hub Outer synchromesh ring Intermediate ring Inner synchromesh ring 1 speed gear driven 1 speed gear roller bearing Safety ring Output shaft roller bearing Output shaft Oil recovery pipe gb Fiat Grande Punto OK 2005 Fiat Auto S p A All rights reserved CON DO vd FP OO N gt 12 11 10 9 8 f 6 Position of the top gear shaft components Top gear shaft seal ring Roller bearing Top gear shaft 17 speed gear driving 200 speed gear driving Top gear shaft screw Differential Top gear shaft bearing 6 speed gear driving 10 11 12 4 speed gear driving Spacer bushing gid pth speed gear RI gb Fiat Grande Punto OK 336 532 2005 Fiat Auto S p A All rights reserved 5 3 Configuration jn la TZ e G en ER er Sen Ls Te o e E i 7 NW ech aloni 0 Se gA lC a R Fi E ue GE i La s E eh pa tee dae ka gd val d d pe n L al m B E r S E CH 1 LI i I i R Se Vr alla 1 r k ie Z Lk z i Ls i LB d il ml h Z Zeie l L l Iw ZZ Kb d L L M f deii ARAM A H el z i Pa r NN e a Tle Ke le RUT Transverse with 3 shafts supported on ball bearings 6 forward gears reverse gear Transmissible torque 230 Nm Total length from the engine flywheel 332 mm RW gb Fiat Grande Punto OK 337 532 2005 Fiat Auto S p A All rights
207. n and test incomplete condition SDM status SDM IPC airbag warning light Status Airbag warning indications L C Airbag Passenger s front airbag warning light deactivation indication Passengers front airbag deactivation warning light Airbag warning light IPC side Upon key ON the airbag warning light will if the AIRBAG and passenger s AIRBAG deactivation warning lights are ON be kept ON by the IPC It will illuminate upon key ON for a preset time regardless of the signals form the SDM After this check time the warning light control will be based again on the signals received from the SDM Warning messages from the airbag IPC side The SDM will start its diagnosis activity upon key ON thus it will be able to detect any airbag system trouble S gb Fiat Grande Punto OK 510 532 2005 Fiat Auto S p A All rights reserved Signalling warning light Class A errors any error that represents a risk of incorrect minimum actuation of the airbag squibs With this type of error the warning light will remain ON even when the error is intermittent and has been solved until the ECU is reset Class B errors any error that does not represent a risk of incorrect actuation of the airbag squibs With this type of error the warning light will remain ON for 30 seconds and then will go out 9 8 Fire protection In the late 1990s the introduction of the new European regulations on th
208. n anomaly is found the corresponding rear fog light failure signal will be actuated Indicator emergency lights Following the indicator light controls by means of the steering column stalk left lever upon key ON the trip computer will drive the single indicator light bulbs of the selected vehicle side front side and rear left or front side and rear right Simultaneously with the bulb driving an acoustic signal will be generated inside the vehicle If the lever is moved to the rest position again the lights and the other turning indications will go out The indicator lights will if they are ON be switched off upon key OFF Following the emergency light control with both key ON and key OFF the trip computer will drive all the 6 indicator bulbs front side and rear both left and right moreover the LED will light up on the emergency button and an acoustic signal will be generated inside the passenger compartment If the emergency button is pressed with indicator lights the lights indications previously ON will keep on operating intermittently with no interruption or delay lf an anomaly is found on any of the front or rear indicator light bulbs on the vehicle side selected for the indicator light function or still for the emergency light function the failure indication will light up and simultaneously the blinking frequency of the corresponding visual indication and the acoustic signal will increase
209. nals 4 wire electric connection different channelling of the air flow which hits against the sensitive measuring element new by pass turret welded to the air flowing duct protection grid at the air flowing duct outlet section with oil vapour condensing function gb Fiat Grande Punto OK 175 532 2004 Fiat Auto S p A All rights reserved The HFM6 air flow meter features a new plastic grid 1 positioned on the sensor housing duct outlet section which protects the measuring sensor sensitive element against the blow by vapour that might flow back during the engine switch off phase In the digital air flow meter the turret 2 is welded to the sensor housing duct and cannot therefore be separated from it In the analog air flow meter the turret is secured to the duct by means of two screws gb Fiat Grande Punto OK 176 532 2004 Fiat Auto S p A All rights reserved Diagram for sucked air temperature ground digital meter a A temperature value digital output B power supply 12 V C ground E air flow value digital output 1 function generator 2 data memory 3 A D converter DIGITAL AIR FLOW METER OPERATION Temperature signal trend In the digital air flow meter the temperature value sent to the engine management control unit is a signal of the PWM duty cycle type fixed frequency The working voltage is 5 V whereas the measuring interval ranges between 50
210. ncies gb Fiat Grande Punto OK 489 532 2005 Fiat Auto S p A All rights reserved full range loudspeakers 40 W diameter 130 mm located on the rear side frames which can reproduce the entire range of the sound frequencies These components feature the water resistant technology sub woofer box of the bass reflex type 6 5 7 volume including a loudspeaker 100 W diameter 130 mm to reproduce the lowest frequencies This box is fitted into the luggage compartment on the right wheelbox side single channel sound power amplifier located inside the sub woofer box and used for sub woofer drive CAR RADIO BLAUPUNKT The Radio Receiver node RRM is held in a DIN compartment whereas the front radio mask on the dashboard occupies one and a half compartment Two versions are available radio CD player and radio CD MP3 player All the versions are set for connection with the low speed CAN interface on the B CAN line in order to allow data to be exchanged with the other system nodes The following information is transferred through this interface anti theft code ignition control for switch off logic volume control depending on the vehicle speed lighting control FIAT gb Fiat Grande Punto OK 490 532 2005 Fiat Auto S p A All rights reserved remote controls from the steering wheel where available radio information repetition on the vehicle panel General
211. ncreased when the rain sensor is operating a windscreen wiper stroke will occur to indicate that the modification has been made In case of rain sensor anomaly sensor failure the following strategies will be performed if the anomaly occurs upon actuation when the ring is being turned from the rest position to the intermittent automatic operation position the windscreen wiper will be immediately set to the intermittent operation regardless of whether rain is found on the windscreen If the anomaly occurs during operation the ring has already been turned to the intermittent automatic operation position with resulting rain sensor actuation the windscreen wiper will be driven according to the latest command sent by the rain sensor until the user either selects other speeds continuous speed 1 or 2 or turns the windscreen wiper operation off ring position OFF In the event that any of the above mentioned actions is carried out any further resumption of the intermittent automatic position will make the windscreen wiper to operate in the intermittent mode regardless of whether rain is found on the windscreen In any case the instrument board will signal the sensor failure this makes it possible to inform the user of wrong sensor operation The failure indication will remain ON until the failure is no longer found Smart front washing By pulling the steering column stalk lever to the right front washing will be actuated If the lever
212. nd send a failure message gb Fiat Grande Punto OK 452 532 2005 Fiat Auto S p A All rights reserved Any failure error will be immediately signalled by means of the vehicle panel and an acoustic signal General position of sensors 9 2 8 External audio amplifier for the hi fi system The external audio amplifier is an electronic component connected through the body to front cable harness The audio amplifier receives the signals from the audio outputs of the radio receiver node RRM Moreover it receives the consent to actuation from the radio receiver node itself RRM 9 2 9 Spiral cable The spiral cable is an interconnecting component supplied with the steering column stalk control module CSM which ensure connection between the dashboard cable harness the controls on the steering wheel SWC audio and telephone systems and the airbag modules gb Fiat Grande Punto OK 453 532 2005 Fiat Auto S p A All rights reserved 9 2 10 Rain sensor control unit RLS The rain sensor control unit RLS is an electronic component connected to the Body Computer node BCM through a LIN serial line It manages together with a control located on the steering column stalk module CSM the windscreen wiper stroke speed setting function The rain sensor control unit is connected through a special bridle located on the internal rear view mirror which is connected to the front body wiring harness It is mad
213. ndard 0 Standard A Toe in 175 65 R15 84T 1 2 8V 2 mm 1 mm 1 88 mm 1mm 1 3 Multijet 16V 90 cv 2mm 1mm 1 88 mm 1mm 1 4 16V 185 65 R15 88T 1 88 mm 1mm 1 3 Multijet 16V 90 cv 2 mm 1mm 1 88 mm 1mm 1 9 Multijet 8V 120 cv 2 mm 1 mm 1 88 mm 1mm 1 4 16V 2 mm 1 mm 1 87 mm 1mm 195 55 R16 87H 1 9 Multijet 8V 120 cv 1 87 mm 1mm FIAT PUNTO 50 532 2004 Fiat Auto S p A All rights reserved Camber angle Engine versions Tyres Standard 0 Standard A 22 20 27 20 22 20 2 20 175 65 R15 84T 1 2 8V 22 20 27 20 22 20 27 20 26 20 28 20 1 3 Multijet 16V 90 cv 26 20 28 20 1 4 16V 185 65 R15 88T 26 20 28 20 1 3 Multijet 16V 90 cv 26 20 28 20 1 9 Multijet 8V 120 cv 26 20 28 20 19 20 21 20 1 4 16V 19 20 21 20 195 55 R16 87H 1 9 Multijet 8V 120 cv 2 11 2 Rear Toe in Engine versions Standard 0 Standard A 1 3mm 2mm 1 5mm 2mm 1 3mm 2mm 1 5mm 2mm 175 65 R15 84T 1 2 8V 1 3mm 2mm 1 5mm 2mm 1 3mm 2mm 1 5mm 2mm 1 3 Multijet 16V 90 cv 1 3mm 2mm 1 5mm 2mm 1 3 Multijet 16V 90 cv 1 3mm 2mm 1 5mm 2mm 1 9 Multijet 8V 120 cv 1 3mm 2mm 1 5mm 2mm 1 4 16V 1 3mm 2mm 1 5mm 2mm 195 55 R16 87H 1 9 Multijet 8V 120
214. nde Punto OK 250 532 O 2004 Fiat Auto S p A All rights reserved 1 Revs sensor Engine pulley L FI DI a gb Fiat Grande Punto OK 251 532 2004 Fiat Auto S p A All rights reserved The engine revs sensor seat has no adjustments therefore the sensor assembling poses no problem Pin out Component oo Component l O S Function Receiving item pin connector pin Engine revs signal A 9 ECM connector B Engine revs number sensor Engine revs signal B 23 ECM connector B FIAT gb Fiat Grande Punto OK 252 532 2004 Fiat Auto S p A All rights reserved Fiat Auto S p A 8 VALVE 1 4 FIAT PUNTO TRAINING OUTLINE ENGINE After Sales Training 4 4 4 Phase sensor Description The sensor is of the Hall effect type A semiconductor layer through which current flows immersed into a standard magnetic field generates a potential difference known as Hall voltage at its ends gb Fiat Grande Punto OK 253 532 O 2004 Fiat Auto S p A All rights reserved Operation The pulley on the cam axle is made up of 4 projections During the pulley rotation the distance between the pulley and the phase sensor varies and a low voltage signal is generated at each projection Conversely when these projections are not found the sensor will generate a higher voltage signal It follows that the high signal alternates with the low signal four times every single e
215. nditions a a cae 293 4 5 17 Pio EE 293 4 5 18 EE 295 4 5 19 o 297 4 6 4 6 1 4 6 2 N G FIAT PUNTO 7 532 2004 Fiat Auto S p A All rights reserved M20 GEARBOX 5 1 EIA 325 eZ COMPONENT E 326 it MIL E 326 Re DI 329 72 Dati 330 5 3 CORIO 337 5 4 SPEBD GEAR ARRANGEMENT W 339 5 5 KINEMATIC ROUTE OF THE SINGLE GEARS EE 340 BRARED S E 344 6 1 Eer e 344 6 2 POWER TRA E sisi i 347 6 3 Para 348 6 4 IA TEN RR RO EEA 350 TT ABS E IV deis 351 OA E 350 6 5 blica 354 DS PPT Rtl 356 005 E EE 357 033 ANA EE WE 358 004 Miri 359 A E 359 AAA O 361 Tal DESCRIPTION ciao EA sete E le i noe E E E E E 361 12 ELECTRIC POWER STEERING EPS EE 362 7 3 IIE er 365 7 4 TEE ING COL ee 366 SUSPENSION Sarai 367 8 1 DE AT e UT 367 8 2 PRONTSUSPENSI N A E E E E E A A E E E E E E E E A 368 GE E EE 368 062 EE 370 8 3 EES EENEG 373 ol VO EE 373 FIAT PUNTO 8 532 2004 Fiat Auto S p A All rights reserved aa e 9 BORG TRG SYSTEM E 376 9 1 GENERAL BSc ET OE THE SYSTEM eegener ee 376 SI Gila 377 E EE 378 Ci aci 380 914 Diagnosis instrument adapter iii 383 oro ACA ION EE 384 OIO a A EE 386 91 7 Remote control switeh Fuse holder T 390 U AI E E EEEE AEE EE A EE E 393 OLD EE 396 9 2 DESCRIPTION OR COMPONENTS glia 398 O21 En etmecomparimentcontrolunit EDO dota 398 922 ET E 399 CEE OZ AO EE 400 IO GA PAIA 409 e E E EE 433 O AIR 447 927 UA A A e o A 448 9 2 8 External audio amplifier for the hi
216. ne rotation speed Below are the main features of the fuel feed system high injection pressure 1 400 bar 75 HP 1 600 bar 90 HP the injection pressure can be modulated from 150 to 1 400 1 600 bar under any working condition of the engine fuel is let in up to 50 mm3 cycle within engine speeds of 100 to 5 200 r p m accurate injection control both as advance and duration one or two pilot injections before the T D C manages according to the revs number and the engine load which make it possible to distribute the pressure into the combustion chamber more evenly with lower noise levels FIAT PUNTO 99 532 2004 Fiat Auto S p A All rights reserved PILOT MAIN FUELLING S COMBUSTIO soRATE From the pilot injection To the multiple injection PILOT PRE MAN AFIER POST COMBUSTION RATE Construction The fuel feed system is divided into a low pressure circuit and a high pressure circuit Low pressure circuit It is made up of the following items auxiliary electric pump immersed into the tank fuel filter with inner cartridge fuel return manifold pipe connecting pipes FIAT PUNTO 100 532 2004 Fiat Auto S p A All rights reserved By pass from OVF E a o _ o _ CH o o Cen Cen Ce i I E E E EF TI E Injectors a i E De i E E E E E l E Low pressure line cit a gd l Bi e LC ll Low pressure line Low pressur
217. ngine cycle This signal together with the T D C and revs signal allows the control unit to recognize the cylinders and determine the injection and ignition point Electric features 1 Ground 2 Output or signal 3 Supply voltage ES 050 1 usos F J NE 9 50 2 H i HB A J Bi U B LO d 1 ECM 2 Phase sensor Pin out Component Component 1 0 S Receiving item pin connector pin Ground from the ECU 7 ECM connector B Phase sensor se Phase sensor signal 24 ECM connector B Power supply from the ECU 13 ECM connector B gt gb Fiat Grande Punto OK 256 532 2004 Fiat Auto S p A All rights reserved 4 4 5 Engine coolant temperature sensor Description It is fitted to the thermostatic unit and measures the water temperature by means of a NTC sensor with negative resistance coefficient Construction The figure below illustrates the sensor construction 1 NTC resistor 2 Sensor body 3 Electric connector Operation The reference voltage for the injection system NTC element is 5 V Since the input circuit in the control unit has been designed as a voltage divider such voltage is distributed between a resistor available in the control unit and the sensor s NTC resistor It follows that the control unit is capable of evaluating the sensor resistance variations through the voltage variations and thus obtaining the temperature piece of infor
218. ntent KA ESO ii AA E Sensor 2 throttled body position 0 01 mA 16 V Intake pipe pressure 0 1 mA 5V 32 O Oxygen sensor upstream the catalyst 14A 16V 33 O Cylinder 4 injector 12A 16V Cylinder 2 injector eee F sig GND ECU Throttled body sensor ground Engine water temperature sensor sig GND ECU ground zi ees e LG e mee v mem I EA AT free neger e snsorcounsicam e ba uerge s p Dommen en mengs Sensor olii body poston LI e nsnewaeriomporsie sensor mmer ml mem E O SR Not connected gb Fiat Grande Punto OK 201 532 2004 Fiat Auto S p A All rights reserved 8 sig GND ECU Knock sensor dara 0 01 mA 5V K AIN AAA LI ST AA LL AAA cl AA AAA A AA A A 57 L Throttled body actuator positive 6A 16V Pin O S Supply source Function Max content Ground for oxygen sensor downstream sig GND ECU 0 01 mA 5V the catalyst Not connected ss connected D 1 for oxygen sensor upstream the sig GND ECU 0 01 mA 5V catalyst e mee __ e I poeren ege CC HRE RTT gb Fiat Grande Punto OK 202 532 O 2004 Fiat Auto S p A All rights reserved 4 3 Components 4 3 1 Electric injectors Description The electric injectors are of the miniature Pico type they are powered with 12 V and feature internal resistance of 13 8 15 2 Q at 20 C The injectors are secured by the fuel manifold which pushes the injectors thems
219. nto OK 153 532 2004 Fiat Auto S p A All rights reserved 3 10 10 Max torque restraint check The control unit calculates depending on the revs number the following values on preset maps the limit torque the permitted smoke limit level It compares these minimum values and corrects the same by means of other parameters cooling fluid temperature engine revs number vehicle speed air temperature The control unit also controls the amount of fuel to be injected pressure regulator electric injectors gb Fiat Grande Punto OK 154 532 2004 Fiat Auto S p A All rights reserved 3 10 11 Max r p m restraint check When the engine reaches 5 200 r p m the control unit cuts off injector drive as a result the feed pressure will be reduced Ss gb Fiat Grande Punto OK 155 532 2004 Fiat Auto S p A All rights reserved 3 10 12 Preheating spark plug check During the phases below starting phase post starting phase the control unit manages timed operation of the spark plug preheating control unit BITRON depending on the engine temperature 3 10 13 Air conditioning system actuation check The control unit drives the air conditioner compressor by turning it ON OFF when the respective switch is pressed by turning it off temporarily i e a few seconds in case of heavy acceleration or when the maximum power is requested
220. nto OK 342 532 2005 Fiat Auto S p A All rights reserved gb Fiat Grande Punto OK I emm em mm wm em e A Ci I mi i SCH ot E wi net WE __ a I Te Eas ERAT E aS J H y l h 343 532 Reverse speed 2005 Fiat Auto S p A All rights reserved 6 Brakes 6 1 Description The braking system fitted to Nuova Punto includes in its fullest version the following items ABS wheel antilock system EBD electronic braking distributor between the front and rear wheels ESP electronic vehicle stability control available on request ASR traction control MSR wheel antilock function in case of excessive exhaust braking Hill holder with ESP a device that allows the driver to park and start the vehicle again along steep roads without using the handbrake HBA emergency braking assist device The braking system is of the hydraulic power assisted type and is made up of 2 self contained crossed circuits each circuit acts on a front wheel and the diagonally opposing rear wheel in order to ensure braking and vehicle stability even when one of the circuits is broken gb Fiat Grande Punto OK 344 532 2005 Fiat Auto S p A All rights reserved Ventilated front disc Rear disc gb Fiat Grande Punto OK 345 53 2005 Fiat Auto S p A All rights reserved The new braking system features different characteristics due to the different
221. ol switch 2 ECM 3 Oxygen sensor upstream the catalyst 4 Oxygen sensor downstream the catalyst 5 Junction fuos vnosa 3 3 A 0 50 ES 9 50 aaa gb Fiat Grande Punto OK 247 532 2004 Fiat Auto S p A All rights reserved Pin out Component Receiving item Component connector pin 43 ECM Oxygen sensor signal connector B 60 ECM connector B Ground from the ECU sensor upstream the Oxygen sensor heating 32 ECM catalyst control connector B The wire 7 Junction reaches FDU until pin D3 Component a Component Receiving item Din Remarks connector pin 42 ECM connector B 58 ECM connector Oxygen sensor B downstream the Power supply from the battery catalyst Oxygen sensor heating 64 ne connector control 4 4 3 Engine revs number sensor Description It is fitted to the engine base and overlooks the phonic wheel positioned on the drive shaft pulley It is of the inductive type i e it works through the magnetic field variation generated by the passage of the phonic wheel teeth 60 2 teeth gb Fiat Grande Punto OK 248 532 2004 Fiat Auto S p A All rights reserved The injection control unit uses the revs sensor signal to determine the rotation speed determine the angular position of the drive shaft Operation The sensor is made up of a tubular casing 1 which incorporates a permanent magnet 3 and
222. ol unit the engine control unit will based on this signal reduce the ignition advance until the phenomenon disappears Next the advance is gradually restored to the base values Position on the vehicle 1 phase sensor 1 SS i 4 gb Fiat Grande Punto OK 241 532 2004 Fiat Auto S p A All rights reserved Operation The molecules of a quartz crystal are characterized by electric polarization In rest conditions A the molecules doe not feature a peculiar orientation When the crystal is subjected to pressure or a collision B the molecules orient themselves the higher the pressure to which the crystal is subjected quartz characteristic the more pronounced the molecule orientation Such orientation generates a voltage at the crystal ends Therefore such voltage is the result of the vibrations generated by the burst in the various cylinders The reference wave amplitudes are mapped in the engine control unit with correct engine operation The engine control unit interprets the wave amplitudes differing from the reference ones as failed ignition therefore it will actuate an emergency program P A Rest position B Position under pressure gb Fiat Grande Punto OK 242 532 2004 Fiat Auto S p A All rights reserved Electric features e resistance 532 588 Q at 20 C 41 C UU L 50 1 ECM 2 Knock sensor R ran E gb Fiat Grande Punto OK 243 532 2004 Fiat
223. olant temperature sensor Sucked air temperature and pressure sensor Accelerator pedal sensor Knock sensor T D C and revs sensor Ignition switch Oxygen sensor pre catalyst Fuel electric pump Radiator electric fan high low speed control remote control switches Speedometer odometer Oxygen sensor post catalyst Injection phase sensor Fuel level sensor Atmospheric pressure sensor 4 2 2 Main features The control unit is fitted onto the engine compartment on a support integral to the engine see photos and is able to withstand high temperatures It is of the digital microprocessor operated type and features very high calculating capacity low energy consumption and no maintenance requirements The function of the electronic control unit is to process the signals from the various sensors by applying software algorithms and also drive the actuators in particular the electric injectors ignition coils and the power driven throttle in order to achieve optimum engine operation The introduction of the Fiat CODE protection system does not make it possible to exchange control units among different Fiat Punto vehicles of the same engine version a hi O 6 45 L e R e ECM engine control unit do c FIAT i i U S gb Fiat Grande Punto OK 196 532 2004 Fiat Auto S p A All rights reserved Control unit pin out gb Fiat Grande Punto OK 197 532 O 2004 Fiat Auto S p A A
224. on This function makes it possible to obtained timed illumination outside the vehicle e g low beam headlamps even after the vehicle has been stopped for safety reasons safe homecoming etc The vehicle panel display will show the F XXX or Follow me XXXs writing where F Mode panel or Follow me Comfort and Matrix panels represents the Follow me home function message XXX indicates the illumination time seconds set through the steering column stalk A maximum of 7 steering column stalk pulses i e 210 seconds is permitted The writing will be displayed for about 20 seconds after the latest pulse given unless the function is deactivated through the steering column stalk EXAMPLE Mode panel P SS V FI AU L j gb Fiat Grande Punto OK 424 532 2005 Fiat Auto S p A All rights reserved Dualogic robotized gearbox function Comfort and Matrix panels The vehicle panel is capable of managing all the robotized gearbox displaying functions The gearbox information is always made available under any operating condition Telephone displaying through the Convergence module Comfort panel The panel displays the Convergence status BLUETOOTH status telephone company name a Bluetooth Status Telephone company name d L I j i j v l di FIAT gb Fiat Grande Punto OK 425 532 2005 Fiat Auto S p A All rights r
225. on exhaust smoke level control exhaust gas recirculation E G R control max torque restraint control peak r p m restraint control preheating spark plug control air conditioning system actuation control vehicles equipped with A C auxiliary fuel pump control FIAT PUNTO 130 532 2004 Fiat Auto S p A All rights reserved timing cylinder position control main and multiple injection advance control injection pressure closed cycle control electric balance control IMA injector calibration It is fitted to the engine compartment The control unit is of the flash e p r o m type i e it can be re programmed from outside without acting on the hardware The injection control unit incorporates the absolute pressure sensor 3 8 2 PIN OUT ii i i KkapGGpGpOiDOOGoGDGGODD0i DGpGpppoopnoOoooGopGGppnpoO Q DoGGOoODpGo oOooGO A EH EH FR GG ag D D G G 0 G GOTU UDO DG00000906060600G6000000 0 00000000090000000000p 15 30 29 7 CONNECTOR A Cylinder 4 injector positive Not connected Not connected Fuel pressure regulator positive Positive from the main relay Fuel pressure sensor negative Not connected Fuel pressure sensor positive FIAT PUNTO 131 532 2004 Fiat Auto S p A All rights reserved Low engine oil pressure sensor signal Air flow meter air temperature signal Not connected Not connected Not connected Air flow meter air flow rate signal
226. on line W Not connected Brake pedal switch signal N C Not connected Preheating control unit diagnosis input Not connected Not connected Not connected Spark plug preheating relay control Fuel pump relay control Fuel heater relay control Not connected Injection system failure warning light MIL Air conditioning compressor control Main relay control Not connected Not connected Accelerator potentiometer race 1 power supply Not connected Not connected Not connected Air conditioner linear sensor signal Diagnosis line K Not connected Diesel fuel filter water presence sensor signal Not connected Brake pedal switch signal N A Clutch pedal switch FIAT PUNTO 136 532 2004 Fiat Auto S p A All rights reserved 3 8 3 Types of configuration 75 HP system with CP1 pump Lo 0 l p Lo d D E E DI a E o S 2004 Fiat Auto S p A All rights reserved 137 532 FIAT PUNTO 90 HP system with quantity control valve downstream the CP1 H pump eid Pressure Lines RL ou Pressure Lines 3 8 4 Operation Operation logic The MARELLI MJD6F3 Euro 4 engine control system with EOBD features multiple injection control from which the term Multijet is derived Below is a short description of the system FIAT PUNTO 138 532 2004 Fiat Auto S p A All rights reserved Multiple injection The multiple injection operati
227. on makes it possible to switch both the dimmers and the license plate lights on with the vehicle key OFF in order to signal the presence of the vehicle when the latter is stationary parking It can be actuated only with the key OFF by turning the steering column stalk light ring from OFF dimmers or low beam headlights The function can be deactivated by moving the steering column stalk light ring to OFF or upon the key ON The latter operation will reset the function and the trip computer will control the lights according to the control selected on the steering column stalk ring Every time the key is next OFF the function will no longer be active it can be actuated again by repeating the aforesaid actuating operation gb Fiat Grande Punto OK 479 1 532 2005 Fiat Auto S p A All rights reserved Fog lights The fog lights can be switched on by pressing the fog light button only if the dimmers have already been switched on They can be switched off if the same button is pressed again or the dimmers are switched off Switching the dimmers on again will not involve switching the fog lights on again The trip computer will also actuate the indication on the panel When the fog lights are ON switching to key OFF will cause the fog lights to be turned off Upon the following key ON the fog lights will remain OFF they can be switched on again by pressing the button With both the panel and the fog lights ON starting the veh
228. on strategy makes it possible to accurately control the combustion process within the cylinder Injections are modulated so as to avoid too high pressure gradients which would cause the combustion noise to increase and the mechanic components to be stressed unnecessarily Multiple injections make it possible to reduce the pollutants to a significant extent while ensuring optimum engine performance The engine management control unit can perform up to 5 injections per engine cycle which are referred to as follows PILOT injection PRE injection MAIN injection AFTER injection POST injection PILOT PEE MAIN AFTER POST Injection i I H E i Combustion factor Four work areas can be identified in this application 1 PILOT injection PRE MAIN 2 PRE injection MAIN 3 PILOT injection PRE MAIN with dwell time between PILOT and PRE gt 1000 usec 4 MAIN injection FIAT PUNTO 139 532 2004 Fiat Auto S p A All rights reserved E Dei i ee ee e ee ee e Kee ee e d Se EEN a O C C SOC EE d PSA SS L MRS Se K RR o a BMEP bar L m S EGR limit 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Engine speed r p m Below is the information processed by the control unit to control the amount of fuel to be injected engine revs cooling fluid temperature boosting pressure air temperature from the air flow meter sucked air amount battery volta
229. ons Acquiring from the B CAN line the airbag status signal ON OFF Flash from the SDM Transmitting on the B CAN line through the airbag warning light signal the airbag warning light status ON OFF Fail Diagnosing the airbag warning light and the front passenger s airbag deactivation warning light and storing possible faults permanently until their are remedied into the IPC memory If the signal from the SDM in the B CAN is delayed the IPC shall make the airbag warning light to come on ee gb Fiat Grande Punto OK 41 4 53 2005 Fiat Auto S p A All rights reserved Trip Computer The trip computer makes it possible to show on the vehicle panel display the values relative to the route consumption and the distance covered by the vehicle Two trip computer modes A and B are provided for the Comfort and Matrix panels which are fully independent from each other and can be shown on the display by pressing the TRIP button dedicated located on the right lever of the steering column stalk The Mode panel features only the Trip A mode Data displaying by the driver follows a pre established sequence see list below TRIP A TRIP B Driving time Driving time The values shown can be represented by means of the decimal system km k p h k p l 1 100 km or the British system miles m p h m p g depending on the driver s choice see the set up menu The trip computer is reset new mis
230. ontrol unit by means of a remote control switch The pump is stopped e if the engine speed falls below approximately 40 r p m after some time approximately 6 seconds when the ignition switch has been set to the MAR position and the starting operation is not carried out timed enable e if the inertia switch has come into action UI 4 5 12 Electric injector control The electric injector control is of the phased sequential type i e the single injections correspond to the intake phases of every single cylinder However the electric injectors will during the starting phase be first driven in parallel full group The electric injector control timing varies depending engine speed and the sucked air pressure in order to improve cylinder filling with advantages in terms of consumption driveability and pollution prevention 4 5 13 Knock control The purpose of this strategy is to detect any knock condition by processing the signal from the respective sensor This strategy continuously compares the signal from the sensor with a threshold value which is continuously updated to allow for basic noise levels and engine ageing If the system recognizes that knock is present the strategy will act so as to reduce the ignition advance until the phenomenon disappears Next the advance will be gradually restored up to the base value or until the phenomenon occurs again In particular the advance increas
231. ontrols within switch holder modules The modules are listed in the table below together with the other controls CDC RDC Passenger s rear front door window regulator control New Stop switch Common component derived from Opel CSM Steering column stalk control module Derived from Ypsilon Switch on the clutch Common component derived from Opel Control dashboard on the driver s side front door New CSS Central control dashboard New ELC Left control dashboard Gearshift control lever Steering wheel controls for the horn and the audio telephone systems New Information communication roof control dashboard on the ceiling light New fixture The derived components feature the same interface to the vehicle wiring wiring diagram connector as the reference model d L E K FIAT gb Fiat Grande Punto OK 397 532 2005 Fiat Auto S p A All rights reserved 9 2 Description of components 9 2 1 Engine compartment control unit FDU The FDU control unit is a branching off unit with sheared circuits installed in a sealed container located in the engine compartment in the left headlamp area which holds fuses and remote control switches and protects the electric loads The FDU node is interconnected to the front bodywork cable harness the front cable harness and the engine service pre wired cable harness A o E WM alu o bh Lo A Functions The front distribution nodes manage
232. ow warning light check it starts over for the warning lights driven by the panel and continues for the warning lights driven by a signal in a discrete fashion indicators zeroing is permitted in order to carry out total recovery Checking upon key ON it starts over Automatic service messages they are displayed again Checking upon key ON Upon every key ON the check phase will start for all the electronic control units fitted to the vehicle and some warning lights will illuminate on the panel Comfort and Matrix panels The standard screen time and date will be displayed on the panel In the event that any anomaly is found during the check phase the same will be displayed 5 seconds after the key ON Illumination The vehicle panel lighting provides for two different modes active with the lights ON indicators graphic elements display active with the key ON key ON display gb Fiat Grande Punto OK 432 532 2005 Fiat Auto S p A All rights reserved 9 2 5 Steering column stalk control module CSM The steering column stalk control module CSM incorporates the external lighting controls on the light lever located on the left and the window rear window wiping and washing controls on the wiper lever located on the right The module may include the Trip function available on all the body versions and the Cruise Control function available as an option It is interconnected through the dashboard
233. ower driven drive by wire throttled body and PCB control unit fitted onto the engine gear pump for forced lubrication optimized rod piston crank mechanism for reduction of the alternate mass which is the main cause of engine vibration excitation single block coils with ignition elimination of lost sparks and knock control on a cylinder by cylinder basis Magneti Marelli engine control unit of the torque based type resistant to the engine s mechanic and thermal stress very low consumption and exhaust gas levels diagnosis through EOBD connector 2 heated oxygen sensors and trivalent catalytic converter compliance with the Euro 4 standard The optimization of the valve gear timing and the introduction of such items as electronically controlled hydraulic continuous phase variator variable turbulence combustion chamber special intake and exhaust ducts special inlet manifold gb Fiat Grande Punto OK 188 532 2004 Fiat Auto S p A All rights reserved make it possible for the vehicle to reach optimum performance levels and also circulate within the combustion chamber a significant amount of the exhaust gas approximately 25 thus reducing to a considerable extent fuel consumption and exhaust emission when the vehicle is being driven with a partial load 8 valve 1 4 litre engine specifications Engine type Displacement Bore Stroke Intake valve diameter Exhaust valve diameter g
234. p A All rights reserved Nuova Punto features a standard occupant protection system made of up of the items below front safety restraint system including driver s and passenger s front airbags of the dual stage type front safety belts with pre tensioner and load limiter my car electronic system for passenger s side front and side airbag disable Moreover the following optional items are available side bag on the front seats to ensure higher protection of the thorax and pelvis window bags located in the rails below the roof to better protect the occupants heads against dangerous penetrating objects and parts When designing Nuova Punto Fiat has paid great attention to the safety of the children on the vehicle and the pedestrians as well Children safety is ensured by devices that make it possible to achieve the maximum protection that can be obtained at present i e isofix mounts on the rear seats and passenger s airbag disable through the vehicle s trip computer Pedestrian safety has also been enhanced though it has somehow affected the vehicle s style solutions adopted to meet the newer law requirements that establish specific conditions to protect the pedestrians in case of accidents Finally passive safety is further enhanced by features such as the controlled deformation body the collapsible steering column and steering pedals and the anti whiplash seats option FIAT PUNTO 21 532 2004
235. pressing the button again and again on the same side still within the time range of 60 to 300 ms the panel will jolt along until it reaches the maximum closing position gb Fiat Grande Punto OK 529 532 2005 Fiat Auto S p A All rights reserved 11 2 3 Window shades The passenger compartment interior luminosity can be modified by means of two window shades one for the front mobile panel one for the fixed rear panel The window shades are made of polyester each of them slides and can be rolled up along sliding guides thus preventing the guides from being detached They can be opened manually and be either fully closed or opened no intermediate positions The window shade closing is independent from the front panel opening position 11 3 Sunroof closing anti pinch feature The antipinch system managed by the electronic control unit conforms to the requirements of EC Directive 2000 4 and comes into action during horizontal and vertical closing of the front panel when an obstacle e g finger hand etc is found as far as the horizontal closing motion is concerned the system is active over the entire travel if the glass is opened for more than 4 mm when an obstacle is found on the front side of the glass panel it reverses the glass motion over a distance of 100 mm from the point where the motion has been reversed as far as the vertical closing motion is concerned the system Is active over the entire travel
236. put 4 radiator output FIAT PUNTO 95 532 2004 Fiat Auto S p A All rights reserved It is fitted on the rear side of the cylinder head and is used to keep the engine at the optimum temperature if the temperature if less than 80 2 C the thermostatic valve closed diverts the fluid directly toward the pump if the temperature is more than 80 2 C the thermostatic valve open conveys the cooling fluid toward the radiator The engine water temperature sensor connected to the injection control unit and the main panel is fitted onto the thermostat 3 4 2 Water temperature control devices Electric fans The 2 speed electric cooling fans make it possible to increase the heat discharge capacity of the radiator and or air conditioning system condenser They are controlled directly by the injection control unit according to a specific operating logic 3 4 3 3 5 Service control Construction The single engine member drive belt 5 is of the poly V type it drives the alternator 1 water pump 3 and air conditioning compressor 6 where available Tensioning is obtained by means of an automatic idler 2 that makes preventive maintenance operations useless The drive shaft pulley 4 incorporates an elastic sector that reduces the torsion vibrations of the drive shaft and the stress on the belt and therefore on the engines auxiliary members FIAT PUNTO 96 532 2004 Fiat Auto S p A All ri
237. r very high side rigidity to improve road holding when cornering Moreover the body attachment rigidity has been increased The greater rigidity of the upper attachment dome made of aluminium makes it possible to reduce the noise let into the body thus improving the comfort The front Suspension crossbar is the lowest part of the vehicle since the body struts have been lowered to improve the vehicle performance during the crash test Only toe in can be adjusted on the front suspension gb Fiat Grande Punto OK 369 532 2005 Fiat Auto S p A All rights reserved Camber angle ENGINE VERSIONS 1 2 120 a 54 148V LE O LE 1 3 MJet 70 enaner 1 2 12 1 3 MJet 70 amaer Bt A TARV 1 3 MJet 90 eum 1 3 MJet 90 Riccia 1 9 MJet 120 CV 8 2 2 Characteristic angles tt al mari a ms D TT T LRT HS C 2 A a R15 84T 185 65 R15 88T Loading conditions 22 20 22 KMA 20 22 eb 20 22 KMA 20 22 eg 20 27 20 22 KMA 20 27 20 26 ae 20 26 ob E 20 28 20 26 20 28 20 2 20 27 20 27 20 27 20 1 9 MJet 120 CV 195 55 R16 87H 19 20 21 20 gb Fiat Grande Punto OK 370 532 2005 Fiat Auto S p A All rights reserved Toe in N i FIAT gb Fiat Grande Punto OK 371 532 2005 Fiat Auto S p A All rights reserved Loading conditions EN
238. rande Punto OK 295 532 2004 Fiat Auto S p A All rights reserved The control unit temporarily controls the compressor switch off for a few seconds e when very high engine power is requested heavy acceleration e upon engine pick up gb Fiat Grande Punto OK 296 532 2004 Fiat Auto S p A All rights reserved 4 5 19 Phase variator control The phase variator is fully managed by the engine management control unit which measures the camshaft position through the phase sensor modifies such position depending on the engine operation point according to a calibrated map keeps the camshaft position under control The phase variator motion takes place through the pressure of the engine oil that flows into the advance delay openings A box solenoid valve makes the oil flow into the advance openings the variator will move in the direction of the advance which corresponds to the rest position or the delay openings the variator will move in the direction of the delay or into the advance and delay openings alternately and continuously the variator remains in the controlled position The control unit drives the variator driving solenoid valve through a duty cycle command 4 6 Procedures 4 6 1 Camshaft assembling position self learning procedure When and why should this procedure be carried out This procedure allows the ECM to self learn the camshaft position with respect to the phonic wheel
239. rande Punto OK 320 532 2004 Fiat Auto S p A All rights reserved Position tappet cover 1a onto the head then draw fastening screws 1b closer Fit tappet cover centring tool 2000004300 gt gb Fiat Grande Punto OK 321 532 O 2004 Fiat Auto S p A All rights reserved Tighten the tappet cover screws previously drawn nearer to the specified torque 0 8 1 0 daNm Remove the tappet cover centring tool previously fitted Fit the phase sensor Fit the injection control unit support Wal DI gb Fiat Grande Punto OK 322 532 2004 Fiat Auto S p A All rights reserved Fit the power unit support valve gear side then secure it by means of the fasteners to the specified torque 5 4 6 6 daNm and the front support elastic dowels 4 5 5 5 daNm Remove the engine oil sump arm lifting device Connect the intermediate junction of the degassing pipe Connect the revs sensor electric connection Connect the minimum oil pressure switch electric connection Fit the timing belt protection lower cover then secure it by means of its respective screws Fit the drive shaft pulley then tighten the screws to the specified torque 2 2 2 7 daNm Act on the belt stretcher to fit the auxiliary member belt Fit the timing belt upper cover Fit the ignition coil module then tighten the respective screws to the specified torque 0 8 1 0 daNM Connect the ignition coil module electric connection
240. release shall be installed on the Examiner in order to access all the functions The CAN A16HS high speed interface is made up of an EOBD standard connector a Bantamate female connector for connection with the Examiner which includes an electronic circuit and a yellow green LED for indicating the operating status Installation and diagnosis Insert the CAN A16HS high speed interface between the vehicle s diagnosis connector and the Examiner extension cord After making the connection the take off LED will blink then it will blink steadily in a green colour After actuating communication with the control unit on the CAN line the LED will be ON steadily yet it will turn yellow The continuous blinking of the yellow LED indicates that a communication error has occurred C CAN network terminating resistors Terminating resistor Brake node Gn The terminating resistor on the C CAN network is available both in the ECM and the BCM and features a value of 120 Q for both of them gb Fiat Grande Punto OK 383 532 2005 Fiat Auto S p A All rights reserved 9 1 5 B CAN low speed line RETE B CAN BASE BCM RAN A B CAN P 38 Loy Speed CAN Craneo vor ai Low Feed CAN Cramscoivat E ER gb Fiat Grande Punto OK 384 532 2005 Fiat Auto S p A All rights reserved FULL B CAN NETWORK BASE A CAN NETWORK BASE B CAN NETWORK CAVO_BODY_TO_FRONT PREC_CLIMATIZZATORE E ZER B CAN A NS 0 35
241. reserved Fg dE SC S SE 3 SEA KE L0011814 Shaft position The cutaway figure below illustrates the position of the respective shafts according to the 3 shaft arrangement in the M20 6 speed gearbox 1 Upper output shaft 3 Lower output shaft 2 Top gear shaft 4 Differential Oblique tapered roller bearings are used with all the shafts in this gearbox unit These bearings require some bearing play as well as a bearing pre load Both the bearing play and preload are obtained during the manufacture by using compensating washers under the oblique tapered roller bearings in the transmission case gb Fiat Grande Punto OK 338 532 2005 Fiat Auto S p A All rights reserved 5 4 Speed gear arrangement 10 Position of the speed gears on their respective shafts 1 speed gear 2 speed gear 5 speed gear 6 speed gear 3 45 speed gear 6 speed gear 4 speed gear CON DO dI FP OO N a 4 speed gear 9 Reverse speed gear 10 3 speed gear This 3 shaft gearbox unit is advantageous in that the 3 speed gear on the top gear shaft is also used for the 5 speed Fi 8 FIAT e CH gb Fiat Grande Punto OK 339 532 2005 Fiat Auto S p A All rights reserved 5 5 Kinematic route of the single gears fa at r a Sr cop age E gb Fiat Grande Punto OK 340 532 2005 Fiat Auto S p A All rights reserved gb Fiat Grande Pu
242. reserved Fuel pressure sensor RDS 4 It is fitted to the end of the rail single fuel manifold pipe and is used to provide the injection control unit with a feedback signal in order to adjust the injection pressure adjust the injection time The sensor is powered directly by the engine management control unit with 5 V The output voltage varies in a linear fashion between 0 5 V 0 bar and 4 5 V 1 500 bar gb Fiat Grande Punto OK 180 532 2004 Fiat Auto S p A All rights reserved Fuel pressure sensor pin out Type of Pin Name d signal 1 Ground Ground Analog 2 Sensor output output 3 Power supply Input 5 V If the sensor is faulty the control unit drives through emergency mapping the quantity control valve DRV2 so as to raise the bottom pressure by 100 bar from 250 bar to 350 bar N B The engine can be started and operate even if the sensor is faulty Accelerator pedal potentiometer The sensor is made up of a frame secured to the accelerator pedal which houses a shaft placed in an axial position and connected with the two potentiometers main potentiometer and safety potentiometer A helical spring fitted onto the shaft ensures proper compressive strength whereas one further spring ensures the return when releasing Redundant signal reading makes it possible to continuously monitor the plausibility of measured values so as to ensure full driving safety e
243. responding to the fault the message corresponding to the description of the anomaly and or the actions to be taken by the driver The display will illuminate at its maximum brightness except for Ice danger and the feedback messages The most important warnings and messages are accompanied by an acoustic signal simultaneous with the message displaying All the information contained in the display section reserved for message displaying will be replaced by the information on the anomaly The messages are displayed upon very key ON until the malfunction is identified and remedied In any case the displaying can be interrupted by the driver by pressing the Menu Esc button When the message displaying has been completed and if the anomalous condition persists the warning light and or the icon on the Matrix panel will remain ON In the event that several anomalies are found simultaneously the display will show in a rolling fashion each of the anomaly messages ideographs over the duration of one displaying cycle All the messages that fall within the abovementioned four classes are managed as follows Comfort panel on displaying strings each of them lasts 1 5 seconds max and occupies 5 rows max these strings make up a displaying cycle Matrix panel on one single screen gb Fiat Grande Punto OK 427 1 532 2005 Fiat Auto S p A All rights reserved The displaying time may vary depending on the class of the me
244. rotection Side limiter protection Rear protection gb Fiat Grande Punto OK 507 532 2005 Fiat Auto S p A All rights reserved Recovery R1 Accelerometer signal X actuation not ensured Accelerometer signal Y front airbags and pretensioners enabled side and head airbags disabled Power reserve actuation not ensured ASIC actuation ensured Microprocessor actuation disabled Memory actuation disabled ECU reset sensor safing front airbag and pretensioner disabled side and head airbags ensured R2 unsafe actuation due to faults R3 in case of collision the control unit will try actuation R4 passenger s front airbag disable and passenger s airbag warning light lighting R5 actuation ensured R6 actuation disabled by the control unit R7 the CAN communication will stop for 1 second The passenger s airbag will be switched off during this time R8 relative to side and head airbag disable The opposed side and head airbags will be ensured The front airbags and pretensioners will be ensured R9 actuation available It may be cleared off the event memory when all of the following conditions apply one airbag and pretensioner is not actuated pretensioner actuation other than the third one side airbag actuation other than the third one R10 front and passenger s airbag disabled and passenger s airbag warning light ON R11 if the passenger s airbag deactivation warning l
245. rove the dynamic response when cornering Great attention has been devoted during the component design phase to the comfort features by introducing technical solution typical of upper class vehicles such as the use of a dome dowel of the double type dual path at the front and the positioning of the vertical shock absorber at the rear These measures have made it possible to reduce to a large extent the effect of the vibrations generated by the road surface without affecting the structural rigidity to the detriment of higher driving accuracy The elastic bushing dimensions have been increased to improve the damping of road roughness and increase the driving comfort Shock absorbers with 22 mm stems on all versions to increase the stability limit conditions when cornering gb Fiat Grande Punto OK 367 532 2005 Fiat Auto S p A All rights reserved Increased structural rigidity of the suspension anchoring front crossbar to achieve better acoustic vibration Both the front and rear suspensions feature as we have said above an increased wheel track compared with the current Punto both to adapt to the greater outer dimensions of the new model and to improve the driving stability 70 mm at the front and 75 mm at the rear on average 8 2 Front suspensions 8 2 1 General remarks The front suspensions feature an independent wheel configuration of the Mc Pherson type In particular the main components of
246. rrect operation of the system any of the following restore conditions shall be met a key OFF key ON operation a downward movement actuated by the user of the window at issue In the event that the battery is disconnected and re connected the following procedure shall be carried out in order to resume correct operation of the front windows gb Fiat Grande Punto OK 4781532 2005 Fiat Auto S p A All rights reserved move the right or left front window to its lower end of travel and keep the opening control depressed for a time of 5 to 10 seconds then carry out the same operation with the upper end of travel by keeping the closing control depressed for a time of 5 to 10 seconds 9 5 External lighting General remarks and components Dimmers When the user turns on the dimmers with the key ON or requests the parking light or Follow me home with the key OFF function the trip computer will command the actuation of the dimmer bulbs left right front rear Except for the Follow me home function some requests will involve switching the license plate lights on Low beam high beam headlights With the low beam headlights ON the actuation of the high beam headlight control will disable the low beam headlights Subsequent deactivation of the high beam headlight control still with the low beam headlight control ON will involve switching the low beam headlights on again Parking lights This functi
247. rries both windings l ce i Es o al Ct US SUA ON SSN dd Operation The windings are covered by a stamped plastic container and insulated by being immersed into a epoxy resin and quartz compound that gives them outstanding dielectric mechanic and thermal properties since they are able to withstand very high temperatures too The vicinity of the primary to the magnetic core makes it possible to reduce the magnetic flux loss thus making the most of the coupling on the secondary gb Fiat Grande Punto OK 208 532 2004 Fiat Auto S p A All rights reserved N B When the ignition module is being assembled first tighten the two screws located outside and then tighten the central screws to the specified torque value Otherwise the module might be broken Position of components 1 1 2 Tightening order for the ignition module fastening screws gb Fiat Grande Punto OK 209 532 2004 Fiat Auto S p A All rights reserved 1 2 3 4 Spark plug outlets Electric features Primary circuit resistance 0 5 Q 10 at 23 3 C Secondary circuit resistance 6 0 kQ 10 at 23 3 C i gb Fiat Grande Punto OK 21 0 53 2004 Fiat Auto S p A All rights reserved Cylinder 3 Cylinder 4 Cylinder 2 Cylinder 1 OH 0 75 1 ECM 2 FDU engine management remote control switch 3 Ignition module 4 Junction 5 Engine ground B gb Fiat Grande Punto
248. s released The ASR antispin function takes priority over the Cruise Control for safety reasons Geff NM d gb Fiat Grande Punto OK 163 532 2004 Fiat Auto S p A All rights reserved Summarizing list of components mm T PRS Te E x A A Boosting pressure sensor S air temperature pgn S air temperature DPF OPT Control system DRV2 on the rail MPROP in CP1 H DRV2 on the rail Multiple injection Multiple injection EGR control DPF control Oxygen sensor control Functions l l Cylinder balancing control Injection correction control IMA procedure EGR control DPF control Oxygen sensor control Cylinder balancing control Injection correction control IMA procedure VGT control gb Fiat Grande Punto OK 164 532 2004 Fiat Auto S p A All rights reserved 3 11 Sensors Revs sensor It is fitted onto the engine base and faces towards the phonic wheel positioned on the engine flywheel It is of the induction type i e it operates through the variation of the magnetic field generated by the passage of the phonic wheel teeth 60 2 teeth The injection control unit uses the revs sensor signal to determine the engine rotation speed determine the angular position of the drive shaft The figure illustrates the revs sensor components gb Fiat Grande Punto OK 165 532 2004 Fiat Auto S p A All rights reserved 1 Brass metal bushing 2 Permanent
249. s the frequency of the windscreen wiper strokes can be set depending on the amount of water found on the windscreen Such frequency may vary from no stroke at all no rain dry windscreen to continuous speed 2 heavy rain wet windscreen The rain sensor actuation drives the execution of a windscreen wiper stroke acting as a feed back for sensor switch on The user may vary the rain sensor sensitivity by means of the vehicle set up menu on the instrument panel If the vehicle is switched off and the lever ring is left in the intermittent automatic operation position no wiping cycle will be carried out when the vehicle is next started even if is rains this will avoid unintentional actuation To restore the system s automatic operation the user shall move the ring from the intermittent automatic operation position to any other position and then return to intermittent automatic operation position When the rain sensor operation is resumed a windscreen wiper stroke will occur regardless of the windscreen conditions to inform the user that the operation has been resumed gb Fiat Grande Punto OK 440 532 2005 Fiat Auto S p A All rights reserved When the steering column stalk ring is moved from the speed 1 position to the intermittent automatic operation position a windscreen wiper stroke will occur to indicate that the rain sensor has been actuated If the rain sensor sensitivity is modified i e its value is i
250. s reserved To improve the engine operation the solenoid valve control is inhibited by keeping the same closing position under the operating conditions listed below e throttle valve in the closing position engine speed of less than 1500 r p m e intake manifold pressure lower than a limit value calculated by the control unit depending on the revs number 4 5 18 Air conditioning system control The injection ignition control unit is connected from the operational viewpoint to the air conditioning system since it receives the request for compressor actuation and implements the respective actions additional air e enables compressor actuation when the conditions envisaged by the strategies have been checked e receives the information about the linear pressure switch condition and implements the respective actions radiator electric fan control If the engine runs at idling speed the control unit will increase the throttle opening and therefore the air flow rate in advance compared with the compressor actuation and conversely will resume the normal throttle position behind time compared with the compressor switch off The control unit will automatically control the compressor switch off e with engine coolant temperatures of more than 120 C with engine speed of less than 650 r p m The compressor will be switched on again when the engine speed reaches 750 r p m again si P gb Fiat G
251. s the following functions headlamp washing right and left side rear view mirrors rear heated window cigar lighter horns engine cooling fans Wal AT gb Fiat Grande Punto OK 398 532 2005 Fiat Auto S p A All rights reserved Fiat Auto S p A ELECTRIC FIAT PUNTO TRAINING OUTLINE a j SYSTEM After Sales Training 9 2 2 Luggage compartment node This node is located in the left bottom part of the luggage compartment next to the rear headlamp It also houses some fuses used to protect the systems managed by the node gb Fiat Grande Punto OK 399 532 2005 Fiat Auto S p A All rights reserved 9 2 3 Body Computer node BCM The Body Computer node is located inside the instrument board in the bottom left part under the left control dashboard It can be easily located since it houses the instrument board fuses see figure below Body Computer node BCM The Body Computer node is interconnected to the front bodywork cable harness and the dashboard cable harness gb Fiat Grande Punto OK 400 532 2005 Fiat Auto S p A All rights reserved Position on the vehicle To gain access to the fuse holder control unit on the instrument board unscrew screws A then remove the cover Functions managed The Body Computer node BCM is an electric electronic component used both to distribute the electric power power PCB and manage the vehicle s serial lines
252. se its motion The system causes the window regulator motion to be reversed every time an obstacle e g finger hand etc is detected during the window travel thus avoiding accidental crushing This feature ensure a very high degree of safety even in the event that a window regulator is unintentionally actuated by a child on the vehicle This makes it possible to actuate window superior opening closing when you leave the vehicle The anti pinch function is ON during both manual and automatic operation of the window Two zones inversion and non inversion can be defined fro the anti pinch system the inversion zone corresponds to the space included between 200 mm from the upper edge and the latter the non inversion zone corresponds to the remaining space If an obstacle is detected in the inversion zone during the window upward movement the system will interrupt the upward movement and will immediate reverse the direction If on the contrary an obstacle is detected in the non inversion zone during the window upward movement the system will interrupt the upward movement No control will be accepted during this time If the anti pinch protection comes into operation five times in a row within one minute or is out of order the automatic window upward operation will be disabled i e it will only be allowed with jerks lasting half a second with button release for the subsequent operation To resume the co
253. sing the respective button When the latter is released the motor will stop The window regulating function can be actuated on both sides right amp left only when the key is inserted Following the key OFF the front windows can only be actuated manually over a period of 3 minutes After this time has elapsed the system will not be acquiring new commands any more Version equipped with the automatic device on the driver s side The driver s side window regulator can be operated both manually and automatically The passenger s side window can be operated in manual mode only gb Fiat Grande Punto OK 472 532 2005 Fiat Auto S p A All rights reserved The window regulating function can be actuated on both sides right amp left only when the key is inserted Following the key OFF the front windows can only be actuated manually over a period of 3 minutes After this time has elapsed the system will not be acquiring new commands any more ALZACRISTALLI ANTERIORI con AUTOMATISMO E SENZA ANTIPINCH GSX E GDX BASIC WERSION Plancetta comandi porta ant lg Comando specchi elettrici Passenger side Driver side Light ing PORTA_ANT_LG v a a Bei at CAVO_BOUY_TO_FRONT gb Fiat Grande Punto OK 473153 2005 Fiat Auto S p A All rights reserved Controls and operation versions with 4 window regulators All the window regulators can be operated both manually and automatically d
254. sion manually by the user by pressing the TRIP button for some time automatically when the covered distance reaches the maximum value 9999 9 km miles for the Comfort and Matrix panels or 3999 9 km miles for the Mode panel or when the driving time reaches 99 59 99 hours and 59 minutes every time after the battery is reconnected gb Fiat Grande Punto OK 415 532 2005 Fiat Auto S p A All rights reserved When the maximum kilometre distance that can be displayed on the trip odometer is reached the latter will display 0 0 again Example Mode panel Trip Computer items Fuel distance km or miles it indicates the estimated distance hat can be covered with the fuel found in the tank by assuming that the driver will keep on driving by following the same driving behaviour Covered distance km o miles it indicates 0 to 9999 9 for the Comfort and Matrix panels 0 to 3999 9 for the Mode panel the distance covered by the vehicle from the start of the mission i e since the trip odometer has been reset by the driver The indication is consistent with the value shown on the odometer The display is updated every 100 metres Average consumption k p l or I 100 km or m p g it indicates the average consumption from the start of the mission The unit of measurement k p I cannot be selected in the Mode panel Instant consumption k p l or I 100 km or m p g it indicates th
255. sion the sensor also incorporates the boosting temperature sensor 28 gt 0 3 12 6 W s il F Se gb Fiat Grande Punto OK 172 532 2004 Fiat Auto S p A All rights reserved Q Lu 5 5 to 16 V i 680 kf l Reference 68 k Ge i Fressure Signal Temperature Signal 1 5 nE 33nPF 3 Il Res MES KE GND 1 5 nF 33 nF a L 7 OUT Pin out 1 Pressure signal output 2 Power supply from the control unit 5 V 3 Temperature signal output 4 Ground gb Fiat Grande Punto OK 173 532 2004 Fiat Auto S p A All rights reserved Engine water temperature sensor It is fitted to the thermostat and measures the water temperature by means of a NTC with negative resistance coefficient Engine water temperature sensor features Temperature _ Resistance KQ C 40 48 80 30 27 41 20 15 97 10 9 62 0 5 97 10 3 81 20 2 0 30 1 68 40 1 15 90 0 81 60 0 58 70 0 42 80 0 31 90 0 23 100 0 18 110 0 14 120 0 11 130 0 08 3 12 Air flow meter with built in air temperature sensor HFM 6 Below are the advantages of the new air flow meter greater protection of the sensitive element put into the sensor against the air impurities particles water oil vapour etc greater measurement accuracy Below are the differences between the HFM6 air flow meter and the earlier versions air flow rate and temperature digital sig
256. sponds both to oversteering and understeering and is set to resume the vehicle s stability condition while allowing the driver to fully control the vehicle The system continuously monitors the vehicle motion conditions side acceleration longitudinal and angular speed road grip and the driver s setting steering wheel angle accelerator pedal The system corrects the vehicle motion when it feels that the vehicle is about to reach a condition of instability sideslip understeering oversteering etc in this case it acts on the deflecting torque control and applies a proper braking torque distributed to each of the four wheels Direction is controlled by taking advantage from the tyre s longitudinal grip the different braking action between the two vehicle sides generates a rectifying yawing torque that stabilizes the vehicle The ESP function is managed by the ABS control unit which monitors by processing the values of the quantities acquired from the various sensors side acceleration sensor yaw sensor steering angle sensor wheel revs sensors and pressure sensors through algorithms implemented in the software the dynamic control parameters wheel slip axle drift trim angle and interprets the mistakes if any made by the driver thus taking adequate actions in order to resume the vehicle s stability condition The system is made up of the following components 4 wheel speed sensors fitted into special seats on the front
257. ssage high priority anomalies 20 seconds Matrix panel or 8 cycles Comfort panel warning low priority anomalies 10 seconds Matrix panel or 4 cycles Comfort panel feedback 5 seconds Matrix panel or 1 cycle Comfort panel Anomalies that require being checked with the engine running the following warnings and messages shall only be displayed when the engine is running battery charge status icon Matrix panel low engine oil pressure message engine check required message Message displaying Mode panel On the Mode panel the anomalies are signalled by the lighting of their respective warning lights Moreover the messages below are displayed speed limit exceeded for 10 seconds inertia switch actuation the respective message is displayed in place of the odometer the message will remain ON until such the inertia switch is being actuated Speed limit exceeded Inertia switch actuation Acoustic buzzer Some functions and warnings are accompanied by an acoustic signal The vehicle panel features an internal buzzer that performs the following functions alarm warning danger signalling robotized gearbox request signalling where the robotized gearbox is available parking sensor signalling where the parking sensor is available safety belt reminder signalling Wu SS de gb Fiat Grande Punto OK 428 532 2005 Fiat Auto S p A All rights reserved
258. ssing the or button briefly press the MENU ESC button to go back to the submenu screen or press the button for a long time to go back to the main menu screen without storing in the memory gb Fiat Grande Punto OK 467 532 2005 Fiat Auto S p A All rights reserved press the MENU ESC button again for a long time to go back to the standard screen or the main menu depending on the menu point reached Deadlock device This is a safety device where available that disables the operation of the following items inner handles locking unlocking button thus preventing the doors from being opened from inside the passenger compartment in the event that an attempt at breaking into the vehicle has been made e g glass breaking Therefore the deadlock ensure the best protection against any attempt at theft It is recommended that the system is actuated every time the vehicle is left parked Passenger s side front door locking actuator Rear right door locking actuator Dead lock Lock Unl ack Dead Lock DOOR ira 1312 11 29 2 Lo Lik Lik LR LH uo Roe zi BODY TO FRONT CABLE T T IBODY TO FRONT CABLE it PASSENGER S SIDE FRONT Ill REAR RIGHT DOOR Sie G 1 5 290 A SS Computer node NBC Rear left door locking actuator Lock Unlock G ECH gn 8 x anu a ao Ze 1 1 1 k DI Ech Ci eg ha sw Dead lock BODY TO FRONT CABLE REAR LEFT DOOR
259. t VR Seet z P R EE YA i 7 Air conditioner FULL AUTO FULL AUTO G at DD alii 58 Y G2 a y Gs Gei Automatic two zone air conditioner With reference to the figure illustrating the automatic two zone air conditioner the button functions are as described below 1 single differentiated temperature selection control MONO button yellow LED 2 compressor enable disable control button yellow LED 3 air recirculation control button yellow LED 4 display 6 system deactivation control OFF button yellow LED 7 MAX DEF function control button yellow LED 8 rear heated window yellow LED 9 passenger compartment temperature sensor protection grid 10 AUTO SX button for automatic control of left hand temperature left hand air distribution fan compressor and air recirculation 11 driver s side temperature selection knob 12 left hand air distribution selection buttons three green LEDs 13 fan speed pivoting button increase decrease 14 right hand air distribution selection buttons three green LEDs f A S N d FIAT gb Fiat Grande Punto OK 523 532 2005 Fiat Auto S p A All rights reserved 15 AUTO DX button for automatic control of right hand temperature right hand air distribution fan compressor and air recirculation 16 passenger s side temperature selection knob The system makes it possible to adapt the passenger compartment air te
260. t Auto S p A All rights reserved DRV 2 pressure regulator It is fitted onto the rail and controlled by the injection control unit It is used to control the fuel feed pressure to the electric injectors FIAT PUNTO 111 532 2004 Fiat Auto S p A All rights reserved The pressure regulator is essentially made up of the following items 3 5 Ne SE Nec IS be sesch G ER an A ELA e FAN S NIC EEA MI ASTE 8 Round shutter Pin Valve Preload spring max sealing pressure 50 bar Coil Body Anchorage Filter CON O dI FP OO N gt Current graph depending on the DRIVING DUTY PWM FIAT PUNTO 112 532 2004 Fiat Auto S p A All rights reserved Pressure regulator OFF P 50 bar PWM 1 000 HZ I 1 600 bar 1 3 A valve current Ze Pressure driving parameters 75 HP Idling engine rail pressure 250 bar Max engine speed rail pressure 1 400 bar 90 HP Idling engine rail pressure 250 bar Max engine speed rail pressure 1 600 bar 3 6 4 Electric injectors and pipes CR1 MI 2 2 electric injectors The electric injectors are fitted onto the cylinder head and controlled by the injection control unit The electric injector can be divided into two parts 1 actuator nozzle 2 control solenoid valve FIAT PUNTO 113 532 2004 Fiat Auto S p A All rights reserved The electric injector operation can be divided into three phases
261. tage Short to Ground see page 125 Front Driver Airbag 2nd Stage Short to Battery see page 125 Front Driver Airbag 2nd Stage Value too low see page 125 Front Driver Airbag 2nd Stage Value too high see page 125 Driver Head Bag Short to Ground see page 126 Driver Head Bag Short to Battery see page 126 river Head Bag Value too low see page 126 river Head Bag Value too high see page 126 Passenger Head Bag Short to Ground see page 126 assenger Head Bag Short to Battery see page 127 assenger Head Bag Value too low see page 127 assenger Head Bag Value too high see page 127 river Knee Bag Short to Ground see page 127 river Knee Bag Short to Battery see page 127 Driver Knee Bag Value too low see page 128 Driver Early Crash Sensor Defective Signal see page 128 Driver Early Crash Sensor Internal Error see page 125 Configuration Mismatch see page 128 Pretensioner Crash Data see page 128 F LO ront Airbag and Pretensioner Crash Data see page 129 river Side Crash Data see page 129 assenger Side Crash Data see page 129 CAN no message see page 129 BCM signal below allowable see page 129 NOS node mute see page 124 OS signal below allowable see page 129 OS node mute see page 129 gb Fiat Grande Punto OK 509 532 2005 Fiat Auto S p A All rights reserved Airbag warning light This function describes how the SDM signals the system status error conditio
262. ted fuel in every single electric injector i e it varies the injection time 3 10 7 Engine jerk prevent check The control unit processes the signals from the various sensors engine revs vehicle speed engine temperature accelerator pedal potentiometer brake and clutch switches and corrects the amount of fuel to be injected in order to improve driveability by reducing the running jerks through the opening time of electric injectors CR1MI2 2 and the amount control valve DRV2 gb Fiat Grande Punto OK 151 532 2004 Fiat Auto S p A All rights reserved 3 10 8 Checking the exhaust smoke level during acceleration In order to reduce the smoke during quick transients the control unit reduces depending on the signals from the accelerator pedal potentiometer the air flow meter and the engine revs the amount of fuel to be injected through pressure regulator DRV2 the injection time of electric injectors CR1MI2 2 3 mn gb Fiat Grande Punto OK 152 532 2004 Fiat Auto S p A All rights reserved 3 10 9 Exhaust gas recirculation E G R check According to the EURO 3 4 anti pollution regulatory standard the control unit reduces depending on the engine load and the signal from the accelerator pedal potentiometer the amount of sucked fresh air by partially sucking the exhaust gas through the adjustment of the electric E G R valve opening gb Fiat Grande Pu
263. ter one safety potentiometer Operation The sensor is made up of a frame secured to the accelerator pedal support which incorporates a shaft placed in an axial position and connected to the dual race potentiometer A helical spring fitted onto the shaft ensures proper compressive strength whereas one further spring ensures the return when releasing Operating range 0 to 70 mechanic stop at 88 Electric features 1 2 1 ECM 2 Junction 3 Dual accelerator pedal potentiometer f 1 k LC FIAT Ka y gb Fiat Grande Punto OK 267 1 532 O 2004 Fiat Auto S p A All rights reserved Pin out Component Receiving item Receiving Component connector 1 0 S l i l pin item pin pin Potentiometer 2 power l 3 ECM ooo 5 Junction supply from the ECU connector A Potentiometer 1 power l 2 ECM 2 S 4 Junction supply from the ECU connector A 51 ECM Potentiometer 1 signal 8 Junction Accelerator connector A i Potentiometer 1 45 ECM potentiometer 14 Junction ground from the ECU connector A Potentiometer 2 15 ECM 15 Junction ground from the ECU connector A l l l 38 ECM Potentiometer 2 signal 9 Junction connector A Recovery The injection control unit implements the following recovery strategies under the conditions below in case of failure to either potentiometer it allows the throttle to open up to a maximum of 40 over a very long time per
264. the local and driver s side control The rear window actuation is managed both by the local controls one per window and the driver s side controls gb Fiat Grande Punto OK 474 532 2005 Fiat Auto S p A All rights reserved Electric window regulator control mask The driver s side door inner armrest incorporates two or where provided for five switches that allow you to carry out with the starting key turned to position the following operations front left window opening closing front right window opening closing rear left window opening closing where provided for rear right window opening closing where provided for rear door switch control disable where provided for gt gb Fiat Grande Punto OK 475 532 2005 Fiat Auto S p A All rights reserved Fiat Auto S p A ELECTRIC FIAT PUNTO TRAINING OUTLINE i SYSTEM After Sales Training Central window actuation 4 window regulators This function makes it possible to fully close the side windows by one single operation The central locking function can be implemented through the remote control or the door lock latch of the driver s side front door external handle and is actuated only upon key OFF The window central closing opening actuation is not simultaneous for the 4 windows it follows a programmed sequence gb Fiat Grande Punto OK 476 532 2005 Fiat Auto S p A All rights reserved XS 1900
265. the steering column stalk Follow me home actuation Follow me home time increase with both the dimmers and the low beam headlights ON the trip computer will every time the flashing lights are actuated increase the lights ON time by further 30 seconds up to a maximum time of 210 seconds The control for increasing the lights ON time is valid only if less than 7 controls have been provided after the Follow me home function has been last actuated and is still ON Function deactivation keeping the flashing light control for more than 2 seconds causes both dimmers and the low beam headlights to be switched off the lights ON time to be reset and the counter for the 7 valid commands to be reset N B The deactivation control shall not necessarily provided within 2 minutes after key OFF nor shall any of the 7 valid commands to increase the lights ON time It will be valid provided that the follow me home function is ON After deactivation the Follow me home function can be switched on again by actuating the flashing light lever within 2 minutes after key OFF Shifting from key OFF to key ON with the Follow me home function ON will cause the latter to be switched off End of function when the lights ON time expires the Follow me home function will be switched off therefore both the dimmers and the low beam headlights will be switched off gb Fiat Grande Punto OK 488 532 2005 Fiat Auto S p
266. the user TA Traffic Announcements automatic PTY search automatic TP Traffic Program search automatic and manual station search provision for Local Distance control for automatic frequency search storing provision 18 FM stations 6 of which can be stored through the Autostore function 6 MW stations 6 LW stations 6 stations for PTY types of programs FM only Scan mode listening to a station for a short time and shifting to the next station automatically scanning on the used frequency band scanning on the stored channels CD features power driven eject loading pause selection of the next previous track FF F REW TPM Track Program Memory function for 30 CDs of 40 tracks each track scanning function Mix function Track Repeat function CD naming 8 characters for 30 CDs CD display displaying the name of the disc track elapsed time gb Fiat Grande Punto OK 492 532 2005 Fiat Auto S p A All rights reserved printed audio CD CD R and CD RW play CD MP3 player features power driven eject loading MP3 Info function directory UP DOWN selection track UP DOWN selection pause FF F REW track scanning function Mix function random playing of the tracks included in a folder or the entire disc Repeat function repetition of one single track or single folder MP3 display folder ID3 TAG information tr
267. through which the oil sent to the nozzles flows thus ensuring better piston cooling Coupling with the pin is carried out by means of two copper alloy bushings 1 Piston 2 Electric injector 3 Preheating spark plugs 4 Air inlet 5 Exhaust gas outlet FIAT PUNTO 7131532 2004 Fiat Auto S p A All rights reserved 3 2 10 Connecting rods The connecting rods are made of hardened and tempered steel with a copper bushing 1 driven for coupling with piston pin 2 The pins of the float type are retained by two expansion snap rings 3 found in the special slots obtained within the pin housing Coupling between the connecting rod and the cap through machined surfaces To withstand specific pressure values in the 90 HP engine the upper bronze bushings have been modified Refer to the diagram FIAT PUNTO 74 1532 2004 Fiat Auto S p A All rights reserved Con rod bearing New material due to increased specific pressure 70HP 90HP Main bearing lower AS16 AS16 Main bearing upper AS16 AS16 Conrod lower side CL157 CLI57 Conrod upper side Foto TE03043 6 90HP better than 70 HP even if the specific pressure is higher Foto TE03043 1 FIAT PUNTO 751532 2004 Fiat Auto S p A All rights reserved 3 2 11 Camshaft drive The camshaft drive is of the direct type and takes place by means of a chain 1 Driven gear 2 Driving gear 3 Moving shoe 4 Fixed shoe 5 Timing ch
268. thus reducing the system s efficiency The right side of the condenser incorporates the seat for the cylindrical fully integrated dehydrating filter 1 This arrangement makes it possible to optimize the system layout The pollen filter features a rectangular shape It can be replaced by removing the plastic guard located inside the passenger compartment on the passenger s side under the glove compartment EIB gb Fiat Grande Punto OK 520 532 2005 Fiat Auto S p A All rights reserved 10 2 5 Expansion valve The figure below illustrates a sectional view of the expansion valve together with the main components of the same 1 Evaporator outgoing fluid pipe 2 Thermo sensitive element 3 To the compressor intake coupling 4 Pressure fluid 5 Contrast spring 6 Calibrated hole and ball 7 Expanded fluid to the evaporator inlet coupling 8 Valve body 9 Rod C To the compressor F To the dehydrating filter Ei Inlet evaporator Eu Outlet evaporator 10 2 6 Fluids The compressor oil 80 cm is of the ND8 grade type and must not be replaced The amount of the R134A coolant is 500 40 g for all the engine versions The points for connection with the recharge apparatus are different depending on the models in any case they can be easily located 10 3 Operation logic The air conditioner control layout varies according to the body versions heater manual g OO T K TE d g
269. tor motor on the rear door with automatic functioning both during the up and down movement and anti pinch protection The control receives the power supply for ideograph lighting and correct operation of the control itself from the disable control placed on the control board on the driver s side front door 9 2 13 Switch on clutch pedal The clutch pedal signalling switch is fitted to the clutch pedal and is connected through the body to front cable harness It informs the engine management control unit about the pedal Status 9 2 14 Central control board CSS Lil AL C I HT TE T_T ae HSH T 8 ES L A ss OFF 1 PCN The central control board CSS includes the following buttons City button for actuation deactivation of the City mode on the electric drive L LI E 3 FIAT gb Fiat Grande Punto OK 457 532 2005 Fiat Auto S p A All rights reserved ASR deactivation and its respective optical indicator LED on the button door locking unlocking and its respective LED the LED signals the door locking status when the button is pressed and is lit continuously moreover it lights up intermittently to serve as a deterrent when the vehicle is locked from the outside boot opening Hazard button for emergency light blinking ECO button to select the Economy mode versions equipped with robotized gearbox 9 2 15 Left control board ELC
270. ts turned from the structural viewpoint to restraining the passenger compartment deformation and avoiding damage to the fuel tank which may cause fire Child protection Nuova Punto features all the devices that make it possible to ensure the maximum child safety that can be achieved at present Below are the main child safety devices isofix mounts on the rear seats for correct installation of child seats passenger airbag deactivation directly through the trip computer to protect the fitted child seat Description The occupant protection system fitted to Nuova Punto consists of the following components Driver s and passenger s front airbags with dual actuation stage front seat belts with pre tensioner with electronic control and load limiter electronic system for passenger s airbag deactivation Moreover a side protection system is available as an optional item which features two bags on the front seats and two curtain bags in the rails under the roof and two side collision detecting sensors gb Fiat Grande Punto OK 496 532 2005 Fiat Auto S p A All rights reserved The protection system also benefits from the collapsible steering column support and the special seat design that allows part of the energy to be absorbed during both head on and side collisions Moreover Nuova Punto features front seat headrests with heightwise control and lowering lock combined with the new bio mechanic antiwhiplash s
271. tyres 17 Side skirts Leather sports steering wheel perforated central rungs and coloured seams Special measuring instrument Sports design front seats greater restraint Car radio CD player Air conditioner Below are other optional items Knee airbag Window bag Side bag Front seat anti whiplash whiplash restraint Rear electric window regulators 5 door versions Front armrest Electric lumbar adjustment Automatic air conditioner Cruise control Rain sensor Parking sensor Tyre pressure sensor TPMS Leather upholstery Alloy wheel rims different designs and dimensions Skydome sunroof Rear spoiler Bumper bands Car radio CD MP3 player Hi fi system Kit Bluetooth Headlamp washer 6 speed gearshift 1 3 Multijet 16V 90 HP 1 2 4 Engines Below are the engines fitted to the vehicle at the commercial launch PETROL ENGINES 1 2 8V 65 HP 1 4 8V 75 HP DIESEL ENGINES 1 3 Multijet 16V 75 HP 1 3 Multijet 16 V 90 HP 1 9 Multijet 8V 120 HP 1 2 5 Gearbox Nuova Punto comes with four types of gearbox which ensure when properly optimized excellent gear control actuation and very high operation smoothness GEARBOX NO OF SPEEDS ENGINE 1 2 8V and 1 4 8V B 1 3 Multijet 16V 75 and 90 HP 1 3 Multijet 16 V 90 HP option 8 1 9 Multijet 8V 120 HP 1 2 6 Range DA b e n DIESEL PETROL ENGINES ae ore mem en weg eme are E weg Tam maer Taar mm
272. ular conditions e g pressing the brake or clutch pedal If the gearbox is of the mechanic type it is recommended that the same speed previously selected is maintained If a speed value has not yet been stored into the memory or the vehicle conditions do not permit this pressing the button will produce no effect at all ON OFF function this function makes it possible to actuate and deactivate the Cruise Control system by actuating the ring switch Manual switch off Main ring switch set to OFF engine switch off or key OFF action on the brakes including the handbrake the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button action on the clutch the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button request for gear shift through the lever with the Dualogic gearbox unit in the manual mode the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button vehicle speed below the established minimum value 40 k p h the latest set speed will remain stored in the memory it can be recalled by pressing the resume RES button action on the accelerator in this case the system will not be actually switched off yet the request for acceleration will take priority over the system thus allowing the manoeuvre requested by the driver In any cas
273. ved 67 532 3 2 4 CYLINDER HEAD The cylinder head is of the single structure type and is made from aluminium and silicium alloy Two overhead camshafts made of ductile cast iron are housed within an overhead the drive is of the combined chain gear type The four valves per cylinder parallel and vertical are located in their respective guides and driven by rocker arms actuated by the cams of the cam axles and kept into contact with the valves by means of hydraulic tappets The valve guides are driven into the respective cylinder head housings by interference The inner diameter is optimized after assembling by means of a special boring machine Compared with the cylinder heads with precombustion chamber the entire combustion process takes place in the combustion chamber obtained on the piston The gasket between the cylinder head and the engine base is made of metal moreover the cylinder head shall not be retightened during the entire engine life On the versions fitted with the 90 HP engine the combustion system has been necessarily modified in order to improve the input and output flows The inlet duct design has been modified by increasing the flow capacity at the same time volumetric efficiency at high speeds has been improved following a reduction of the swirl level The combustion chamber design has been modified by increasing the chamber diameter and as a result reducing the compression ratio from 18 1 to
274. ven in case of failure Operation The accelerator pedal position is converted into an electric voltage signal and sent to the Injection control unit from the potentiometer connected with its respective pedal The accelerator pedal position signal is processed together with the revs number data to obtain the injection time and pressure S gb Fiat Grande Punto OK 182 532 2004 Fiat Auto S p A All rights reserved Type of Pin Name di signal Race 2 power 1 Input 5 V supply Race 1 power 2 Input 5 V supply 3 Race 1 ground Ground Analog 4 Race 1 signal output 5 Race 2 ground Ground Analog 6 Race 2 signal output Technical features of the Bosch sensor Supply voltage 5 V 0 3 V Resistance at the potentiometer cursor terminals 1 KQ 0 4 KQ Race 1 resistance 1 2 KO 0 4 KQ Race 2 resistance 1 7 KO 0 8 KQ Technical features of the hella sensor Supply voltage 5 V 0 3 V Resistance at the potentiometer cursor terminals 1 KO 0 4 KO Race 1 resistance 0 9 KQ 35 1 4 KQ 35 Race 2 resistance 1 2 KQ 35 2 0KQ 35 gb Fiat Grande Punto OK 183 532 2004 Fiat Auto S p A All rights reserved 3 13 VGT solenoid valve LC rd a Ill Q E e B D wm 50 60 MW 80 wg 100 a Pim Duri ie 1 Solenoid valve Rated voltage 12 V ELECTRIC FEATURES OF Operating voltage range 10 16 V THE ACTUATOR Control signal PWM modulated square wave Modulat
275. ves the regulator in order to obtain optimum line pressure 3 10 18 Electric balance check The control unit varies the idling speed depending on the battery voltage it increases the injection time of electric injectors CR1MI2 2 it controls the line pressure by means of the pressure regulator DRV2 e ES KC gb Fiat Grande Punto OK 161 53 2004 Fiat Auto S p A All rights reserved 3 10 19 Electric fan check Depending on the engine water temperature and the coolant pressure in the air conditioning system the control unit drives the actuation of the electric fans to the first or second speed S gb Fiat Grande Punto OK 162 532 2004 Fiat Auto S p A All rights reserved 3 10 20 Cruise Control system check where available Depending on the position of the Cruise Control control lever the control unit directly controls the amount of injected fuel to control and keep the vehicle speed stored in the memory A warning light actuated by the control unit on the dashboard indicates the system s operation or deactivation state The Cruise Control is temporarily disabled by pressing the brake pedal by pressing the clutch pedal the speed stored in the memory will be resumed by pressing the Resume button The Cruise Control will not be disabled in case heavy acceleration is requested e g when overtaking and will resume the vehicle s set speed as soon as the accelerator pedal i
276. vs 8 500 number of pistons 5 minimum displacement 0 cm rev maximum displacement 126 cm rev amount of lubricant 80 cm gb Fiat Grande Punto OK 518 532 2005 Fiat Auto S p A All rights reserved TT HECK L musi E LF el The compressor is made up of 5 pistons 1 secured to an oscillating plate 2 The pistons move inside the cylinders obtained in the compressor body and are set moving by the plate oscillations The plate motion is generated by the rotation of the propeller shaft 3 The latter is made to rotate by the pulley connected to the engine by means of the auxiliary member belt The coolant flow rate is controlled by varying the compressor displacement and also the inclination of the rod holder plate 2 gb Fiat Grande Punto OK 519 532 2005 Fiat Auto S p A All rights reserved 10 2 4 Filters and condenser The condenser is a heat exchanger located in front of the engine cooling radiator The coolant at the gaseous state flows through the condenser pipes and is liquefied at a temperature of 60 C on average The condenser is skirted by the external air generated by the vehicle motion When the vehicle is stationary or runs slowly in a column or queue the air flow is generated by the engine radiator fan Insufficient thermal exchange in the condenser will cause the pressure to increase in the system and the coolant to be condensed only in part
277. w engine revs number and small exhaust gas amount 2 High engine revs number and large exhaust gas amount FIAT PUNTO 83 532 2004 Fiat Auto S p A All rights reserved 3 2 17 Inlet manifold The air capacity box made of plastic material receives pressure air cooled by the intercooler and conveys the same directly to the cylinder head The overpressure sensor connected to the injection control unit is fitted onto the box A diffuser is positioned at the manifold intake which is used to let in the exhaust gas from the E G R valve and flowing toward the cylinders 3 2 18 Exhaust pipes and silencer The engines exhaust gas flows through the manifold to the turboblower and next to the oxidizing catalytic converter 1 A flexible element 2 is found in the front part of the exhaust pipe which is used to reduce the transmission of vibrations The rear exhaust section is made up of a intermediate pipe 3 and a rear silencer 4 Special guards reduce heat diffusion toward the body The various components are supported by means of special supports 5 and snap rings 6 secured to the underbody FIAT PUNTO 84 532 2004 Fiat Auto S p A All rights reserved 3 2 19 Exhaust emission control system 3 3 Catalytic converter The oxidizing catalyst is a post treatment device to oxidize the CO HC s and particulate so as to transform the same into carbon dioxide CO2 and water vapour H20 The c
278. weight and rating of the various engine versions 1 2 8V engine version front solid disc diameter 257 x 12 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 43 cm rear drum diameter 203 mm 1 4 8V amp 1 3jtd 70 HP engine version ventilated front disc diameter 257 x 22 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 43 cm rear drum diameter 228 mm 1 3jtd 90 HP engine version ventilated front disc diameter 284 x 22 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 52 cm rear drum diameter 228 mm 1 9 jtd 120 HP engine version ventilated front disc diameter 284 x 22 mm Bosch ZOH brake calipers with piston diameter of 54 mm brake pad surface area 52 cm Bosch BIR II brake caliper solid disc 264 x 11 mm 6 2 Power brake Nuova Punto features a 10 power brake with 15 16 pump and tank Be Kl gb Fiat Grande Punto OK 347 532 2005 Fiat Auto S p A All rights reserved 6 3 Pedal unit Il EU CA sa l Nuova Punto incorporates a pedal unit with plastic supports which includes the brake clutch and accelerator pedals The accelerator and clutch pedals are made of plastic The pedal unit features a device that allows the brake pedal to collapse in case of collision thus minimizing its penetration into the passeng
279. write them down on the new vehicle panel gb Fiat Grande Punto OK 422 532 2005 Fiat Auto S p A All rights reserved Other functions Clock As regards the Mode and Comfort panels the hour minute indication will always be available both upon key ON and key OFF As regards the Matrix panel the hour minute indication will be available only upon key ON the clock will not be displayed upon key OFF Time setting as an item of the set up menu As regards the Comfort and Matrix panels the 24 h 0 23 h or 12 h 1 12 h mode can be selected from the set up menu The AM and PM indications will not be displayed As regards the Mode panel only the 24 h mode can be displayed since the respective set up menu item is not available Headlamp trim correction C A F The headlamp trim correction function provides for 4 preset vertical headlamp orientation These positions can be obtained by pressing the CAF light beam raising and CAF light beam lowering buttons an electric motor connected inside the headlamp causes the reflectors to be rotated automatically The current headlamp position is signalled on the vehicle panel by the headlamp inclination icon and the corresponding number 0 to 3 The C A F buttons are active only when the key is ON and the low beam headlamps have been switched on Upon key OFF the function is disabled and the vehicle panel memorizes the position of t
280. y one further wiping every 6 seconds to remove dripping In the event that the rear window wiper has already been actuated prior to actuating the washing control through the lever the smart washing logic will only be performed to actuate the same in the intermittent mode K gb Fiat Grande Punto OK 442 53 2005 Fiat Auto S p A All rights reserved Front right engine compartment ground PE STITT LO 6003 6001 AAA ee PTT TTT TET TTT TT S Co Engine compartment control unit CVM Headlamp n washina nimn N H Power supgly fran F32 115 21 i 15 90 N Windscreen wiper motor HN 8 35 25 115 relay coil 35 ninuy 0 gt un Wl YN 0 Ka LE O pam lt l lt a We O lt 2 LL LO CN 2 5 HG ZEN G 5Y Steering column stalk 2 5H Rear wiper Body Computer node NBC n digital input NO AGAD 29 H D 3 relay cail Law side driver v q 22 digital input 0 GND w d 24 digital weg NO GOND CSM Reference Ground N Bi directional pl PolteGHona pump Left side dashboard area ground LO o m 154 315 1 5 8 BI supply fron F42 123b re 15 56 St DIS D I apply fron T21 F61 st G 5 set fron FAZ 1299 H st Hz supply fron 437 125 87 Ke wpply fron 3497 Teo 873 FRONT CABL BODY TO FRONT CABLE o LL o ya LD 4 K i o o La 3 Ww w LL z Rear left headlamp area ground 2 S _ 007 ee AA 9 o H EELER o
281. ystem optional item This system comes into operation in case of a collision following the heavy load transfer caused by the occupant s body pushing against the seat back after the crash and allows the headrest to further draw near the occupant s head so as to soften the bump gb Fiat Grande Punto OK 497 532 2005 Fiat Auto S p A All rights reserved Driver s side knee bag Passengers side front airbag P Spiral cable CVS Airbag control unit ground man IHI FRE pia l m Level 1 Be dirar m24 H B S dp AEE E i R a x x Laval 2 Bag driver Airbag node Early crash sensor ECS R er e DND T19 Web SE D L e T 05 AS B RE RE ETE h 3 A Tlo 5 GM W TIbefb W T5 8 5 1 Passenger s side pretensioner h in ininin CEA SE DO Da cn En L DEE Pe E S S x min n in DE GS es Drivers side En head airbag Driver s side pretensioner gb Fiat Grande Punto OK 498 532 2005 Fiat Auto S p A All rights reserved 9 7 2 Smart 2 airbag system The vehicle occupants are protected during head on collisions by an innovative restraint system called Air Bag Smart 2 which is capable of adapting the actuation parameters automatically depending on the seriousness of the accident Driver s and passenger s front airbags with dual actuation stage in fact the current restraint systems are inevitably dimensioned to guarantee adequate protection only

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