FIAT SCUDO - FC Connect

FIAT SCUDO - FC Connect
Fiat Auto S.p.A.
FIAT SCUDO
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FIAT SCUDO
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DOCUMENTATION MODIFICATIONS / UPDATES
Date
Referent
File Name
Description of modification
© 2006 - 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 is continuously updated: Fiat Auto S.p.A.
disclaims all responsibilities for any errors, omissions, damage or loss that might result
from the use of outdated information
This publication is issued for training purposes only.
Exhaustive, updated technical information for servicing purposes can be found in the
service manual and any other service information for the vehicle model concerned.
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CONTENTS
1. BRIEFING..........................................................................................................................8
1.1 I CONTENTS IN BRIEF .......................................................................................................................8
1.2 ENGINES .........................................................................................................................................9
1.3 VEHICLE IDENTIFICATION DATA ........................................................................................................9
1.4 BODYWORK VERSIONS...................................................................................................................11
2. TECHNICAL DATA ..........................................................................................................13
2.1 ENGINE .......................................................................................................................................13
Engine type..................................................................................................................................................... 13
Engine data .................................................................................................................................................... 13
Injection ......................................................................................................................................................... 13
2.2 GEARBOX...................................................................................................................................14
2.3 BRAKES......................................................................................................................................14
2.4 VEHICLE FEATURES .................................................................................................................15
Size................................................................................................................................................................. 15
2.5 SCHEDULED MAINTENANCE ...................................................................................................17
2.6 LIQUIDS ......................................................................................................................................18
Characteristics of Fluids and Lubricants ........................................................................................................ 19
Capacity of Fluids and Lubricants .................................................................................................................. 19
3. ENGINE ...........................................................................................................................20
3.1 1.6 MULTIJET 90CV ENGINE ( DV6UTED4) ..............................................................................20
Engine markings............................................................................................................................................. 22
Technical specifications of 1.6 Multijet Engine............................................................................................... 23
exploded view of engine................................................................................................................................. 24
Monobloc ........................................................................................................................................................ 24
Cooling the top of the cylinders with galleries between the liners.................................................................. 25
Crankcase base.............................................................................................................................................. 26
Cylinder head ................................................................................................................................................. 27
Hydraulic tappets............................................................................................................................................ 28
Operation of hydraulic tappets ....................................................................................................................... 29
Camshaft support (tappet cover).................................................................................................................... 29
Construction ................................................................................................................................................... 30
Head gasket ........................................................................................... Errore. Il segnalibro non è definito.
Crankshaft ...................................................................................................................................................... 32
Bearing identification ...................................................................................................................................... 33
Flywheel ......................................................................................................................................................... 33
Pistons............................................................................................................................................................ 34
Piston rings..................................................................................................................................................... 35
Connecting rods ..................................................................................... Errore. Il segnalibro non è definito.
Camshaft drive ............................................................................................................................................... 37
Spring tensioner ............................................................................................................................................. 38
Camshafts ...................................................................................................................................................... 39
Fuel filter......................................................................................................................................................... 40
Air supply circuit diagram ............................................................................................................................... 41
Air route .......................................................................................................................................................... 41
Turbocharger .................................................................................................................................................. 42
Exhaust system .............................................................................................................................................. 42
Catalytic converter.......................................................................................................................................... 43
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EGR system.................................................................................................................................................... 43
Flow meter ...................................................................................................................................................... 45
Crankcase oil vapour recovery system........................................................................................................... 46
Engine lubrication system............................................................................................................................... 47
Oil pump ......................................................................................................................................................... 49
Oil pressure .................................................................................................................................................... 49
Oil filter and heat exchanger........................................................................................................................... 50
Engine cooling circuit...................................................................................................................................... 51
Coolant pump ................................................................................................................................................. 52
Thermostat...................................................................................................................................................... 52
Supply/Expansion Tank .................................................................................................................................. 52
Fuel circuit ...................................................................................................................................................... 53
List of Equipment for 1.6 Multijet 90CV Engine.............................................................................................. 54
Glow plug pre-heating system ........................................................................................................................ 55
Engine oil temperature and level sensor ........................................................................................................ 55
Fuel temperature sensor ................................................................................................................................ 56
Electro-injectors .............................................................................................................................................. 57
Fuel pressure sensor ...................................................................................................................................... 58
Rpm sensor .................................................................................................................................................... 59
Timing sensor ................................................................................................................................................. 59
Overpressure sensor ...................................................................................................................................... 60
Sucked air temperature .................................................................................................................................. 60
Engine temperature sensor ........................................................................................................................... 62
Air flow meter with incorporated air temperature sensor................................................................................ 63
Accelerator pedal potentiometer..................................................................................................................... 63
BOSCH EDC16C34 Engine management wiring diagram............................................................................. 64
3.2 2.0 MULTIJET 120CV ENGINE ( DW10UTED4)..........................................................................65
General information on the PCR system ........................................................................................................ 65
Diesel Common Rail pump ............................................................................................................................. 68
Fuel internal transfer pump ITP ..................................................................................................................... 68
Volumetric control solenoid valve VCV........................................................................................................... 68
High pressure pump HPP ............................................................................................................................... 68
Pressure control solenoid valve PCV ............................................................................................................. 68
Volume of the high pressure side ................................................................................................................... 69
Piezo Injectors ................................................................................................................................................ 69
Injectors .......................................................................................................................................................... 71
Operation ........................................................................................................................................................ 72
Common Rail pump ........................................................................................................................................ 74
Fuel route in the diesel Common Rail pump (DCP) ....................................................................................... 77
Marking of the diesel Common Rail pump (DCP) .......................................................................................... 78
3.3 TIMING BELT ..............................................................................................................................81
3.3.1 Removal................................................................................................................................................. 81
3.3.2 Assembly ............................................................................................................................................... 81
Tools for 2.0 MULTIJET engine overhaul....................................................................................................... 81
4. GEARBOX ....................................................................................................................... 81
4.1 BE4R ( 1.6 MULTIJET 90CV )......................................................................................................81
DISMANTLING ............................................................................................................................................... 81
REASSEMBLY ............................................................................................................................................... 81
Tools for 1.6 MULTIJET 90CV Gearbox overhaul.......................................................................................... 81
4.2 ML6C ( 2.0 MULTIJET) ................................................................................................................81
Dismantling ..................................................................................................................................................... 81
Reassembly .................................................................................................................................................... 81
Tools for 2.0 Multijet Fiat NScudo Gearbox overhaul..................................................................................... 81
5. BRAKING SYSTEM ........................................................................................................ 81
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5.1 ABS BOSCH 8.0..........................................................................................................................81
General........................................................................................................................................................... 81
System diagram.............................................................................................................................................. 81
Diagram of ABS without ESP ......................................................................................................................... 81
Diagram of ABS with ESP .............................................................................................................................. 81
Functions of the ABS system ......................................................................................................................... 81
ESP ( Electronic Stability Program )............................................................................................................... 81
ASR SYSTEM (Antislip Regulator)................................................................................................................. 81
HH ( Hill Holder ) ............................................................................................................................................ 81
5.2 PARKING BRAKE (ADJUSTMENTS).........................................................................................81
Parking brake with cable tension adjuster...................................................................................................... 81
6. STEERING........................................................................................................................81
6.1 HYDRAULIC POWER STEERING ( 1.6 MULTIJET 90 CV ) ................................................................81
6.2 POWER STEERING WITH ELECTRO-HYDRAULIC INTERLOCK (2.0 MULTIJET ).................81
Functional diagram ......................................................................................................................................... 81
Operation........................................................................................................................................................ 81
Motor pump assembly .................................................................................................................................... 81
Pump assembly location ................................................................................................................................ 81
Oil top-up tank location................................................................................................................................... 81
Pump dismantling ........................................................................................................................................... 81
Pump operation .............................................................................................................................................. 81
Electro-hydraulic steering control unit ............................................................................................................ 81
Electro-hydraulic steering control unit pin-out ............................................................................................... 81
7. SUSPENSION SYSTEM...................................................................................................81
7.1 STANDARD REAR SUSPENSION SYSTEM..............................................................................81
7.2 PNEUMATIC REAR SUSPENSION SYSTEM WHERE APPLICABLE.......................................81
System composition ....................................................................................................................................... 81
System electronic control unit ........................................................................................................................ 81
Control Unit Pin Out ....................................................................................................................................... 81
Air springs....................................................................................................................................................... 81
Location of air springs .................................................................................................................................... 81
Compressor assembly.................................................................................................................................... 81
Height sensors................................................................................................................................................ 81
Push-buttons/switch unit ................................................................................................................................ 81
Buzzer ........................................................................................................................................................... 81
Air reserve tank (additional) ........................................................................................................................... 81
Air circuit and pipes ........................................................................................................................................ 81
Air circuit functional diagram .......................................................................................................................... 81
8. ELECTRIC SYSTEM .......................................................................................................81
8.1 GENERAL ...................................................................................................................................81
Power supplies ............................................................................................................................................... 81
Multiplexing architecture................................................................................................................................. 81
CAN HS IS NETWORK .................................................................................................................................. 81
CAN LS CAR NETWORK .............................................................................................................................. 81
CAN LS CONFORT NETWORK .................................................................................................................... 81
CAN DIAGNOSTICS NETWORK................................................................................................................... 81
K diagnosis line ............................................................................................................................................. 81
8.2 INSTRUMENT PANEL .......................................................................................................................81
Table listing fault/alert warning lights: ............................................................................................................ 81
PIN-OUT......................................................................................................................................................... 81
8.3 DOOR CONTROL........................................................................................................................81
General........................................................................................................................................................... 81
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Remote control functions ................................................................................................................................ 81
Push-buttons inside the vehicle...................................................................................................................... 81
Operation ........................................................................................................................................................ 81
Wiring diagrams.............................................................................................................................................. 81
8.4 POWER WINDOWS AND REAR-VIEW MIRRORS ..................................................................................81
General ........................................................................................................................................................... 81
Switch unit ...................................................................................................................................................... 81
Wiring diagrams.............................................................................................................................................. 81
Operation ........................................................................................................................................................ 81
Location of power window and rear-view mirror relays .................................................................................. 81
8.5 AIRBAGS.....................................................................................................................................81
Functional configuration diagram ................................................................................................................... 81
SBR sensor..................................................................................................................................................... 81
CNB sensor .................................................................................................................................................... 81
CNB sensor operation .................................................................................................................................... 81
Messages on the CAN network ...................................................................................................................... 81
Passenger compartment cable bundle ........................................................................................................... 81
Airbag control unit........................................................................................................................................... 81
Side impact satellite sensors .......................................................................................................................... 81
Passenger AirBag disabling switch ................................................................................................................ 81
Front Airbags (driver and passenger)............................................................................................................. 81
Curtain Airbag and chest airbag .................................................................................................................... 81
Wiring diagrams.............................................................................................................................................. 81
8.6 CLIMATE CONTROL ........................................................................................................................81
Heater system ( CH ) ...................................................................................................................................... 81
Heater operation ( CH ) .................................................................................................................................. 81
Manual climate control system ( RF ) ............................................................................................................. 81
Manual climate control operation ( RF ) ......................................................................................................... 81
Two-zone automatic climate control system ( RFTA ).................................................................................... 81
Additional rear climate control system............................................................................................................ 81
Supplementary hot water heating circuit ........................................................................................................ 81
Rear air-conditioning controls cluster ............................................................................................................. 81
Rear air-conditioning enabling button............................................................................................................. 81
Rear climate control unit ................................................................................................................................. 81
Upper rear ventilation ..................................................................................................................................... 81
Lower rear ventilation ..................................................................................................................................... 81
Passenger compartment water and gas pipe passage .................................................................................. 81
Hot water circuit solenoid valve ...................................................................................................................... 81
Additional heating circuit operation with solenoid valve ON........................................................................... 81
Additional water pump .................................................................................................................................... 81
Pipes ............................................................................................................................................................... 81
Wiring diagrams.............................................................................................................................................. 81
8.7 “BLUETOOTH” HANDS-FREE SYSTEM ( KML : KIT MAINS LIBRES ) ..................................................81
Functional diagram: ........................................................................................................................................ 81
List of compatible mobile phones ................................................................................................................... 81
KML control unit location ................................................................................................................................ 81
Functional system checks............................................................................................................................... 81
Human-Machine Interface ( IHM ) .................................................................................................................. 81
General functional information........................................................................................................................ 81
SMS text messages........................................................................................................................................ 81
Customer Centre Call ..................................................................................................................................... 81
Voice commands ............................................................................................................................................ 81
Electronic diagnosis........................................................................................................................................ 81
8.8 ALARM ........................................................................................................................................81
General ........................................................................................................................................................... 81
Functional diagram ......................................................................................................................................... 81
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Operation........................................................................................................................................................ 81
Position of components .................................................................................................................................. 81
8.9 PARKING SENSORS ..................................................................................................................81
Turning off Sensors ........................................................................................................................................ 81
Trouble ........................................................................................................................................................... 81
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1. BRIEFING
1.1 I Contents in brief
Commercial Vehicle customer requirements are continually evolving and, to keep on being a market
leader, it is necessary to be able to satisfy and anticipate these needs. For this reason, Fiat Scudo is now
presented with entirely renewed and punchier styling as well as many features that will continue to make
this vehicle a point of reference in its segment for its style, breadth of range, versatility, functionality,
performance, driving comfort and quality of life in the vehicle.
The product's evolution can be summarized in four macro-areas of operation:
style renewal
greater capacity/ease of loading
greater power/torque of the engines
greater comfort
lower running costs
Especially:
- new range of Multijet diesel engines, in compliance with the Euro4 standard: more powerful, more
elastic, more dependable and more cost-effective. The 2.0 136CV top version is equipped with an F.A.P.
antipollution system ;
- Two-zone climate control with additional rear climate control;
- Rear air suspensions with variable loading deck height to make loading and unloading goods easier;
- Improved safety:
with a latest generation ABS system and the choice of the full version with ESP, ESR, MSR, HBA
and Hill Holder;
Two Airbag versions with or without “Windows Bag”
- Two ranges of bodywork for the following versions:
"Long or short wheelbase" Van with high or low roof;
"Long or short wheelbase" Combi with low roof;
- More pleasurable driving with the power steering system featuring an electro-hydraulic fluid pump;
- To improve comfort the vehicle can also be fitted with a Bluetooth hands-free system.
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1.2 Engines
The new SCUDO is equipped right from its sales launch with the following engines:
1560 Multijet 90CV (66 KW) Engine – Max Torque 180Nm at 1750 rpm.
1997 Multijet 120 CV (88KW) Engine – Max Torque 300Nm at 2000 rpm.
1997 Multijet 140 CV (103KW) Engine – Max Torque 320Nm at 2000 rpm.
The following table gives the engine-clutch-gearbox combinations for the vehicle at issue:
Engine
1.6 90CV
2.0 120CV
2.0 140CV
F.A.P.
No
No
Yes
Clutch
Luk
Luk
Luk
Gearbox
BE4R (5 gears)
ML6C (6 gears)
ML6C (6 gears)
1.3 Vehicle identification data
The vehicle identification data are stamped on specific plates; they are located as follows:
1. Bodywork paint identification plate on front left-hand door
2. Chassis frame marking in central position at the base of the windscreen
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3. Identification data summary dataplate on the pillar of the front right-hand door
4. Engine marking on the crankcase
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1.4 Bodywork versions
The new Scudo is available with two bodywork versions: Combi or Van, both of which can be ordered
with a short or long wheelbase.
Besides these two versions there are others according to the number of seats.
The following table gives the bodywork code numbers according to the version and engine:
1.6 90CV Engine
( 270XXAIA AA ) Combi short wheelbase – 5/6 seats
( 270XXAIA AB ) Combi short wheelbase – 8/9 seats
( 270XXAIA AAL ) Combi long wheelbase – 5/6 seats
( 270XXAIA ABL ) Combi long wheelbase – 8/9 seats
( 270KXAIA ABL )Combi long wheelbase (greater capacity) – 8/9 seats
( 270ZXAIA ZA ) Combi short wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXAIA ZA ) Combi long wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXAIA ZA ) Van short wheelbase 10Q (low roof) – 2/3 seats
( 270ZXAIA WA ) Van short wheelbase 12Q (low roof) – 2/3 seats
( 270ZXAIA WAL ) Van long wheelbase 12Q (low roof) – 2/3 seats
( 270ZXAIA ZA ) Van long wheelbase 12Q (high roof) – 2/3 seats
( 270ZXAIA ZA ) Deck long wheelbase 12Q – 2/3 seats
2.0 120CV Engine
( 270XXCIB AA ) Combi short wheelbase – 5/6 seats
( 270XXCIB AB ) Combi short wheelbase – 8/9 seats
( 270XXCIB AAL ) Combi long wheelbase – 5/6 seats
( 270XXCIB ABL ) Combi long wheelbase – 8/9 seats
( 270KXCIB ABL ) Combi long wheelbase (greater capacity) – 8/9 seats
( 270ZXCIB ZC ) Combi short wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXCIB ZCL ) Combi long wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXCIB ZA ) Van short wheelbase 10Q (low roof) – 2/3 seats
( 270ZXCIB WA ) Van short wheelbase 12Q (low roof) – 2/3 seats
( 270ZXCIB WAL ) Van long wheelbase 12Q (low roof) – 2/3 seats
( 270ZXCIB WBL ) Van long wheelbase 12Q (high roof) – 2/3 seats
( 270ZXCIB ZAL ) Deck long wheelbase 12Q – 2/3 seats
2.0 136CV Engine
( 270XXDIB AA ) Combi short wheelbase – 5/6 seats
( 270XXDIB AB ) Combi short wheelbase – 8/9 seats
( 270XXDIB AAL ) Combi long wheelbase – 5/6 seats
( 270XXDIB ABL ) Combi long wheelbase – 8/9 seats
( 270KXDIB ABL ) Combi long wheelbase (greater capacity) – 8/9 seats
( 270ZXDIB ZC ) Combi short wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXDIB ZCL ) Combi short wheelbase ( Cat. NI ) – 5/6 seats
( 270ZXDIB ZA ) Van short wheelbase 10Q (low roof) – 2/3 seats
( 270ZXDIB WA ) Van short wheelbase 12Q (low roof) – 2/3 seats
( 270ZXDIB WAL ) Van long wheelbase 12Q (low roof) – 2/3 seats
( 270ZXDIB WBL ) Van long wheelbase 12Q (high roof) – 2/3 seats
( 270ZXDIB ZAL ) Deck long wheelbase 12Q – 2/3 seats
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The following figures illustrate the Van version with high and low roofs. Both versions can be ordered with
a short or long wheelbase.
The following figure illustrates the Combi version with a low roof, which can be ordered with the short or
long wheelbase.
In addition, the Combi version can have the back with two doors or a hatchback:
- Version featuring back with two doors:
- Version featuring back with hatchback:
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2. TECHNICAL DATA
2.1 ENGINE
Engine type
Type code
Position
No. of cylinders
Cylinder
arrangement
No. of valves per
cylinder
Cycle
Timing system
Fuel supply
1,6
DV6UTED4
2.0
2.0
4
4
4
16
16
16
Diesel
Diesel
Diesel
Common Rail
Diesel
Common Rail Diesel
Common Rail Diesel
fitted at 0.4°
Engine data
Bore (mm)
Stroke (mm)
Total displacement
(cm³)
Compression ratio
Maximum power
output (kW/CV)
Maximum power
speed (rpm)
Maximum torque
(Nm)
Peak torque speed
(rpm)
1,6
75
88.3
2.0
2.0
1560
66 / 90
4000
180
1750
Injection
1,6
Type
BOSCH EDC16.34
Injection order
1-3-4-2
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2.0
2.0
1-3-4-2
1-3-4-2
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2.2 GEARBOX
Gearbox
Clutch
Drive
90 Multijet
Five forward gears plus reverse
with synchronisers for coupling
the forward gears
Self-adjusting with pedal
with no loadless travel
Front
120 Multijet - 140 Multijet
Six forward gears plus reverse
with synchronisers for coupling
the forward gears
Self-adjusting with pedal
with no loadless travel
Front
2.3 BRAKES
90 Multijet - 120 Multijet - 140 Multijet
Service brakes:
front
rear
Parking brake
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disc ( self-ventilating for applicable versions )
disc or drum ( on some versions )
governed by hand lever acting on rear brakes
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2.4 VEHICLE FEATURES
Size
A+B+C
N
A+B+C
B
C
D
E
F
G
DIMENSIONS
Total length
Total height
Wheelbase
Front overhang
Rear overhang
Total width:
flush with bodywork
with buffer bands
with rear-view mirrors collapsed
with rear-view mirrors open
Front track
Rear track
Height of goods compartment
with mechanical suspensions
with air suspensions
SHORT WHEELBASE
4805
1894 - 1942 / 2204 - 2276 (*)
3000
975
830
LONG WHEELBASE
5153
1894 - 1942 / 2204 - 2276 (*)
3122
975
1038
1870
1895
1968
2194
1574
1574
1870
1895
1968
2194
1574
1574
562 - 604
491 - 500
562 - 604
491 - 500
(*) versions with high roof
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N
O
DIMENSIONS
Useful height of two rear doors
Useful width
two rear doors
rear hatch (where applicable)
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REAR DOORS
1272 - 1630 (*)
1237
1237
(*) versions with high roof
P
Q
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DIMENSIONS
Height
Width
SLIDING SIDE DOOR
1293 - 1301
924
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2.5 SCHEDULED MAINTENANCE
Servicing must be done every 30,000 km
Thousands of kilometres
Check conditions/wear of tyres and if necessary
adjust pressure
Check lighting system operation
( headlamps, direction indicators, hazard, goods compartment,
instrument panel warning lights, etc.)
Check operation of wiper/washer system
and adjust nozzles if necessary
Check position/wear of wipers
Check conditions/wear of brake pads and operation of
front and rear disc wear indicator
( where applicable )
Check conditions/wear of rear drum brake linings
( where applicable )
Inspect conditions and integrity:
outside bodywork and underbody protection, pipes
exhaust-fuel-brakes)
rubber parts (caps-sleeves-bushings-etc.)
brake and fuel system hoses
Inspect conditions/tensioning of belts driving
accessories (except for engines with automatic tensioners)
Check and if necessary adjust hand brake travel
Check exhaust gas emissions/smokiness
Check cleanliness of locks and lever mechanism lubrication
Change engine oil and oil filter
Drain diesel filter
Change diesel filter
Change air filter cartridge
Check and if necessary restore fluid levels
(engine cooling-brakes-power steering-windscreen washeretc.)
Check tension of driving belt(s) for accessories
Inspect conditions of belt(s) driving accessories
Inspect conditions of timing system toothed belt
Renew timing system toothed belt (*)
Check functionality of engine check systems (with diagnosis
socket)
Change brake fluid (or every 24 months)
Change pollen filter (or every 24 months)
Restore specific fluid for particulate filter (version:
140 Multijet)
Change particulate filter (140 Multijet)
30 60 90 120 150 180
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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x
x
x
x
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x
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x
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x
x
(*) It is recommended to renew the timing belt every 180,000km/10years
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2.6 LIQUIDS
The following figures illustrate the location of the tanks for checking levels.
Version with 1.6 90CV engine
Version with 2.0 120CV and 136CV engine
Key:
1. Engine coolant
2. Windscreen / rear window / headlamp washer fluid
3. Brake fluid
4. Engine oil
5. Power steering fluid
6. Seat for engine oil top-up funnel
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Characteristics of Fluids and Lubricants
Use
Lubricants for
diesel engines
Lubricants
and greases for
the transmission
Brake fluid
Qualitative characteristics of the fluids and
lubricants for the vehicle to function correctly
Lubricants with synthetic base of grade SAE 5W40
qualification FIAT 9.55535-N2
genuine fluids
and lubricants
Synthetic oil SAE 75w-85 exceeding the
specification API G4 and MIL-L-2105 D LEV
Lithium soap based greases with molybdenum
bisulphide, consistence NGLI 2
Synthetic fluid F.M.V.S.S. no. 116 DOT 4,
ISO 4925,SAE J-1704, CUNA NC 956-01
TUTELA
MATRYX
TUTELA
MRM 2
TUTELA TOP 4
SELENIA WR
Protective agent with antifreeze action (red in
colour)
PARAFLU UP
for monoethylene glycol based cooling systems
inhibited with organic formula based on the
technology of O.A.T.. It exceeds the specifications
of CUNA NC 956-16 astm d 3306
Liquid for
Mixture of spirits, water and surfactants
TUTELA
windscreen/rear
CUNA NC 956-11
PROFESSIONAL
window/headlamp
SC 35
washer
Radiator
protection
Change
frequency
According to
Scheduled
Maintenance Plan
Mechanical
gearboxes
and differentials
Homokinetic joints
Hydraulic brakes
and hydraulic controls
clutch
Cooling circuits
Percentage used:
50% down to -35°C
To be used pure or
diluted in the
wiper/washer
systems
Capacity of Fluids and Lubricants
90
Multijet
Fuel tank: litres
Including a reserve of:
litres
Engine cooling
system:
litres
Engine sump and filter:
litres
Gearbox/differential casing kg
Hydraulic brakes circuit with
ABS devices (with ESP)
kg
Tank for windscreen, rear
window,
headlamp washer fluid
litres
120
Multijet
140
Multijet
80
8
80
8
80
8
6,2
-
9
5,25
1,9
9
5,25
1,9
Specified fuels and
genuine lubricants
Diesel for motor vehicles
(Specification EN 590)
Mixture of water and fluid
PARAFLU UP at 50%
SELENIA WR
TUTELA CAR MATRYX
0,519
0,519
0,519
TUTELA TOP 4 (*)
Mixture of water and fluid
7,5
7,5
7,5
TUTELA PROFESSIONAL SC
35
(*) The brake fluid must be changed at least every 2 years (van version)
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3. MOTORE
3.1 MOTORE 1.6 MULTIJET 90CV ( DV6UTED4)
The 1.6 MULTIJET 90CV 4-cylinder engine made entirely of aluminium is a first for Fiat. The main aim in
developing this engine was to achieve such a level of dependability as to ensure mileage of 240,000 km
or 15 years without any mechanical breakdown (values of dependability that do not concern warranty).
These aims have been achieved also thanks to a highly rigid production process, called “red card”. In
practice, each phase of assembly is carefully checked and if any trouble is found a red card is attached to
the engine to avoid other parts pointlessly getting fitted on that engine which is already assigned for
rejection.
•
•
•
•
•
Maximum power output of 66 kW (90CV) at 4000 rpm
Maximum torque of 180 Nm (18.3 kgm) at 1750 rpm
Reduced maintenance (every 30,000 km, timing belt 240,000km, hydraulic tappets)
Weight 120 kg
Exhaust emissions EURO 4
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Sixteen-valve engine with hydraulic tappets; the aluminium head is composed of two blocks: an upper
block housing the two camshafts joined together by a chain; and a lower block housing the valves.
The monobloc is made of aluminium alloy with cast-iron cylinder liners inserted.
The pistons are designed with an internal oilway, with the oil being sprayed by special nozzles to
better dispose of the heat.
The cast-iron connecting rods are fracture split.
The steel crankshaft has heat treated main journals and crank to withstand mechanical stress better.
The cast-iron main bearing caps are sunk in an aluminium casting (crankcase base).
The crankcase base is secured to the crankcase and gearbox with special screws, thereby forming a
rigid structure that limits crankshaft bending, reducing main journal noise and wear of the main
bearings and big end bearings.
The oil sump is made of aluminium in order to dispose of the heat better. It is closed at the bottom
with a plate cover which has the oil drain plug screwed in.
The motion of the timing system is transmitted from the crankshaft to the intake camshaft by a
toothed belt and from the intake camshaft to the exhaust camshaft by a chain.
The oil pump is a gear pump coaxial to the crankshaft.
The flywheel is a single piece and the clutch, with torsion springs, uses a pressure plate with a
Belleville thrust washer with no plate wear recovery system.
This engine features:
• a Bosch EDC16C34 multijet injection system with a CP1H BOSCH injection pump with three
pumping elements and a built-in transfer pump.
• a turbocharging system with air/air exchanger, fixed geometry turbine with wastegate and overboost system governed by the engine control unit.
• Exhaust gas recycling system composed of:
1. an EGR valve to let the exhaust circuit communicate with the intake circuit
2. a throttle valve in the intake circuit to create sufficient vacuum to increase the quantity of EGR.
• an exhaust system with catalyst
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Engine markings
b
a
c
d
Class of main bearing
housings
(stamped on
timing system
side)
Engine identification
a : manufacturer's
reference
b : regulation type
c : member
reference
d : manufacture
order number
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Industrial
machining marking
Year of manufacture
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Technical specifications of 1.6 Multijet Engine
Type of engine
Power
kW
power
Cv/DIN
output
output
DV6UTED4
66 KW
90 cv
Torque
180 Nm
Displacement
1560 cm3
Bore / Stroke
75 / 88,3
Turbo
Fixed geometry
Injection type
BOSCH EDC16.34
antipollution
Euro4
Particulate filter
none
All
aluminium
engine
120 kg
Gearbox
BE4
Fitting (angle)
Engine fitted at 0.4°
Injection system
Bosch Common Rail
(1600 bar)
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exploded view of engine
Monobloc
The monobloc is made of die-cast aluminium alloy. Suitable coolant and oil galleries are provided in the
walls.
The cylinder liners are made of cast iron and inserted dry (in direct contact with the metal of the
monobloc).
To improve the coupling between the cylinder liners and the aluminium monobloc, they are coated with a
layer of aluminium.
This enables: reducing the risk of cracking (due to different coefficients of expansion) in the zone between
the cylinders and improving liner heat disposal.
The following figures show the difference between a cylinder liner coated with aluminium and one
not coated.
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Cooling the top of the cylinders with galleries between the liners
Remarks: Facing the monobloc and boring the cylinders are not envisaged.
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Crankcase base
The crankcase base is made of aluminium alloy, with the cast-iron main bearing caps sunk into the
casting.
The finishing machining of the supports and main bearing caps is done together with the upper
crankcase.
The coupling with the upper crankcase is made with screws and centring pins, which ensure assembly
precision.
The crankcase base stiffens the monobloc, main bearing cap and gearbox assembly, limiting crankshaft
bending and thereby reducing main journal noise and wear of the bearings.
The features of the crankcase base:
•
•
•
•
•
Light alloy structure that integrates the five cast-iron caps of the crankshaft inserted in the
casting,
No spur for the position on the lower main bearings,
The crankcase base is secured to the casing-cylinders by 26 screws and 10 solid split pins,
(10 M9x125 for the caps and 16 M6x100 for the crankcase base).
Impermeability between the crankcase base and casing-cylinders is ensured by "single
component silicone."
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Cylinder head
1. camshaft support casing (tappet cover)
2. cylinder head
H height of cylinder head when new: H = 124 ± 0.05 mm.
Detail:
• material: aluminium alloy
• 4 valves per cylinder
• valve seats: steel
• steel intake valve guides
• steel exhaust valve guides
Permissible flatness error = 0.05 mm
Maximum permissible grinding = 0.4 mm
Cylinder head secured on monobloc with 10 TORX screws
Check length before reusing as prescribed in the manual
CONSTRUCTION
The cylinder head is made of aluminium and silicon alloy.
The four, parallel and vertical, valves per cylinder are fitted in their respective guides and operated by two
overhead camshafts whose cams act on the hydraulic tappets with roller rocker arms placed in between.
The valve guides are an interference fit in the seats in the cylinder head and the internal diameter is
perfected, after assembly, with a specific reamer.
Compared to heads with a pre-chamber, the entire combustion process takes place in the combustion
chamber obtained in the piston.
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1. intake camshaft
2. exhaust camshaft
3. rocker arm with roller bearing
4. hydraulic tappet
Hydraulic tappets
The valves are operated by roller rocker arms whose fixed support is a hydraulic tappet (b, with automatic
clearance recovery,).
a – roller rocker arm
b – hydraulic tappet
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Operation of hydraulic tappets
1 and 2 - Phase of clearance recovery between the cam and valves.
• When there is clearance, the piston (c) rises under the action of the spring (d). This movement
creates a vacuum in the lower chamber (e) that opens the valve (f).
• When the pressure is balanced between the chambers (g) and (e) the valve (f) closes under the
action of the spring (h), the two chambers are isolated.
3 – Compression stroke (valve opening).
When the cam rests on the rocker arm, the pressure in the lower chamber (e) rises and pushes the valve
(f), in its seat.
Thanks to this hydraulic block, the movement is transmitted entirely to the valve.
Camshaft support (tappet cover)
2
1. camshaft support
2. intake camshaft
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The camshafts are secured with supports to the tappet cover.
The intake camshaft is driven by the toothed belt of the timing system.
The two camshafts are linked together by a chain.
The exhaust camshaft drives the vacuum pump.
Construction
It is made of aluminium alloy and is secured to the cylinder head with screws. There is a bead of sealant
between the cover and the cylinder head to prevent oil leakage.
Head gasket
The cylinder head has a multi-layer metal gasket and it is not designed to be retightened for the entire life
of the engine.
There are five classes of gasket. The choice depends on the piston stand-out.
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“a” shows the type of engine on which it can be fitted
Engine type
Number of
reference marks
DV6 TED4
3
“b” shows the thickness
Number of
reference
marks
Gasket
thickness
1
2
3
4
5
1.35
1.25
1.30
1.40
1.45
Piston standout
DV6 TED4
0.685 - 0.734
0.533 - 0.634
0.635 - 0.684
0.735 - 0.784
0.785 - 0.886
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Albero motore
a
b
a. counterweight
b. crank pin
c. main journal
c
1
3
2
d. upper bearing
e. lower bearing
f. thrust bearings
the crankshaft is made of steel and has five supports and eight counterweights.
The side clearance is adjusted at the level of support 2 with two thrust shims.
There is only one class of thrust shims.
The crankshaft is closed between the monobloc and the crankcase base.
The seal between the monobloc and the crankcase base is ensured by a bead of sealant.
The upper bearings are identical and are identified by a mark of black paint.
Whereas there are three classes of lower bearings to be able to adjust the clearances of the shaft line.
These bearings are identified by a mark of paint corresponding to their class.
Fitting the lower bearings requires using a tool.
The upper bearings have a positioning spur.
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Bearing identification
The lower bearings are divided into three classes and are identified by colour.
They are made of aluminium alloy and have a screen-printed shell and an internal gallery for oil to flow
through for cooling.
A = BLUE
B = BLACK
C = GREEN
The choice of lower bearings is made with the aid of the following diagram.
Crankshaft
markings
(Timing system
side)
A B C D E G H I K M N P Q R S T U X Y Z
A
Markings on
cylinder casing
(Timing system side)
B
C
D
E
G
H
I
K
M
N
P
Q
R
S
T
U
X
Y
Z
Volano
CONSTRUCTION
Cast iron, with inserted steel ring gear.
The flywheel is secured to the crankshaft by a flange with bolts.
OPERATION
The flywheel is an energy storage device that stores energy during the power stroke and gives up energy
during the combustion stroke to smooth out engine rotation.
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Flywheel size is designed to enable engine idling and overcome friction developed during idling.
Pistoni
This member, on receiving the engine pulse directly from the pressure of the combustion gases, via the
connecting rod, transmits the drive to the crankshaft.
The piston comprises two parts:
• head, or area where the piston rings sit; its diameter is slightly smaller than the cylinder bore to
accommodate heat expansion.
• Skirt or guide block of the connecting rod small end which withstands its axial thrust. The skirt
accommodates two sleeves for the gudgeon pin.
They are made of aluminium alloy, with a toroidal sombrero-type of combustion chamber on the head,
suited for swirling the gases, and the seats for the valves.
The two areas of the skirt have a graphite coating, with a low coefficient of friction.
The gudgeon pin is the floating type and is held by two rings that prevent it from coming out.
The piston orientation is given by the arrow and the marking “Dist ".
An internal oilway has been made inside the pistons, with the oil being sprayed by special nozzles to
better dispose of the heat from the area of the head.
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Piston rings
In the area of the head of the piston there are three grooves accommodating three piston rings: two for
compression and seal to ensure gas tightness and in addition keep the sliding surfaces constantly lubricated and
a scraper ring that prevents the lubricant from flowing into the combustion chamber.
The seat of the first compression ring is made of steel to withstand the mechanical stress better.
The compression ring is a semi-inserted double trapezium. It is inserted in an appropriate steel seat.
The seal ring has a tapered profile and is coated with chromium to eliminate the risk of consumption.
The scraper ring is laminar with a spiral spring and chrome-plated tapered profiles.
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Connecting rods
The connecting rod is the main element joining the piston with the crankshaft. It is composed of a body or
leg, with a straight axis, that rigidly joins the connecting rod small end, pivoted to the gudgeon pin with a
bushing in between, and the connecting rod big end, pivoted in the button or crank pin with bearings in
between.
TT DV6 connecting rods:
1. connecting rod body
2. bearing shells
The connecting rod big ends are fracture split by an expanding mandrel after tracing with a laser.
Precautions for repairs.
• During disassembly, mark the bearing shells as there are no
reference marks.
• When fitting the lower bearing shells you need to use a specific
template as there is no positioning spur.
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Semi-cuscinetto
inferiore
Attrezzo
Attrezzo
Semi-cuscinetto
Gioco di
posizionamento
Gioco di
posizionamento
Semi-cuscinetto
Attrezzo
Camshaft drive
Features
The timing system is driven by a teflon toothed belt 25.4mm wide and equipped with 137 teeth.
Renewing the timing belt is not envisaged.
The belt drives the intake camshaft that in its turn drives the exhaust camshaft with a chain with
single links.
1
2
1. timing reference for camshaft pulley
2. timing reference for diesel pump pulley
3. timing reference for phonic wheel
3
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Riferimento di
fase
Pignone pompa
iniezione
galoppino
tenditore
Riferimento di
fase
Pompa acqua
Spring tensioner
CONSTRUCTION
Timing chain tension is controlled by an automatic tensioner that eliminates the need for tension
adjustments.
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Camshafts
The camshafts are tubular with steel cams, inserted.
The purpose of this method of manufacture is to decrease the weight.
The motion is transmitted from the crankshaft to the intake camshaft by a toothed belt and from the
intake camshaft to the exhaust camshaft by a chain with the hydraulic tensioner in between.
Shaft timing is done by making the two coloured links of the chain coincide with the marks on the
gears (7 links between the two marks).
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Fuel filter
The fuel filter is fitted on the engine on the flywheel side.
The fuel filter is equipped with a bleed valve (1), a moisture sensor (2) and a diesel heater (3).
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Air supply circuit diagram
1.
2.
3.
4.
5.
Air inlet
Air filter
Air flow meter
Turbo inlet
turbo noise attenuator
6.
7.
8.
9.
10.
Intercooler
Flow meter
air pressure sensor
air temperature sensor
oil vapour valve
Air route
1. The intake air passes via the filter (2)
2. It crosses the air flow meter (3) where the mass and temperature are measured
3. It passes via the turbine (4), where it is compressed to increase the volumetric efficiency of the
engine
4. It crosses the air/air heat exchanger (6) (intercooler) that lowers its temperature (this stage is
useful to recover the loss of air density due to the effect of the increase in temperature during the
compression stroke in the turbine).
5. The flow of air can be metered during the phase of action of the EGR by a throttle valve body (7)
to create a pressure difference that helps exhaust gas intake.
6. Immediately afterwards the pressure and temperature are detected via the relevant sensors (8)
and (9)
7. It is divided into the cylinders by the manifold.
Another two systems interact in the intake circuit:
• Oil vapour recirculation
• Exhaust gas recirculation
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Turbocharger
ADJUSTMENT VALVE
It is of the Fixed Geometry type and permits turbocharging.
The turbocharging pressure is regulated by the “regulating” valve.
Exhaust system
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Catalytic converter
EGR system
This system recirculates part of the exhaust gases to the intake under certain particular operating
conditions.
This lowers peak temperature in the combustion chamber so as to reduce nitrogen oxide (NOx) formation.
The E.G.R. solenoid valve governed by the injection control unit, performs the function of introducing some
of the exhaust gases taken from the exhaust manifold (4) into the engine intake.
A heat exchanger enables partial cooling of the exhaust gases thereby helping to lower the combustion
temperature and as a result the NOx.
The control percentage can vary from 0% (when you want to leave the passage of the exhaust gases
closed) to 100% (when you want to fully open the passage of the exhaust gases).
A position sensor is mounted on the EGR.
The injection control unit continually monitors the quantity of recycled gas via the information 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 - Quantity of recycled gases
The atmospheric pressure signal is used when controlling the E.G.R. solenoid valve to identify the
condition of driving at altitude so as to reduce the quantity of recycled gas and prevent engine
smokiness.
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Pin 1: + 5 V
Pin 2: Ground
Pin 3: EGR command (RCO)
Pin 4: EGR position signal
Pin 5: Ground
Resistances between:
• pin 2 and 3 = 4 ? (EGR motor)
• pin 1 and 5 = 5870 ? (potentiometer track)
• pin 1 and 4 = 0.17 ? (with EGR closed)
• pin 5 and 4 = 5950 ? (with EGR closed)
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Flow meter
In the intake circuit, between the intercooler and the intake manifold, there is a throttle valve body (air flow
meter) that is normally open; when commanded it reduces the flow of air so as to create a vacuum that
helps the gases from the EGR enter the intake. Its operation is therefore subordinate to that of the EGR.
1.
2.
3.
4.
5.
6.
Exhaust gas leaving the head
Solenoid valve for regulating and recycling
the exhaust gases
EGR heat exchanger
Flow meter throttle valve
Air/air exchanger ( intercooler )
Air leaving the turbo
The throttle valve moves by means of a motor governed by the engine control unit and its position is
controlled by a sensor as follows:
THROTTLE
VALVE
POSITION
Control
percentage
100%
99% and
1%
0%
Control
Return
signal in
relation
to
ground
Remark
1v
BSM
CCM
12v
12v
No difference in potential
between
1v and 4v
12v
Partial
grounding
Progressive increase in potential
difference by the CCM
4v
12v
Complete
grounding
12v potential difference
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Particular conditions
The flow meter throttle valve functions at constant speed or in acceleration with a temperature greater
than 15°C and altitude between 0 and 1000 m.
This means that with a temperature under 15°C and altitude greater than 1000 m the intake air flow is not
modified.
Crankcase oil vapour recovery system
The oil vapour emissions are controlled by a system of internal galleries that convey the vapours released
from the crankcase towards the cover (1) that produces partial condensation.
The already condensed vapours are sent to the air intake sleeve before the turbocharger.
There is a regulating valve on the vapour transfer cover with a spring that, under normal conditions, acts on
a diaphragm keeping it open, thereby allowing the oil vapours from the oil separator to flow through.
When the vacuum inside the pipe exceeds the spring setting, it moves the diaphragm thereby closing the
gallery from the oil separator preventing oil intake from the sump.
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Engine lubrication system
The system is originally filled with 6.2 litres of oil. For subsequent changes use 5.8 litres since it is
estimated that 0.4 litres remain in the circuit.
Circuit
The following figure shows the lubrication circuit.
Filtro olio a
cartuccia
Valvola anti
svuotamento
Scambiatore
acqua-olio
Pompa
olio
pescante
Spruzzatori olio
per pistoni
Ingresso lubrificante
Vite + Filtro
Ritorno lubrificante
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Detail of the Turbo Lubrication pipe
The Turbo Lubrication pipe is not rigid: it has articulated couplings at the ends.
With no oil pressure the pipe is slack, as soon as the oil pressurizes the pipe stiffens and the seal is
ensured.
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Oil pump
The oil pump is driven by the crankshaft. The impermeability between the oil pump and the cylinder
casing is ensured by a sealing paste. An anti-drain valve is fitted on the pump.
A pressure limiter (b) located on the lubrication line of the camshaft supports limits the pressure at the top
of the engine. An anti-drain valve (c) fitted in the head holds back a quantity of oil necessary for operation
of the tappets.
View of the oil pump
paraolio
Oil
Sede chiavetta
e zona spianata
Valvola
antisvuotamento
View of the head
pressure
The oil pressure values must be greater than 1.3 Bar at 1000 rpm and greater than 3.5 Bar at 4000 rpm.
The pressure is measured at the level of the oil filter using the reducer tool that replaces the oil filter
cover.
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Oil filter and heat exchanger
The paper filtering cartridge (h) is separated from the casing-cylinders by a specific support (f).
The latter also integrates a "water/oil" heat exchanger (g).
A valve (j) on the filtering cartridge helps drain off the oil after removing the cover.
f
j
g
h
f
-
Support
g -
Exchanger
h -
Cartridge
i
-
gasket
j
-
Valve (assembly reference)
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i
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Engine cooling circuit
The figure below shows the layout of the engine cooling circuit.
The dotted portion shows the additional heater circuit (OPT ).
1.
2.
3.
4.
Additional heater water pump
Additional burner
3-way solenoid valve
Additional water pump Additional
CLIM
5. ADD CLIM secondary radiator
6. Radiator
inside
passenger
compartment
7. Bleed screw
8. EGR exchanger
9. Water inlet coupling to the engine
coolant pump
10. Expansion tank
11. By-pass valve
12. Double acting thermostat
13. Radiator
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Coolant pump
Centrifugal vane pump secured to the crankcase and operated directly by the timing belt.
Thermostat
It is fitted on the rear side of the cylinder head, and is used to keep the engine at the optimum
temperature:
· with temperature < 83 ± 2°C the thermostatic valve (closed) conveys the coolant towards the coolant
pump.
· with temperature > 83 ± 2°C the thermostatic valve starts to open, until it is fully open at 95°C, diverting
the flow of coolant towards the radiator.
The engine coolant temperature sensor is fitted on the body of the thermostat and connected to the
Engine Control Node.
Supply/Expansion Tank
The tank feeds coolant to the circuit and takes up excess coolant when it expands from heat as engine
temperature rises.
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A calibrated valve in the sealed plug
•
•
lets air exit the circuit; this is the air drawn from the pipe coming from the thermostat.
air flows in when the circuit is in vacuum condition (due to engine cooling)
Fuel circuit
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List of Equipment for 1.6 Multijet 90CV Engine
Designation
Code
Blade
1,870,718,000
plate
1,845,028,000
plate
2,000,005,000
drift tool
1,870,465,000
drift tool
1,870,426,000
slide hammer
1,870,007,000
drift tool
1,870,632,000
drift tool
1,860,990,000
Flywheel locking tool
Wrench for r.i. Ring nut
on Fuel pump
2000022500
Valve guide drift tool
Valve spring
compressor cage
Cylinder head cover
centring pins
High pressure fuel
pump timing pin
Crankshaft pulley
timing pin
Camshaft pulley timing
pin
Corteco drift tool on
crankshaft flywheel
side
Corteco drift tool on
crankshaft timing
system side
Corteco drift tool on
camshaft
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2000022600
2000022700
2000022800
2000022900
2000023000
2000023100
2000023200
2000023300
2000023400
2000023500
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Function
Blade
plate
plate
drift tool
drift tool
slide hammer
drift tool
drift tool
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Glow plug pre-heating system
Engine oil temperature and level sensor
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Fuel temperature sensor
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Electro-injectors
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Fuel pressure sensor
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Rpm sensor
Timing sensor
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Overpressure sensor
Sucked air temperature
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Engine temperature sensor
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Air flow meter with incorporated air temperature sensor
Accelerator pedal potentiometer
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BOSCH EDC16C34 Engine management wiring diagram
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3.2 2.0 MULTIJET 120CV ENGINE ( DW10UTED4)
General information on the PCR system
The Common Rail system is the only diesel system in which there is no direct angular dependence
between the crankshaft and the generation of high pressure.
The SIEMENS Piezo Common Rail (PCR) diesel injection system is a latest generation Common Rail
injection system that uses injectors controlled by an electric Piezo actuator.
It is composed of the diesel Common Rail pump, high pressure pipe supply line and injectors controlled
by piezo actuators
The diesel Common Rail pump comprises:
volumetric control solenoid valve (VCV),
fuel internal transfer pump (ITP)
high pressure pump (HPP)
pressure control solenoid valve (PCV).
The conception of the diesel Common Rail pump permits rejecting the fuel as needed and therefore
increasing the efficiency of the diesel engine.
The fuel internal transfer pump (ITP) draws the diesel fuel from the tank and drives it into the volumetric
control solenoid valve (VCV). This regulated the quantity of fuel feeding the high pressure pump (HPP).
The fuel internal transfer pump and the high pressure pump are driven directly by the engine. The high
pressure pump drives the fuel into the supply line (bar) with a pressure that can go up to 1500 bar.
The high pressure pipes connecting the rail to the injectors.
The Piezo injectors permit very short command times and permit freely choosing the start and the
injected quantity according to the data required by the engine control unit (ecu)
The system pressure generated by the diesel Common Rail pump is optimally adjusted to every kind of
operation, irrespective of the engine speed.
Because of the reserve volume in the rail the injection pressure remains virtually constant throughout the
injection process.
The system authorizes pre-injection and main injection.
Pre-injection decreases the combustion noise level and, in many cases, reduces the emission of exhaust
gas.
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Key
1 air filter
2 air flow meter with intake air temperature sensor
3 turbocharger
4 catalyst
5 overpressure valve (Wastegate)
6 accelerator pedal
7 accelerator pedal sensor
8 coolant temperature sensor
9 crankshaft position sensor
10 high fuel pressure sensor
11 engine control unit (ecu)
12 fuel level sensor
13 fuel tank
14 starter hand pump
15 diesel fuel filter
16 diesel Common Rail pump with
a pressure control solenoid valve (PCV)
b high pressure pump (HPP) outlet
c volumetric control solenoid valve (VCV)
d fuel internal transfer pump (ITP)
17 pre-heating relay
18 fuel temperature sensor
19 rail
20 injector
21 camshaft position sensor
22 vacuum pump
23 exhaust gas recycling valve (EGR)
24 vacuum control solenoid valve (EPW) of the EGR
25 motorized air throttle valve
26 vacuum throttle control solenoid valve (EPW)
C1 cylinder 1
C2 cylinder 2
C3 cylinder 3
C4 cylinder 4
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Diesel Common Rail pump
D Diesel
C Common Rail
P Pump
The diesel Common Rail pump is composed of elements that are all incorporated in a single casing
Fuel internal transfer pump ITP
I Internal
T Transfer
P Pump
The fuel internal transfer pump is a rotary vane pump that draws fuel from the tank through the fuel filter
and supplies the high pressure pump.
Volumetric control solenoid valve VCV
V Volumetric
C control
V solenoid valve
The volumetric control solenoid valve controls the transfer of fuel into the high pressure part of the pump
and thereby permits supplying it as it requires.
High pressure pump HPP
H high
P pressure
P pump
The high pressure pump is a radial pump with 3 pistons and supplies the rail with the pressure necessary
for system injection.
Pressure control solenoid valve PCV
P pressure
C control
V solenoid valve
The pressure control solenoid valve controls the outlet pressure of the high pressure pump.
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Volume of the high pressure side
• high pressure pipe to the supply rail
• rail
• 4 high pressure pipes connected to the injectors
• high pressure sensor.
Piezo Injectors
The Piezo injectors permit very fast and exact metering of the quantity of fuel.
The Piezo injector opening and closing times are four times faster than with conventional systems,
permitting short and variable intervals between pre-injection and main injection.
Following table key:
1 diesel Common Rail pump:
a high pressure pump (HPP)
b fuel internal transfer pump (ITP)
c volumetric control solenoid valve (VCV)
d pressure control solenoid valve (PCV)
2 supply rail with high pressure sensor
3 injectors
A fuel in
B fuel return
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injectors
The Piezo injectors connected to the rail inject the fuel necessary for the various types of engine
operation into the combustion chambers.
The injection quantity per engine cycle is composed of a pre-injection quantity and a main injection
quantity. This division provides “smooth„ combustion for the diesel engine.
The opening and closing times are very short thanks to the Piezoelectric control.
The injected amount of fuel can therefore be controlled and proportioned very precisely.
The injectors are controlled by the engine control unit (ecu).
1 Piezo actuator
2 electric connector
3 high pressure connector
4 fuel return
5 injector head
6 injector stem
7 injector
1 high pressure connector
2 fuel return
3 connector connected to the engine
control unit (ecu)
4 Piezo actuator
5 mechanical amplifier lever
6 opening control piston
7 closing mushroom head
8 needle control piston
9 injector needle
10 high pressure chamber
11 injector orifices (5)
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Operation
• Injector not controlled:
The high pressure of the fuel from the rail comes through the high pressure supply line (1) into the control
chamber (2) and into the high pressure chamber (3) of the nozzle.
The fuel return opening (5) is closed by a mushroom head spring (4).
The hydraulic force (F1) applied by the high pressure of the fuel on the needle control piston (6) in the
control chamber (2) is stronger than the hydraulic force (F2) applied at the tip of the needle since the
surface area of the control piston of the needle in the control chamber is greater than the surface area of
the tip of the needle.
The nozzle orifice is closed.
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Injector controlled:
The Piezo actuator (7) acts in cascade on the amplifier lever (8), on the opening piston (9) and on the
closing mushroom head (4) that on opening sets the control chamber (2) in communication with the fuel
return.
There is a drop in pressure in the control chamber and the hydraulic force (F2x) applied at the orifice of
the needle is greater than the force (F1x) on the needle control piston in the control chamber.
The injector needle (6) rises and the fuel enters the combustion chamber through the 5 nozzle orifices.
With the engine stationary, the valve connecting the control chamber to the fuel return and the injector
needle is closed by the force of the two springs.
A small quantity of fuel is carried by the high pressure directly into the fuel return to lubricate the contact
between the injector needle and the needle guide.
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Injector markings
a: Manufacturer No.
b: PSA part No.
c: Year of production
X = 2000
A = 2001
B = 2002
C = 2003 ...
d: Month
A = January
B = February
C = March
...
L = December
e: Day
f Part No.
00001 – 99999
Common Rail pump
The variable high pressure diesel Common Rail pump is a radial piston pump designed for supply
adapting to need. It has three pumping units that are intervalled by an angle of 120°.
The diesel Common Rail pump generates high fuel pressure in the rail and thereby supplies the injectors
with the necessary amount of fuel for the types of engine operation
1 internal transfer pump ITP
2 volumetric control solenoid valve VCV
3 high pressure pumping unit
4 pressure control solenoid valve PCV
a fuel in
b high pressure connection
c fuel return
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Functional diagram of the diesel Common Rail pump
1 fuel internal transfer pump ITP
2 volumetric control solenoid valve VCV
3 pumping element of the high pressure part
4 pressure control solenoid valve PCV
5 overpressure valve
6 spring lubrication valve
7 filter-sieves
8 disc filter
a fuel in
b high pressure connection
c fuel return
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Fuel route in the diesel Common Rail pump (DCP)
The fuel internal transfer pump ITP (1) draws diesel from the tank through the fuel filter. The fuel is
afterwards driven towards the lubrication valve (6) and towards the volumetric control solenoid valve VCV
(21)
The overpressure valve (5), parallel to the fuel internal transfer pump, opens when the volumetric control
solenoid valve is closed and directs the fuel towards the fuel transfer pump.
The fuel reaches the interior of the pump via the lubrication valve (6) and from there goes to the fuel
return (C).
The volumetric control solenoid valve, governed by the engine control unit, determines the quantity of fuel
that supplies the elements of the HPP (3).
The high pressure outlets of the three pumping elements are gathered in a pipe and towards the high
pressure outlet (b) of the diesel Common Rail pump DCP.
Between the high pressure line and the fuel return there is the pressure control solenoid valve (4) that
governs the quantity of fuel that goes towards the high pressure outlet and in this way the fuel pressure in
the rail
Operation of the high pressure elements
• fuel intake:
When the piston (1) moves down it creates a vacuum in the pump cylinder that opens the inlet valve (2)
overcoming the strength of the spring. The fuel (a) coming from the volumetric control solenoid valve is
drawn in.
At the same time, the exhaust valve (3) closes due to the difference in pressure between the pump
cylinder and the pressure of the fuel in the circular gallery.
• fuel removal:
The cam (4) pushes the piston (1) upwards, the inlet valve (2) closes pushed by the strength of the spring
and the increasing pressure in the pumping cylinder.
The exhaust valve (3) opens when the pressure in the pumping cylinder is greater than the pressure of
the fuel in the circular gallery (b).
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Marking of the diesel Common Rail pump (DCP)
a manufacturer code number
b PSA spare parts No.
c year of production
T: 2000
U: 2001
V: 2002
W: 2003
X: 2004
LÀ:2005
Z: 2006
d week
e pump no. in the week's production
f end series control no.
Volumetric control solenoid valve VCV
The volumetric control solenoid valve VCV regulates the entry of fuel that goes from the fuel internal
transfer pump, incorporated in the diesel Common Rail pump DCP, towards the high pressure pumping
elements.
This permits drawing in only the amount of fuel needed by the engine.
The power consumption of the high pressure pump is reduced and engine efficiency is increased.
The volumetric control solenoid valve VCV is fitted sideways, directly on the diesel Common Rail pump
DCP.
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1 return spring
2 cylinder
3 piston
4 control coil
5 control pin
Operation of the volumetric control solenoid valve VCV
• volumetric control solenoid valve VCV not controlled:
The piston not controlled electrically blocks the passage of diesel into the high pressure pump. The piston
is held by the pressure of the return spring
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a) fuel supply from the internal transfer pump ITP
volumetric control solenoid valve VCV controlled:
The force of the control coil is proportional to the electric current that acts against the return spring
In this way the opening between the two connections is proportional to the electric current
a) fuel supply from the internal transfer pump ITP
b) quantity of fuel going to the high pressure pump HPP
Characteristic curve of the volumetric control solenoid valve VCV
Q) flow of fuel volume
I) control current
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3.3 TIMING BELT
3.3.1 Removal
- Remove the subsidiary member drive belt.
- Lock the engine flywheel with the specific
tool 1.860.846.000.
1. Remove the phonic wheel from the
crankshaft.
2. Unscrew the screws (2a) and the nut
(2b), take the bottom cover off the timing
system (2c).
1. Unscrew the screw (1a) and remove the
crankshaft pulley (1b).
- Remove the tool for locking the engine
flywheel.
1. Unscrew the screw (1a) and remove
the rpm sensor (1b).
1. Unscrew the screw (1a) and take the
top cover off the timing system (1b).
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1. Position the crankshaft in phase locking it
with the specific tool 1.860.863.000.
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3.3.2 Assembly
1. Centre the driving toothed pulley with the
specific tool 2.000.020.300.
- Lock the engine flywheel with the specific
tool 1.860.846.000.
1. Fit the toothed belt on the driven pulley
(1a) and lock it with a clamp (1b).
2. Tension the side “A” of the belt and fit it
onto the driving pulley.
3. Keeping the belt taut, fit it onto the pulley
driving the coolant pump (3a) then onto the
movable tensioner (3b).
1. Lock the driven toothed pulley (1a) with an
8 mmcalibrated pin (1b).
2. Loosen the screw (2a) and remove the belt
(2b).
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- Remove the clamp from the driven toothed
pulley.
- Remove the centring tool of the driving
toothed pulley.
1. Turn the movable tensioner (1a)
anticlockwise by using a suitable hex wrench
on the impression (1b) until the pointer (1c)
exceeds the reference mark (1d).
2. Tighten the screw fastening the movable
tensioner to the prescribed torque.
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1. Unscrew the screw (1a), turn the movable
tensioner (1b) anticlockwise by using a
suitable hex wrench on the impression (1c)
until the pointer (1d) is positioned on the
reference mark (1e). Tighten the screw (1a)
fastening the movable tensioner to the
prescribed torque.
- Turn the crankshaft 2 turns in the direction
of rotation of the engine and check that the
pointer of the movable tensioner has not
moved; if it has then do the belt tensioning
again.
1. Fit the engine rpm sensor (1a) into place
and tighten the screw (1b) to the prescribed
torque.
- Remove the calibrated pin locking the
driven toothed pulley.
- Remove the tool for the timing of the
crankshaft 1.860.863.000.
- Remove the tool for locking the engine
flywheel 1.860.846.000.
- Turn the crankshaft 10 turns in the direction
of rotation of the engine.
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1. Fit the bottom cover of the timing system
(1a) into place and screw on the screws
(1b) and the nut (1c).
2. Fit the phonic wheel into place on the
crankshaft.
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Lock the engine flywheel with the specific
tool 1.860.846.000.
1. Fit the auxiliary member belt drive pulley
(1a) into place, spread a specific threadlocking product onto the thread of the pulley
retaining screw, and tighten the screw (1b) to
the prescribed torque.
1. Fit the top cover of the timing system
(1a) and screw in the screw (1b).
- Remove the tool for locking the engine
flywheel 1.860.846.000.
- Fit on the subsidiary member drive belt.
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ìì
Tools for 2.0 MULTIJET engine overhaul
Designation
Code
Function
Counter-torque
1,860,846,000
Bracket
1,871,001,000
Clutch centre
2,000,020,600
Clutch kit
1,871,003,100
Extractor
2,000,020,200
Counter-torque
1,860,964,000
Flywheel locking
Engine support
Centre the clutch
Pressure plate
compression
Electro-injector
extraction
Disassembly/Assembly
driven toothed pulley
Disassembly/Assembly
driven toothed pulley
Grip
1,860,831,000
Cut sealant
Blade
1,870,718,000
Bracket
1,860,815,000
Goniometer
1,860,942,000
Piston ring tightening
tape
1,860,700,000
Drift tool
1,860,855,000
Crankshaft rotation
Tightening to angle
Fitting pistons in the
cylinders
Oil seal insertion
Piston stand-out
measurement
Dial gauge base
1,870,404,000
Drift tool
1,870,821,000
Oil seal insertion
Disassembly/Assembly
driven toothed pulley
Grip
1,860,831,000
Drift tool
1,860,806,000
Engine flywheel kit
Flywheel locking tool
2,000,020,700
1,860,863,000
Template
2,000,020,300
Corteco insertion on
crankshaft flywheel
side
Engine flywheel
centring
Crankshaft timing
Driving toothed pulley
centring
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Pliers
1,881,138,000
Bracket
1,860,470,000
Wrench
2,000,003,100
Valve retaining base
1,860,804,000
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Removal/insertion of
rings
Cylinder head support
Removal/tightening
heater plugs
Valve retainer
Valve extraction lever
1,860,644,000
Valve spring-pressing
lever
Compress valve spring
Cage
1,870,881,000
Pliers for valve oil
seals
1,870,894,000
Valve guide oil seal
extraction
Drift tool
2,000,020,800
Insert oil seals on valve
seats
Compress valve spring
Cage
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1,870,890,000
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4. GEARBOX
4.1 BE4R ( 1.6 MULTIJET 90CV )
MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL
DISMANTLING
-
Place the gearbox on the rotary stand
with the specific support.
1. Unscrew the gearbox drain plug and
remove.
1. Screw two retaining bolts (1a) onto the
support (1b).
1. Remove the reverse gear sensor.
2. Remove the gearbox air intake.
1. Unscrew the filler and level plug and
remove.
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1. Remove the beat assembly.
2. Unfasten the outer part of the fork from
the outside and remove it from the inside.
1. Remove the drive shaft oil seal.
1. Unscrew the retaining screws.
- Cut the bead of sealant with the specific
tool.
- TOOL_ 1.870.718.000
2. Remove the casing.
- Turn the stand.
1 Remove the drive shaft oil seal
2. Unscrew the retaining screws.
3. Remove the tachometer
assembly.
pinion
1. Remove the split pin retaining the fork.
- Engage 2nd gear.
- Engage another gear.
2. Remove the clip.
3. Unscrew the nut on the transmission shaft.
3. Unscrew the nut on the main shaft.
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1.
Using the extractor (1a) remove the retaining
washer (1b). Protect the shaft with the plug
(1c).
- TOOL_ 1.845.028.000
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1. Remove the hub assembly and the
engine pinion.
1. Remove the spacer and the supporting bush.
2. Unscrew the transmission shaft rotation
setscrews.
3. Unscrew the screw holding the shaft of the
reverse gear.
4. Remove the segment (use two tapered bits
and, if necessary, raise the shaft to help
free it).
5. Unscrew the screws and nuts fastening
the cover.
1. Extract the synchronizer by hand.
2. Remove the fork, levering on the side of
the rods.
Remove the box cover (use a mallet to free
the casing from the centring bushes).
1. Unscrew the retaining screw and remove
it.
2. Remove the fork rod fastener.
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1. Remove the oil vent.
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1. Unscrew the retaining screws.
2. Remove the differential cover.
1. Remove the differential assembly.
1. Remove the rod of the 5th gear.
1. Remove the two centring pins.
1. Free the fork rod and extract it upwards.
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1. Extract the pinion (1a) and the shaft (1b)
of the reverse gear.
2. Remove the shafts with the forks.
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1. Extract the idler fork.
1. Using a drift (1a), beat on the split pin
(1b) of the selector taking care to have it
come out into the specific seat and retrieve
it.
1. Unscrew one screw from the outside.
2. Remove the reverse gear fork.
1. Extract the split pin of the idler rod.
2. Extract the idler rod.
1. Remove the selector rod.
2. Remove the spring assembly of the
selector.
3. Remove the selector oil seal.
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1. Unscrew the retaining screws.
1. Remove the idler rod gasket.
1. Renew the rear plug of the selector lever.
Turn the stand.
1. Unscrew the retaining screws.
2. Remove the support of the main shaft.
3. Unscrew the pin of the bottom fork.
1. Remove and renew the plastic support of
the transmission shaft.
2. Remove the main shaft bearings.
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REASSEMBLY
- Fit the support of the main shaft in place in
its seat.
- Tighten the retaining screws to the stated
torque.
- Tighten the pin of the bottom fork to the
stated torque.
- Fit a new idler rod gasket into place in its
seat.
- Fit a new plastic support of the
transmission shaft in place in its seat.
- Fit a new bearing of the main shaft in
place in its seat.
- Fit the support of the selector in place in
its seat.
- Tighten the retaining screws of the
selector support to the stated torque.
- Fit the spring assembly of the selector in
place in its seat.
- Fit the selector oil seal gasket in place in
its seat.
- Fit the selector rod in place in its seat.
- Insert a new selector split pin.
- Fit the idler fork into place in its seat.
- Fit the idler rod into place in its seat.
- Insert the split pin of the idler rod.
- Fit the reverse gear fork into place in its
seat.
- Tighten the screw of the reverse gear fork
from the outside to the stated torque.
- Fit the shafts with the forks into place in
their seat.
- Fit the pinion and the reverse gear shaft
into place in their seat.
- Fit the two differential casing centring pins
into place in their seat.
- Fit the differential internal box into place in
its seat.
- Fit the differential casing into place in its
seat and tighten the related retaining
screws to the stated torque.
- Fit the fork rod into place in its seat.
- Fit the rod of the 5th gear into place in its
seat.
- Fit the oil vent into place in its seat.
- Fit the box cover into place in its seat,
centring it on the centring bushes.
- Tighten the retaining screws and nuts of
the cover to the stated torque.
- Fit a new segment of the transmission
shaft into place in its seat.
- Tighten the screw holding the reverse
gear shaft to the stated torque.
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- Tighten the transmission shaft rotation
setscrews to the stated torque.
- Fit the spacer and the supporting bush
into place in its seat.
- Fit the hub assembly and the engine
pinion into place in its seat.
- Fit the fork rod fastener into place in its
seat.
- Tighten the retaining screw and to the
stated torque.
- Fit the fork into place in its seat.
- Fit the synchronizer into place in its seat.
- Fit a new retaining washer into place in its
seat.
- Tighten the nut on the main shaft to the stated
torque.
- Tighten the nut on the transmission shaft to the
stated torque.
- Fit the clip into place in its seat.
- Engage the 3rd or 4th gear.
- Engage the 5th gear by hand.
- Fit a new fork retaining split pin into place
in its seat.
- Apply a bead of sealant along the surface
of contact of the gearbox.
- Fit the gearbox casing into place in its
seat.
- Tighten the gearbox casing retaining
screws to the stated torque.
- Fit the fork of the main shaft into place in
its seat, working from the inside.
- Fit the beat assembly into place in its
seat.
- Fit the tachometer pinion assembly into
place in its seat.
- Tighten the retaining screws of the
tachometer pinion to the stated torque.
1. Fit the axle output gaskets (1a) into place
in their seat using the specific drift tool (1b).
- TOOL _ 1.870.426.000
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- Tighten the filling and levelling plug to the
stated torque.
- Tighten the gearbox drain plug to the stated
torque.
- Fit the gearbox air intake into place in its
seat.
- Fit the reverse gear sensor into place in its
seat and tighten it to the stated torque.
- Support the gearbox with a hydraulic lift.
- Unscrew the fasteners and remove the
gearbox with the differential from the
supporting tool.
- TOOL _ 1.871.001.014 _ Support for
1.871.000.000 _ Support for fixing gearbox
for dismantling - TiT
- Remove the supporting tool from the
overhaul stand.
- TOOL _ 1.871.000.000 _ Rotary stand
supporting gearbox _ Fixing gearbox for
dismantling _ TiT
- Fit the gearbox with the differential in place
on a suitable board.
- Turn the stand.
1. Fit the axle output gaskets (1a) into place
in their seat using the specific drift tool
(1b).
- TOOL _ 1.860.990.000 _ Drift tool _
Corteco insertion _ 1.6
Tools for 1.6 MULTIJET 90CV Gearbox overhaul
Designation
Code
Adjuster for differential rolling
2000023600
extractor
extractor
extractor
Trade
472/1-2 usag
472A/2 usag
454 N/1 usag
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Function
extractor
extractor
extractor
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4.2 ML6C ( 2.0 MULTIJET)
MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL
Dismantling
1. Place the gearbox on the rotary stand (1a) with the
support (1b).
1. Cut the sealant with tool (1a) and remove the top
cover (1b).
1. Unscrew the screws (1a) and remove the
retaining flange (1b) of the transmission
shaft.
1. Unscrew the retaining screws.
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1. Engage a gear and keep the main shaft locked
with the tool.
1. Remove the drain plug.
1. Unscrew the ring nut on the main shaft (1a) and
the ring nut on the transmission shaft (1b), remove
the tool.
1. Unscrew the plugs (1a) and remove the springs
(1b) and the balls (1c).
1.
Unscrew the retaining screws of the gearbox gearing case.
1. Unscrew and remove the reverse gear sensor.
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1. Unscrew the retaining screws (1a) and remove the
gear engagement selection/actuator assembly (1b).
1. Cut the sealant with tool (1a) and remove the
gearbox gearing case (1b).
1. Remove the assembly of the selection fork rod and
reverse gear engagement shaft with related gearing.
1. Extract the oil conveyor.
1. Unscrew the retaining screws (1a) of the
differential flange (1b).
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1. Cut the sealant with tool (1a) and remove the
differential flange (1b).
1. Remove the main shaft and the transmission shaft
with the three forks.
1. Unscrew the retaining screws (1a) and the stud
(1b) and remove the cover of the differential (1c).
1. Remove the oil conveyor.
1. Remove the metal shavings magnet.
1. Remove the differential box.
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1. Remove the external rolling race of the thrust
bearing (1a) using the tool (1b) and the tool (1c).
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1. Remove the retaining base of the pressure plate
lever.
1. Unscrew the screws (1a) and remove the pressure
plate guide sleeve (1b).
1. Fit the retaining clips (1a) and remove the pressure
plate assembly (1b).
1. Remove the oil seal (1a) from the pressure plate
guide sleeve (1b).
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Reassembly
- Clean all the contact surfaces affected by the
sealant.
- Wash the complete gearbox case and the gearing
case.
1. Fit the fork comprehensive of joint and pressure
plate.
1. Fit the sealing gasket on the gearbox taking care
to make the oil passage on the gasket coincide with
the one on the box.
1. Fit the transmission shaft oil conveyor in its seat.
1. Fit the sleeve of the pressure plate (1a) and tighten
the screws (1b) to the prescribed torque.
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1. Fit the external race of the thrust bearing into place
in its seat.
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1. Fit the reverse gear shaft (1a) in its seat centring
the pin (1b) in the seat on the gearbox.
1. Fit the main shaft with the fork into place in its
seat.
1. Fit the gear selector/engagement
mechanism (1a) and the reverse gear fork
(1b).
1. Fit the transmission shaft with the forks into place
in its seat.
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1. Fit the reverse gear selector bracket (1a) and the
pin (1b).
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1. Remove the outer ring of the bearing supporting
the main shaft (1a) and the shim (1b) from the
gearing case by using tools (1c) and (1d).
1. Fit the oil conveyor onto the reverse gear control
rod.
1. Fit the shim (1a) and the outer ring of the bearing
supporting the main shaft (1b) in their seat using
tools (1c) and (1d).
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-Position the magnet in its seat in the gearing case.
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1. Engage a gear and keep the main shaft locked
with the tool.
1. Apply the sealant and fit the cover of the gearing
case. Tighten the screws to the prescribed torque.
1. Fit the oil conveyor gasket.
1. Fit the bracket fixing the transmission shaft (1a),
screw on the retaining screws of the main shaft (1b)
and of the transmission shaft (1c) to the prescribed
torque. Remove the locking tool.
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1. Use the dial gauge (1a) to check the end float of
the main shaft (1b) by applying pressure from the
bottom. The measured play must be between 0.06
mm and 0.15 mm. If the measurement is not between
0.06 mm and 0.15 mm renew the shim.
1. Fit the balls (1a), springs (1b) and screw on the
plugs (1c).
1. Apply the sealant, fit the cover (1a) into place and
tighten the screws (1b) to the prescribed torque.
1. Fit the differential box (1a) and the outer races of
the bearings (1b) and (1c) into place.
1. Fit the reverse gear sensor, screw down to the
prescribed torque.
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1. Fit the differential case cover (1a) and tighten the
screws (1b) to the specified torque.
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1. On the bench, insert a new oil seal gasket (1a)
onto the flange on the gearbox side (1b) using the
drift tool (1c) and (1d).
1. Apply the sealant, fit the flange (1a) on the
differential case and tighten the screws (1b) to the
specified torque.
1. Install a new oil seal gasket (1a) on the clutch side
using the drift tool (1b).
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- Fit the drain plug and tighten to the specified torque.
- Support the gearbox with a hydraulic lift.
- Unscrew the fasteners and remove the gearbox with
the differential from the supporting tool.
at the level of the differential shaft. The measured
play must be no greater than 0.10 mm. If the
measurement is greater than 0.10 mm renew the
crown side adjuster shim.
1. Using the tool (1a) and a torque wrench (1b),
check that the rolling torque of the side pinions and
crown wheels comes within the specified values
- Remove the supporting tool from the overhaul
stand.
- Fit the gearbox with the differential in place on a
suitable board.
PROCEDURE FOR CHECKING DIFFERENTIAL CLEARANCE
- Set the differential on the case side in a vice.
1. Using the tool (1a) and dial gauge (1b) check the
axial play of the differential by applying pressure from
the bottom in the seats (1c) with two screwdrivers.
The tool (1a) should be positioned so that the lower
grooves stay at the level of the differential shaft. The
measured play must be no greater than 0.10 mm. If
the measurement is greater than 0.10 mm renew the
case side adjuster shim.
- Set the differential on the crown side in a vice.
- Using the tool and dial gauge check the axial play of
the differential by applying pressure from the bottom
in the seats with two screwdrivers. The tool (1a)
should be positioned so that the lower grooves stay
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Tools for 2.0 Multijet Fiat NScudo Gearbox overhaul
Designation
Code
Function
Fixing gearbox for
dismantling
Rotary stand
supporting gearbox
1,871,000,000
Support for fixing
gearbox for dismantling
Support for
1.871.000.000
1,871,001,014
Blade
1,870,718,000
Sealant removal
Main shaft stop
2,000,021,200
Main shaft locking
Reaction plate
1,870,808,000
Bearing removal
Plates
Plates
1,846,992,000
2,000,005,000
Slide hammer
1,875,088,000
Drift tool
1,870,152,000
Fitting main shaft
bearing
Drift tool
1,870,899,300
Fitting main shaft
bearing
Drift tool
1,860,488,000
Fitting bearing
Grip
1,874,365,000
Fitting bearing
Slide hammer
2,000,004,700
Transmission shaft
bearing disassembly
Drift tool
Drift tool
Drift tool
1,870,632,000
1,875,059,000
1,870,658,000
Adjuster
2,000,021,100
Drift tool
1,874,088,000
Transmission shaft
bearing disassembly
Supporting plates
Removal/fitting main
shaft bearing
Fitting transmission
shaft bearing
Fitting corteco
Bearing drift tool
Tool to check end float
Bearing drift tool
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Designation
Code
Function
USAG tool
468/2
Bearing removal
USAG tool
468A/6
Bearing removal
Removal/fitting main
shaft bearing
USAG extractor
427A/3
USAG tool
Usag 472/3
Bearing removal
USAG tool
Usag 472A/3
Bearing removal
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5. BRAKING SYSTEM
5.1 ABS BOSCH 8.0
Braking system
General
The ABS Bosch 8.0 system, an integral part of the braking system, prevents one or more wheels locking and as a
result slipping on a slippery road surface or when braking sharply, thereby ensuring vehicle control even during
emergency braking.
The ABS system has a hydraulic control unit with 8 solenoid valves (12 for ESP versions), 4 active
sensors and 4 channels with electronic braking force distribution (EBD) , which permits dividing the braking
action between the front and rear wheels.
System diagram
On a braking system with rear disc brakes, the parking brake is obtained in the disc brakes with a system
called “Drum in Hat” that consists of a drum brake inside the brake disc.
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Functional diagram
The following figures show the functional diagrams for the ABS 8.0 braking system with and without ESP.
Diagram of ABS without ESP
Diagram of ABS with ESP
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Functional diagrams key:
1. Front left wheel sensor
2. Front right wheel sensor
3. Rear left wheel sensor
4. Rear right wheel sensor
5. Brake wear switch
6. Brake fluid switch
7. ABS control unit
8. Body Computer
9. Instrument panel
10. Engine control unit
11. Steering angle sensor
12. Yaw/side acceleration and longitudinal acceleration sensor
13. High speed Can line ( HS IS )
14. Comfort Can line ( LS )
15. Brake lights control signal
16. ESP cut-out switch
17. Brake pedal switch
18. BSM Engine compartment fuse box
E. Solenoid valves inside the ABS electro-hydraulic unit
M. Electric motor of the ABS electro-hydraulic unit
P. Pressure sensor inside the ABS electro-hydraulic unit
+APC: Key-controlled power supply
Functions of the ABS system
The ABS 8.0 braking system incorporates the following functions:
- ESP ( Electronic Stability Program )
- ASR ( Antislip Regulator )
- MSR ( Motor Speed Regulator )
- HH ( Hill Holder )
- HBA (Hydraulic Brake assistant )
ESP ( Electronic Stability Program )
This is a vehicle stability control system that helps maintain directional control if the tyres lose grip.
The system triggering is signalled by a warning light blinking on the instrument panel to tell the driver that the
vehicle has critical conditions of stability and grip.
The ESP system automatically engages on starting the vehicle and can be turned off by pressing a button (A) among
the central controls on the dashboard.
Turning off is signalled by the LED (B) on the button lighting up.
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In the event of trouble the ESP system cuts out automatically and the warning light comes on steady on the
instrument panel.
ASR SYSTEM (Antislip Regulator)
This is a traction control system for the vehicle that trips automatically if one or both driving wheels slip.
Two different control systems are actuated, depending on the slip conditions:
if both driving wheels slip, the ASR trips reducing the power output transmitted by the engine;
if only one driving wheel slips, the ASR comes into operation by automatically braking the slipping wheel.
The action of the ASR system is especially useful under the following conditions:
inside wheel slipping on a bend, due to dynamic changes in the load or excessive acceleration;
excessive power transmitted to the wheels, even depending on the road surface conditions;
vehicle acceleration on slippery, snow-covered or icy road surfaces;
loss of grip on a wet surface (aquaplaning).
The ASR automatically turns on every time the engine is started.
Turning off the ESP system automatically turns off the ASR system too.
If the ASR is turned off while driving, when later starting it will automatically turn back on again.
When driving on a snow-covered surface with snow chains fitted, it may be useful to turn off the ASR: under these
conditions the slip of the driving wheels in the pick-up phase makes greater traction possible.
In the event of trouble the ASR system cuts out automatically and the warning light comes on steady on the
instrument panel.
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WARNING: For the ESP and ASR system to work properly it is essential for the tyres to be of the same brand and
type on all the wheels, in perfect condition and above all of the specified type, make and size.
MSR ( Motor Speed Regulator )
This system is an integral part of the ASR that trips in the event of a sharp change of gear when climbing, giving
torque back to the engine and thereby avoiding excessive drive of the driving wheels
that, especially when there is poor grip, can lead to a loss of stability of the vehicle.
HH ( Hill Holder )
This is an integral part of the ESP system that helps hill starts.
It is turned on automatically under the following conditions:
• uphill: vehicle stationary on a road with a gradient steeper than 5%, engine running, clutch and brake
pedals pressed and gearbox in neutral or any gear engaged other than reverse.
• downhill: vehicle stationary on a road with a gradient steeper than 5%, engine running, clutch and brake
pedals pressed and reverse gear engaged.
Operation : In the pick-up phase the ESP system control unit keeps the braking pressure at the wheels until the
driving torque needed for starting is reached, or anyhow for a maximum time of 2 seconds, making it possible to
easily move the right foot from the brake pedal to the accelerator.
After the 2 seconds, without starting, the system automatically turns off, gradually releasing the braking pressure.
During this release phase it is possible to hear a typical mechanical uncoupling noise from the brakes, indicating that
the vehicle is about to move.
Any trouble with the system is signalled by the warning light on the instrument panel.
WARNING The Hill Holder system is not a parking brake, therefore do not leave the vehicle without applying the
handbrake, switching off the engine and engaging the first gear.
HBA (Hydraulic Brake assistant )
Electro-hydraulic braking assistant that automatically increases the pressure of the braking circuit during
panic braking.
Component layout
ABS control unit
The electronic control unit is incorporated in the electro-hydraulic assembly and is located in the engine
compartment on the left-hand side.
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Yaw/side acceleration and longitudinal acceleration sensor
This sensor is located in the middle of the vehicle between the two front seats. It is interfaced with the
electric system via the high speed CAN line ( HS IS ).
This sensor is used by the ESP and Hill Holder system.
Steering wheel angle sensor
The steering wheel angle sensor is incorporated in the stalk unit.
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Wiring diagram of ABS without ESP
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Wiring diagram of ABS with ESP
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Wiring diagrams key:
21-- : brake lights control signal ( from Body Computer )
2100: brake lights control signal ( from Body Computer )
44-- : Brake pad wear switch
4410 : Brake fluid switch
7010: rear left wheel sensor
7015: rear right wheel sensor
7020: ABS control unit
7308: Brake pedal switch
7800: ABS control unit
7810: front left wheel sensor
7815: front right wheel sensor
CAV : Steering angle sensor
Capteur ESP : Yaw/side acceleration and longitudinal acceleration sensor
Combinè: Instrument panel
CMM: Engine control unit
CV00 : MODULE DE COMMUTATION SOUS VOLANT (COM 2000)
C001 : Diagnosis connector
CTC-PLAQ-AVO: Brake wear switch
CAP COS ARG : Rear left wheel ABS sensor
CAP COS ARD : Rear right wheel ABS sensor
CAP COS AVG : Front left wheel ABS sensor
CAP COS AVD : Front right wheel ABS sensor
BCM2: Controls cluster on the dashboard
BFDB : Max fuses on the battery positive cable
BB00 : Battery
CA00 : Ignition block
PSF1 : PLATINE DE SERVITUDE-BOITE FUSIBLES
BSI : Body Computer ( NBC )
BSM: Engine compartment fuse box
0004 : Instrument panel
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5.2 PARKING BRAKE (ADJUSTMENTS)
Parking brake with cable tension adjuster
The parking brake uses a cable with a cable tension adjuster device.
4. Mechanical divider
5. Left secondary cable
6. Right secondary cable
7. Rear axle
Key:
1. Cable towards passenger compartment
lever
2. Automatic adjuster
3. Main cable
Position of components
The parking brake adjuster device is located under the vehicle on the driver's side (LH).
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A: adjuster device B: Main cable C: Mechanical cable divider
Parking brake tension adjuster device
The figure shows the internal composition of the adjuster device.
Key:
1. Cable (towards parking brake lever)
2. Body of the device
3. Spring
4. Nut
5. Screw
6. Main cable sheath
7. Movable part
8. Fixed part
Operation of the tensioning device
The tensioning device has two operating positions:
- locked 1.B (padlock closed),
- unlocked 2.S (padlock open).
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1.B : device locked 2.S : device unlocked
In position (1.B) the screw and nut are locked and cannot slide since the saw-tooth portion (3 and 6) of
the screw and nut is aligned. In this position no adjustments are possible.
In position (2.S) the screw and nut are unlocked and therefore the screw can slide because the saw-tooth
portion (3) of the screw (1) coincides with the smooth portion (5) of the nut (2).
In this position, pushing the main sheath towards the device adjusts the tension of the parking brake
cables.
Note: Do not leave the adjuster device in the unlocked position (position 2.S).
5. Smooth part of the nut
6. Knurled part of the nut
1.B Rotation to lock the device
2.S Rotation to unlock the device.
Key:
1. Screw
2. Nut
3. Knurled part of the screw
4. Smooth part of the screw
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Procedure for parking brake cable tension adjustment.
1 Set the vehicle on a lift to provide access to
the underbody.
2 Turn the bottom and align the arrow on the
device with the open padlock.
10 Raise the lift to provide access to the
underbody
11 Turn the bottom and align the arrow on the
device with the open padlock.
3 With one hand grip the main sheath of the
parking brake and push towards the device to
align the yellow reference mark with the
impermeability joint.
12 Turn the bottom and align the arrow on the
device with the closed padlock.
4 Turn the bottom and align the arrow on the
device with the Closed padlock.
13 Lower the vehicle until the wheels make
contact with the ground.
14 Get into the vehicle and operate the
handbrake lever 15 times.
15 Get out of the vehicle and make sure the
parking brake is disengaged.
16 Raise the lift to provide access to the
underbody
17 Turn the bottom and align the arrow on the
device with the open
padlock.
5 Lower the vehicle until the wheels make
contact with the ground.
6 Get into the vehicle and start the engine.
7 Operate the brake pedal 3 times.
8 Switch off the engine.
9 Get out of the vehicle.
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18 Turn the bottom and align the arrow on the
device with the closed padlock.
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19 Using a torque wrench measure 8Nm at
pick-up (that is when the wheel starts to turn)
without knocking.
Note:
- Turn the wheel in the vehicle's direction of
travel.
- Parking brake disengaged.
20 If the measurement exceeds 8 Nm, carry out
the parking brake adjustment procedure again
.
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6. STEERING
6.1 Hydraulic power steering ( 1.6 MULTIJET 90 CV )
The power steering with belt-driven hydraulic pump is the type with variable assistance in relation to the
engine speed.
The operating principle is tied to the characteristics of the pump that reduces the oil flow rate and as a
result the level of interlocking as the engine rpm increases.
Key:
1 - power steering box
2 - steering column coupling
3 - power steering fluid tank
4 - power steering pump
5 - pipes
6 - cooling coil (where applicable)
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6.2 POWER STEERING WITH ELECTRO-HYDRAULIC INTERLOCK (2.0 MULTIJET )
The following figure shows a diagram of the power steering system with pump driven by an electric motor.
5. High pressure pipe (pump outlet)
6. Return pipe
7. Pump assembly ( GEP )
8. Coil for oil cooling
Key:
1. Power steering
2. Return pipe
3. High pressure pipe (power steering inlet)
4. OIl top-up tank
Functional diagram
The following figure shows the flow of information needed for operation of the power steering system with
an electric pump.
The GEP control unit receives the following information from the CAN HS IS network:
A : Thermal status of the engine
B : Steering wheel rotation speed
C : Vehicle speed
D : Interlock status
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According to this information the control unit (ECU) commands the electric motor (M) of the steering
interlock hydraulic pump.
In its turn the GEP control unit sends the Interlock Status (D) to the Body Computer Node (NBC) via the
Can HS IS network.
Operation
GEP system interlock is obtained by changing the speed of rotation of the electric motor of the pump
assembly.
The reference parameters are:
Vehicle speed
Steering wheel angle speed
The following graph illustrates the interlock map.
3
2
1
Example: ( B: 20 Km/h - C: 240 °/s )
The vertical passing through point (1) determines the command strategy (2) on the graph for the electric
motor of the mechanical oil pump. This command is translated into keeping the electric motor at an exact
number of revs (3) that, in its turn, determines a certain pressure in the hydraulic circuit corresponding to
the required level of steering interlock.
Graph key:
A: Electric motor revs ( GEP )
B: Vehicle speed
C: Steering wheel angle speed
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Motor pump assembly
The motor pump assembly is composed of three main sections:
Electric motor section ( 7 )
Central section accommodating the electronic control unit (1 )
Mechanical gear pump section ( 3 )
Key:
1.
2.
3.
4.
5.
6.
7.
Electro-hydraulic steering control unit.
Electric connectors.
Oil pump cover/tank.
Oil outlet (high pressure)
Oil inlet from the oil top-up tank
Oil return inlet
Pump electric motor
Pump assembly location
The following figure shows the position of the pump assembly ( GEP ).
The pump assembly is located in the area of the left wheelhouse.
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Oil top-up tank location
The figure below shows the position of the oil top-up tank.
The oil top-up tank is located in the engine compartment on the left-hand side.
Pump dismantling
The figures below illustrate the details of the power steering system oil pump.
This pump is divided into three parts:
- A : Pump cover and seat of the oil pressure regulator valve.
- B : Support of the gear pump (D) and oil intake and compression chamber.
- C : Base of the pump and interface with the electric motor. Here is the seat of the H.P. oil outlet
- D : Oil gear pump
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Pump operation
The oil enters through the coupling ( 7 ) filling the oil tank ( 5 ). The mechanical pump ( 1 ) draws in oil
through the line ( 2 ) and drives it through the outlet ( 6 ). The high pressure oil supplies the power
steering system through the coupling ( 8 ).
If the safety pressure threshold is exceeded, the mechanical spring valve ( 4 ) opens activating a by-pass
( 3 ) between the high and low pressure.
5. Oil tank
6. Oil outlet from mechanical pump (high
pressure)
7. Oil inlet from the oil top-up tank
8. Oil outlet for steering box (high pressure)
Key:
1. Oil mechanical gear pump
2. Mechanical pump oil inlet
3. Oil outlet from pressure regulator
4. Pressure regulator
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Electro-hydraulic steering control unit
The electro-hydraulic steering control unit is an integral part of the motor pump assembly.
The electronics incorporate:
A temperature sensor to prevent excessive and hazardous overheating.
A Hall effect sensor to measure the speed of the electric motor.
Electro-hydraulic steering control unit pin-out
Connector A ( 3-way )
Pin
Description
1
Can H
2
+ 15 ( +APC )
3
Can L
Connector B ( 2-way )
Pin
Description
1
+30 ( + Batt )
2
Ground ( GND )
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Wiring diagram
Wiring diagram key:
7122 : Power steering control unit (GEP)
BSI : Body Computer ( NBC )
BB00 : BATTERY
BFDB : Max fuses on the battery positive cable
MFAV : Safety fuse
CA00 : Ignition block
C001 : DIAGNOSIS CONNECTOR
CV00 : SWITCHOVER MODULE UNDER STEERING WHEEL (COM 2000)
MC58 : Ground
M000 : Battery ground
PSF1 : SERVICES FUSE BOX PLATE
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7. SUSPENSION SYSTEM
7.1 STANDARD REAR SUSPENSION SYSTEM
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7.2 PNEUMATIC REAR SUSPENSION SYSTEM WHERE APPLICABLE
Description of the system
Most industrial vehicles are subjected to load constrictions for thousands of miles. This use
generates mechanical stress on the suspension, reduction in drive, but above all it alters the
vehicle's dynamic behaviour.
The air suspension remedies these drawbacks by allowing vehicles equipped with it to keep in
good running trim no matter what load is transported.
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The rear air suspension equips some versions shown in the following table:
Rear air suspension
Rear air suspension with air
reserve
Van
L1
O
Van
L2
S
Combi
L1
O
Combi
L2
S
Combi
L3
-
O
S
O
O
S
The system can operate in the following modes:
- Automatic corrections, both lengthways and vertically, to bring the vehicle back into its reference
trim ( Fig. 2–3 ) on exceeding the speed of 10 Km/h
- Manual with two optional push-buttons (up/down) on the rear right-hand pillar, with the vehicle
stationary ( Fig. 1-2 ).
Fig. 1
Fig. 2
Fig. 3
In addition the system can interact with the ESP system, which constantly sends the suspension
control unit the transverse acceleration and steering wheel angle, which prevents trim adjustment,
in automatic mode, according to the following thresholds:
1] 0.5 g for speeds < 50Km/h
2] 0.2-0.3 g for speeds > 50Km/h
Beyond these thresholds the suspension control unit, on detecting a height difference (driver or
passenger side) of the vehicle 4mm greater than the reference, activates correction to restore trim.
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Suppliers
The system components are made by the following firms:
- Compressor : WABCO
- Control unit and Software: WABCO
- Pneumatic spring: Vibracoustic
- Air reserve tank: WABCO
- Pipes and couplings: MGI
System composition
The rear air suspension with Adjustable Load Height is composed of:
Standard circuit:
- 1 System electronic control unit
- 2 Air springs
- 1 Compressor assembly / 3 solenoid valves
- 1 Pressure sensor
- 1 Compressor ambient air temperature sensor
- 2 Height sensors
- 1 Passenger compartment air intake filter
- 4 Air pipes
- 1 System failure and system inhibition warning light
Complete circuit:
- 1 Compressor assembly / 4 solenoid valves
- 1 Push-buttons / switch unit
- 1 Loading deck height variation inhibition warning light
- 1 Buzzer
- 1 Air reserve tank
Key:
1. Electronic control unit
2. Compressor assembly
3. Air tank
4. Right air spring
5. Left air spring
6. Right height sensors
7. Left height sensors
8. Switch unit
9. Buzzer
10. Battery
11. BFDB ( fuses )
12. BSI ( Body Computer )
14. MFAV ( fuses )
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System electronic control unit
The system control unit is connected to the Can IS network and is located in the engine
compartment near the left headlight.
NR
MR
The electronic control unit, besides managing vehicle height control, ensures the system
components receive the correct supply of electric power according to the following table:
Component
Left height sensor
Right height sensor
Pressure sensor
Push-buttons (up/down)
Inhibition switch
Power supply (Volt)
5V
5V
12V
12V
12V
Control Unit Pin Out
The control unit supplied by WABCO is fitted with two 28 pin connectors
NR
1
6
19
MR
5
18
28
1
6
19
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18
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CONNECTOR ( MR )
Pin
1
2
3
4
5
6
7
8
9 - 13
14
15 - 28
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14 - 15
16
17
18
19
20
21
22
23
24
25
26
27
28
Description
(+) Battery direct ( B7715 )
(+) Pump motor supply ( 787 )
n.c.
(-) Pump motor ground ( 788 )
(-) Control unit ground ( M7715 )
(+) Manual height reduction control ( 7707 )
(+) Manual height increase control ( 7706 )
(+) Push-button power supply ( 7870 )
n.c.
(+) System inhibition button LED control ( 7890 )
n.c.
CONNECTOR ( NR )
Description
(+) Compressor Solenoid Valve Power Supply ( 7880 )
Left spring solenoid valve control ( 7882 )
Right spring solenoid valve control ( 7881 )
Air discharge solenoid valve control ( 7884 )
Tank solenoid valve control ( 7877 )
Can IS – H network ( 9000 ) connection with ABS
(-) Left height sensor ground ( 7741 )
Can IS – H network ( 9010 ) connection with BSI
Left height sensor signal ( 7742 )
(+) Left height sensor power supply ( 7740 )
(+) Pressure sensor power supply ( 7885 )
Pressure sensor signal ( 7887 )
(-) Pressure sensor ground ( 7886 )
n.c.
(+) Information on status of activity/wake-up of control unit - RCD (
7842)
(+) Buzzer command ( 7780 )
n.c.
Can IS – L network ( 9001 ) connection with ABS
(-) Right height sensor ground ( 7744 )
Can IS – L network ( 9011 ) connection with BSI
Right height sensor signal ( 7745 )
(+) Right height sensor power supply ( 7743 )
(+) Electronic control unit power supply ( BE771 )
n.c.
(-) System inhibition manual control ( 7891 )
Air temperature sensor signal ( 7888 )
(-) Air temperature sensor ground ( 7889 )
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Air springs
There are two air springs used on the rear suspension and the air capacity of
each cushion is 2.5 litres at a pressure of 4 bar.
Key:
1. air coupling ( in/out ) - 2. air cushion - 3. cone
Location of air springs
The air springs are connected to the body by the top (3 ) and the bottom ( 2 ) to the arm of the
suspension.
Key:
1. air coupling ( in/out ) - 2. bottom spring support – 3. top spring support
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Compressor assembly
The compressor assembly is entirely enclosed in casing with no oil. Depending on whether there is
an additional air tank, there are two versions:
- compressor assembly (with no additional air tank).
- compressor assembly (with additional air tank).
The compressor uses an air flow rate of 15 litres a minute.
The compressor assembly is composed of:
- 1 Piston
- 1 Air inlet single-acting valve (on the head of the piston)
- 1 Connecting rod (lubricated for life)
- 1 Cylinder
- 1 Electric motor
- 1 Granule air dehumidifier
- 1 Pressure sensor
- 1 Compressor ambient air temperature sensor
- 3 solenoid valves with no additional air tank or 4 solenoid valves with additional
air tank
The compressor can be divided into 4 main sections:
- section ( A ): cylinder – piston ( Fig. 1 )
- section ( B ): electric motor ( Fig. 1 )
- section ( C ): solenoid valve unit ( Fig. 1 )
- section ( D ): dehumidifier unit ( Fig. 2 )
Fig. 1
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Fig. 2
Air pipe couplings on compressor assembly
The pump assembly is fitted with couplings for the related pipes.
The figure below shows the following:
1. air pipe coupling “RH air spring“ ( diameter 4 mm )
2. air pipe coupling “LH air spring“ ( diameter 4 mm )
3. pipe coupling “Additional tank” ( diameter 6 mm )
4. pipe coupling “Air pump intake“( diameter 10 mm )
Compressor control management
The time it takes for the compressor to switch on depends on the surrounding temperature of the
compressor.
The compressor ambient air temperature, measured by a specific sensor, is sent to the air
suspension control unit that, whenever the temperature exceeds the critical threshold, stops the
operation of the compressor and solenoid valves.
This condition is saved as an error condition ( 95°C ).
The compressor is switched back on when the temperature falls to a safe level after a time of 10
min.
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The longest working time for the compressor is 3 min. The stoppage required between 2 uses is 3
min. It is doubled after another two cycles of operation. During the phase of stopping the
compressor the control unit inhibits any request for moving the loading deck, signalling it with an
audible warning.
Actions
Inflation
springs
2S
T max :
3min
T max :
3min
T max :
3min
T max :
3min
T max :
3min
T max :
6min
Push
Start
T [ms]
3 beeps of the Buzzer: impossible to activate inflation
Functional diagram of compressor without air reserve
The diagram below shows the electric connections and air lines inside the compressor for the
system without an air reserve tank.
Functional diagram of compressor with air reserve
The diagram below shows the electric connections and air lines inside the compressor for the
system with an air reserve tank.
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Functional diagrams key:
1. Air discharge solenoid valve
2. Left air spring solenoid valve
3. Right air spring solenoid valve
4. Air reserve tank solenoid valve ( * )
5. Compressor motor
6. Pressure sensor ( * )
7. Compressor ambient air temperature sensor
8. Air inlet
9. Outlet for air reserve tank ( * )
10. Air outlet for left air spring
11. Air outlet for right air spring
Note: ( * ) : Specific component for system with air reserve
Compressor assembly Pin Out with and without air reserve
CONNECTOR A ( NR )
Pin Wire
Info
1
788 (-) Pump motor ground
2
787 (+) Pump motor supply
CONNECTOR B ( NR )
Info
Pin Wire
1 7880 (+) Solenoid valve power supply
2 7881 Right spring solenoid valve control
3 7882 Left spring solenoid valve control
4 7877 Tank solenoid valve control ( * )
5 7884 Air discharge solenoid valve control
6 7885 (+) Pressure sensor power supply
7 7886 (-) Pressure sensor ground ( * )
8 7887 Pressure sensor signal ( * )
9 7888 Air temperature sensor signal
10 7889 (-) Air temperature sensor ground
Note: ( * ) : Function only present for system with air reserve
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Height sensors
Two height sensors are fitted (output signal in PWM) for both the right and left sides of the vehicle.
A height difference ( > 4mm ) signalled by the related right and left sensors causes a correction
operation to bring the vehicle back into its reference trim.
Besides providing information on the height of the vehicle, the sensors allow the control unit to
check blocking during the movement (anti-crushing function). In effect, if the sensors detect
blockage of the movement of one or both shock absorbers up or down, the system blocks and
moves back by 3mm.
For the system to work properly, these sensors need calibration with the aid of the diagnosis
instrument.
Location height sensors
The height sensors are connected between the body and the right and left oscillating arm of the
suspension, as shown in the figures below:
Left height sensor
Right height sensor
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Height sensors Pin Out
The following tables show the electric connections between the sensor and electronic control unit
of the air suspensions:
Pin 1 = (+) Power supply
Pin 2 = Signal ( PWM )
Pin 3 = Ground
Left height sensor 7753
Sensor
Control unit
pin
pin
1
NR 10
2
NR 9
3
NR 7
Right height sensor 7754
Sensor
Control unit
pin
pin
1
NR 23
2
NR 22
3
NR 20
Height sensor characteristics
Angle of measurement: +/- 45°
Power supply voltage: 5 V +/- 0.25 V
Input current: < 15 mA
Working temperature: from - 40° C to +125° C
Output signal: PWM at 200 Hz +/- 25 Hz
PWM use: from 12.5%(+45°) to 87%(-45°)
Support tightening torque: 8 NM +/- 25%
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Graph
The following graph shows the correspondence between the angular position of the movable arm
of the sensor and the corresponding PWM percentage.
100 %
Diagnosis B
95 %
Not used
87,50 %
- 45 °
Normal use
50 %
0°
+ 45°
Not used
12,50 %
Diagnosis A
5%
0%
The 0° position corresponding to a PWM signal with Duty Cycle of 50%. The zero position is
obtained by resetting with the diagnosis instrument. This trim will be considered by the control unit
as the reference for future corrections.
Reference trim is used to mean the distance between the wheel centre and the body.
Key :
a. wheel axis centre
b. Reference on vehicle body
R 2. Wheel axis centre height
L 2. Vehicle reference height
H 2. Body height
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Push-buttons/switch unit
The push-buttons/switch unit, fitted only in the configuration with an additional air tank, enables
lowering the vehicle manually to facilitate goods loading and unloading operations.
To turn off the system you need to keep the button pressed until an audible warning is emitted.
Turning off is confirmed by a subsequent double audible warning and by the LED on the button
lighting up. After turning off the system, to switch it back on (solely with the vehicle stationary) keep
the button pressed until an audible warning is emitted. Turning back on again is confirmed by a
subsequent double audible warning and by the LED on the button lighting up.
- The push-buttons have 3 operating states: up / neutral /down plus audible feedback during the
handling operation.
- The switch has two operating states: On - Off
Automatic trim return to the Rated or reference setting after using the down/up buttons is
envisaged:
1 . By briefly double pressing the opposite button to the manoeuvre carried out.
2. 10 seconds after closing the loading area.
3. When the vehicle speed exceeds the parking speed (10 Km/h ).
Location of the push-buttons/switch unit
The push-buttons/switch unit is located on the rear right pillar
Key:
1. System inhibition switch – 2. Up button – 3. Down button
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Switch/push-buttons unit Pin Out
The following tables show the electric connections: between the switch/push-buttons unit and the
electronic control unit of the air suspensions:
System inhibition switch connector
Pin 2 : (+) System inhibition switch LED power supply
Pin 4: ( -) System inhibition manual control
Pin 5: Ground
Inhibition switch - 7738
Conn. Switch
Control unit
pin
pin
1
n.c.
2
MR 14
3
n.c.
4
NR 26
5
Ext. Ground
6
n.c.
Up/down control request connector
Pin 2: (+) Push-button power supply
Pin 3: (+) Manual height increase control
Pin 4: (+) Push-button LED power supply
Pin 6: (+) Manual height reduction control
Down/up buttons - 7749
Conn. PushControl unit
buttons
pin
pin
1
2
MR 8
3
MR 7
4
?
5
6
MR 6
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Buzzer
The buzzer beeps when changing the height of the loading deck.
Correction
Mode
Buzzer sound
User Action
Emission condition
OFF
vehicle speed > 10 Km/h,
corrections are prevented
Automatic
CONTINUOUS DISCONTINUOUS
X
X
Default Mode
Keep pressing the
push-button (updown) for 2 sec.
under conditions of
upper and lower max
trim
Manual
Pressing the pushbutton (up-down)
X
Corrections are prevented
As long as the system is
running until a software stop
is reached.
When the software stop is
reached, as the system stops.
If the software stop is
reached, when again pressing
the button to pass by it.
Reference trim reached:
interruption in correction,
even if the tilter is kept
pressed.
Return to the reference trim:
double pressing the button in
the opposite direction to the
position reached.
If the manual control is
deactivated (due to a fault or
if the electronic management
deactivates it,…)
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X
X
X
X
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Location of the buzzer
The buzzer is fitted behind the covering of the rear left pillar
Buzzer Pin Out
The following tables show the electric connections: between the Buzzer and electronic control unit
of the air suspensions:
Buzzer connector
Pin 1: (+) Buzzer command
Pin 2: (+) Buzzer command
Pin 5: (-) Ground
Buzzer - 7769
Buzzer
Control unit
pin
info
pin
info
NR 17
7780
1
7780
NR 17
7780
2
7780
3
n.c.
4
n.c.
5
M776B
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Air reserve tank (additional)
The additional air tank is only present when the customer has chosen to install the option of
manually changing the height of the loading deck.
The tank has a capacity of 5 litres of air with pressure from 15 to 20 bar max.
Warning: If removing and refitting the tank, first start the system pressure discharge procedure.
Key:
1. Air pipe coupling of 6 mm
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Wiring diagram of electric system with air reserve
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System wiring diagram key:
7715: Air suspension control unit
7737: Compressor assembly
7738: System inhibition button
7749: Loading deck height variation manual control assembly
7753: Left height sensor
7754: Right height sensor
7769: Buzzer
C001: Diagnosis socket
BB00: Battery
CA00: Ignition block
BSI : Body Computer
BFDB: Fuses on the battery positive pole
MFAV: Junction unit
PSF1: Junction unit
MCxx: Grounding points on the body
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Air circuit and pipes
Depending on the vehicle (short or long wheelbase), the air circuit pipes can be of different sizes to
adapt to the length of the vehicle.
If performing maintenance on the pipes (7), (8) and on the air springs (3), (4) take care over the
following pressures:
- 2 bar : minimum operating pressure (spring discharged)
- 4 bar : max operating pressure (spring charged)
- 15-20 Bar : air reserve tank
Key:
1. Pump assembly
2. Additional tank
3. Right air spring
4. Left air spring
5. Passenger compartment air intake
filter
6. Piping between pump assembly and
additional tank
7. Piping between pump assembly and
right air spring
8. Piping between pump assembly and
left air spring
9. Piping between pump assembly and
air filter
The impermeability/seal between the pipes and couplings is made with a joint with an O-Ring.
Key: 1. Pipe – 2. safety ring – 3. Pipe support – 4. O-Ring – 5. Component
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Procedure for removing and refitting pipes
Fitting pipes
The pipe assembly operations need no specific equipment, just insert the pipe into the coupling,
keeping it in axis with the coupling, as far as the second yellow position ring:
Note: Any counter-traction will confirm correct pipe fitting.
Warning: Any buckling in the pipe in the splining zone will cause a leak in the pneumatic system.
Before assembly then check there are none of the following defects in the pipe fitting:
- choking
- crushing
- scoring
Pipe disassembly
The pipe disassembly operations need specific equipment for:
- Air spring pipe diameter ∅ 4
- Air reserve tank pipe diameter ∅ 6
- Air intake and exhaust pipe diameter ∅ 10
that aids the pressure on the safety ring of the coupling.
Note: When extracting the pipe, keep it in line with the coupling
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Air circuit functional diagram
Pneumatic circuit without air reserve tank
Increase in the height of the loading deck
Figure ( C – 1A ) shows the automatic/manual loading deck adjustment operation (height increase)
using the air springs (6) and (7).
The air drawn into the circuit initially passes through the passenger compartment air filter (1) and
then through the dehydrator filter (2) to remove any traces of moisture. By compressing the air, the
compressor raises the pressure in the circuit, making the mechanical single-acting valve open (4).
In the meantime the electronic control unit, with an electric signal, keeps the solenoid valves (5) and
(8) open, simultaneously or singly depending on the signals received from the height sensors.
To prevent dangerous kickbacks in the air circuit when switching on the air compressor, the
solenoid valve (9) is initially modulated with a signal at a frequency of 400 MHz.
Reduction in height of the loading deck
Figure ( C – 2A ) shows the automatic/manual loading deck adjustment operation (height decrease)
using the air springs (6) and (7).
The electronic control unit, with an electric signal, initially keeps the solenoid valves (5) and (8)
open; simultaneously or singly depending on the signals received from the height sensors and
afterwards it commands the solenoid valve (9) to discharge the circuit and thereby lower the
vehicle.
With the solenoid valve (9) open, the air passes through the mechanical single-acting valve (10)
and the choke in pipe (11) to then reach the dehydrating filter (2) and the air filter (1).
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Key Figure C-1A and C-2B:
1. Air filter
2. Dehydrating filter
3. Air compressor
4. Mechanical single-acting valve
5. Right air spring solenoid valve.
6. Right air spring.
7. Left air spring.
8. Left air spring solenoid
valve.
9. Air discharge solenoid valves
10. Mechanical single-acting valve
11. Air pipe reduced cross-section
Pneumatic circuit with air reserve tank
The basic difference with the standard circuit is that there are the following components:
- of the solenoid valve (14)
- air reserve tank (15)
- Pressure sensor (5)
Increase in the height of the loading deck
Figure ( C-1B e C-2B) shows the automatic or manual loading deck adjustment operation (height
increase and decrease) using the air springs (7) and (8).
This operation can be performed in two ways:
- with the aid of the compressor ( 3 ) when the reserve in the tank (15) is not sufficient. See figure
C1-B.
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with the aid of the air reserve in the tank ( 15 ) by means of the solenoid valve command ( 14 ).
See figure C2-B
Reduction in height of the loading deck
Figure ( C – 3B ) shows the automatic or manual loading deck adjustment operation (height
reduction) using the air springs (7) and (8).
The electronic control unit, with an electric signal, initially keeps the solenoid valves (6) and (9)
open; simultaneously or singly depending on the signals received from the height sensors and
afterwards it commands the solenoid valve (10) to discharge the circuit and thereby lower the
vehicle.
With the solenoid valve (10) open, the air passes through the mechanical single-acting valve (11)
and the choke in pipe (12) to then reach the dehydrating filter (2) and the air filter (1).
Recharging the air reserve tank
(Figure C – 4B ) shows the procedure for restoring the air reserve in the tank (15).
The control unit checks the signal of the pressure sensor (5) with the solenoid valves (6), (9) and
(10) closed and the solenoid valve (14) open.
If the pressure is lower than 15 bar the control unit activates the compressor to restore the pressure
of 20 bar. In these conditions it closes the solenoid valve (14).
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To prevent dangerous kickbacks in the air circuit when switching on the air compressor, the
solenoid valve (10) is initially modulated with a signal at a frequency of 400 MHz.
Key Figure C-1B, C-2B , C-3B, C-4B :
1. Air filter
2. Dehydrating filter
3. Air compressor
4. Mechanical single-acting valve
5. Air pressure and temperature sensor
6. Right air spring solenoid valve.
7. Right air spring.
8. Left air spring.
9. Left air spring solenoid valve.
10. Air discharge solenoid valve
11. Mechanical single-acting valve
12. Air pipe reduced cross-section
14. Air reserve solenoid valve
15. air reserve tank
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8. ELECTRIC SYSTEM
8.1 GENERAL
Power supplies
The vehicle has the following power supplies:
Power supply “+ ACCESSORIES (+ACC)”
Power supply “+ CONTACT KEY (+APC)” Literally power supply after contact Apres Conatct) Power
supply with key on drive distributed by the Body Computer Node
Power supply “+ CONTACT KEY (+APC)” (as above) distributed by the Engine Compartment Junction
Node
Power supply “+ BATTERY” interrupted in park mode (+BAT-MP)
Power supply “+ BATTERY” permanent (+BAT)
Power supply “+ CAN”
Control “+ RCD” (literally remote controlled wake-up), function of the Body Computer Node to activate the
CAN network in advance to manage some functions of the Engine Control Node and Air Pressure
Control Node)
The electric supply of the various vehicle systems depends on need and can be:
permanent
when the Body Computer Node wakes up
The Body Computer Node wake-up can be due to:
- an action on the remote control.
- opening a door.
- an action of + RCD (without turning the key onto the drive position).
LESTAGE (load activation) DELESTAGE (load deactivation) of the electric network
Lestage and Delestage are only possible with the alternator in its operating state and the combustion engine
running
Lestage enables increasing the combustion engine temperature more quickly in order to improve the
reconditioning of the FAP particulate filter on diesel vehicles.
Increasing the resistant torque of the alternator increases the torque of the combustion engine and, as a
result, the temperature of the combustion engine too.
The Body Computer Node recognizes a lestage request from the Engine Control Node and forces activation
of some electric charges. During this phase the driver is not told of the activation of the loads
Delestage if the engine is running and there is an extended imbalance of the electric balance the operation
of some large services will momentarily be prevented.
Example: The Body Computer Node deactivates the activated loads for reconditioning the FAP.
Vehicle configuration
PARC mode
This configuration is used for vehicle storage
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It enables not powering some large services directly from the permanent battery +BAT and therefore
decreasing the energy consumption in order to ensure engine starting.
The +BAT supply shunt is moved into the “Shunt Parc” position so as to permit a power supply +APC
Note: The “Shunt Parc “ configuration permits access to the vehicle. (the door and boot locks are operative
Customer Mode
This is the vehicle operating mode when it is delivered to the customer
The customer mode corresponds to normal operation
The customer mode is activated after performing the following actions:
change the shunt parc position into the customer position on the Body Computer Node
General layout Vehicle weights
The layout below highlights the locations of the various weights located in the vehicle.
Key:
- M000 : Body weight
- MC10 : Front left side weights
- MC11 : Front left weights
- MC14 : Front left side weights
- MC15 :
- MC16 : Front left weights
- MC19 : Front left side weights
- MC20 : Front right weights
- MC21 : Front right side weights
- MC22 :
- MC34 : instrument panel cross member
weights - left
- MC40 : instrument panel cross member
weights - right
- MC50 : front seat floor weights
- MC55 : front right floor weights
- MC80 : rear left pillar weights
- MC85 : rear right pillar weights
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Multiplexing architecture
General
The vehicle's electric/electronic architecture enables the following performance:
communication and operation of the different system elements
diagnosis
reprogramming the control units.
The electric architecture is composed of the following communication networks:
CAN network ( HS IS ) (500Kbit/s) relating to the set of control units on the engine assembly
CAN CAR network ( LS ) (125Kbit/s) relating to the safety systems
CAN CONFORT network ( LS ) (125Kbit/s) relating to the human/machine interface
CAN diagnosis socket
principal diagram key
Two-way arrows K diagnosis line
Multiplexed network triple lines
Single remote wake-up control line
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CAN HS IS NETWORK
The CAN network ( HS IS ) is equipped for message transmission speeds of 500Kbit/s (High Speed) and is
composed of the following control units:
NBC ( Body Computer Node )
NCM ( Engine control unit node )
NFR ( Brake control unit Node )
CAV ( Steering Angle Node )
GEP ( Electro-hydrauylic steering node )
CAAR ( Rear air suspension control unit node )
NYL ( Yaw sensor node for ESP )
EOBD ( diagnosis socket )
GMV ( engine cooling fan assembly )
The CAN network is the multi-master type so all the control units transmit their messages within the network
and these messages are read by the control units according to their use.
Some nodes are connected to the remote control wake-up line (RDC) that permits early wake-up.
NOTE Cutting a cable in the CAN network (CAN High) or (CAN Low) does not allow network communication
Control unit location related to the CAN HS IS network
The following layout shows the location of the control units related to the CAN HS IS network
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CAN LS CAR NETWORK
The CAN LS CAR network is equipped for message transmission speeds of 125 Kbit/s (Low Speed) and is
composed of the following control units:
NBC ( Body Computer Node )
EOBD ( diagnosis socket )
COMM 2005 ( Stalk Unit Node )
ALM ( Alarm Node )
RBG ( Air Bag Node )
BSM ( engine compartment junction node )
CDPL ( photocell and rain sensor node )
BTC ( bodywork conversion control unit node ) integrates also the BSR (trailer control
unit)
S1 ( Alarm siren )
The Body Computer Node manages communication in the network and the +CAN power supply.
I Nodes in the CAN CAR network have their termination resistors and are powered depending on the case by
+CAN, +BAT or +APC via the NDVM
NOTE Cutting a cable in the CAN network (CAN High) or (CAN Low) or a short circuit between the cables
permits network communication, with error information.
Control unit location related to the CAN LS CAR network
The following layout shows the location of the control units related to the CAN LS CAR network
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CAN LS CONFORT NETWORK
The CAN LS CONFORT network is equipped for message transmission speeds of 125 Kbit/s (Low Speed)
and is composed of the following control units:
NBC ( Body Computer Node )
AAS ( rear parking sensors node )
KML ( Hands-free kit node – Bluetooth )
RD4 ( Receiver Radio node )
EMF ( Multifunction screen node )
RT3 ( Satellite Navigator node )
NCLP ( Rear A/C node )
NCLA ( Front A/C node )
CDC ( CD Changer Node )
CMB ( instrument panel node )
TDC RF ( Manual A/C control unit )
TDC CH ( Heater control unit )
The Body Computer Node manages communication in the network and the +CAN power supply.
The control units of the CAN CAR network have their termination resistors and are powered depending on
the case by +CAN, +BAT or +APC via the NDVM.
NOTE Cutting a cable in the CAN CONFORT High or CAN CONFORT Low network or a short circuit
between the cables permits network communication, with error information.
Control unit location related to the CAN LS CONFORT network
The following layout shows the location of the control units related to the CAN LS CONFORT network
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Diagnostics socket
The diagnostics socket permits connecting the diagnosis instrument (Examiner) to the vehicle and dialoguing
with all the control units equipped with auto-diagnosis.
The diagnosis socket is a 16-way connector
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Signals
+APC
N.C.
CAN DIAGNOSTICS (High)
Tester ground
Signal ground
CAN (high)
K line for the automatic transmission and engine control unit
CAN DIAGNOSTICS (Low)
N.C.
N.C.
N.C.
Control unit K line of the CAN lines
K lines of the control units not connected to any network
CAN (Low)
N.C.
+ Battery
CAN DIAGNOSTICS NETWORK
The transmission speed of the CAN DIAGNOSTICS network is 500 Kb/s.
The CAN DIAGNOSTICS network permits:
diagnosis of the control units on the CAN, CAN CAR, and CAN CONFORT network.
the CAN DIAGNOSTICS network replaces the old K line and permits dialoguing more easily with the
varioius control units
accessing the necessary information for the EOBD standard (European On Board Diagnostic) making
it possible to check the anti-pollution information.
Note: Not all the control units in the CAN network can be diagnosed via CAN DIAGNOSTICS, so they will
keep the old K line
The CAN DIAGNOSTICS network permits uploading the programs to the control units of the CAN CAR, CAN
CONFORT network and Body Computer Node
Note: This line at the diagnosis level is not used by Examiner.
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K diagnosis line
The transmission speed of the K line is 10400 bauds
The K diagnostics line permits:
diagnosing the errors on the control units of the CAN network not transmitted by the CAN
DIAGNOSTICS network
retrieving the necessary information for the EOBD standard (European On Board Diagnosis).
Putting the networks on stand-by
When there are all the conditions for putting on stand-by and there is no request for activation in progress:
the Body Computer Node sends a "putting on stand-by" message over the CAN, CAN CAR and CAN
CONFORT buses, to go onto stand-by; at the same time, the Body Computer Node starts a timeout and
transmits the "putting on network stand-by" messages, the Nodes no longer communicate, unless there is a
request for activation, before the end of timeout, the CAN, CAN CAR and CAN CONFORT buses pass onto
stand-by, the +CAN is interrupted by the Body Computer Node
at the end of timeout, the Body Computer Node goes onto stand-by.
Battery disconnection/connection
When disconnecting or connecting the battery, the networks go onto stand-by, irrespective of their previous
state.
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8.2 Instrument panel
There are 5 Instrument Panel versions.
Left-hand drive:
- With clock, Rev counter and speedometer with black background.
- Without clock, Rev counter and speedometer with black background.
- Without clock, Rev counter and speedometer with beige background.
Right-hand drive:
- With clock, Rev counter and speedometer with black background.
- Without clock, Rev counter and speedometer with black background.
The right-hand drive instrument panel has a double speedometer scale with the miles symbol "mph"
printed large and the kilometres symbol "km/h" small in the middle.
Warning:
- The left-hand drive instrument panel, configured in kilometres, cannot change unit of measurement.
- The right-hand drive instrument panel, configured in miles, can change unit of measurement into km.
All versions of the instrument panel have two central push-buttons for the following functions:
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Version with clock:
Push-button (1): Rheostat for lighting, Clock adjustment
Push-button (2): Trip odometer reset, Km reset
Version without clock:
Push-button (1): Rheostat for lighting
Push-button (2): Trip odometer reset, Km reset
Central display
In the middle of the instrument panel there is a display that can show different information.
The information shown on this display can change depending on whether there is a clock.
Display with clock:
Key:
1. Water in diesel filter, glow plugs, Clock
2. Cruise Control, Km/h or MPH trip counter,
3. Service, Total Km or MPH.
Display without clock:
Key:
1. Cruise Control, Vehicle speed,
2. Water in diesel filter, glow plugs, Km/h or MPH trip counter
3. Service, Total Km or MPH
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Table listing fault/alert warning lights:
Name Indicator light
Low-beam headlamps
Main beam headlamps
Fog lamps
Rear fog lights
Left direction indicator
Right direction indicator
EOBD failure
ESP failure
ABS failure
AIRBAG failure
Passenger AIRBAG inhibition
Fuel reserve
SERVICE
Preheating glow plugs
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Name Indicator light
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Symbol
Presence of water in the diesel
fuel filter
Battery
Oil pressure and temperature
Water temperature and level
Doors open
Electro-drive failure
STOP
Seat belts
CAAR - Rear air suspensions
Tyre puncture
Anti-particulate filter (FAP)
Brake wear
ECO
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PIN-OUT
The instrument panel is equipped with an 18-way connector for hooking up with the vehicle's electric
system:
Pin
Description
1
Sortie Témoin de non bouclage conducteur (uniquement
sur combiné sans montre)
2
Sortie Témoin de non bouclage passager avant
(uniquement sur combiné sans montre)
3
Sortie Lunette Chauffante
4
Sortie Détection Obstacle de Proximité
5
Sortie Warning
6
Entrée ESP
7
Entrée Demande d’enclenchement des CTP
8
Entrée Lunette chauffante
9
Entrée A/C Climatisation
10
+Permanent (fonction montre uniquement)
11
Sortie ESP
12
Entrée Détection Obstacle de Proximité (AAS)
13
Entrée Demande de cylindrée Maximum du compresseur
14
CAN_H - CAN LS CONF (125 Kb/s)
15
CAN_L - CAN LS CONF (125 Kb/s)
16
+ CAN
17
Sortie Témoin inhibition Airbag (uniquement sur combiné
sans montre)
18
Ground
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Input and output signals
The following tables give the Instrument Panel's input and output signals:
Input signaiInput signals
INPUT SIGNAL
A/C Off/On
Heated rearscreen
Request from A/C to turn on CTP ?
Request for max compressor displacement
Parking sensor signal (AAS)
ESP push-button activation
Output signals
OUTPUT SIGNAL
Parking sensor signal (AAS)
Heated rearscreen
WARNING
Front passenger Airbag
Passenger Airbag inhibition
Driver's belt not fastened
Request for Driver's belt not fastened warning light
blinking
Passenger's belt not fastened
Request for Passenger's belt not fastened warning light
blinking
Type of power steering installed on the vehicle
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8.3 DOOR CONTROL
General
The central locking system does not have a dedicated control unit, but is managed directly by the Body
Computer Node (NBC).
The vehicle can be configured with different solutions:
Classic Front Doors,
Sliding mechanical Side Doors (2nd door is optional),
Rear hatchback or two-door back.
Note: Only the driver's door and the rear hatch door have a lock and key.
The system controls door locking and unlocking according to the commands given by the user or by
specific system settings:
- Remote control,
- Mechanic key,
- Push-button on the dashboard,
- Orders for opening.... for example after an accident,
- Orders for automatic locking with the vehicle in motion,
- Alarm cut-in and cut-off,
The central locking system has two types of remote control depending on the version of the vehicle:
Key:
A: Locking control button
B: Unlocking control button
C: Selective control button (sliding side doors and hatchback )
T1 = Combi vehicle version
T2 = Van vehicle version
Remote control functions
Van model:
Simple locking,
Super locking,
Automatic locking with vehicle in motion,
Child safety,
Vehicle localization.
Combi model
- Simple locking,
- Super locking,
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- Automatic locking with vehicle in motion,
- Selective locking.
Push-buttons inside the vehicle
Inside the vehicle on the central dashboard to the left of the radio, depending on the version of the
vehicle, there are the buttons shown in the figure.
Key:
A: Child safety button
B: Central locking button
C: Side sliding door and rear hatch locking/unlocking button
P1: Combi vehicle version
P2: Van vehicle version
Operation
The following tables describe the operating strategies of the central locking with remote control or
mechanical key.
REMOTE CONTROL T1 AND T2 – BUTTON A
Control
Single press
Single press, with vehicle
closed for less than 5sec.
Single press, with vehicle
Initial state
Event generated
Vehicle unlocked
Cab unlocked
Goods
compartment
unlocked
Request to lock the vehicle
Vehicle locked
No action
Vehicle locked
Request to locate the vehicle
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closed for more than 5sec.
REMOTE CONTROL T1 AND T2 – BUTTON B
Control
Initial state
Single press
Vehicle unlocked
Goods compartment
locked
Cab unlocked
Vehicle unlocked
Single press
Single press
Single press
Event generated
Request to unlock the cab
Request to unlock the vehicle
Request to unlock the vehicle
No request
REMOTE CONTROL T2 – BUTTON C
Control
Initial state
Single press
Vehicle locked
Single press
Cab unlocked
Goods compartment
unlocked
Single press
Event generated
Request to unlock the goods
compartment
Request to unlock the vehicle
No action
Driver's door lock
Control
Turn of key
Turn of key, with vehicle closed
for less than 5sec.
Turn of key, with vehicle closed
for more than 5sec.
Turn of key
Turn of key
Turn of key
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Initial state
When locking
Vehicle unlocked
Cab unlocked
Goods
compartment
unlocked
Event generated
Request to unlock the vehicle
Vehicle locked
No request
Vehicle locked
No request
When unlocking
Vehicle locked
Request to unlock the cab
Goods compartment
Request to unlock the vehicle
unlocked
Cab unlocked
No request
Vehicle unlocked
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Rear hatch lock
Control
Turn of key
Turn of key, with vehicle closed
for less than 5sec.
Turn of key, with vehicle closed
for more than 5sec.
Initial state
When locking
Vehicle unlocked
Cab unlocked
Goods
compartment
unlocked
Event generated
Request to lock the vehicle
Vehicle locked
No request
Vehicle locked
No request
When unlocking
Turn of key
Vehicle locked
Turn of key
Cab unlocked
Vehicle unlocked
Goods
compartment
unlocked
Turn of key
Request to unlock the goods
compartment
Request to unlock the vehicle
No request
Wiring diagrams
The diagrams shown are the following:
Wiring diagram 151: Central Locking - Vehicle with Door
Wiring diagram 154: Central Locking - Hinged rear doors
Wiring diagram 157: Central Locking - Vehicle with Door
Wiring diagram 160: Central Locking - Hinged rear doors
Wiring diagram 163: Super Central Locking - Vehicle with Door
Wiring diagram 166: Central Locking - Hinged rear doors
Wiring diagram 169: Super Central Locking - Vehicle with Door
Wiring diagram 172: Super Central Locking - Hinged rear doors
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Wiring diagram 151
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Wiring diagram 154
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Wiring diagram 157
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Wiring diagram 160
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Wiring diagram 163
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Wiring diagram 166
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Wiring diagram 169
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Wiring diagram 172
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Diagrams key
6202 : ENSEMBLE SERRURE PORTE CONDUCTEUR
6207 : ENSEMBLE SERRURE PORTE PASSAGER
6210 : CONTACTEUR PORTE OUVERTE ARRIERE
6212 : ENSEMBLE SERRURE PORTE ARRIERE GAUCHE
6215 : CONTACTEUR PORTE OUVERTE ARRIERE DROIT
6217 : ENSEMBLE SERRURE PORTE ARRIERE DROITE
6218 : ENSEMBLE SERRURE PORTE BATTANTE
6222 : ENSEMBLE SERRURE COFFRE
6294 : RELAIS COMMUN COFFRE
6287 : RELAIS OUVERTURE COFFRE
BSI : Body Computer ( NBC )
BCM1 : BLOC COMMUTATEUR MULTIFONCTIONS GAUCHE
BB00 : BATTERY
BFDB : Max fuses on the battery positive cable
BFH5 : 40A fuse
C001 : CONNECTEUR DIAGNOSTIC
CV00 : MODULE DE COMMUTATION SOUS VOLANT (COM 2000)
MC58 : Ground
M000 : Battery ground
PSF1 : PLATINE DE SERVITUDE-BOITE FUSIBLES
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8.4 Power windows and rear-view mirrors
General
The power windows system does not have a dedicated control unit, it is managed directly by the Body
Computer Node (NBC).
The vehicle can be configured with different solutions, see the table:
Component
2nd sliding side door
Back with two doors
Child safety
Super locking
Passenger power window
button
Passenger power window
button with automation
Adjustable external electric
and manually tilting rearview mirrors.
Adjustable external and
electric
tilting rear-view mirrors.
Fourgone
L1
Fourgone
L2
Combi
L1
Combi
L2
Leisur
etime
Combi
L2
Busine
ss
O
S
O
O
S
O
O
S
S
O
O
S
O
S
S
O
S
S
-
-
-
-
-
S
S
S
O
S
O
S
S
O
O
O
O
O
Depending on the setup used there are different versions of the switch unit on the doors, according to the
following table:
Switch unit
1B
3B
1C
3C
4C
9D
9E
Left
Right
Power Windows
Driver
Passenger
A
A
A
A
A
-----
E
E
A
A
A
E
A
Adjustable external
Adjustment
Tilting
M
E
M
E
E
M
M
M
M
M
M
E
M
M
Table key:
- E : electric control
- A : electric control with automatic function
- M : manual control
Note: The switch unit with automatic function ( A ) has anti-pinch safety
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Switch unit
The following figures show the different setups of the power window switch unit.
1B
3B
1C
3C
9E
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Wiring diagrams
The diagrams shown are the following:
diagram 145 : Power windows – version Level 1
diagram 148 : Power windows – version Level 2
diagram 175 : External rear-view mirrors with electric adjustment and manual tilting
diagram 178 : External rear-view mirrors with electric adjustment and tilting
Operation
- The setup illustrated in diagram 145 is for the power window system with vehicle version level 1.
In this setup the Body Computer ( NBC ) supplies a direct battery positive protected by fuses and by key
positive ( +APC ).
- The setup illustrated in diagram 148 is for the power window system with vehicle version level 2.
In this setup the Body Computer ( NBC ) supplies a direct battery positive protected by fuses and by key
positive ( +APC ).
The difference with the wiring diagram 145 consists in the different connection of the passenger power
window motor.
- The setup illustrated in diagram 175 is for the ext. rear-view mirror system with electric adjustment and
manual tilting.
In this setup the Body Computer ( NBC ) supplies a key positive ( +APC ).
- The setup illustrated in diagram 178 is for the ext. rear-view mirror system with electric adjustment and
tilting.
In this setup the Body Computer ( NBC ) supplies a key positive ( +APC ) and two command signals ( C1
and C2 ) for the relays related to the polarity reversal of the power supply of the motors for opening
(6408) and closing (6409) the ext. rear-view mirrors.
Note: Points C3 and C4 with non-controlled relays have a potential of 0 Volt ( ground ).
In its turn the Body Computer ( NBC ) receives the command ground signal (S) for opening and closing
the ext. rear-view mirrors from the driver control assembly (6436).
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Wiring diagram 145
Wiring diagram 148
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Wiring diagram 175
Wiring diagram 178
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Power window wiring diagrams key
6004 : Passenger power window switch
6031 : Front passenger power window motor
6032 : Front driver power window motor
6035 : Driver's anti-pinching
6036 : Rear power window control - driver
6045 : Passenger power window motor
Electric mirror wiring diagrams key
6408 : Ext. rear-view tilting relay ( mirrors closed )
6409 : Ext. rear-view folding relay ( mirrors open )
6410 : Driver rear-view mirror
6415 : Passenger rear-view mirror
BSI : Body Computer ( NBC )
BB00 : BATTERY
BFDB : Max fuses on the battery positive cable
BFH5 : 40A fuse
MC58 : Ground
M000 : Battery ground
Location of power window and rear-view mirror relays
6408 : Ext. rear-view tilting relay ( mirrors closed )
6409 : Ext. rear-view folding relay ( mirrors open )
6410 : Rear windows relay
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8.5 AIRBAGS
The Airbag system ( BOSCH ) equipping the vehicle triggers after front or side impact with medium-high
severity to protect the occupants and in this regard the Airbag system governs the different safety
mechanisms:
1 front driver airbag,
1 driver belt pretensioner,
1 side driver chest airbag,
1 front middle passenger pretensioner
1 front right passenger front airbag,
1 front right passenger pretensioner
1 front right passenger chest side airbag,
1 left curtain side airbag,
1 right curtain side airbag,
Warning: For the Airbag system to be able to perform its function with the utmost effectiveness it is
necessary for the occupants to use the safety belts correctly.
The setups of the front seats are given in the following summary table:
Van
Front seat version
Fixed 2-passenger bench
seat
2 seats with height/angle
adjustment
Heated seats
Combi
Level 1
Level 2
Level 1
Level 2
5-6 seats
8-9 seats
8-9 seats
O
O
O
O
S
S
S
O
O
O
O
O
The different setups of the front seats require a specific setup of the airbags and specifically:
2 front seat version:
- Driver:
front airbag
chest side airbag
belt pretensioner
- Passenger:
front airbag
chest side airbag
belt pretensioner
Version with 1 front seat + 1 bench seat:
- Driver:
front airbag
chest side airbag
belt pretensioner
- Passenger:
front airbag
belt pretensioner
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Functional configuration diagram
Key:
1. front driver airbag
2. side driver chest airbag
3. left curtain side airbag
4. driver belt pretensioner
5. left side impact satellite sensor
6. double driver belt pretensioner ( fitting )
7. passenger front airbag
8. passenger chest side airbag
9. right curtain side airbag
10. passenger belt pretensioner
11. right side impact satellite sensor
12. Passenger belt fastened switch (CNB) + passenger sensor (SBR)
13. double passenger belt pretensioner ( fitting )
14. middle passenger belt pretensioner ( with bench seat only )
15. passenger airbag disabling key switch
16. Air Bag control unit
17. Driver seat
18. Double seat ( 18 + 19 = bench seat )
19. Passenger seat
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Passenger belt fastened switch (SBR) and passenger sensor (CNB)
Sensors SBR (4731) and CNB (4737) are connected to the Airbag control unit (6570) that in its turn
sends the status information, over the Can LS CAR network, to the Body Computer ( NBC ) to control the
related warning lights on the instrument panel. The information relating to the driver belt switch (4730) is
sent directly to the NBC.
Sensors SBR (4731) and CNB (4737) are connected in series.
SBR sensor
The vehicle is equipped with the system called S.B.R. (Seat Belt Reminder).
The job of the sensor is to tell the Airbag control unit whether the passenger's seat belt is fastened. If the
seat belt is not fastened the system generates a warning message ( warning light on the panel + audible
warning).
The audible warning can be temporarily turned off (until the engine is next switched off) with the following
procedure:
allacciare la cintura di sicurezza lato guida e lato passeggero;
ruotare la chiave di avviamento in posizione M;
attendere più di 20 secondi quindi slacciare la cintura sicurezza ( guidatore o passeggero ).
CNB sensor
The passenger sensor is resistive and has the job of detecting a passenger on the seat and subsequently
activating or not activating the airbags for passenger protection.
The sensor is under the upholstery of the passenger seat.
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CNB sensor operation
The following graphic shows the strategy for detecting a passenger on the seat.
The graphic is divided into three areas, specifically:
A. Graphic highlighting the condition (ON) or (OFF)
ON : passenger present
OFF : passenger not present
B. Graphic highlighting the count by the Airbag control unit
0 : passenger not present
3 : passenger present
C. Graphic highlighting the resistance levels for detecting a passenger.
Resistance : (Lo) 390 O ÷ 510 O ( passenger present )
(HI) 870 O ÷ 1020 O ( passenger not present )
- The airbag control unit increases the count ( zone B ) when the resistance of the SBR sensor is less
than the limit (LO). See points: 6, 12, 13, 15, 16, 22, 23, 25.
Note: The points in zone (C) 26, 27 do not increase the count but keep the maximum permissible value,
that is 3.
- The airbag control unit decreases the count ( zone B ) when the resistance of the SBR sensor is greater
than the limit (HI). See the points in zone (C): 8, 18, 19, 20, 29, 30, 31, 32.
Note: The points in zone (C) 1, 2, 3, 4, 9, 10, do not decrease the count but keep the minimum
permissible value, that is 0.
- The airbag control unit blocks the count ( zone B ) when the resistance of the SBR sensor is between
the (LO) and (HI) settings. See the points in zone (C): 5, 7, 11, 14, 17, 21, 24, 28.
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Messages on the CAN network
Airbag node:
Receives
The status of the air bag system failure warning light.
The status of the front passenger air bag inhibition warning light.
The vehicle speed.
Emits
The "air bag system failure" information.
The "front passenger airbag inhibited" information.
Computer Body Node:
Receives
The "air bag system trouble" information.
The "front passenger airbag inhibited" information.
The status of the air bag system failure warning light.
The status of the front passenger air bag cut-out warning light.
The vehicle speed
The type of impact
Emits
The "air bag system trouble" information.
The "front passenger airbag inhibited" information.
The vehicle speed.
The status of the air bag system failure warning light.
The status of the front passenger air bag cut-out warning light.
The type of shock.
Instrument Panel Node:
Receives
The "air bag system trouble" information.
The "front passenger airbag inhibited" information.
Emits
The status of the air bag system failure warning light.
The status of the front passenger air bag cut-out warning light.
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Passenger compartment cable bundle
The following illustration shows the route of the cable bundle in the vehicle for the AirBag system.
Key:
1. Front driver airbag
2. Passenger front airbag
3. Front seat connections
4. Air Bag control unit
5. Passenger belt pretensioner
6. Driver belt pretensioner
7. Right curtain side airbag
8. Left curtain side airbag
9. Right side impact satellite sensor
10. Left side impact satellite sensor
11. Passenger airbag disabling key switch
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Airbag control unit
The Airbag control unit is located in the middle of the vehicle between the front seats and it interfaces with
the vehicle wiring by means of two 24 pin connectors, one black and one grey.
The Airbag control unit has the job of analysing the signals from the impact sensors and actuating the
most appropriate safety strategies for the event of the accident.
Note: The arrow indicates the vehicle's direction of travel.
Side impact satellite sensors
The side satellite sensors have the job of informing the Airbag control unit of any side impact. Thi signal is
used by the airbag control unit to activate the curtain and chest arbags.
The figure below illustrates the position of the satellite sensors. They are locked by a screw on the front
right and left pillar.
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Passenger AirBag disabling switch
The passenger AirBag disabling switch is located inside the front glove compartment. See figure.
Front Airbags (driver and passenger)
The explosive charge related to the driver's Airbag is located on the steering wheel while the explosive
charge of the passenger Airbag is on the dashboard.
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Curtain Airbag and chest airbag
The explosive charges related to the curtain airbag are under the covering of the roof on the right and left
side, while the explosive charges related to the chest airbag are on the backrest of the driver and
passenger seats.
Note: Components in bold type.
Wiring diagrams
The diagrams shown are the following:
diagram 181: System related to the version with Windows Bag and two front seats.
diagram 184: System related to the version without Windows Bag and front bench seat.
diagram 187: System related to the passenger sensor + Passenger safety belt switch.
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Wiring diagram 181
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Wiring diagram 184
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Wiring diagram 187
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Wiring diagrams key:
4730 : Driver safety belt switch
4731 : Passenger safety belt switch
4737 : Passenger seat sensor (NAPPE)
4746 : TNB control unit
6539 : Front middle pretensioner
6551 : Right curtain airbag ( Windows Bag )
6552 : Left curtain airbag ( Windows Bag )
6562 : Front right side airbag
6563 : Front left side airbag
6564 : Passenger Airbag
6569 : Passenger Airbag disabling key switch
6570 : Airbag control unit
6573 : Front left satellite sensor
6574 : Front right satellite sensor
6575 : Front left pretensioner
6576 : Front right pretensioner
CV00 : SWITCHOVER MODULE UNDER STEERING WHEEL (COM 2000)
C001 : Diagnosis connector
BFDB : Max fuses on the battery positive cable
BB00 : Battery
CA00 : Ignition block
PSF1 : SERVICES FUSE BOX PLATE
BSI : Body Computer ( NBC )
0004 : Instrument panel
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8.6 Climate Control
The climate control for the new Fiat Scudo is summarised in the following table:
Additional heating (Webasto)
Heater (CH)
Manual climate control (RF)
Automatic climate control (RFTA)
Rear additional climate control (*)
Fourgone
N1
O
Fourgone
N2
O
Combi
N1
O
Combi
N2
O
Combi
N2
O
O
-
S
-
O
-
S
O
O
S
S
(*) : together with Automatic Climate Control (RFTA)
The quantity of R134a gas varies depending on the setup used:
- Manual and automatic climate control: 600 g
- Climate control with additional rear unit: 925 g
Heater system ( CH )
The Heating System comprises two types of different control assembly due to whether there is the heated
rearscreen control button.
Key:
1. Controls assembly without
rearscreen
2. Controls assembly with
rearscreen
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3. Air ventilation unit
4. Particle filter
5. Heater and distribution unit
6. WEBASTO additional heater
heated
heated
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Heater operation ( CH )
The controls related to distribution and mixing are accomplished with cables.
The air is made to enter by means of a motor (3), governed directly by the control assembly (1) and the
resistance module (2) for the change in air speed.
Key:
1. Controls assembly
2. Resistance module
3. Air ventilation motor
4. BSM
5. BSI
6. Instrument panel
7. Air recirculation motor
8. Can CAR network
9. Can CONF network
Controls assembly pin-out ( CH )
The controls assembly interfaces with the vehicle's electric system by means of 2 connectors:
E1 with 12 pins - E2 with 6 pins
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Origin
Connector ( E1 )
Destination
Désignation
Training Academy
Pin
Description
Controls
assembly
(TDC)
BSI
Demande
LUCH
1
Mise à la masse
BSI
Controls
assembly
(TDC)
Voyant LUCH
+ Veilleuse
+ APC
2
3
4
Mise au +12V
+ 12V piloté
+ 12V
Controls
assembly
(TDC)
Vehicle
Weights
5
0V
---
---
6
Mise à la masse
-------------
-------------
7
8
9
10
11
12
n.c.
n.c.
n.c.
n.c.
n.c.
n.c.
Info Tout
Chaud
-------------
Connector ( E2 )
Origin
Controls
assembly
(TDC)
Destination
Air
recirculation
motor
Désignation
Pin
+ Alimentation
1
Air extérieur
Recyclage
partiel
Recyclage total
2
3
Description
4
---
---
---
5
n.c.
---
---
---
6
n.c.
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Manual climate control system ( RF )
The manual climate control system comprises two types of different control assembly (1) due to whether
there is the heated rearscreen control button.
Key:
1. Controls assembly without heated
rearscreen
2. Controls assembly with heated
rearscreen
3. Air ventilation unit
4. Particle filter
5. Compressor
6. Heater and distribution unit
7 WEBASTO additional heater
Manual climate control operation ( RF )
The controls related to distribution and mixing are accomplished with cables.
The air is made to enter by means of a main motor (3), governed directly by the control assembly (1) and
the resistance module (2) for the change in air speed.
Key:
1. Controls assembly (TDC)
2. Resistance module
3. Air ventilation motor
4. Antifrost sensor
5. BSM
6. R134a gas compressor
7. Can network ( CAR )
8. External air temperature sensor
9. BSI
10. Can network ( CONF )
11. Can network ( IS )
12. Engine control unit
14. Fan motor assembly (GMV)
15. R134a gas pressure sensor
16. Water temperature sensor
18. Instrument panel
19. Air recirculation motor
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Controls assembly pin-out ( RF )
The controls assembly interfaces with the vehicle's electric system by means of 2 connectors:
E1 with 12 pins - E2 with 6 pins
Connector ( E1 )
Destination
Désignation
Origin
Pin
Description
Controls
assembly (TDC)
BSI
Demande LUCH
1
Mise à la masse
BSI
Controls
assembly
(TDC)
Voyant LUCH
+ Veilleuse
+ APC
2
3
4
Mise au +12V
+ 12V piloté
+ 12V
Vehicle
Weights
5
0V
Instrument
panel
Info Tout Chaud
6
Mise à la masse
BSI
Demande AC
7
Mise à la masse
-----------
-----------
8
9
10
11
12
n.c.
n.c.
n.c.
n.c.
n.c.
Controls
assembly (TDC)
Controls
assembly (TDC)
Controls
assembly (TDC)
-----------
Connector ( E2 )
Origin
Destination
Désignation
Pin
+ Alimentation
1
2
Description
Controls
assembly
(TDC)
Air
recirculation
motor
Air extérieur
Recyclage
partiel
Recyclage total
3
---
---
---
5
n.c.
---
---
---
6
n.c.
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Two-zone automatic climate control system ( RFTA )
The two-zone automatic climate control system comprises an electronic control assembly (1), from which
it is possible to manage all the functions, and the following components:
- 1 Compressor
- 1 Evaporator temperature sensor
- 1 Left air temperature sensor
- 1 Right air temperature sensor
- 1 Air distribution motor
- 2 mixing motors
The heater and distribution unit is governed via electric motors by the controls assembly (1).
Key:
1. Controls assembly
2. Air ventilation unit
3. Particle filter
4. Compressor
5. Heater and distribution unit
6. WEBASTO additional heater
Two-zone automatic climate control operation ( RFTA )
The front controls assembly (TDC CLIM AV ) is connected to the Body Computer (NBC) by means of a
CAN LS connection ( 125 Kbit/s ), it ensures the following functions:
- CAN interface with NBC
- Acquisition of the set of buttons comprising the controls assembly (TDC)
- Acquisition of the different temperature sensors, ventilated air 1 and 2, evaporator, solar radiation ),
- Management of controls assembly lighting (TDC) (rheostato, day/night),
- Management of the messages of the functions performed by TDC,
- Air ventilation motor control
- Control of motors for distribution, recirculation, mixing left and right,
- Diagnosis of the components connected to the controls assembly (TDC)
- Trouble and recovery management.
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The NBC ensures:
CAN interface with controls assembly (TDC),
Management of climate control adjustment,
Management and control of the heated rearscreen,
Management of the compressor.
The BSM ensures:
Management of the supply of the air ventilation motor,
Control of the compressor.
12. External air temperature sensor
14. Can network ( HS / IS )
15. Engine control unit
16. Fan motor assembly (GMV)
18. R134a gas pressure sensor
19. Water temperature sensor
20. Can LS network ( CONF )
21. LIN network
22. Air distribution motor
23. Air recirculation motor
24. Driver air mixing motor
25. Passenger air mixing motor
Key:
1. Controls assembly (TDC)
2. Antifrost sensor
3. Mixed air temperature sensor no. 1
4. Mixed air temperature sensor no. 2
5. Solar sensor
6. Air ventilation motor module
7. Air ventilation motor
9. R134a gas compressor
8. BSM
10. Can LS network ( CAR )
11. BSI
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Controls assembly pin-out ( RFTA )
The controls assembly (TDC) interfaces with the vehicle's electric system by means of 2 connectors:
E1 with 12 pins - E2 with 18 pins.
Connector ( E1 )
Origin
Destination
Désignation
Pin
Description
---
---
---
1
n.c.
---
---
---
2
n.c.
---
---
---
3
n.c.
---
---
---
4
n.c.
Vehicle
Controls
assembly (TDC)
Ground
5
Electronic ground
---
---
---
6
n.c.
---
---
---
7
n.c.
+ CAN
8
+ 12 Volt (max 3A)
BSI
Controls
assembly (TDC)
CAN H
9
Can ( CONF )
BSI
Controls
assembly (TDC)
CAN L
10
Can ( CONF )
---
---
---
11
n.c.
---
---
---
12
n.c.
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Origin
Mixed air temp.
sensor 1
Mixed air temp.
sensor 2
Antifrost sensor
Solar sensor
Controls
assembly (TDC)
Air ventilation
motor module
Controls
assembly (TDC)
-----------
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Destination
Connector ( E2 )
Désignation
Sensor power supply
ground
Sensor power supply
ground
Controls
assembly (TDC) Sensor power supply
Signal
Power supply
Signal
Training Academy
Pin
Description
1
2
3
4
5
6
7
8
+ 5 Volt
ground
+ 5 Volt
ground
+ 5 Volt
ground
Motor command
9
Signal 0 -> 5 Volt
Controls
Feedback signal
assembly (TDC)
10
Signal 0 -> 5 Volt
Power supply
Stepper motors (
LIN Serial line
*)
ground
-----------
11
12
13
14
15
16
17
18
+ 12 Volt ( LIN )
LIN network
Electronic ground
n.c.
n.c.
n.c.
n.c.
n.c.
Air ventilation
motor module
ground
( * ) Motor: air distribution; air recirculation; driver air mixing; passenger air mixing.
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Additional rear climate control system
The rear additional climate control system can be combined solely with the two-zone automatic climate
control system ( RFTA ).
Key:
1.Front controls assembly (TDC AV)
2. Antifrost sensor
3. Mixed air temperature sensor no. 1
4. Mixed air temperature sensor no. 2
5. Solar sensor
6. Air ventilation motor control module
7. Front air ventilation motor
8. BSM
9. R134a gas compressor
10. Can network ( CAR )
11. NBC ( Body Computer )
12. External air temperature sensor
14. Can network ( HS / IS )
15. Engine control unit
16. Fan motor assembly (GMV)
18. R134a gas pressure sensor
19. Water temperature sensor
20. Can network ( CONF )
21. LIN network
22. Air distribution motor
23. Air recirculation motor
24. Driver air mixing motor
25. Passenger air mixing motor
26. Rear controls assembly (TDC AR)
27. Rear air-conditioning enabling button
28. Hot water circuit solenoid valve (2-way)
29. Additional water pump
30. Rear climate control unit
31. Rear air ventilation motor
32. Distribution / mixing motor
33. Rear anti-frost sensor
The NBC node manages the following functions:
- CAN network interface with Front controls assembly
- CAN network interface with Rear controls assembly
- Management of climate control adjustment.
- Compressor control management
The BSM node manages the following functions:
- The power supply of the front air ventilation motor.
- The power supply of the rear air ventilation motor.
- Control of the compressor.
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Supplementary hot water heating circuit
6. Engine coolant radiator
7. Engine
8. Expansion tank
9. EGR
10. Main front climate control heater
Key:
1. Additional rear climate control heater
2. Additional water pump
3. Solenoid valve (2-way)
4. Webasto
5. Engine thermostat
Rear air-conditioning controls cluster
The figure shows the controls panel on the roof that has:
• mixing and distribution control knob (2).
• fan speed control knob (1).
• rear climate control indicator light (3).
The supplementary unit's mixing and distribution are regulated by an electric actuator (stepper motor)
controlled via a LIN serial line.
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With the control knob (2) it is possible to move both the mixing flap and the distribution flap at the same
time according to the following strategies:
1. By setting knob (2) on full heat the air flow distribution will use only the vents on the rear right
side panel.
2. By setting knob (2) on full cold the air flow distribution will use only the vents on the roof.
3. By setting knob (2) on the middle position the air flow distribution will take place simultaneously
from both the vents on the roof and the vents on the rear right side panel.
Rear climate control unit pin out
Origin
Antifrost sensor
Water circuit
solenoid valve (3way)
Front controls
assembly
Air motor control
module
Destination
Rear controls
assembly
Rear controls
assembly
Air motor
control module
Front controls
assembly
Rear controls
assembly
Rear unit
stepper motor
-------------------
-------------------
Connector ( E1 )
Description
Pin
Description
1
2
3
(+) Positive
(-) Ground
(+) Positive
4
(-) Ground
Command signal
5
0 – 5 Volt
Command check signal
6
0 – 5 Volt
Power supply
LIN BUS
7
8
(+) Positive
Power supply
9
-------------------
10
11
12
13
14
15
16
17
18
Sensor power supply
Solenoid valve power supply
(-) Electronic
ground
n.c.
n.c.
n.c.
n.c.
n.c.
n.c.
n.c.
n.c.
n.c.
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Origin
Vehicle
Rear controls
assembly
Vehicle
FIAT SCUDO COURSE OUTLINE
Destination
Connector ( E2 )
Description
Training Academy
Pin
Rear controls
CAN power supply
assembly
1
On-Off switch
On-Off switch LED command
2
Rear controls
assembly
CAN H
On-Off switch status
3
4
5
CAN L
6
On-Off switch
Vehicle
Rear controls
assembly
Rear controls
assembly
Water circuit
relay
---------
---------
Additional water pump
command
Water circuit solenoid valve
command (3-way)
---------
Description
(+) Positive
(-) Ground
7
8
9
10
11
12
n.c.
n.c.
n.c.
n.c.
Rear air-conditioning enabling button
The rear climate control enabling button is on the front instrument panel.
Key : 1. rear climate control on 2. rear climate control off
The status ( on/off ) of the rear climate control enabling button is acquired with the key on drive ( + APC )
and engine off. In this condition the rear climate control unit does not govern the following components:
- Rear air ventilation motor
- Mixing/distribution motor
- Gas circuit solenoid valve
- Hot water circuit solenoid valve
- Additional water pump
The rear climate control can only be turned on with the key on drive ( + APC ) and engine running. In this
condition if the enabling button is ON ( 1 ) the indicator light on the button and the one on the rear
controls assembly will light up at the same time.
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Operation with enabling button ON
The rear controls assembly governs as requested by the NBC:
•
•
•
•
Gas circuit solenoid valve.
Hot water circuit solenoid valve.
Additional water pump.
Mixing/distribution motor depending on the position of the right-hand rotary knob of the rear
controls assembly.
The rear controls assembly (TDC AR) sends the NBC node the following information:
- Mixing hatch position ( 0 to 100% ).
- Air flow speed ( position from 0 to 4 ).
- Air temperature at the evaporator outlet.
Rear climate control unit
The rear climate control unit is located behind the rear right panel.
The unit is composed of an evaporator and heater to permit mixing the flow of air, a ventilation motor
governed by an electronic module controlled by the rear controls assembly, expansion valve, antifrost
sensor and a stepper motor to regulate the temperature and distribution of the air flow at the same time.
Key:
1. Air ventilation motor module
2. Air ventilation motor
3. Stepper motor for air distribution/mixing
4. Water pipe couplings
5. Antifrost sensor
6. R134a gas pipe couplings
7. Evaporator
8. Vehicle wiring connection
9. Air ventilation motor connection
Upper rear ventilation
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The following figure shows the air circuit relating to the upper ventilation, made with a vertical duct and a
duct incorporated in the roof covering panel.
Key:
1 . Upper air flow vent
Lower rear ventilation
The following figure shows the air circuit relating to the lower ventilation (2), made with a duct
incorporated in the rear right panel.
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Passenger compartment water and gas pipe passage
On the right of the passenger compartment (see figure below) there are the pipes of the refrigerant gas
circuit and heating circuit of the additional rear climate control unit.
The above-mentioned pipes, depending on the vehicle version (short or long wheelbase), can have
different lengths.
Key:
1. Refrigeration circuit pipes (R134a gas)
2. Water heating circuit pipes
3. Rear additional climate control unit supply cables
Hot water circuit solenoid valve
The supplementary solenoid valve in the vehicle's heating circuit has the job of activating a
supplementary branch of the circuit related to the rear climate control unit.
Key:
1. Hot water inlet from the engine thermostat or from the Webasto when applicable
2. Water outlet towards main front heater
3. Water outlet towards additional rear heater
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Additional heating circuit operation with solenoid valve OFF
With the solenoid valve OFF, the additional water heating circuit is off.
Additional heating circuit operation with solenoid valve ON
With the solenoid valve ON, the additional water heating circuit works in parallel with the main front one.
4. Engine
5. Solenoid valve (2-way)
6. Rear controls assembly
7. Additional water pump
8. Rear climate control unit
9. Front climate control unit
Key:
1. Hot water inlet from the engine
thermostat or from the Webasto when
applicable
2. Water outlet towards main front heater
3. Water outlet towards additional rear
heater
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Additional water pump
The additional water pump can improve the flow of water when the rear climate control unit is working.
In operation the water pump assures a charge of coolant to the rear climate control unit of approximately
900 litres/h. at a relative pressure of 2.5 bar.
Key:
1. Hot water inlet from the 2-way solenoid valve
2. Water outlet towards additional rear heater
3. Electric connector
Component location (2-way solenoid valve; water pump)
The solenoid valve and water pump are fitted under the body of the vehicle on the left-hand side.
Key:
1. 2-way solenoid valve
2. Water pump
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Pipes
Specific GAS pipe for DV6 engine
Specific GAS pipe for DW10 engine
Single gas pipe key:
1. Condenser
2. R 134a gas pressure sensor
3. Compressor
4. Front climate control unit
5. Rear climate control unit
A. Pipes for version without rear climate control unit
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B. Pipes for version with rear climate control unit
Specific Water pipe for DV6 engine
Key:
1. Thermostatic valve of the DV6 engine
2. EGR
3. Front climate control radiator
4. Rear climate control unit
5. 2-way solenoid valve
6. Additional electric water pump
7. Webasto unit
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Specific Water pipe for DW10 engine
Key:
1. Thermostatic valve of the DW10 engine
2. Expansion tank
3. Front climate control radiator
4. Rear climate control unit
5. 2-way solenoid valve
6. Additional electric water pump
7. Webasto unit
Wiring diagrams
The diagrams shown are the following:
Wiring diagram 226: Heater
Wiring diagram 232: Manual climate control
Wiring diagram 238: Automatic climate control
Wiring diagram 241: Additional rear climate control
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Wiring diagram 226
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Wiring diagram 232
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Wiring diagram 238
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Wiring diagram 241
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Wiring diagrams key
0004 : ?
1320 : Engine control unit
1220 : CAPTEUR TEMPERATURE EAU MOTEUR
1313 : CAPTEUR REGIME MOTEUR
8006 : THERMISTANCE EVAPORATEUR (SI SEPARE)
8009 : CAPTEUR DE PRESSION DE FLUIDE FRIGORIFIQUE
8011 : RELAIS DE COMMANDE POMPE A EAU BOUCLE
8013 : ELECTROVANNE CLIMATISATION - EV CLIM ADDIT
8017 : RELAIS DE COMMANDE ELECTROVANNE
8020 : COMPRESSEUR REFRIGERATION
8024 : THERMISTANCE D'AIR HABITACLE GAUCHE
8025 : FACADE CLIMATISEUR (SI SEPARE)
8026 : FACADE CLIMATISATION ADDITIONNELLE
8028 : THERMISTANCE D'AIR HABITACLE DROITE
8033 : THERMISTANCE D'ENSOLEILLEMENT
8045 : MODULE COMMANDE PULSEUR(SI SEPARE)
8046 : RESISTANCE VITESSE PULSEUR (SI SEPARE)
8048 : Relè MODULE COMMANDE PULSEUR(SI SEPARE)
8050 : MOTEUR PULSEUR (SI SEPARE)
8059 : MOTEUR PULSEUR CLIMATISATION ADDITIONNELLE
8063 : MOTOREDUCTEUR VOLET DE MIXAGE DROIT
8064 : MOTOREDUCTEUR VOLET DE MIXAGE GAUCHE
8070 : MOTOREDUCTEUR VOLET ENTREE AIR
8071 : MOTOREDUCTEUR VOLET DE DISTRIBUTION
8093 : POMPE A CARBURANT CHAUFFAGE ADD ADDITIONNEL
BCM3 : BLOC COMMUTATEUR MULTIFONCTIONS GAUCHE
BSI : Body Computer ( NBC )
BB00 : BATTERY
BFDB : Max fuses on the battery positive cable
CA00 : Ignition block
C001 : CONNECTEUR DIAGNOSTIC
PSF1 : PLATINE DE SERVITUDE-BOITE FUSIBLES
BFH5 : fuse F39
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8.7 “Bluetooth” hands-free system ( KML : Kit Mains Libres )
The Hands-Free System (KML), thanks to the Bluetooth communication protocol, enables connecting a
mobile phone, at a maximum distance of 10 metres, with the vehicle's radio system.
This speakerphone system allows the user to be able to concentrate on driving and have his hands on
the steering wheel, subsequently improving the level of safety.
5. Stalk unit ( Comm 2005 )
6. KML control unit
7. Instrument panel
8. Car radio
9. Multifunction screen ( VMF)
10. Mobile phone
Key:
1. Condenser
2. Engine junction unit (BSM)
3. Intelligent services control unit (BSI)
4. Microphone
The Hands-Free System (KML), connected to the “CAN LS CONF” network, in order to function needs to
integrate with the vehicle's radio system composed of the following elements:
- Multifunction screen ( type C ),
- Audio system composed of a radio:
- RD4 with a multifunction screen (VMF) type ( C - ).
- Audio amplifier (optional),
- Controls on the steering wheel with specific function buttons,
- Integrated microphone
- Compact disc loader (optional).
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Functional diagram:
Key:
1. Instrument panel
2. KML control unit
3. Bluetooth signal
4. Microphone
5. Mobile phone
6. Stalk unit ( Comm 2005 )
7. Intelligent services control unit (BSI)
8. Multifunction screen ( VMF)
9. CD-Changer
10. Car radio
11. Electric connection
12. Audio signal output from KML control
unit
14. Can LS Confort network (125 Kb/s)
List of compatible mobile phones
•
•
•
•
•
•
•
•
•
•
•
•
•
NOKIA 6310(i)
NOKIA 8910(i)
NOKIA 3650
NOKIA 6600
NOKIA 6650 (07/2003 UMTS)
ERICSSON T68i
ERICSSON T68i
ERICSSON P800
ERICSSON T610
SIEMENS S55
SIEMENS S56 (version US)
PHILIPS 820
PHILIPS 825
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KML control unit location
The Hands-Free Kit control unit ( KML ) is behind the covering under the steering wheel on the left-hand
side.
Functional system checks
The different functional checks of the Hands-Free system (KML) can be summarised as in the following
list:
-
phone present or not (bluetooth connection)
-
GSM mobile phone signal level and transmit the correct information to display to the multifunction
screen ( VMF ). The conversion is for the KML (see GSM / Battery level graph display chapter).
communication status
read the different phone logs, max 30 numbers:
- last 10 calls made
- last 10 calls received,
- last 10 unanswered calls
read the content of the:
- SIM card address book
- Phone book
- SIM card + Phone address book
-
-
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Warning: When there are phone numbers saved in both the SIM card and phone memory, there will be
a request to delete the double that is done to the advantage of the number in the phone memory.
- incoming SMS on the phone
- mobile phone battery status and transmit the correct information to display to the multifunction screen
( VMF ). The conversion is for the KML (see GSM / Battery level graph display chapter).
- operator's name
- network roaming
- incoming message on the phone's answering service. This information is retransmitted over the CAN
network.
- call resend present or missing. This information must be retransmitted over the CAN network.
- Last name of the mobile phone connected. This information must be retransmitted over the CAN
network.
Note: Certain functions depend on the mobile phone used.
Human-Machine Interface ( IHM )
This user interface (IHM - Interface Homme-Machine ) gives all the information normally contained on the
display of the mobile phone:
General functional information
Call management
Call emission is authorised under the following conditions:
- The KML is authorised to forward calls only when the KML is on.
Ringtone management
If the KML cannot trace the phone ringtone it must generate one of its own.
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Incoming calls
When a call arrives, the KML signals the incoming call to the radio and the screen.
A popup window appears on the screen stating that a call can be taken. The phone ringtone is
retransmitted to the vehicle's speakers. The user can then decide whether to take or reject the call with
the aid of the remote control under the steering wheel or with voice commands uttered by the driver. From
the moment the call is accepted, the KML transmits the set of information of the communication to the
multifunction screen ( VMF).
Outgoing calls
- An outgoing call can be emitted from the log (outgoing, received, unanswered calls). The information,
name and number will be transmitted to the multifunction screen ( VMF).
- An outgoing call can be emitted from the phone keypad. The information, name and number will be
transmitted to the multifunction screen ( VMF).
- An anonymous call from the call log does not permit making an outgoing call.
Double call
The KML can manage double calls:
- Swapping over (between two calls)
- Outgong calls dialled on the phone
- Incoming calls
This management can be done either from the phone or from the controls assembly under the steering
wheel ( CSV).
Swapping over permits passing from call 1 to call 2 and vice versa.
It can be done either with the mobile phone or with the KML, in both cases the KML will signal the call
changes with messages displayed on the multifunction screen (VMF).
With no user selection, when the time managed by the multifunction screen (VMF) elapses, this window
will be closed without any other action.
Communication with
« Robert »
in progress …
00 :08 :16
Change
Hang up
Communication with
« Alex »
in progress …
00 :08 :16
Change
Hang up
If the user hangs up on one call the system will automatically pass onto the waiting call.
Note: In “double call” mode the KML system manages two communication time meters relating to call 1
and call 2.
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When the user is already on a call and there is an incoming call, the KML warns the user with a visual
popup message and a beep.
End the call
« Robert » ?
Yes
No
If the selected option is "Yes", then the communication will pass on to the last incoming call and the first
call will be put on hold.
If the selected option is "No", when the screen-managed popup time elapses, the call will be ended and
the communication in progress will continue.
Presentation of the number
The KML recognises the caller's name and / or number. This is valid for double and single calls. When the
KML does not recognise the caller because he or she is not in the log, it only displays the number of the
incoming call. If the name and number of the caller are not communicated by the network the system will
display “private number”.
Confidential communication mode (microphone mute)
The confidential mode function (MUTE) enables cutting off the communication between the KML user and
the other person. This is done by turning off or reactivating the microphone.
The confidential mode is possible only in communication.
In order to turn the mode (MUTE) on/off the user must access the menu via the controls assembly under
the steering wheel ( CSV).
Language management
The languages supported by the KML are the following:
•
•
•
•
•
•
•
French
English
German
Spanish
Italian
Dutch
Portuguese
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List management
The KML system must manage several lists, the log list, received, outgoing and missed calls list, service
calls list and the lists concerning twinned phones (connected via bluetooth).
List management is divided into 3 parts:
• opening
• navigation
• closing
The three phases are ensured by buttons on the following devices:
• Radio (RRT)
• Controls assembly under the steering wheel (CSV)
Opening the menu lists or validating an item is ensured by the “OK” button
• Button on the front of the radio (RRT)
• Controls assembly button under the steering wheel (CSV)
Line to line navigation [ Up () e Giù () ] :
• Buttons on the front of the radio (RRT)
• Controls assembly buttons under the steering wheel (CSV)
Page to page navigation [ search Up () e ricerca Giù () ] :
• Buttons on the front of the radio (RRT)
Closing the menu lists is ensured by the “ESC” button or due to “Time out” (30 seconds).
• Button on the front of the radio (RRT)
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Buttons on the front panel of the radio used by the KML
Context
Type of
support
OK
Lists
AS
Menu activation or Selection validation
AC
ESC
---
AS
Cancel
Exit menu. Return to the screen of the
current application
Top line shift
AM
Top line repetitive shift
AS
Bottom line shift
AM
Bottom line repetitive shift
Button
Lists
Lists
AL
AS
Spostamento riga superiore in
tutti gli elenchi KML ad
eccezione
del
repertorio
misto.
Spostamento lettera/lettera (A
®Z) nel repertorio misto
Liste
AM
Control
AS
Spostamento ripetitivo riga
superiore in tutti gli elenchi
KML
ad
eccezione
del
repertorio misto.
Spostamento riga inferiore in
tutti gli elenchi KML ad
eccezione del repertorio misto
Spostamento lettera/lettera (Z
® A) nel repertorio misto.
Liste
AM
Spostamento ripetitivo riga
inferiore in tutti gli elenchi
KML
ad
eccezione
del
repertorio misto.
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Control buttons under the steering wheel (CSV)
Button
Context
Type of
support
OK
Lists
AS
Lists
Lists
AS
AM
AS
AM
AS
Control
Menu activation or Selection
validation
Top line shift
Top line repetitive shift
Bottom line shift
Bottom line repetitive shift
Spostamento
riga
superiore in tutti gli elenchi
KML ad eccezione del
repertorio misto.
Spostamento lettera/lettera
(A ®Z) nel repertorio misto
Liste
AM
Spostamento ripetitivo riga
superiore in tutti gli elenchi
KML ad eccezione del
repertorio misto.
Spostamento riga inferiore
in tutti gli elenchi KML ad
eccezione del repertorio
misto.
AS
Spostamento lettera/lettera
(Z ® A) nel repertorio
misto.
Liste
AM
Spostamento ripetitivo riga
inferiore in tutti gli elenchi
KML ad eccezione del
repertorio misto.
Key (type of support)
AS: Single press (right from starting to press on the button)
AC: Short press (if pressed and held for longer than 2 seconds)
AL: Long press (if pressed and held for longer than 2 seconds)
AM: Press and hold
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SMS text messages
The KML must manage the SMS messages and warn the user of a received text message.
When the phone's SMS memory is full, the KML informs the user of the phone's status when a new SMS
text message arrives.
Reading text messages on the multifunction screen (VMF) is prohibited with the vehicle in motion.
The operations of reading, writing and deleting SMS text messages on the SIM card must be done by
using the phone's keypad and display.
Message on the phone's answering service
Reading text messages on the multifunction screen (VMF) is prohibited with the vehicle in motion.
The operations of reading, writing and deleting SMS text messages on the SIM card must be done by
using the phone's keypad and display.
Service Call
The KML manages 3 different services that are in order:
1. Customer Centre
2. Mechanical Assistance
3. Emergency Assistance
If one or more services are not available, the order is changed so as to register the first service available.
Example: ''Repair Service'' not available, the order becomes:
1 Customer Centre
2 Emergency
Customer Centre Call
The number of the Customer Centre is a specific number for the user providing a response to functional
problems with the vehicle.
Remarks:
- This number is not displayed on the multifunction screen (VMF).
- This number is specific and depends on the make of the vehicle.
- Double calls are possible when this number is dialled.
Mechanical Assistance Call
The Repair number is a specific number for the user for requesting assistance in the event of trouble with
the vehicle.
Remarks:
- This number is not displayed on the multifunction screen (VMF).
- This number is specific and depends on the make of the vehicle.
- Double calls are possible when this number is dialled.
Emergency Assistance Call
The KML manages emergency calls , (112 for Italy). This number is displayed on the multifunction screen
(VMF) at the start of the call.
Remarks:
- Only the user can forward an emergency call manually.
- No double calls are possible when this number is dialled.
- The emergency call (112) can be forwarded even without an SIM card.
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Voice Recognition
Turning the "Voice Recognition” function on and off is only possible by starting a manual action on the
button on the:
- Controls assembly under the steering wheel (CSV)
Turning the "Voice Recognition” function on and off is signalled by an audible signal of 3 distinct notes
followed by an audible announcement, voice synthesis by the KML.
During a session of voice recognition there is a “Time-out” of 5 seconds within which the user must utter
the message. After this time the session will be ended.
If the voice message uttered by the user is not recognised the KML system informs the user with the
following announcement: Repeat, please!
Voice commands
The following table lists the user voice commands:
Terms / symbols function
Delete the last digit
Forward a call
#
+
*
0
1
2
3
4
5
6
7
8
9
Voice command
Change
Call
Hash
Plus
Asterisk
Zero
One
Two
Three
Four
Five
Six
Seven
Eight
Nine
The following table lists the voice commands emitted by the KML system:
Voice announcements emitted by the system
Number dialling abandoned
Last Digit(s) Deleted
Call in progress
Say the number
Number deleted. Restart dialling the number from the start
Repeat, please!
To use voice dialling, utter one or more digits in succession. To change the last digits,
say "change". To start the call, say
No digit to delete.
No number recorded. Call impossible
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Service continuity
If the user is on a phone conversation and in the meantime gets into the vehicle and an authorised
bluetooth connection is made, the KML system will allow the conversation to continue with the vehicle's
audio system.
On the contrary, if the user is on a phone conversation in the vehicle and interrupts the Bluetooth
connection, the conversation will continue on the mobile phone.
The observation holds whether the user is in the vehicle or outside the Bluetooth communication area.
Warning: A bluetooth connection can be interrupted by the user either on purpose or by going outside
the limit of the area of coverage ( 10 metres ).
Connection of a Bluetooth phone
For the KML system to connect to a mobile phone via a bluetooth connection, some conditions must be
met:
- KML On
- No mobile phone connected.
- No twinning in connection.
Electronic diagnosis
Reading parameters
The diagnosis tool enables reading the following parameters:
• Identification number
• Functional reference number
• Supplier’s code
• Complementary number (parent company supplier reference number)
• Software release (software release according to supplier's coding)
• Calibration version (according to supplier's need)
• KML internal diagnosis version
• Parameters and defects code (DTC)
• Type of application
• (for needs of manufacture or warranty)
• Serial number (for needs of manufacture or warranty)
• Date of manufacture (for needs of manufacture or warranty)
Configurations of the (KML)
The KML system can be configured with the diagnosis instrumentation for the following parameters only:
• Definition of the different service numbers
• Name of the Hands-Free Kit (KML)
• Definitions of the microphone gain, presence of an anti-echo, anti-interference filter
• Voice commands
Graphic display of the GSM / Battery level
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There are many versions of mobile phone on the market and each one of them could have a different
graphic scale of the GSM / Battery signal level.
To this regard, the rules for conversion between the GSM mobile phone level bars and the value
displayed on the multifunction screen ( EMF C - ) are given here:
A, Case of a phone with 4 level bars
B, Case of a phone with 5 level bars
C, Case of a phone with 6 level bars
D, Case of a phone with 7 level bars
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Wiring diagram 274
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Wiring diagram key
7215 : Multifunction screen
8415 : CD loader
8417 : Radio-receiver fan
8420 : Front LH door speaker
8425 : Front RH door speaker
8430 : Rear LH door speaker
8435 : Rear RH door speaker
8440 : Front LH Tweeter speaker
8445 Front RH Tweeter speaker
8480 : Telematics transceiver
8482 : Radio Phone microphone
BSI : Body Computer ( NBC )
BB00 : BATTERIA
BFDB : Max fusibili sul cavo positivo batteria
CA00 : Blocchetto avviamento
C001 : DIAGNOSIS CONNECTOR
PSF1 : SERVICES FUSE BOX PLATE
0004 : Quadro strumenti
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8.8 ALARM
General
The car is equipped with an electronic alarm that can only be activated with a remote control, with
perimeter (external) and volumetric (internal) protection.
The alarm is the ultrasound type and has the job of managing:
• volumetric detection,
• power supply and management of the ultrasound sensors,
• perimeter detection,
• siren.
Functional diagram
The following figure illustrates the connections between the various elements.
Key:
1. Blinker
2. Central locking button
3. Side sliding door switches
4. Rear door switch
5. Front door switches (driver and
passenger)
6. Remote control antenna
7. Stalk unit
8. Siren
9. Ultrasound sensor (TX)
10. Ultrasound sensor (RX)
11. Bonnet switch
12. Volumetric sensor off button
13. Alarm control unit
14. Can LS CAR network ( 125 K/bit )
15 . Body Computer
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Operation
Volumetric surveillance is ensured by two ultrasound sensors, located in the front courtesy light, that
enable detecting a movement or a change in volume.
The perimeter control is managed:
• by the Body Computer as regards the signals from the contacts on the front doors, side doors and
rear hatch.
• by the Alarm node as regards the signal from the switch on the bonnet release mechanism.
In case of break-in:
• the Body Computer turns on the left and right direction indicators for the visual signals,
• the Alarm node turns on the audible warning (siren) and the alarm LED.
The system status is indicated by a LED on the dashboard with the following modes:
• blinking LED (frequency 1HZ): alarm on,
• LED with fast blinking (frequency 5HZ): saving an attempted break-in,
• LED off: alarm off,
• LED on (steady light): alarm on with inhibition of the volumetric surveillance function.
Position of components
- The Alarm Node: is located behind the passenger glove compartment, to the side of the Body Computer.
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- The siren: is secured on the related support between the mudguard and the shoulder of the front right
mudguard.
- The volumetric surveillance off button: is located on the left-hand side of the dashboard for left-hand drive
vehicles and on the right-hand side for right-hand drive vehicles.
- The volumetric sensors: are located in the front middle courtesy light.
Wiring diagram
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Wiring diagram key
6202 : Driver's door lock
6207 : Passenger door lock
6210 : Left sliding side door lock switch
6215 : Right sliding side door lock switch
6222 : Rear hatch lock
8602 : Alarm control unit
8607 : Ultrasound sensor - emitter
8608 : Ultrasound sensor - receiver
8605 : Alarm siren
8611 : Bonnet lock switch
BCM2 : Volumetric off switch ( right panel )
BCM1 : Central locking switch ( left panel )
BSI : Body Computer ( NBC )
BB00 : Battery
BFDB : Max fuses on the battery positive cable
CA00 : Ignition block
C001 : Diagnosis connector
PSF1 : SERVICES FUSE BOX PLATE
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8.9 PARKING SENSORS
Installed in the vehicle's rear bumper, their function is to detect obstacles near the back
of the vehicle with an intermittent audible warning.
The frequency of the acoustic signal increases as the vehicle gets nearer the obstacle.
Turning off Sensors
Momentary turning off, press button A on the right-hand side of the middle instrument
panel. Indicator light B on the button lights up when turned off.
Trouble
This is signalled by engaging reverse gear with an audible warning and simultaneous lighting of indicator
light B, accompanied by a message on the display.
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Wiring diagram
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Wiring diagram key
7500 : Parking sensor control unit
7510 : Parking sensor
7511 : Parking sensor
7512 : Parking sensor
7513 : Parking sensor
2200 : Reverse gear switch
BCM2 : Volumetric off switch ( right panel )
BSI : Body Computer ( NBC )
BFDB : Max fuses on the battery positive cable
CA00 : Ignition block
0004 : Instrument panel
C001 : Diagnosis connector
PSF1 : SERVICES FUSE BOX PLATE
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