Technical Official Fiat Solutions

[koalar]

​

all 1.2 8v versions 1056 1 801 RA INJECTION CONTROL UNIT Vehicle cutting out irregularly - Service Solution FAULT COMPLAINED OF​ With the vehicle stationary or almost stopped, the engine cuts out on release when loads are switched on (air conditioning compressor) TECHNICAL CAUSE​ Engine management control unit software calibration. OPERATIONS IN PRODUCTION​ Control unit calibration setting. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organization No. all versions in question Tychy - 507195 00243013 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -When this problem is reported and confirmed, reassure the Customer that it can be solved by a reprogramming operation.-After the operation show the Customer what has been done and make sure they are satisfied. SERVICE SOLUTION​ If this problem is reported and confirmed, carry out the reprogramming with the new software (CD Flash 4.50 or higher) as described in the Operating Cycle below. OPERATION CYCLE​ If this problem is reported, carry out the reprogramming using the Examiner with release 6.40 (or higher) using the CD FLASH 4.50 (or higher). It should be remembered that, for the programming, the vehicle battery must be fully charged or supported by a battery charger/additional battery in order to guarantee the rated voltage of 12V. AVALABILITY OF PARTS​ Version Description Part No. Qty. all versions in question CD Flash 4.50 1806574000 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 1056180 1 RA - .30

 

[koalar]

​

Version: 500, Panda (169) and Grande Punto with 1.2 8 V and 1.4 8/16 V engine 1048 0 000 AA ENGINE STARTING Long/difficult starting and/or irregular idle - Network Information FAULT COMPLAINED OF​ Long and difficult starting and/or irregular idling. TECHNICAL CAUSE​ Fouling of the combined sensor and of the intake duct. OPERATIONS IN NETWORK​ Once the customer's claimed fault is confirmed, before any repair and/or replacement operations, carry out the controls described hereby and restore the correct operating conditions of the intake circuit, according to the Operating Cycle below. OPERATION CYCLE​ Check the correct operation of the intake circuit components, proceeding as follows. Check the correct conditions of the earth connections of the power unit - C002, C003, C012, C040, C060 - disconnecting and carefully cleaning their fastening seats, with reference to the Service Manual, Electric System E1020 EARTHS and Repair Procedures. Check the conditions of the battery, with reference to SN 55.05.11. Restore its correct conditions or replace it, if damaged. Check the engine oil level. Check the conditions of the throttle body and carefully clean it if fouled: for removal and installation, refer to Op. 1056B15 of the Service Manual. Check the correct operation of the intake air temperature/pressure sensor, with reference to Test 1056BU. If necessary, remove and carefully clean it or replace if damaged, with reference to Op. 1056B54 of the Service Manual. Use the diagnosis equipment, in Parameter function, to check the correct operation of the switch on the clutch pedal. If necessary, restore its correct operating conditions or replace it if damaged, with reference to Op. 1056B78 of the Service Manual. Use the diagnosis equipment, in Parameter function, to check the correct operation of the potentiometer on the accelerator pedal. If necessary, restore the correct operating conditions or replace the accelerator pedal, if it is damaged, with reference to Op. 1068A20 of the Service Manual. Use the diagnosis equipment to check the correct intake pressure with idle speed, without any load engaged. If it ranges between 290 mbar and 330 mbar, the value is correct. Otherwise, proceed as below described: check that there are no air leaks from the intake manifold, with reference to Op. 1072B10 of the Service Manual. If required, restore its correct operating conditions. make a compression test. check whether the timing system works properly, with reference to Op. 1072B10 of the Service Manual. If required, restore its correct operating conditions. for 1.2 8v engine only, check that the tappet clearance is correct, with reference to Op. 1036H14 of the Service Manual. The correct values are the following: Intake valve clearance in closed position - 0.3 mm; Exhaust valve clearance in closed position - 0.4 mm; If necessary, restore the correct values. Using the diagnosis equipment, reset the adaptive parameters and make a new self-learning; test the vehicle and check whether the fault occurs again. If the fault persists, replace the throttle body, with reference to Op. 1056B15 of the Service Manual. During refitting, replace: seals, oil seal rings, spring washers, safety plates, self-locking nuts, pretreated screws and shear bolts.

 

[koalar]

​

All 1.2 8v Petrol and 1.2 8v Natural Power, 1.1 8V models 1056 2 051 RA INJECTION CONTROL UNIT Injection system/engine control failure warning light on with Examiner Errors P0351-P0352 - Service Solution Cancels and replaces SN 10.32.10 of 03/05/2011. FAULT COMPLAINED OF​ The injection system/engine control failure warning light switches on. Examiner shows the presence of one or both the following errors: -P0351 - Coil 1-P0352 – Coil 2 TECHNICAL CAUSE​ Electromagnetic interference / non-optimal injection ECU software calibrations. OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -Once the customer's claimed fault is confirmed, reassure the Customer that the fault will be solved by reprogramming injection control unit software.-After the intervention, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ Once the customer's claimed fault is confirmed, reprogramme the injection ECU using the new software (WEB Flash 8.13.0 or higher) as shown in the following Operating Cycle. OPERATION CYCLE​ Once the Customer's claimed fault is confirmed, use Examiner or Witech + (Examiner Emulator) release 8.20.2 (or higher) to reprogramme the injection ECU using the WEB Flash 8.13.0 (or higher) available from Examiner Web. To reprogramme, the car battery must be fully charged or supported by a battery charger/booster battery, so as to guarantee the rated voltage of 12 V. Control unit codes​ The following information is available on Examiner WEB as well. The following tables show the hardware (HW) and software (SW) codes of the Magneti Marelli IAW 4AF/4EF/59F/5AF EOBD injection control unit, before and after reprogramming. 1.1 8V Petrol Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20B8W5Q 0000 IAW4AFHW407 00 20B8W5S 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBW5T 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20B8WFQ 0000 IAW4AFHW407 00 20B8WFS 0000 IAW4AFHW407 00 20BBWFT 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBWFU 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B6W5E 0000 IAW5AFHW607 00 20B6W5J 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B8W5R 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B6WFE 0000 IAW5AFHW607 00 20B6WFJ 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B8WFR 0000 1.1 8v Petrol ECO (France) Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBWR0 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBWRP 0000 1.2 8v Petrol Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20B8W6E 0000 IAW4AFHW407 00 20B8W6G 0000 IAW4AFHW407 00 20B8W6H 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBW6L 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20B8WHE 0000 IAW4AFHW407 00 20B8WHG 0000 IAW4AFHW407 00 20B8WHH 0000 IAW4AFHW407 00 20BBWHM 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BCWHN 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B6W61 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B8W6F 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B6WH1 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW5AFHW607 00 20B8WHF 0000 Before programming, the control unit must have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BBWHL 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW4AFHW407 00 20BCWHP 0000 1.2 8v Natural Power Before programming, the control unit must have the following data HW number HW version SW number SW version IAW5AFHW603 00 21BAWG3 0000 After programming, the control unit will have the following data HW number HW version SW number SW version IAW5AFHW603 00 21BBWG4 0000 CLAIM REPORT DATA​ Version Operation Part Fault Position Time allowance All models in question 1056205 1 RA - 0.30

 

[koalar]

​

All 1.2 8v and 1.4 8v models, excluding LPG and methane versions - Idea, 500, Panda, Grande Punto, Punto Evo, Linea, Doblò (119 / 223) 1080 1 581 BC OIL VAPOUR RECIRCULATION PIPE Engine oil vapour recovery pipe (blow-by) deterioration - Service Solution Cancels and replaces SN 10.33.10 of 10/11/2010. FAULT COMPLAINED OF​ Smell coming from the engine compartment. TECHNICAL CAUSE​ Deterioration of the engine oil vapour recovery pipe (blow-by), causing leaks and smell. OPERATIONS IN PRODUCTION​ On 500, Panda, Grande Punto and Punto Evo models: implementation of a new engine oil vapour recovery pipe (blow-by), with improved features; for the other models, the pipe path has been improved. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organisation No. 500 Tychy - 534957 7174858 Panda Tychy - 1736150 3198462 Grande Punto Punto Evo Melfi 1 667046 1656356 Grande Punto Punto Evo Melfi 2 1656281 1656352 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -Once the claimed fault is confirmed, reassure the Customer that the fault will be solved by fitting a new engine oil vapour recovery pipe (blow-by) with improved features.-After the operation, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ Once the customer's claimed fault is confirmed, replace the engine oil vapour recovery main pipe (blow-by), then check the engine oil vapour recovery pipe at idling speed and, if damaged, replace it according to the Operating Cycle below. OPERATION CYCLE​ Cycle a - replacement of the oil vapour recirculation pipe (blow-by)​ -Remove the air filter with cold air intake (A - Fig. 1) operating as described in Op. 1048A10 of the Service Manual;-Loosen the retaining bands (1) and remove the oil vapour recirculation pipe (2) operating as described in Op. 1080D22 or 1080D24 of the Service Manual.-Loosen the fixing band and disconnect the engine oil vapour recovery pipe (3) at idling speed. Fig. 1 -Install the new engine oil vapour recovery pipe (blow-by), from the Spare Part Dpt., connecting it to the tappet cover and to the air filter and secure it with the bands.-Refit the air filter with cold air intake (A - Fig. 1) operating as described in Op. 1048A10 of the Service Manual. Check the conditions of the pipe (2 - Fig. 2) for engine oil vapour recovery at idling speed and, if damaged or worn, replace it, as described in the following cycle B. Cycle b – replacement of the engine oil vapour recovery pipe at idling speed​ If the engine oil vapour recovery pipe at idling speed is damaged or worn, replace it operating as described. -Open the clip (1 - Fig. 2) retaining engine oil vapour recovery pipe at idling speed.-Disconnect the engine oil vapour intake pipe (2) from the intake chamber, with reference to Op. 1080D of the Service Manual. Fig. 2 -Install the new engine oil vapour recovery pipe at idling speed, taken from the Spare Parts Dpt., connecting it to the intake chamber, with reference to Op. 1080D of the Service Manual. AVALABILITY OF PARTS​ Version Description Part No. Q.ty All models in question Engine oil vapour recovery pipe (blow-by) 71769083 1 All models in question Engine oil vapour recovery pipe at idling speed 51777763 1 CLAIM REPORT DATA​ Version Operation Part Fault Position Time allowance All models in question - Cycle A 1080158 1 BC - 0.25 All models in question - Cycle A + B 1080161 1 BC - 0.35

 

[koalar]

​

All models, 1.2 8v Petrol Euro 4, Natural Power and LPG 1032 1 171 KB TIMING CONTROL BELT PROTECTIVE COVER Overheating - Service Solution Cancels and replaces SN 10.14.10 of 02/04/2010 through the addition of new contents. FAULT COMPLAINED OF​ The Customer complains of one or more of the following problems: 1 - Overheating marks on the timing control belt cover, next to the heat shield of the exhaust manifold. 2 - Occasional hard starting with rpm sensor error (P0335). 3 - Switching on of insufficient engine oil pressure warning light. TECHNICAL CAUSE​ In especially hard utilisation conditions, the heat shield thermal insulation could be inefficient, causing one or more of the claimed faults. OPERATIONS IN PRODUCTION​ Application of an additional heat shield on the timing cover. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organisation No. All models in question Natural Power versions Tycky - 1570204 - All models in question LPG versions Tycky - 1570197 3155129 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -Once the customer's claimed fault is confirmed, reassure the Customer that it can be solved by fitting an additional heat shield on the timing cover.-After the operation, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ If the claimed fault is confirmed, apply an additional heat shield on the timing cover and, if required, restore the correct conditions of the electric cables for rpm sensor, engine oil insufficient pressure switch and of the timing control protective cover, according to the Operating Cycle below. OPERATION CYCLE​ Position the vehicle on the lift: - disconnect the negative battery terminal. - remove the timing control protective cover, with reference to Op. 1032D12 of the Service Manual and, if it is damaged, replace it with a new one from the Spare Part Dpt. - check the conditions of the rpm sensor and of the engine oil insufficient pressure switch cables: -if they are intact, engage the cables in the places inside the protective cover and apply a heat shield, contained in the kit no. 55229609 from the Spare Part Dpt., as described in cycle C.-if the cables are damaged, repair the wiring, by the kit no. 55231912 from the Spare Part Dpt., as described in cycle A: for the wiring of the engine oil low pressure switch, as described in cycle B: for the wiring of the rpm sensor. Then, apply the heat shield, as described in cycle C. Cycle A - Repair of the wiring for the engine oil low pressure switch -disconnect the electrical connection for the engine oil low pressure switch (1 - Fig. 1);-remove the insulating tape and take out from the corrugated sheath (2) the cable for the engine oil insufficient pressure switch; Fig. 1 -cut the cable (1 - Fig. 2) for the engine oil insufficient pressure switch at about 100 mm from the branch;-strip the cable end on the branch side by about 10 mm, as shown. Fig. 2 -complying with Op. 5590B01 or 5590B04 of the Service Manual: connect to the engine oil insufficient pressure switch the harness (1 - Fig. 3) available in the kit, by the junction thermal shrinking tube (2) in the same package.-engage the cable for the engine oil low pressure switch inside the corrugated sheath and engage the same, by insulating tape, in the corrugated sheath (3) of the engine pre-wired cable branch. Fig. 3 Cycle B - Repair of engine rpm sensor wiring -disconnect the electrical connection for the engine rpm sensor (1 - Fig. 4); Fig. 4 -then cut the cable (1 - Fig. 5) of the rpm sensor at about 190 mm from the branch;-fit the section of thermal shrinking sheath (2) available in the kit in the cable section connected to the engine pre-wiring;-strip the cable end by about 40 mm, as shown in figure and divide the shielding braid from the signal cables. Fig. 5 Working on Natural Power versions -strip by about 10 mm the signal cable ends and, complying with Op. 5590B01 or 5590B04 of the Service Manual: connect the signal cables (1 - Fig. 6) of the harness available in the kit and the shielding braid (2), by the thermal shrinking junction tubes in the same package. Fig. 6 -Wrap the area concerned with the operation with the sticky aluminum sheet (1 - Fig. 7) available in the kit, to restore the harness shielding. Fig. 7 Working on Petrol and LPG versions -strip by about 10 mm the signal cable ends and, complying with Op. 5590B01 or 5590B04 of the Service Manual: connect the signal cables (1 - Fig. 8) of the harness available in the kit and cut the excess of the shielding braid (2), in the wiring inside the repair kit. Fig. 8 Working on all versions -slide the section of thermal shrinking sheath (1 - Fig. 9), until symmetrically covering the junction area;-use a drier to heat the sheath so that it moulds on the harness and makes a perfect seal. Fig. 9 -engage, by insulating tape sections, the two harnesses of the rpm sensor and of the engine oil insufficient pressure switch, then engage them in the relevant places on the protective cover.-connect the electrical connections to the engine rpm sensor and to the engine oil insufficient pressure switch.-then, install the heat shield kit carrying out the following Cycle C. Cycle C - Application of the heat shield kit on the timing control protective cover. -undo the fixing screws and nuts and move the exhaust manifold heat shield to one side, as shown in Fig. 10. Fig. 10 -undo the lower screw (1 - Fig. 11) of the timing belt protective sheet;-position the heat shield (2) available in the kit, as shown;-Fasten the heat shield with the fixing screw (1) for the previously removed sheet Fig. 11 -manually shape the heat shield (1 - Fig. 12) on the timing belt guard, as shown;-fasten the heat shield to the timing belt guard fin, using the screw (2) available in the kit. Fig. 12 -Position again the exhaust manifold heat shield in place and tighten the fixing bolts and nuts.-Complete the refitting operations for the removed components, with reference to Op. 1032D12 of the Service Manual,-Connect the negative battery terminal; Remove the vehicle from the lift. AVALABILITY OF PARTS​ Version Description Part No. Q.ty All models in question Upper protective cover 55192315 1 All models in question Lower protective cover 55193759 1 All models in question Heat shield kit 55229609 1 All models in question Kit with harness for insufficient oil pressure switch + rpm sensor 55231912 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance All models in question 1032118 (*) 1 KB - 0.90 (*) All models in question 1032117 (**) 1 KB - 1.20 (**) (*) Operation Code and Time allowance for: -timing control protective cover replacement;-heat shield application. (**) Operation Code and Time allowance for: -timing control protective cover replacement;-repair of wiring for engine rpm sensor and for engine oil insufficient pressure switch;-heat shield application.

 

[koalar]

​

all 1.1 8v and 1.2 8v versions (Seicento - Panda - Punto - Palio/Strada - Doblò) 1084 B 300 AA ENGINE OIL FILTER Network Information As already stated in the Parts Catalogue, starting from engine number 1890665 (for 1.1 8v engines) and from September 2003 (for 1.2 8v engines) on the models in question, in order to standardize them with the 1.2 16v engines, a special oil filter no. 46544820 has been fitted replacing the previous version no. 46808398. The new oil filter differs from the previous one through the different dimensions (see table), in particular through the seal (1 - Fig. 1). Fig.1 Part A B Gasket Inner diameter Outer diameter Pre-modification filter no. 46808398 77.9 mm 68 mm 62 mm 72 mm Post-modification filter no. 46544820 68.5 mm 85 mm 54 mm 62 mm The two filters (new and previous) are not interchangeable and, in the case of replacement, the specific filter must be used depending on the version (pre or post modification). It should be pointed out that the correct number and the use of the new oil filter is indicated in the Parts Catalogue and can be identified by the modification code C/D 7145. THE USE OF THE INCORRECT FILTER MAY RESULT IN OIL SEEPAGE/LEAKS.

 

[koalar]

​

versione: all 1.1 and 1.2 8v versions 1056 1 741 RA POTENTIOMETER ON THROTTLE CASING Irregular idling - Service Solution FAULT COMPLAINED OF​ If the engine is idling and the gear lever is in neutral, when the accelerator pedal is pressed and released the idle speed stabilizes at around 2000-3000 rpm or it fluctuates repeatedly. TECHNICAL CAUSE​ Fault produced by the throttle casing throttle potentiometer signal. OPERATIONS IN PRODUCTION​ Fitting of throttle casings with improved throttle potentiometer. IMPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis n. Organization n. all versions in question Poland - 189965 1105703 OPERATIONS IN NETWORK​ Network behaviour standards towards the Customer .When this problem is reported and confirmed, reassure the Customer that it can be solved by checking the injection system and, if necessary, replacing the throttle casing potentiometer..After the operation, show the Customer the work that has been done and make sure that they are satisfied. Service Solution: If this problem is reported and confirmed, check the condition of the injection cable loom connector on the potentiometer and the continuity/tightening of the earth on the injection control unit. If no faults are found, replace the throttle casing potentiometer as described in the Operating Cycle below. OPERATING CYCLE​ -Disconnect the battery negative terminal.-Detach the air filter assembly.-Remove the throttle casing (Op. 1056B14). The fixing bolts and the seal with the intake manifold should be scrapped. -Clean the throttle casing.-Place the throttle casing in a vice with protection.-Take the extractor (A - Fig. 1) from the tool kit (no. 1871008200). Fig. 1 A Tool for extracting potentiometer B Tool for fitting potentiometer -Fit the extractor on the potentiometer (Fig. 2). The extractor tool should be in contact with the throttle casing and properly inserted in the potentiometer connector.Fig. 2 -Tighten using the special spanner (Fig. 3).Fig. 3 -Extract the potentiometer (Fig. 4).Fig. 4 -Clean the potentiometer housing.-Fit the potentiometer with the seal on the throttle casing shaft.-Rotate the potentiometer so that it engages on the shaft. Fit the potentiometer matching the projection, on the opening (A - Fig. 5), with the flat part of the shaft (B - Fig. 5). Fig. 5 -Rotate the potentiometer slightly so that the tooth enters the splining on the throttle casing as illustrated in Fig. 6.Fig. 6 -Lock the potentiometer on the throttle casing proceeding as described belowosition the tool (B - Fig. 1) (no. 1871008200) on the potentiometer;-tap gently using a hammer (Fig. 7) until the tool is not in the end of travel position.-Release the fitting tool (B - Fig. 1).Fig. 7 -Refit the throttle casing after having replaced the seal with the one in the potentiometer kit using the new bolts supplied with the kit.-Refit the air filter.-Reconnect the negative battery terminal. Any time the potentiometer is removed from the throttle casing it should always be scrapped and replaced. AVAILABILITY OF PARTS​ Version Description Order n. Qty. all versions in question Potentiometer kit (*) 71738921 1 all versions in question Tool kit 1871008200 1 (*) the potentiometer kit comprises: -Potentiometer-Seal between throttle casing and intake manifold.-Throttle casing fixing bolts. CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 1056174 1 RA - .65

 

[koalar]

​

all versions 2125 1 261 L F GEAR ENGAGEMENT/SELECTION CABLES Seizing, hardening - Service Solution FAULT COMPLAINED OF​ Difficult or impossible to engage all the gears TECHNICAL CAUSE​ Seizing of the gear engagement cable due to the deterioration of the (PTF) tube inside the outer casing that guides the steel cable. OPERATIONS IN PRODUCTION​ Fitting of engage engagement/selection cables that conform guaranteed. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organization No. all versions in question Tichy - 554771 267630 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ If this problem is reported and confirmed, reassure the Customer that it can be solved by replacing the gear engagement/selection cables. After the operation show the Customer what has been done and carry out a test to make sure they are satisfied. SERVICE SOLUTION​ Only for vehicles in the batch of chassis from 175913 to 554770, check that the problem reported is due to the gear engagement/selection cables and, if necessary, replace them following the Operating Cycle below. OPERATION CYCLE​ Before replcing the gear engagement/selection cables, check that the hardening of the gear control cable in all gears is confirmed proceeding as described below: A) release the cables on the gearbox side (see Service Manual Op 2125C30) and check that the fault is still present using the gear lever in the passenger compartment. If after having carried out point A) the fault is no longer present, then the cause of the problem should be sought in the gearbox unit and internal controls. B) release the cables on the passenger compartment side (see Service Manual Op 2125C30) and check that the lever in the passenger compartment moves freely for both engagement and selection. If the fault is still present after having carried out point B), carry out a thorough fault diagnosis for the passenger compartment inner control mounting replacing it if a problem is found. C) Replace the gear engagement/selection cables (1 - Fig. 1) with new ones from the Parts Dept. completing the operations already partly carried out in points A and B (refer to the Service Manual - Op 2125C30). Fig. 1 AVALABILITY OF PARTS​ Version Description Part No. Qty. all petrol versions in question Gear selection/engagement cables 55202310 1 all diesel versions in question Gear selection/engagement cables 55234084 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 2125126 1 LF - .95

 

[koalar]

​

Version: all models 4410 1 511 MA FRONT SUSPENSION Noise/knock - Service Solution FAULT COMPLAINED OF​ Knocking type noise while driving, coming from the car front part. TECHNICAL CAUSE​ Too large gap of ball joints for anti-roll bar reaction links. OPERATIONS IN PRODUCTION​ Installation of improved reaction links. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organisation No. All models in question Tychy - 1783113 510632 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ Once the claimed fault is confirmed, reassure the Customer that the fault will be solved by replacing the anti-roll bar reaction links. After the operation, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ Once the customer's claimed fault is confirmed, replace the anti-roll bar reaction links, according to the Operating Cycle below. OPERATION CYCLE​ Position the car on the lift and raise it. With reference to Op. 4410C11 of the Service Manual, perform the following operations working on both sides of the car. Undo the fixing nuts (1 - Fig. 1) for the anchoring link. Remove the link (2) anchoring the end of the anti-roll bar. Replace the removed link with a new one, taken from the Spare Parts Dpt. and secure it by new nuts, taken from the Spare Parts Dpt. Fig. 1 1 - Fixing nuts 2 - Anti-roll bar reaction link Refit the previously removed components. Remove the car from the lift. AVALABILITY OF PARTS​ Version Description Part No. Q.ty All above models, 1.4 16v MY 2009 excluded Reaction link 51856872 2 1.4 16v MY 2009 Reaction link 51856873 2 All models in question Fixing nut 46801948 4 (*) (*) Each pack contains 5 components CLAIM REPORT DATA​ Version Operation Part Fault Location Time allowance All models in question 4410151 1 MA 010-090 1.10 (*) (*) Time allowance for the replacement of both links (left and right)

 

[koalar]

​

Version: all models 5040 1 791 RF AIR CONDITIONING SYSTEM CONDENSER Air conditioning system not very efficient - Service Solution FAULT COMPLAINED OF​ Air conditioning system not very efficient. TECHNICAL CAUSE​ Detachment of the fins from the air conditioner condenser. OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ Once the customer's claimed fault is confirmed, reassure the Customer that it will be solved by replacing air conditioning system condenser. After the operation, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ Once the customer's claimed fault is confirmed, check and, if required, replace the air conditioning system condenser according to the Operating Cycle below. OPERATION CYCLE​ Visually check the air conditioning condenser. In case of corrosions and/or detached fins, replace the air conditioner condenser proceeding as described in Op. 5040A40 of the Service Manual. AVALABILITY OF PARTS​ Version Description Part No. Q.ty 1.4 16v - 1.3 JTD – 1.2 4x4 – 1.3 JTD 4x4 Air conditioning system condenser 51960726 1 1.1 8v – 1.2 8v – 1.4 Natural Power Air conditioning system condenser 51960727 1 CLAIM REPORT DATA​ Version Operation Part Fault Position Time allowance All models in question 5040179 1 RF - 1.30 (*) (*) the time allowance includes the replacement of the condenser plus draining and refilling the air conditioning system coolant.

 

[koalar]

​

Version: 4x4 with manual gearbox 5500 0 000 AA BODY COMPUTER DTC D711 error – Network Information While starting the diagnosis of the Body Computer, due to a special configuration of the Body Computer Proxy, on the 4x4 versions of the model in questions having a chassis number before 1889991, the following DTC error might be found as active: D711 - NCR / NCA Node on C-CAN It is a wrong indication and it should not be taken into account. The presence of this error does not influence the correct operation of the component and of the car. They are still compliant. As a result, no operation is needed; replacement or other service interventions will not be covered by the warranty.

 

[koalar]

​

All models (Saloon and Van) 5540 1 351 TB DIPPED BEAM HEADLIGHTS Failed operation - Service Solution Cancels and replaces SN 55.06.10 of 05/02/2010 for validity extension to currently produced cars. FAULT COMPLAINED OF​ The dipped headlamps do not work. TECHNICAL CAUSE​ Dipped headlamps cable terminals overheating at the body computer connector. OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ Once the customer's claimed fault is confirmed, reassure the customer that it can be solved by restoring the electrical connections for the dipped headlamps. After the operation, show the Customer what has been done and make sure he is satisfied. SERVICE SOLUTION​ Once the customer's claimed fault is confirmed, replace the connector and the two cable terminals for dipped headlamps using the components of kit no. 71745167, following the instructions in the Operating Cycle below. OPERATION CYCLE​ Disconnect the battery negative pole Remove the body computer housing cover from the dashboard Identify the connector B on the body computer (Fig. 1). Fig. 1 Disconnect the 10-pole connector B (Fig. 1) Untape the wiring by about 100 mm (Fig. 2). Fig. 2 Release the secondary lock with lid (1 - Fig. 3) for the connector (2) and open it. With the help of an extractor (3 - Fig. 3) release and take out the terminals (4) from the connector. Fig. 3 Cut the relevant cables: GREY/BLACK cable (1 - Fig. 4) at pin 7 and GREY cable (2) at pin 8, about 50 mm from the metal part of the terminals. Peel the ends of the cables, wiring side, by around 10 mm Fig. 4 Cut the sections of cable (fig. 5), supplied in the kit, about 60 mm from the metal part of the terminals. Peel the ends of the sections of cable by around 10 mm Fig. 5 Insert the thermal shrinking sheath tubes (1 - Fig. 6) in the sections of cable sliding them as far as the terminals, moving them away from the following welding area - which is heat source - to prevent thermal shrinking. Wrap the wiring side and section side exposed lengths of individual cables around one another at the point shown by the arrows and carry out a tin welding. Fig. 6 Place the thermal shrinking sheaths symmetrically on the weldings (Fig. 7). Fig. 7 Heat the thermal shrinking sheaths using a bodywork drier until they have completely shaped onto the cables. Fit the ends of the cables in the new connector, supplied in the kit, making sure that they are correctly positioned as shown in the diagram (Fig. 8). Fig. 8 Pin 1 2 3 4 5 6 7 8 9 10 Cable colour = N S V ZB HG+HG HN H BR A Close the secondary lock (1 - Fig. 9) with lid completely until the fastening teeth can be heard clicking into place. Fig. 9 Tape the wiring in the area of the operation, as far as the connector, using electrician's tape. Before reconnecting the connector, check the conditions of the Body Computer male terminals; if they are damaged, replace the Body Computer (see the Parts Catalogue for the part number). Replace the 10-A fuses (F12 and F13 in Fig. 1) with two new 7.5-A fuses Fit the body computer housing cover in the dashboard Connect the battery negative pole. AVALABILITY OF PARTS​ Version Description Part No. Q.ty All models in question Dipped headlamp connector kit (*) 71745167 1 All models in question 7.5-A fuses 10395990 1 (**) (*) The kit is formed by: no. 1 10-pole grey connector no. 2 cable sections with terminal no. 2 thermal shrinking sheaths (**) Each pack contains 10 fuses CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance All models in question 5540135 1 TB - 0.30 (*) All models in question 5540136 1 TB - 0.40 (**) (*) Time allowance for operation on the connector. (**) Time allowance for operation on the connector plus Body Computer replacement.

 

[koalar]

​

all versions (Cinquecento – Seicento– Panda 141 and 169 – Punto 176 and 188 – New 500 – Grande Punto – Palio/Strada – Idea – Bravo/Brava – Stilo – Marea – New Bravo – Linea – Multipla – Croma - Sedici – Barchetta – Coupé – Ulysse 121 and 179 – Fiorino – Dobló – Scudo 222 and 272 – Ducato 230 – 244 and 250) 5530 B 000 AA BATTERY Battery run down after a stop - Diagnostic procedure FAULT COMPLAINED OF​ Battery run down after a stop. OPERATIONS IN NETWORK​ - After this problem has occurred do not try and start the vehicle using a booster. - The checks listed below must be carried out to ascertain whether the battery is repeatedly run down because of: -excessive current absorption at key off by vehicle electrical system;-incorrect operation of the alternator;-incorrect operation of the battery. Use Midtronics XL505 diagnostic equipment and printer for the fault diganosis of the operating conditions or battery failure. The instrument terminals can be connected directly to the poles of the battery poles, disconnected from the vehicle electrical system. Conversely, for example, taking the measurement with the terminals at the battery control unit (CBA) the reading may be false on account of various contact and cable resistances and therefore the equipment may give an incorrect diagnosis. OPERATION CYCLE​ 1 - Diagnostic procedure for the analysis of the causes of the battery being repeatedly run down. Symptom/Conditions: Failed starting due to battery run down. Diagnosis Step Operations to be carried out Test results 1 CHECK ON BATTERY CONDITIONS ON VEHICLE All OK Problems encountered Operation When the vehicle arrives in the workshop, measure the Loads Outside of the Key (CFC) absorption following the instructions in paragraph 3. If the battery is completely run down, in order to measure the CFC absorption without interrupting the continuity of the electrical circuit a 12V feeder (minimum current 5A) should be placed in parallel to the battery or to another battery (without starting the vehicle). Move on to Step 2 Loads Outside of the Key (CFC) absorption values that do not conform Selective analysis of loads by removing fuses and identification of critical loads for absorption. 2 CHECK ON CONNECTIONS AND BATTERY LEADS CONTINUITY All OK Problems encountered Operation Check the state of the connections and the continuity of the leads between the battery and the alternator; starter motor; engine compartment junction unit; bodyshell earth; engine earth. Move on to Step 3 State of connections and continuity of battery leads do not conform. Replacement/tightening of leads. 3 CHECK ON CONDITIONS OF REMOVED BATTERY All OK Problems encountered Operation Disconnect the battery from the vehicle and carry out the fault diagnosis of the state and conditions following the instructions in SN 55.21.07. - - Battery efficient No operation, refit the batteryin the vehicle and move on to Step 4. Battery efficient, needs recharging Recharge the battery and carry out the final check (as described in SN 55.21.07 - paragraph 3 - Recharging methods) refit the battery in the vehicle and move on to Step 4. Charge / Retest Recharge the battery and carry out a new fault diagnosis (as described in SN 55.21.07 - paragraph 1 - Fault diagnosis of operating conditions or battery faulty) and move on to Step 4. Replace the battery Replace the battery with another one with the same specifications and move on to Step 4. Cell short Replace the battery with another one with the same specifications and move on to Step 4. 4 CFC ABSORPTION MEASUREMENT All OK Problems encountered Operation Measure the CFC absorption (following the instructions in paragraph 3) after each of the 5 - 10 repetitions of the following sequence: Key On - Key Off, door opening and closing Move on to Step 5 CFC absorption values do not conform Selective analysis of loads by removing fuses and identification of critical loads for absorption. 5 ALTERNATOR OPERATION CHECK All OK Problems encountered Operation Alternator supply check (according to instructions in paragraph 2) Move on to Step 6 Alternator supply does not conform. Replace alternator 6 ENGINE WARMING UP All OK Problems encountered Operation Keep the engine idling, at operating temperature, for 20 minutes Move on to Step 7 - - 7 CFC ABSORPTION MEASUREMENT All OK Problems encountered Operation Measure the CFC absorption (following the instructions in paragraph 3) after each of the 5 - 10 repetitions of the following sequence: Key On - Key Off, carried out with the following loads activated: - radio; - interior lighting; - doors open; - air conditioning manually activated (with fans at maximum speed). Vehicles not equipped with CAN: End of diagnosis CFC absorption values do not conform. Selective analysis of loads by removing fuses and identification of critical loads for absorption. Vehicles equipped with CAN: Move on to Step 8 8 CHECK ON SLEEP MODE STATUS - (ONLY FOR VEHICLES EQUIPPED WITH CAN) All OK Problems encountered Operation Check using CAN ANALYZER on EXAMINER starting from release 7.0 of CAN Sleep Mode status. Do not carry out any operations on the vehicle after the launch. No nodes should be activated about 5 minutes after the last Key Off. End of diagnosis Values do not conform. Make a note of the figures and contact Te.Se.O. 2 - Check on alternator operation -CHECK ALTERNATOR TERMINAL "D+" Before taking the measurements, leave the vehicle with the engine off and key off for at least 10 seconds, then: - connect the Examiner in Voltmeter mode with the positive terminal to terminal D+ of the alternator and the negative earthed. - with the ignition on (key on), ensure that the measured voltage is less than 5.5 Volt and that the alternator warning light on the panel is on. - if the voltage is more than 5.5 V then the alternator should be replaced (voltage regulator faulty). - start the engine, keep it above 2000 rpm for more than 3 seconds (activation of fault diagnosis) and return to the idle speed: check that the voltage at D+ is more than 10 Volt and that the recharging warning light in the instrument panel goes out. - if the voltage at D+ is less than 10V and the warning light is on, the alternator should be replaced. - if the voltage at D+ is more than 10V and the warning light is on, check the continuity of the lead from the alternator D+ to the control unit acquiring the D+ signal (body computer or engine management). - if the voltage at D+ is less than 10V and the warning light is off, check the continuity of the recharging lead and the connections between the alternator and the battery. 3 - Procedure for measuring the (CFC) Loads Outside of the Key current absorption. -THE MEASUREMENT OF THE LOADS OUTSIDE OF THE KEY ABSORPTION SHOULD BE CARRIED OUT USING AMMETER PLIERS WITHOUT INTERRUPTING THE CONTINUITY OF THE VEHICLE ELECTRICAL/ELECTRONIC CIRCUIT. The following preliminary operations should be carried out: - Key on (without starting the engine). - Key off. - Open a door (preferably the front driver''s door). - Close the door. Look and check that no consumers are switched on. If the vehicle is equipped with an anti-theft device, keep the bonnet anti-break in button pressed and then place it in the surveillance position. In order to take the measurement it is necessary to wait until all the vehicle electronic control units are in the sleep mode conditions starting with completing the key on/key off manoeuvre and subsequent door transition. The table below contains the waiting times for the various models. Vehicle Time [TR] [TD] Fiat Cinquecento

[TD]
180[/TD]

[TR]
[TD]
Fiat Seicento[/TD]

[TD]
60[/TD]
[/TR]
[TR]
[TD]
Fiat Panda[/TD]

[TD]
180[/TD]
[/TR]
[TR]
[TD]
Fiat Idea[/TD]

[TD]
120[/TD]
[/TR]
[TR]
[TD]
Fiat Palio (FL 2)[/TD]

[TD]
60[/TD]
[/TR]
[TR]
[TD]
Fiat Punto[/TD]

[TD]
60[/TD]
[/TR]
[TR]
[TD]
Fiat Grande Punto[/TD]

[TD]
180[/TD]
[/TR]
[TR]
[TD]
Fiat Stilo (FL)[/TD]

[TD]
120[/TD]
[/TR]
[TR]
[TD]
Fiat Bravo[/TD]

[TD]
120[/TD]
[/TR]
[TR]
[TD]
Fiat Croma[/TD]

[TD]
120[/TD]
[/TR]
[TR]
[TD]
Fiat Multipla[/TD]

[TD]
60[/TD]
[/TR]
[TR]
[TD]
Fiat Doblò[/TD]

[TD]
60[/TD]
[/TR]
[TR]
[TD]
Fiat Ducato (X2/50)[/TD]

[TD]
120[/TD]
[/TR]

To take the measurement, proceed as follows:
- Set the ammeter pliers at 0 current
- Place the ammeter pliers end of scale at a suitable value for the measurement (depending on the instrument specifications).
- Place the ammeter pliers on the negative battery lead so that:
- the actual pincers close perfectly (incomplete closure will make the measurement inaccurate);
- all the leads connected to the negative battery pole are included within the pincers (compatible with the dimensions of the pliers).
- Take the current reading.
The absorption value of the key off current reading should be below the limits listed in the table below:

Vehicle	Current uptake at key-off [mA]
Fiat Cinquecento	less than/equal to 150 mA (**)
Fiat Seicento	less than/equal to 50 mA
Fiat Panda	less than/equal to 100 mA (**)
Fiat Idea	less than/equal to 50 mA
Fiat Palio (FL 2)	less than/equal to 100 mA
Fiat Punto	less than/equal to 100 mA
Fiat Grande Punto	less than/equal to 150 mA (**)
Fiat Stilo (FL)	less than/equal to 50 mA
Fiat Bravo	less than/equal to 50 mA
Fiat Croma	less than/equal to 50 mA
Fiat Multipla	less than/equal to 50 mA
Fiat Doblò	less than/equal to 100 mA
Fiat Ducato (X2/50)	less than/equal to 50 mA
Fiat Ducato (X2/50) with chronotachograph	less than/equal to 110 mA
Fiat Ducato (X2/50) with air springs	less than/equal to 150 mA
Fiat Ducato (X2/50) with chronotachograph and air springs	less than/equal to 210 mA

(**) the current absorption limit at key off for the Grande Punto and Panda goes down to a value of 50 mA after 900 seconds (15 minutes) after the doors are closed.
If the current absorption measured at key off is equal to 0A (impossible condition), check that the ammeter pliers setting is correct in terms of:
- current 0 setting;
- end of scale.
If, after checking the two previous points, the value measured continues to be 0A, the equipment is damaged and must be replaced.
4 - Recommended equipment
-CFC MEASUREMENT
The use of Tecnomotor EX16 ammeter pliers is recommended together with the EXAMINER electrical kit part no. 1806337000.
The pliers are suitable for measuring direct currents from 1mA to 10A with a resolution of 100µA.
Ammeter pliers with the same or better technical specifications than Tecnomotor EX16 pliers can be used as an alternative.
-Alternator current supply measurement
There are no specific references in the catalogue.
The use of ammeter pliers with a minimum current end of scale of 150A is recommended.
-Feeder for CFC measurement with battery completely run down.
There are no specific references in the catalogue. The use of 12V feeder with a minimum current end of scale of 5A is recommended.[/TD]
[/TR]

 

[koalar]

​

all 1.1 8v – 1.2 8/16v - 1.4 8/16v (*) versions 5510 C 260 AA ENGINE RPM SENSOR Irregular operation with error P0335 - Fault diagnosis (*) At the time this Service News is published it is applicable to the following models: 500, 600, Nuova 500, Panda 141,Panda 169, Punto 176, Punto 188, Punto 199, Palio, Bravo/a, Marea, Stilo, Doblò, Idea, Bravo 198, Linea. for all other JTD versions, refer to Service News 10.12.07 - CD 3/2007 FAULT COMPLAINED OF​ EOBD warning light in instrument panel coming on. The fault diagnosis using the Examiner returns the following error (P0335) OPERATIONS IN NETWORK​ To complete the information in the Service Manuals in your possession, we are enclosing a diagnostic procedure to determine the causes of the malfunction of the timing sensor. It is very important that the resistance value (R) is measured at a temperature of 20°C. If measured when hot the R could be considerably higher or when cold lower compared with the recommended values. The precise value of the R for the rpm sensor is given in the table below. For all types of sensors: if during the measurement of the R at 20°C the value conforms it cannot be excluded that when not or in certain temperature bands there may be a momentary interruption. Engine Resistance value (R) at 20 °C Fire 8v (1.1 – 1.2 – 1.4) 1.1 kOhm ± 10% Fire 16v (1.2 – 1.4) 860 Ohm ± 10% Petrol engines (FIRE): signalling of engine failure and EOBD warning light on Symptom/Conditions: engine does not start and fault diagnosis using the Examiner returns error (P0335). Diagnosis Step Operation to be carried out Test results 0 PRELIMINARY CHECKS All OK Problems encountered Operation Check that the error detail is not invalid signal Move on to Step 1 The detail is invalid signal Move on to Step 1 1 ERROR DELETION All OK Problems encountered Operation Delete the errors, turn the ignition OFF and leave it off for more than 20 seconds and check that the errors do not occur again when carrying out a road test End of diagnosis Error P0335 persists Move on to Step 2 2 RPM SENSOR FITTING CHECK All OK Problems encountered Operation Check that the rpm sensor is correctly connected and correctly positioned (perpendicular to the flywheel and in contact with the crankcase). Also measure the gap at the four points on the wheel 90° from one another: - The gap should be between 0.5 mm and 1.5 mm; - The difference between the measurements taken at the 4 points should not exceed 0.2 mm; - Check that the sensor is correctly fastened. Move on to Step 3 Flywheel does not conform Move on to Step 3 Electrical connection unstable Move on to Step 4 Rpm sensor not in contact with crankcase and/or gap outside of the tolerance Restore the correct fitting conditions. Replace the component if necessary. See - Op. 5510C26 Move on to Step 6 3 FLYWHEEL CONDITION CHECK All OK Problems encountered Operation Check that the flywheel conforms Move on to Step 4 Incorrectly fitted; Flywheel damaged; Condition of the reference pin Restore the correct fitting position. Replace the component if necessary. See - Op. 1092A10 Move on to Step 4 4 RPM SENSOR CONNECTION CHECK All OK Problems encountered Operation Check the conformity of the electrical connection for the rpm sensor Move on to Step 5 - connector damaged; - primary lock (red cover) in incorrect position; - seal deteriorated; - traces of water in the wiring; - traces of oxidation at the terminals; - break in the wiring continuity. Restore the correct fitting conditions. Replace the component if necessary. See - Op. 5510C26 Move on to Step 5 5 CHECK ON CONDITION OF RPM SENSOR All OK Problems encountered Operation Remove any traces of water from the wiring. Then check: - that the terminals are not damaged or distorted; - that the resistance between the terminals conforms to the description in the table on page 1 Move on to Step 6 - terminals distorted or damaged; - resistance values do not conform; - break in the wiring continuity. Restore the correct fitting conditions. Replace the component if necessary. See - Op. 5510C26 6 RPM SENSOR OPERATION CHECK All OK Problems encountered Operation Check that the rpm sensor is working properly by carrying out the Test: RPM SIGNAL CHECK End of diagnosis - terminals distorted or damaged; - resistance values do not conform; - break in the wiring continuity. Restore the correct fitting conditions. Replace the component if necessary. See - Op. 5510C26 Rpm signal check​ - Set up the diagnostic equipment to produce a voltage graph (select the voltmeter function on the "Instruments" menu) - Using the diagnostic equipment probes, connect between pin 1 and 2 of the sensor connector. - Press the Start button on the diagnostic equipment to begin creating a graph. - Check that signal amplitude is greater than 1.5 V and that the graph is as specified during engine start-up. If the result of the test is negative: - Restore the continuity of the wiring between the rpm sensor and the engine control unit. - Restore the gap between the rpm sensor and the flywheel (correct value is between 0.5 and 1.5 mm). - Replace the flywheel if it is damaged.

 

[koalar]

​

all 1.1 / 1.2 8v versions 5520 1 211 AC STARTER MOTOR Failed starting - Service Solution FAULT COMPLAINED OF​ Engine fails to start at low ambient temperatures. TECHNICAL CAUSE​ During starting the absorption by Hitachi starter motors creates a fall in battery voltage that exceeds the lower limit of the injection control unit threshold with consequent failed starting. OPERATIONS IN PRODUCTION​ Injection control unit software modified. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organization No. all versions in question Tychy - 746479 1383214 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -When this problem is reported and confirmed, reassure the Customer that it can be solved by reprogramming the injection control unit software.-After the operation show the Customer what has been done and make sure they are satisfied. SERVICE SOLUTION​ On the following vehicles: -from chassis 507546 to chassis 746478 if this problem is reported and confirmed-with chassis below 507546if the starter motor is replaced reprogramme the injection control unit with the new software CD Flash 4.80 (or higher) as described in the Operating Cycle below. OPERATION CYCLE​ If this problem is reported, carry out the reprogramming using the Examiner with release 6.60 (or higher) using the CD FLASH 4.80 (or higher). It should be remembered that, for the programming, the vehicle battery must be fully charged or supported by a battery charger/additional battery in order to guarantee the rated voltage of 12V. AVALABILITY OF PARTS​ Version Description Part No. Qty. all versions in question CD Flash 4.80 1806577000 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 5520121 1 AC - .25

 

[koalar]

​

all versions with Dualogic (MTA) 5550 1 271 RA BRAKE PEDAL SWITCH Failed operation - Service Solution FAULT COMPLAINED OF​ -Engine fails to start.-Gears do not engage (manoeuvre not permitted) TECHNICAL CAUSE​ Switch on brake pedal incorrectly adjusted/defective. OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -When this problem is reported and confirmed, reassure the Customer that it can be solved by carrying out a check on the control unit using the Examiner.-After the operation show the Customer what has been done and make sure they are satisfied. SERVICE SOLUTION​ If this problem is reported and confirmed, carry out a check on the control unit using the Examiner and, if necessary, replace the switch on the brake pedal following the instructions in the Operating Cycle below. OPERATION CYCLE​ When this problem is reported by the Customer: -check the type of fault for the brake lights (failure to come on or on permanently)-check for errors in the control unit using the Examiner If the brake lights are not working properly and/or there is the "simultaneous" presence of the following errors: -P1760 in the Dualogic "MTA" system control unit-P0504 (Diesel versions) or P0571 (petrol versions) in the engine management control unit adjust the travel of the switch push rod on the brake pedal and, if necessary, replace the swith following the instructions in the Service Manual (Op. 5550D10). Otherwise (if the brake lights are working properly and/or only error P1760 is present in the Dualogic "MTA" control unit) delete any error, do not replace the brake pedal switch, but proceed with searching for faults using the checklists in the Service Manual Diagnostic section. If there are no errors in the engine management control unit and error P1760 is memorized in the Dualogic "MTA" control unit, then this could be due to incorrect communication on the CAN. CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 5550127 1 RA - .40

 

[koalar]

​

all petrol versions (1.1 8v - 1.2 8v) 5530 1 201 TB BODYSHELL-GEARBOX BATTERY EARTH LEAD No continuity - Service Solution FAULT COMPLAINED OF​ Difficulties in starting the engine. TECHNICAL CAUSE​ No continuity for the earth lead. Whilst driving the lack of continuity for the earth lead does not allow the alternator to recharge correctly and therefore the battery is gradually run down more or less quickly depending on the electrical loads applied. OPERATIONS IN PRODUCTION​ Fitting of components that conform guaranteed. IPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis No. Organization No. all versions in question Tychy - 223743 101173 OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -When this problem is reported and confirmed, reassure the Customer that it can be solved by restoring the correct earth continuity between the battery and bodyshell-gearbox.-After the operation show the Customer what has been done and carry out a test to make sure they are satisfied. SERVICE SOLUTION​ If this problem is reported and confirmed, shorten the previous earth lead and fit a new earth cable loom in its place as described in the Operating Cycle below. OPERATION CYCLE​ Fit the new earth cable loom following the instructions below. -Remove the earth lead (section from the battery to the bodyshell-gearbox).-Remove the section of the earth lead from the bodyshell to gearbox using cutters (after the eyelet 1 - Fig. 1).-Protect the end of the cable, near the terminal with the eyelet (1 - Fig. 1) using electrician''s tape. Fig. 1 -Fit the modified earth lead from the battery to the bodyshell and make the earth connection using loom no. 51740238 (1 - Fig.2). The fastening of the battery-bodyshell earth and the bodyshell-gearbox cable loom to the bodyshell is made using the same bolt (used previously for the earth only). -Tighten the bolt (2 - Fig. 2) to a torque of 1.5 daNm.-Protect the connection and the terminals using grease or silicon spary. Fig. 2 AVALABILITY OF PARTS​ Version Description Part No. Qty. all versions in question Cable loom 51740238 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 5530120 1 TB - .50

 

[koalar]

​

all versions (left hand drive and right hand drive) 5580 1 691 TD PASSENGER AIR BAG DISABLING SWITCH Irregular operation - Service Solution FAULT COMPLAINED OF​ Air bag warning light coming on incorrectly after the passenger air bag has been deactivated. TECHNICAL CAUSE​ In the ON and OFF positions the passenger air bag disabling switch assumes two resistance values respectively (100 and 400 ohm). These resistance values are affected by the resistance of the electrical system between the disabling switch and the air bag control unit causing the incorrect interpretation by the control unit. OPERATIONS IN PRODUCTION​ Fitting of improved electrical cables guaranteed. OPERATIONS IN NETWORK​ NETWORK BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER​ -When this problem is reported and confirmed, reassure the Customer that it can be solved by replacing the wiring between the disabling switch, the air bag control unit and the earth with different wiring with appropriate electrical resistance.-After the operation show the Customer what has been done and carry out a test to make sure they are satisfied. SERVICE SOLUTION​ If this problem is reported, replace the wiring between the disabling switch, the air bag control unit and the earth with one which has a lower electrical resistance following the instructions inthe Operating Cycle below. OPERATION CYCLE​ It should be pointed out that the figures refer to Right Hand Drive versions; Left Hand Drive versions are symmetrical. Detach the negative battery terminal then, working in the passenger compartment, carry out the following operations: -Remove the trim under the dashboard on the passenger side and the two trims under the dashboard in the middle.-Identify the disabling switch in the oddments pocket on the passenger side of the dashboard.-Release the switch from the housing in the oddments pocket in the dashboard.-Disconnect the disabling switch (Fig. 1). Fig. 1 -Connect the bridge no. 57186224 to the disabling switch.-Tape the terminal to the wiring using electrical tape (Fig. 2). Fig. 2 -Fasten the bridge to the wiring using a strip band no. 14560187 near the disabling switch.-Fit the disabling switch in the housing in the oddments pocket in the dashboard.-Identify the earth point in the middle on the floor under the dashboard (Fig. 3). Fig. 3 -Undo the nut, position the earth terminal and eyelet, superimpose washer no. 12625201 and secure with the nut tightening it fully (Fig. 4). Fig. 4 -Keep the excess wiring as illustrated in figure 5. Fig. 5 -Fasten the excess wiring to the heater casing using a strip band no. 12625201 (Fig. 6). Fig. 6 -Disconnect the multiple connector from the air bag control unit (front connector towards the flame partition) (Fig. 7). the colour of the connector and the wiring may vary depending on the trim level, always refer to the front connector. Fig. 7 -Cut the strip band fastening the wiring to the connector (Fig. 8). Fig. 8 -Extend the tabs for the outer part of the connector using a small screwdriver (Fig. 9). Fig. 9 -Release the contact holder from the outer part of the connector (Fig. 10). Fig. 10 -Identify pin no. 7, extract the cable/terminal and fit the bridge terminal (Fig. 11).-Insulate and tape the terminal to the wiring using electrical tape.-Refit the multiple connector reversing the order of the operations carried out for the removal.-Refit the components reversing the order of the operations carried out for the removal.-Carry out the air bag control unit test using the Examiner. Fig. 11 IDENTICATION THAT REPAIR HAS TAKEN PLACE​ White paint mark on the disabling switch. AVALABILITY OF PARTS​ Version Description Part No. Qty. all versions in question Bridge 51786224 1 all versions in question Strip band 14560187 3 all versions in question Washer 12625201 1 CLAIM REPORT DATA​ Version Operation Piece Fault Position Time allowance all versions in question 5580169 1 TD - .60

 

[koalar]

​

versione: all versions with electrical boot release in tailgate handle 7015 B 300 AA TAILGATE HANDLE Electrical boot release control - Network Information On the versions in question with chassis nos. before 12912, when the doors are locked, if one of the passengers opens their door to get out, they cannot open the tailgate which can only be opened using the soft touch electrical control in the tailgate handle if the driver releases the central locking using the control lever on their door. OPERATIONS IN PRODUCTION​ Starting from the chassis number listed below, new Body Computer software has been adopted which deactivates the electric lock for the tailgate handle control when one of the passenger doors is opened when the doors are locked. IMPLEMENTATION OF MODIFICATION​ Version Factory Line Chassis n. Organization n. all versions in question Tychy - 12912 1012457

 

[koalar]

​

Test results 1 POWER ASSISTED STEERING CHECK All OK Problems encountered Operation Check the power assistance level during manoeuvres - With the City function engaged, the power assistance level is at maximum or lower than expected, and at low speed the steering wheel has trouble returning to the centre Move on to Step 2 2 ELECTRICAL CHECKS All OK Problems encountered Operation Check: - Correct engagement of the electrical connections on the EPS system coming from the body computer - That the battery terminals are correctly tightened - The continuity of the EPS supply wiring Move on to Step 2 Loose connections and/or breaks in continuity at both ends of the wiring detected Adjust the wiring connections. If the problem persists, move on to Step 2 3 FAULT DETECTION CONDITIONS CHECK All OK Problems encountered Operation Check when the problem occurs - The warning light flashes when the vehicle is running Do not adjust the electric steering. Lighting up may be due to faults on the control panel. The warning light stays on. Move on to Step 3 4 CHECK USING DIAGNOSTIC EQUIPMENT All OK Problems encountered Operation Connect the Examiner diagnostic equipment and check that there are no faults End of diagnosis Electric motor fault (error code C1001) Replace the EPS system control unit/electric motor unit Steering column torque/position sensors fault (error code C1002). Replace the power steering kit Vehicle speed fault (error code C1003) Check speed sensor operation and signal on the CAN line. Do not replace EPS system parts Alternator status fault (error code C1004) Check the operation of the alternator and signal on the CAN. Do not replace EPS system parts Warning light damage (error code C1005) Check CAN line signal. Do not replace EPS system parts EPS system fault (error code C1006) Replace the EPS system control unit/electric motor unit Battery fault (error code C1007) Check battery voltage. Do not replace EPS system parts Calibration system (error code C1008) Calibrate the torque/position sensor using the Examiner in active diagnosis. Do not replace EPS system parts CAN line fault (error code U1601) Check operation of CAN line Torque and/or position sensor error (5002) Check and clean earth connections. Cancel the error. If the problem recurs, replace the EPS system No error code Do not intervene

The customer complains that the EPS fault warning light comes on but the system is supplying the correct power assistance