Abarth Grande Punto 2004, Punto Evo 2004 User Manual

TRACK TEACHING FIAT PUNTO

- Fiat S.p.A.

After Sales

Training

Fiat Punto

FIAT PUNTO

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TRACK TEACHING FIAT PUNTO

Fiat Auto S.p.A.

After Sales

Training

CHANGES / UPDATES DOCUMENTATION

Date Contact File Name Description of Change

© 2004 - Fiat Auto S.p.A. All rights reserved. They prohibited the dissemination and reproduction by any instrument. The processing of the material can not include specific responsibility for inadvertent errors or omissions. The information on this media are subject to continuous updates: Fiat Auto SpA assumes no responsibility for consequences arising from the use of outdated information This publication is for educational use only. For technical information, and to keep the charitable purposes, you should refer to manual care and the service information of the model of vehicle.

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Index

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1 Briefing

1.1 General characteristics

1.1.1 Presentation

Born New Point: a new car, dynamic and exciting able to combine

elegance and sportsmanship in an irresistible mix. New Point comes to reaffirm the excellence of

Italian car design and the vocation of the young and sporty Fiat.

Her gritty and determined line, customized by Giugiaro, is the main attraction for

young people who want a car but comfortable and treated in detail.

I'm really young and all those young spirit that New Point is aimed at:

gives the car an agile driving experience and a high comfort level.

New Punto stands out from its main competitors:

STYLE: understood as the ability to understand customer expectations with the final forms and

configurations that offer excitement and desire to possess.

DRIVING PLEASURE: not only as a capacity to make more pleasant and easier

the arrangement in the vehicle by all occupants but as the ability of

emphasize those aspects which, without prejudice to the conditions now expected discounted

as safety, comfort and quality, enhance the technical characteristics of the vehicle offering

driving behaviors that make a difference over the competition.

GLOSS: meaning the ability to combine the right balance between economy

exercise and performance car.

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The product offer to launch consists of two petrol engines and diesel engines by three

whose main characteristics are:

Petrol engines:

1.2 8v 65 hp

1.4 8v 75 hp

Diesel engines:

1.3 Multijet 16V 75 hp

1.3 Multijet 16V 90 horses

1.9 Multijet 16V 120 hp

with four different trim levels, which are characterized by rich content and offers

of engines, capable of satisfying the needs of different target to which New point is

Eligibility: active, dynamic, elegance and sport.

1.1.2 The market and the customer

Today, the New Point segment accounts for 26% of car market in Europe

West, that the "core market" with about 3,750,000 registrations per year.

In Italy however this segment is for 37% of the market, made up 56% of

gasoline and diesel engines by 44%.

FIAT has always been very present in the segment of small / medium cars and despite the

sector crisis point in recent years has been the leading vehicle in Italy and the third best car

sold throughout Western Europe.

Today the goal is to return to New Point market leader not only in Italy but

in the rest of Europe. How? In proposing his dynamic style and expressed particular

Italian design and solutions through the simple and ingenious.

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This step will take forward the process of relaunching the brand started with FIAT

New Panda and Idea with current and Croma.

New Point has as main objective to regain a younger audience

proposing with its dynamic character and sporty offering typically Italian styling

symbol of personality and sophistication. It is, therefore, urges men and women from the spirit

youth who seek to express their own distinctive personality through chosen

a strong emotional component.

To better meet customer needs, new Punto is offered in four levels

construction:

ACTIVE: is addressed primarily to the youngest aged 25 to 30 years, 'constitutive'

sensitive and open to the most prominent expressions of performance values; people

dynamic and full of vitality, with an open mind and flexible.

DYNAMIC: For more mature young, vital and enterprising, torn between an emotional and

rationality, between 30 and 45 years old, youthful energy and 'control' adult.

ELEGANCE: for mature men and women in the choice and take for granted allocations

a higher category and excellent comfort and are sensitive to suggestions that tend

to enter new vitality and impulsiveness in the automotive world

SPORTING: for dynamic young people and athletes looking for performance and exterior traits

markedly distinctive. It caters to both men and women in sports and edgy, What the

audience is looking into the car has style, emotion, comfort, safety and a good price.

What the audience is looking into the car has style, emotion, comfort, safety and a good price.

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With New FIAT Punto is ready to offer:

Distinctive style and Italian

Large living space: 50 mm more than the current point

Security level aligned with the best competition

Robust

Diesel engines in their class: 1.3 75 1.9 120 hp and 90 hp

Taking into account that today the main attraction for the public purchase of the reason is the line,

New Step to regain leadership in its segment relies on its own to a new

modern and attractive, you launch into the world of youth with agility and versatility

that distinguishes it from normal sedans two volumes.

1.2 The vehicle

1.2.1 The style

Point is a new'Self styled lines and explicitly rooted in history and most authentic tradition and characteristic of'Italian motor racing with a surprising

unexpected morphology of the product that brings it into contrast with the guidelines

almost all European car manufacturers.

A line from 'Real' car in which they find themselves pleasantly and originally interpreted, while respecting the'air du temps, Values of style, sportiness, elegance and beauty.

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1.2.2 The size

External

Even the exterior dimensions are a result of market expectations and the consequent

style choices, but much is due to legislative developments, in terms of protection

occupants, has influenced the choices of particular forms.

The end result, for some sizes, poses new point at the top of the segment (see

table below).

Table of comparison with the competition

External dimensions (mm)

L101 Step

L103 car length

Width

L104 Front overhang

L105 Rear Overhang

H100 Car height

N

POINT

199

2510

4030

1687

876

647

1490

P

POINT

188 (5P)

2460

3835

1660

775

600

1480

OPEL

5P RACE

2491

3816

1645

747

578

1442

PEUGEOT

206 5P

2441

3837

1650

787

609

1436

FIESTA

'02

2486

3917

1680

772

659

1467

RENAULT

CLIO '98

2472

3772

1640

714

586

1418

NISSAN

MICRA

2427

3717

1660

685

605

1525

TOYOTA

YARIS 5P

2373

3607

1660

710

524

1516

CITROEN VW POLO

'02 C3 5P

2460

3849

1670

756

633

1534

2460

3897

1650

800

634

1465

P: Current Point

N: New Point

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In summary new Punto is longer than the competing cars in its segment of about 20 cm,

while it is perfectly in line for the width and height.

1.2.3 Preparations

New Point is available in four different preparations of specific content and coatings

internal and customize dashboard, seats and panels:

Active, Dynamic, Elegance and Sporting.

The set ACTIVE offers as standard:

ABS

Electric power steering

power windows

dual airbags

The DYNAMIC setting offers as standard:

ACTIVE content

remote control

height-adjustable driver's seat

double back seats (5-door version)

height adjustable steering wheel

rear headrests

The ELEGANCE trim features standard:

DYNAMIC content

steering wheel and gear knob covered in leather

CD car radio

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air conditioning

alloy wheels

The construction SPORTING offers as standard:

DYNAMIC content

Vehicle Dynamic Control (ESP)

fog light

alloy wheels and tires 17 "

miniskirts

Sports leather steering wheel (central pierced handles and accent stitching)

particular measuring instrument

Front sports seats with shapes (better containment)

CD car radio

air conditioning

Other content is not standard, but options are:

Knee air bag

Window-bag

Side-bag

Anti-whiplash front seats (attenuator whiplash)

Electric rear windows (5p)

Front armrest

Electrical lumbar adjustment

Automatic climate control

Cruise control

Rain sensor

Parking sensors

Pressure sensor (TPMS)

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Leather upholstery

Alloy wheels (different designs and sizes)

Skydome sunroof

Rear spoiler

Side strips

Radio CD MP3

HI-FI

Bluetooth Kit

Headlight washers

Transmission 6-speed (1.3 Multijet 16v 90 HP)

1.2.4 Engines

The engines fitted to the car commercial launch are:

PETROL ENGINES

1.2 8V 65 hp

1.4 8V 75 hp

DIESEL ENGINES

75 bhp 1.3 Multijet 16V

90 bhp 1.3 Multijet 16 V

120 bhp 1.9 Multijet 8V

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1.2.5 Changes

On New Point are four types of change that have appropriately optimized

excellent maneuverability and excellent noise control speed of development.

CHANGE GEAR ENGINES

C 514

C 510

M20

M32

5 1.2 8V, 1.4 8V

5 1.3 Multijet 16V 75 and 90 hp

6 90 bhp 1.3 Multijet 16 V (optional)

6 120 bhp 1.9 Multijet 8V

1.2.6 Range

GASOLINE:

1.2 8V

1.4 8V

65 HP Manual 5 speed X X

77 HP Manual 5 speed X X

Active Dynamic Elegance Sport

DIESEL:

Active Dynamic Elegance Sport

1.3 Multijet 16V

1.9 Multijet 8V

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75 HP Manual 5 speed X X

90 HP

Manual 5/6

marches

X

120hp

Manual 6 speed

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X

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1.2.7 Active Safety

For active safety is the set of technical solutions that help prevent

from accidents.

Among the electronic and mechanical safety, New Point features:

ABS: All versions of the planned integrated anti-lock system that regulates the action

braking in order to prevent locking of the wheels;

EBD: Electronic brake balance between front and rear wheels;

ESP active safety system for the control of the vehicle in dynamic maneuvers on the road

which intervenes in emergency conditions.

ESP is standard only on Sporting. The entire range is equipped with ABS with EBD and

ventilated disc brakes on front wheels (except 1.2 8v engine that drives not mounting

ventilated).

1.2.8 Passive Safety

For passive safety of a vehicle's'Means a set of technical solutions and

product designed to protect occupants in the event of an accident. Research and

the technical solutions adopted are intended to protect the occupants of the car in case

frontal impact, side and rear.

With New FIAT Punto makes new progress on the security front. Fiat introduces on New

Progettative technical solutions, constructive and innovative content and intelligence for

best results in terms of occupant protection.

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New point is equipped with a standard occupant protection system comprising:

FPS Air-Bag, Air-Bag includes driver and front passenger

A dual stage;

front seatbelts with pretensioners and load limiters;

electronic system "my car" to disable Air-Bag front and side passenger side.

Also available as an option:

Side Bag on front seats, have a protective cage and pelvis;

Bag in the Window housed under the roof girders that provide head protection

objects against highly intrusive.

In designing new Punto, Fiat has paid particular attention to the safety of children

board and the safety pedestrians.

The safety of children on New Point provides all the devices that allow

provide maximum protection now feasible to include attacks on isofix seats

rear passenger air bag and the inhibition directly by on-board computer.

Pedestrian safety has somehow influenced style choices to meet the new

legislation establishing specific conditions for the protection of pedestrians in the event of a collision.

The shell to yield, the steering column and pedals and collapsible steering

with anti-whiplash seats (optional), complete the equipment in security

passive.

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1.2.9 Tyres and wheels

To optimize the performance of the car, especially with regard to the road holding,

safety and ride comfort, it was decided to use the following tires:

175/65 R15 - Active / Dynamic

185/65 R15 - Active (opt) / Dynamic (opt) / Elegance / Sport (opt catenabile)

195/55 R16 - Dynamic (opt) / Elegance (opt)

205/45 R17 - Elegance (opt) / Sport

As for the wheels, the new Punto has a wide range, which

different styles, sizes and coatings:

15 "

16 "

17 "

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1.2.10 tire repair kit

The new Punto is equipped with the new version of the kit "Fix & Go" for the repair of

tires in case of punctures (holes of the maximum diameter of 4 mm).

The new kit comprises in a single component, the compressor, the canister of liquid

sealant, the silicone tube for repair of the tire, the tube with a spout for the

control and inflating the tire, the electric cable for feeding through the outlet

lighter.

The use of KIT has been further simplified.

The procedure to repair the flat tire provides substantially

connecting the power cord into the cigarette lighter socket, connect the hose

silicone to the tire valve and the ignition of the compressor of the liquid sealant is

automatically injected into the tire mixed with air. The repair can be

say ended when the tire pressure reaches the predetermined values.

The Fix & Go can also be used to control and restore pressure

tires, by connecting the appropriate tube provided with quick coupling.

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1.2.11 Comfort

New Point of ergonomics and comfort has made its points of excellence (accessibility,

visibility of accommodation):

the position of the pedals,

the alignment of the steering wheel,

the proper position of the armrest,

the correct position of the footrest,

the excellent maneuvering of the gearshift knob

full visibility of the instrumentation and the main controls

seats which contain excellent sections and wrap your body properly even in

more dynamic driving situations.

To make the new reference point in its category in terms of comfort were

deals in particular:

Isolation of the incoming noise in the cockpit

Internal noise

Filtering of the vibrations and rolling noise

Sensitivity acoustic excitation transmitted through solids

Compact car on the road roughness

Dynamical systems: engine, intake and exhaust

1.2.12 Habitability

In the analysis of the car, the customer seems to base its assessment of the Wellness

mainly from the board seat.

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The area around the driver's seat (and the components present in it) is configured so as

the surface portion of the passenger especially significant in order to allow the customer to

arrive at a final judgment about the well-being that the inside as a whole will be able to

offer.

New Step in the draft ergonomics is at the center of attention. In fact it has reached a

good balance between the prerogatives of Style and the indispensable requirements of the customer in

terms

habitability, accessibility, visibility internal (such as the excellent layout of all controls

visible and within reach) and the external visibility favored by the large size of

mirrors.

New Point can comfortably accommodate clients of all sizes, with results

obtained, among other things, without compromising the ability of the boot, which is at least in 263lt

normal running configuration.

"To be well on board," he added, meant to find so much space, but we especially find it there

where needed, new Punto has volumetric values of living space ("cubature") to top the

category.

The profile of the cabin, can accommodate two passengers in the seat

3 back on the car doors, but you can request to apply for approval for

fifth passenger (by adding a third rear seatbelt).

The task of setting the vehicle was conducted according to modern criteria for defining

basic ergonomic functions, consistent with the stylistic and safety prerequisites:

Space and internal volume

Habitability

Accessibility

Visibility

Cargo Compartment

Usability

To these functions correspond parameters which measure the ability of the car to respond

to the requirements of well-being on board the vehicle.

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1.2.13 Air

The well being of those who are on board, is guaranteed by an air conditioning system that

creates ideal conditions for the trip.

The 'offer range includes three different systems:

heater

air conditioning

dual-zone automatic climate control with differentiated between driver and passenger

both the temperature and air distribution.

These systems allow to divide and directing the streams in many ways, so as to ensure

the desired effect, and always uniform throughout the interior.

Very useful is also the function of demisting the windscreen.

The fitting with air conditioner are provided with ducts for air distribution at the foot

rear passengers.

Schematic flows and speakers

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Dual-zone automatic climate control

Layout command climate

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H e a t e r

A i r

C o n d i t i o n e r

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1.2.14 Sunroof

The roof of the new Punto is a specific system for large windows, called

"Skydome", consisting of two glass panels: sliding front, fixed rear ..

The glasses are extended to an extent to replace more than 70% of the surface of the pavilion.

In the opening phase of the moveable panel front slides out of the pavilion (position

"Spoiler").

The extensive glazed roof allows plenty of light to enter.

This helps increase the feeling of space available for the occupants.

The roof aprible Skydome is equipped with sliding curtains which allow to limit the ingress of

light in the cockpit.

1.2.15 Audio System

Audio sources are available based staging: Radio tuner, CD

audio/MP3. The sound system on the car can be of two distinct categories:

Standard

Hi-Fi sound system

Standard system:

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The system consists of n ° 6 speakers, divided into the following types:

mid-woofer speaker 160 mm in diameter, 40W, positioned in the front doors,

designed for the reproduction of the mid / low. The technology used for such

components (water resistant) allowing them to withstand without damage splash

of water present inside the door;

tweeter speakers, 30W, positioned on door handles, designed to reproduce

higher frequencies;

speakers full-range of 130 mm in diameter, 40W, positioned in the rear side panels, in

able to reproduce the full spectrum of audio frequencies. Even for these components is

adopted the technology "water resistant".

Hi-Fi Sound System:

The system consists of n ° 6 speakers and a sub-woofer box containing an amplifier

mono output channel.

The main characteristics of the components are as follows:

mid-woofer speaker 160 mm in diameter, 40W, positioned in the front doors,

designed for the best reproduction of the mid / low, even for such

adopted the technology "water resistant";

tweeter speakers, 40W, positioned on door handles, designed to reproduce

higher frequencies;

speakers full-range of 130 mm in diameter, 40W, positioned in the rear side panels, in

able to reproduce the full spectrum of audio frequencies. Even for these components is

adopted the technology "water resistant";

sub-woofer box type "bass reflex", from 6.5 to 7 liters in volume, containing a speaker

130 mm in diameter, 100W for the reproduction of lower frequencies. This box is installed

in the luggage compartment, right side wheel;

mono audio power amplifier channel, positioned inside the box sub-woofer for the

piloting the sub-woofer.

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1.3 Lineaccessori

New Point accessories have been developed with the specific objective of giving the customer

appropriate solutions to meet your needs to customize the car so emotional and functional.

The development, carried out with the involvement of the Fiat Style Centre, has had as a guideline

the looking for exclusive products, consistent with the identity of the model, in its integrated form

essential and practical value of the research.

The offer can be divided into the following areas:

1.3.1 Sportsmanship

To meet the requirement of living in their cars so we realized a more emotional KIT consists of side skirts, "spoiler" on the tailgate, appendices of aerodynamic front bumper giving the car a modern look aggression.

There are also a kit for alloy wheels 16 "and a 17", respectively 195/55R16 and 205/45R17 tires.

Completing the customization sports steering wheel and shift knob, leather cover aluminum pedals

with rubber inserts for a more secure and comfortable.

1.3.2 Comfort - Utilities - free time

For greater ease of use are envisaged modern car anti turbulence deflectors, Kit rubber protective bumpers, side strips, interior rubber mats over or "carpets", tailored covers for the seats, holding various grid objects, a network dividing specific for the transport dogs, possibly combined with a tank semi-rigid polypropylene for easy cleaning of the luggage compartment.

The availability of an aluminum sill plate to be positioned on the internal threshold of the car

complete the offering for customizing cosmetic / functional.

Especially for leisure, the accessory range offers cross bars on which

You can use the whole line of car rack specification available: SCI - BICYCLES -

SURF.

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For towing a trailer you can choose between two types of hooks, ball type removable.

For owners of Apple I-Pod, Lineacessori also offers a preparation for that allows its use by

managing the contents through the system for radio gear.

1.3.3 Security

The active and passive protection of the car is guaranteed by a specific range of alarms and

KIT from parking sensors to be placed on each side plate.

The traditional alarm, offered in a modular design with remote control

activation / opening-closing doors, communicates via a CAN network with the electronic

present on the vehicle. The potential break is signaled by sirens installed in the

motor.

The CLEAR BOX or GSM-GPS locator is the best that current technology offers the

field of automotive protection / satellite phone.

The form of matched Lineaccessori traditional alarm can have its own

car always under control, clearly identifying the location and receive messages

any break-ins.

The ultrasonic parking sensor, which is activated by the engagement of reverse gear signals

sound barriers are not visible from the rear-view mirrors.

The Bluetooth Hands Free "MetaBlue" are also possible with confidence to

telephone conversations without handling the phone, without any wire connection,

handling calls with a single click of a button control and listening to the voice

call directly on the audio of 'self, both in the case of the factory installed radio

both in the case of device owned by the customer and even in the case of presence of the

only

susceptibility (speakers): safe and comfortable driving in the enforcement of traffic rules.

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Child Safety

For cars equipped with specific attacks ISOFIX child seat is available for UNIVERSAL

weights from 9 to 18 kg

The range is completed with traditional seats such as:

CRADLE up to 10Kg. weight;

Kiddy Life child seat weights from 9 kg. to 36 kg.

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TECHNICAL

2 Specifications

1.4 8V

Type Code

Location in

car

Orientation

No. of cylinders

350A1000 199A3000 199A4000 199A2000 939A1000

Front Front Front Front Front

Transverse Transverse Transverse Transverse Transverse

4 4 4 4 4

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2.1 Engine

2.1.1 Type of motor

1.3 Multijet

16V 90 hp

1.2 8V

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1.3 Multijet

16V 75 hp

1.9 Multijet 8V

120cv

Position

cylinders

N ° valves

cylinder

Cycle

Distribution

Fuel

Supply

fuel

In line In line In line In line In line

2 4 2 4 2

Eight Diesel Eight Diesel Diesel

1ACT with

variator

phase

With tappets

mechanical

Gasoline Diesel Gasoline Diesel Diesel

Electronic MPI

sequential

phased

2ACT 1ACT 2ACT 1ACT

Rocker to

finger with

tappet

hydraulics

Injection

MultiJet direct

Common type

Rail Turbo

-geometry

With tappets

mechanical

Electronic MPI

sequential

phased

Rocker to

finger with

tappet

hydraulics

Injection

MultiJet direct

Common type

Rail Turbo

With tappets

mechanical

Direct injection

MultiJet type

Common Rail

with turbo

geometry

variable and

Intercooler

and Intercooler

variable and

Intercooler

TECHNICAL DATA

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2.

1. 2 D at a E n gi n e

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Bore (mm)

Stroke (mm)

Total displacement

(Cm ³)

Ratio

compression

Maximum power

(Bhp EEC)

Maximum power

(KW EEC)

System of power

maximum speed (r / 1 ')

Maximum torque

(Nm EEC)

Maximum torque

(EEC Kgm)

Conditions of maximum torque

'

Idling

(R / 1 ')

1.4 8V

72 69.6 70.8 69.6 82

84 82 78.86 82 90.4

1368 1248 1242 1248 1910

11:1 17,6:1 11:1 17,6:1 18:1

77 90 65 75 120

56 66 48 55 88

5750 4000 5500 4000 4000

114 200 102.2 190 280

11.6 20.4 10.4 19.4 28.5

3000 1750 3000 1750 2000

750 ± 50 n.a. 750 ± 50 n.a. n.a.

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

TECHNICAL DATA

Valve clearance

Aspiration

Discharge

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2.2 A n g l e s

o f

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Valve clearance

cold operation

Suction (mm)

Valve clearance

cold operation

Drain (mm)

Opening before TDC (°)

Closing after PMI (°)

Opening the first SME (°)

Closing after TDC (°)

1.4 8V

0.3

0.4

1.4

8V

-7 ° n.a. 1 n.a. n.a.

41 ° n.a. 47 n.a. n.a.

1.4 8V

57 ° n.a. 51 ° n.a. n.a.

-9 ° n.a. -3 ° n.a. n.a.

1.3 Multijet

16V 90 hp

-

1.3 Multijet

16V 90 hp

1.3 Multijet

16V 90 hp

1.2 8V

0.3 - n.a.

0.4 - n.a.

1.2 8V

1.3 Multijet

16V 75 hp

1.3 Multijet

16V 75 hp

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

1.9 Multijet

V8 120 hp

1.9 Multijet

V8 120 hp

TECHNICAL DATA

Injection

Ignition

FIAT PUNTO

TRACK TEACHING FIAT PUNTO

4

3 7 / 5 3

©

Fiat Auto S.p.A.

After Sales Training

Type

Injection order

Coils

Number of coils

Candles

ignition

Unit

command

preheated

Glow

preheated

Order

ignition

1.4 8V

Marelli

5SF3

1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

1.4 8V

F.M. BAE

940A

4 - 4 - -

NGK ZKR7A-

10

- Bitron - n.a. n.a.

- Beru 4L01192 - n.a. n.a.

1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

1.3 Multijet

16V 90 hp

Marelli 6F3 Marelli 5SF3 Marelli 6F3

1.3 Multijet

16V 90 hp

-

1.2 8V

F.M. BAE

940A

NGK ZKR7A-

10

1.3 Multijet

16V 75 hp

1.3 Multijet

16V 75 hp

- -

1.9 Multijet

V8 120 hp

Bosh

EDC16C9

1.9 Multijet

V8 120 hp

TECHNICAL DATA

TRACK TEACHING

0

zz

0

7 5

FIAT PUNTO

2.3 Characteris tic curves of the motor

60

55

50

45

40

35

30

25

20

15

10

5

1 3 5

1 3 0

1 2 5

1 2 0

1 1 5

1 1 0

1 0 5

1 0 0

9 5

9 0

8 5

8

Fiat Auto S.p.A.

After Sales Training

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000

Speed [r / 1 ']

Engine 1.4 8V

Maximum torque: 114 Nm at 3000 r / min

Maximum power: 56 kW at 5750 r / min

FIAT PUNTO

Power [kW]

38/534

Torque [Nm]

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

Engine 1.2 8V

Maximum torque: 102.2 Nm at 3000 r / min

Maximum power: 49.5 kW at 5500 r / min

FIAT PUNTO

39/534

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

Engine 120 bhp 1.9 Multijet 8V

Maximum torque: 280 Nm at 2000 r / min

Maximum power: 88 kW at 4000 r / min

FIAT PUNTO

40/534

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

90 bhp 1.3 Multijet 16V

Maximum torque: 200 Nm at 1750 r / min

Maximum power: 66 kW at 4000 r / min

FIAT PUNTO

41/534

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.4 Transmi ssion

1.4 8V

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

Traction

Ant. Trans. Ant. Trans. Ant. Trans. Ant. Trans. Ant. Trans.

2.5 Clutch

1.4 8V

Drive

Command

Load spring

disk n.a. n.a. n.a. n.a. n.a.

(DaN)

A push

Hydraulic

actuator

external

1.3 Multijet 16V

90 hp

A push

Hydraulic

external actuator

1.2 8V

A push

Hydraulic

actuator

external

1.3 Multijet

16V 75 hp

A push

Hydraulic

actuator

external

1.9 Multijet

V8 120 hp

A push

Hydraulic

actuator

external and

with SAC (*)

Supplier

Valeo Luk AP Valeo Luk

(*):-Recovery game

FIAT PUNTO

42/534

TECHNICAL DATA

FIAT PUNTO

TRACK TEACHING FIAT PUNTO

43/534

2 . 6

C u r r e n c y

©

Fiat Auto S.p.A.

After Sales Training

Type

Configuration

Overall length (from flywheel

motor, mm)

Weight kg

Synchronizers 1,2,3,4,5, RM 1,2,3,4,5, RM

Gears

Gear Ratio 1 3.909 3.818 3.818 Gear Ratio 2 2.158 2.053 2.053

Gear Ratio 3 Gear Ratio 4 1.121 0.959 0.959

Gear Ratio 5

Gear Ratio 6

Gear ratio RM

8V/1.2 1.4 8V

C514 C510 M20/M32

2 shafts in a cascade

supported on bearings

ball

372.75

33 Dry (34.5 with

oil)

Gearing HCR (High

Contact Ratio)

1.480 1.302 1.302

0.921 0.744 0.744

- - 0.614

3.818 3.909 3.545

1.3 Multijet 16V

75/90 hp

2 shafts in a cascade

supported on

bearings

ball (rear and

Front shaft

primary)

382.5 (on axis

primary)

Dry 35.5 (37.3

with oil)

HCR gears

(High Contact

Ratio)

1.3 Multijet 16V 90

cv/1.9 Multijet 8V

120 hp

3 shafts supported on

ball bearings

332

45 Dry (46.5 with

oil) / 47 Dry (48.5

with oil)

1,2,3,4,5,6,

RM

Gearing HCR (High

Contact

Ratio)

TECHNICAL

Type

Diameter

cylinder

booster

Plant

anti-lock

TRACK TEACHING FIAT PUNTO

Fiat Auto S.p.A.

After Sales Training

2.7 Brakes

1.4 8V

Hydraulic

Servo

10'' 10'' 10'' 10'' 10''

Bosch 8.0 Bosch 8.0 Bosch 8.0 Bosch 8.0 Bosch 8.0

1.3 Multijet

16V 90 hp

Hydraulic

Servo

1.2 8V

Hydraulic

Servo

1.3 Multijet

16V 75 hp

Hydraulic

Servo

1.9 Multijet

V8 120 hp

Hydraulic

Servo

Disk-type ventilated ventilated

Disc diameter

(Mm)

Thickness

Nominal (mm)

Type calipers

Diameter

piston

Caliper (mm)

1.4 8V

257 284 257 257 284

22 22 12 22 22

Bosch ZOH Bosch ZOH Bosch ZOH Bosch ZOH Bosch ZOH

54 54 54 54 54

1.3 Multijet

16V 90 hp

2.7.1 Front brakes

1.2 8V

Not

ventilated

1.3 Multijet

16V 75 hp

ventilated ventilated

1.9 Multijet 8V

120 hp

2.7 .2 Re ar bra ke s

45/534

2 . 8

S t e e r i n g

TECHNICAL DATA

FIAT PUNTO

TRACK TEACHING FIAT PUNTO

©

Fiat Auto S.p.A.

After Sales Training

Type

Drum diameter (mm)

Nominal Thickness (mm)

Type calipers

Type

Turning circle (m)

Number of turns lock to lock (for

Ratio steering box

(Mm / rev)

Report corner

steering wheel / wheel angle

Overall stroke

Effort on the steering wheel

catch (Nm)

1.4 8V

Drum Drum Drum Drum Disk

228 228 203 228 264

n.a. n.a. n.a. n.a. 11

n.a. n.a. n.a. n.a. Bosch III BIR

1.4 8V

Electric

EPS

10.1 10.76 10.1 10.1 11

2.8 2.8 2.8 2.8 2.8

51 60-44 51 60-44 60-44

15.7 13.4 15.7 13.4 13.4

2.5 (mod.

city)

1.3 Multijet

16V 90 hp

1.3 Multijet

16V 90 hp

EPS Electric EPS Electric EPS Electric

2.5 (mod.

city)

1.2 8V

2.5 (mod.

city)

1.3 Multijet

16V 75 hp

1.3 Multijet

16V 75 hp

2.5 (mod.

city)

1.9 Multijet

V8 120 hp

1.9 Multijet

V8 120 hp

EPS Electric

2.5 (mod. city

)

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.9 Front Suspension

Coil springs

1.4 8V 1.3 Multijet

Wire diameter (mm)

Number of turns profit

Sense of 'propeller

Height of free spring

(Mm)

Height spring package

Height of spring under load

control (mm)

11.2 11.5 11.2 11.5 11.8

4:32 4.82 4.32 4.82 5.32

Dx Dx Dx Dx Dx

353 377 353 377 402

60 67 60 67 75

178 178 178 178 178

FIAT PUNTO

16V 90 hp

46/534

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

TECHNICAL DATA TRACK TEACHING FIAT PUNTO

Shocks

1.3 Multijet

16V 90 hp

Shock cuts

22x32x46.5

(Diameter: stem

/ Piston / tube

ext)

Stop

mechanical

traditional

1.2 8V

Shock cuts

22x32x46.5

(Diameter: stem

/ Piston / tube

ext)

Stop

mechanical

traditional

Type

Length

open (early

tamponade)

1.4 8V

Shock cuts

22x32x46.5

(Diameter: stem

/ Piston / tube

ext)

Mechanical stop

traditional

527 527 527 527 527

Fiat Auto S.p.A.

After Sales Training

1.3 Multijet

16V 75 hp

Shock cuts

22x32x46.5

(Diameter:

rod / piston

/ Ext tube)

Stop

mechanical

traditional

Shock cuts

22x32x46.5

(Diameter:

rod / piston

/ Ext tube)

Stop

mechanical

traditional

1.9 Multijet

V8 120 hp

mm

Length

closed (in

beat) mm

Stroke (mm)

(Different setting)

Front stabilizer bar

Bar diameter

(Mm)

351 351 351 351 351

176 176 176 176 176

1.4 8V

18 19 n.a. n.a. n.a.

1.3 Multijet 16V

90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.10 Rear Suspension

Coil springs

1.4 8V

Diameter of wire

(Mm)

Number of turns profit

Sense of 'propeller

Height of spring

free (mm)

10.5 10.5 n.a. n.a. n.a.

4.2 4.2 n.a. n.a. n.a.

Dx Dx n.a. n.a. n.a.

291.5 279 n.a. n.a. n.a.

1.3 Multijet

16V 90 hp

Height of spring

Theoretical

Project

155 155 n.a. n.a. n.a.

Height of spring

pack (mm)

58 58 n.a. n.a. n.a.

FIAT PUNTO

1.2 8V

48/534

1.3 Multijet 16V

75 hp

1.9 Multijet 8V

120 hp

TECHNICAL DATA TRACK TEACHING FIAT PUNTO

Shocks

1.3 Multijet

16V 90 hp

Shock cuts

14.2x27x38

(Diameter: stem /

piston / tube

ext)

Mechanical stop

traditional

1.2 8V

Shock cuts

14.2x27x38

(Diameter:

stem /

piston /

ext tube)

Stop

mechanical

traditional

Type

1.4 8V

Shock cuts

14.2x27x38

(Diameter: stem /

piston / tube

ext)

Mechanical stop

traditional

Fiat Auto S.p.A.

After Sales Training

1.3 Multijet

16V 75 hp

Shock cuts

14.2x27x38

(Diameter:

rod / piston

/ Ext tube)

Stop

mechanical

traditional

Shock cuts

14.2x27x38

(Diameter:

rod / piston

/ Ext tube)

Stop

mechanical

traditional

1.9 Multijet

V8 120 hp

Length

open (early

tamponade,

(Mm)

Length

closed (in

joke, (mm)

Stroke (mm)

651.0 651.0 651.0 651.0 651.0

388.0 388.0 388.0 388.0 388.0

263 263 263 263 263

Stabilizer bar: absent, replaced by torsion of suitable thickness

Bridge "soft"

(Mm)

Bridge "medium"

(Mm)

1.4 8V

4.5 4.5 4.5 4.5 4.5

5.9 5.9 5.9 5.9 5.9

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet 8V

120 hp

Bridge "Hard"

(Mm)

7.1 7.1 7.1 7.1 7.1

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

Crossbar

1.4 8V

Bridge "soft"

(Mm)

Bridge

"Medium"

(Mm)

4.5 4.5 n.a. n.a. n.a.

5.9 5.9 n.a. n.a. n.a.

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

Bridge "Hard"

(Mm)

7.1 7.1 n.a. n.a. n.a.

2.11 Suspension and steering angles suspensions

Standard A = unladen including spare wheel, tools, accessories, supplies, full

fuel

Standard 0 = downloads including spare wheel, tools, accessories, supplies, with 5 liters of

fuel

NB Only the convergence of the front wheels can be adjusted in the workshop

FIAT PUNTO

50/534

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.11.1 Front

Convergence

Engines Tyres Standard 0 Standard A

1.2 8V

1.4 8V

175/65 R15 84T

1.2 8V

1.4 8V

1.4 16V

1.3 Multijet 16V 90 hp

1.4 16V

1.3 Multijet 16V 90 hp

120 bhp 1.9 Multijet 8V

185/65 R15 88T

1.4 16V

120 bhp 1.9 Multijet 8V

195/55 R16 87H

FIAT PUNTO

+ 2 mm + / - 1 mm + 1.88 mm + / - 1mm

+ 2 mm + / - 1 mm + 1.87 mm + / - 1mm

51/534

TECHNICAL DATA

Camber

FIAT PUNTO

TRACK TEACHING FIAT PUNTO

4

5 2 / 5 3

©

Fiat Auto S.p.A.

After Sales Training

Engines Tyres Standard 0 Standard A

1.2 8V

1.4 8V

1.2 8V

1.4 8V

1.4 16V

1.3 Multijet 16V 90 hp

1.4 16V

1.3 Multijet 16V 90 hp

120 bhp 1.9 Multijet 8V

1.4 16V

120 bhp 1.9 Multijet 8V

175/65 R15 84T

185/65 R15 88T

195/55 R16 87H

-22 '+ / - 20' -27 '+ / - 20'

-26 '+ / - 20' -28 '+ / - 20'

-19 '+ / - 20' -21 '+ / - 20'

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.11.2 Rear

Convergence

Engines Tyres Standard 0 Standard A

1.2 8V

1.4 8V

175/65 R15 84T

1.2 8V

1.4 8V

1.4 16V

1.3 Multijet 16V 90 hp

1.4 16V

1.3 Multijet 16V 90 hp

120 bhp 1.9 Multijet 8V

185/65 R15 88T

1.4 16V

120 bhp 1.9 Multijet 8V

195/55 R16 87H

FIAT PUNTO

53/534

+1.3 Mm + /-2mm +1.5 Mm + /-2mm

TECHNICAL DATA

Camber

FIAT PUNTO

TRACK TEACHING FIAT PUNTO

4

5 4 / 5 3

©

Fiat Auto S.p.A.

After Sales Training

Engines Tyres Standard 0 Standard A

1.2 8V

1.4 8V

1.2 8V

1.4 8V

1.4 16V

1.3 Multijet 16V 90 hp

1.4 16V

1.3 Multijet 16V 90 hp

120 bhp 1.9 Multijet 8V

1.4 16V

120 bhp 1.9 Multijet 8V

175/65 R15 84T

185/65 R15 88T

195/55 R16 87H

-1 ° + / -20 ' -1 ° + / -20 '

e

t

j

e

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.12 Battery and Alternator

Version without air conditioning

1.4

1.3 Multi

Battery

(Ah)

Alternator (A)

40 50

70 75

Versions with air conditioning

1.4

1.3 Multij

Battery

(Ah)

Alternator (A)

50 50

70 90

2.13 Fluids and Lubricants

Oils and fluids

Product Features Recommended

Engine Oil Selenia K Sel

Transmission fluid / differential

front

Brake Fluid Protection

Radiator fluid

FIAT PUNTO

55/534

1.4 8V

Protects car

Paraflu up to

1.

M

Pro car

Pro

Par uo

t

c

Star 3

c

t

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

Fats

Product Features Recommended

1.4 8V

1.3 Mul

CV joint

Front side

differential

CV joint

front wheel side

Wheel hubs, tie rods

steering, various organs

Lubrication protection

organs underbody

Protectio

n MRM

Star Protectio n

n.a. n.a.

Prote

Lubrication

brake circuit components

Steering box and

rack

n.a. n.a.

Lubricant properties

Oils Quantity:

Engine oil (quantity

for substitution

regular cup and

filter, l)

Oil

gearbox / differential

front (Kg)

FIAT PUNTO

56/534

1.4

2.6 3.2

1.5 2.08

1.3 Multije

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.14 Chara cterist ics car

2 . 1 4 . 1 D i m e n s i o n s

FIAT PUNT O

2

57/534

1.4

1.3 Multijet

1.

A

4030 4030 403

B

C

D

It

875 875 875

2510 2510 251

645 645 645

1490 1490 149

F

G

H

1473 1473 147

1687 1687 168

1466 1466 146

i

e

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.14.2 Performance

1.4

Maximum Speed

(Km / h)

Acceleration (s, 0-100

Km / h, 2 pers. + 20 kg)

170 185

12 12

1.3 Multij 16V

* = Exhibition sporting

2.14.3 Supplies

Fuel

(L)

Fuel (liters)

Cooling system

(L)

Engine oil and filter (liters)

Circuit brakes (kg)

FIAT PUNTO

58/534

1.4 8V

45 45

(5-7) (5-7)

5.27 7.4

2.6 3.2

0.5 0.5

1.3 Mult

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.14.4 Consumption

(Dir 199/100/CE liters per 100 km)

1.4 8V

Urban

Suburban

Combined

7.7 5.9 7.9 5.9 7.5 (* 7.6)

5.2 3.9 5.1 4.0 4.5 (* 4.6)

6.1 4.6 6.1 4.7 5.6 (* 5.7)

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

* = Exhibition sporting

2.14.5 Emissions

1.4 8V

CO2 (g / km)

145 122 145 123 149 (* 150)

1.3 Multijet

16V 90 hp

1.2 8V

1.3 Multijet

16V 75 hp

1.9 Multijet

V8 120 hp

* = Exhibition sporting

All engines comply with Euro 4 emission limits.

2.14.6 Tyres

1.4 8V

Equipment

serial

175/65 R15 84T

185/65 R15 88T

Wheels

snow

175/65 R15 84T

185/65 R15 88T

1.3 Multijet

16V 90 hp

185/65 R15 88T

195/55 R16 87H

205/45 R17 88V

185/65 R15 88T

195/55 R16 87H

Rotate

stock

175/65 R15 84T

185/65 R15 88T

185/65 R15 88T 175/65 R15 84T

FIAT PUNTO

1.2 8V

175/65 R15 84T

185/65 R15 88T

175/65 R15 84T

185/65 R15 88T

59/534

1.3 Multijet

16V 75 hp

175/65 R15 84T

185/65 R15 88T

175/65 R15 84T

185/65 R15 88T

1.9 Multijet

V8 120 hp

185/65 R15 88T

195/55 R16 87H

205/45 R17 88V

185/65 R15 88T

195/55 R16 87H

175/65 R15 84T

185/65 R15 88T

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

2.14.7 Inflation Pressures (bar)

Version 1.4 8V

Measure

175/65 R 15 84T

185/65 R 15 88T

Pressure

inflation

medium load

front

2.2 2.1 2.2 2.2

2.2 2.0 2.2 2.2

Pressure

inflation

medium load

back

Pressure

inflation

full load

front

Pressure

inflation

full load

back

Version 1.3 16V Multijet 90 hp

Measure

185/65 R 15 88T

195/55 R 16 87H

205/45 R 17 88V

FIAT PUNTO

Pressure

inflation

medium load

front

2.3 2.1 2.3 2.3

2.3 2.1 2.4 2.4

2.4 2.2 2.5 2.4

Pressure

inflation

medium load

back

60/534

Pressure

inflation

full load

front

Pressure

inflation

full load

back

s

amed

d

s

amed

d

s

amed

d

TECHNICAL DATA

TRACK TEACHING

Fiat Auto S.p.A.

After Sales Training

FIAT PUNTO

Version 1.2 8v

Measure

175/65 R 15 84T

185/65 R 15 88T

Pressure

inflation

medium

load

2.2 2.1

2.2 2.0

Pre

infl

loa

Version 1.3 Multijet 16V 75hp

Measure

175/65 R 15 84T

185/65 R 15 88T

Pressure

inflation

medium

load

2.4 2.1

2.3 2.1

Pre

infl

loa

Version 1.9 8v Multijet 120 bhp

Measure

185/65 R15 88H

195/55 R 16 87H

205/45 R 17 88V

FIAT PUNTO

61/534

Pressure

inflation

medium

load

2.4 2.2

2.6 2.3

Pre

infl

loa

1.3 Multijet TRACK

16V 75 and 90 hp

TEACHING FIAT PUNTO

3 Engine 1.3 16V Multijet 75 hp and 90

3.1 General

Turbocharged diesel engine, direct injection without pre-chamber, 4-cylinder, 1248 cc, four

Fiat Auto S.p.A.

After Sales Training

valves per cylinder with hydraulic tappets, camshafts in the head with transmission

motorcycle gear, air supercharger with turbocharger and intercooler, the empty weight

137 kg (75 hp) 139 kg (90 hp), electronic injection Magneti Marelli MJD 6F3

Common Rail.

These engines adopt a fuel injection system for diesel engines with high pressure

fast "Magneti Marelli Common Rail" fully managed by a central Multijet

MJD6F3

62/534

1.3 Multijet

Fiat Auto S.p.A.

TRACK

16V 75 and 90 hp

TEACHING

After Sales Training

FIAT PUNTO

This engine is able to provide the following benefits:

maximum power of 55 kW (75 hp) EEC at 4000 rpm / min, 66 kw (90 HP) EEC at 4000 r / min

maximum torque 190 Nm (19.4 kgm) at 1750 rpm EEC / min, 200 Nm (20.4 kgm) at 1750 rev / min

For the reduction of polluting emissions these engines are equipped with:

- Exhaust system with oxidising catalytic converter;

- EGR exhaust gas recirculation system (modified to 90 hp) with heat exchanger

- Plant vapors blow / crankcase gases.

- Or UEGO lambda sensor (temperature sensor DPF opt only 90 hp)

- New pressure regulator 2 DRV

- New rail pressure sensor 4 RDS

The group is a system composed by the motor and all the installations involved in its

Operation:

- Fuel system fuel;

- Plant supercharging air;

- Engine cooling system;

- Exhaust system with catalytic converter;

- Plant Oil vapors blow;

- Implantation of exhaust gas recirculation E.G.R. with heat exchanger;

The optimization of the functioning of these plants is achieved by an electronic system of

governed by a control unit.

Understanding the logical operation of the unit allows you to have a

Overall the entire system

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3.2 Components

3.2.1 supports of the powerplant

The supports of the drive train have the function of structural connection between

powertrain and chassis.

They are sized to carry the weight of the powerplant and withstand the loads arising from

torque transmitted from the engine. Modified to support the 90 hp and torque values of weight 200

Nm more

Each support is provided with a gusset rubber - metal that has the task of damping

the vibrations generated by the engine, reducing the vibrations transmitted in large part to the body.

It is a powerplant support barycentric type, consisting of two blocks plus a

reaction rod, which acts as a tie rod, in which the new media are aligned on an axis

passing through the center of gravity of the engine in order to obtain reaction forces with arm

nullo.In more 'on 90 and cv' was introduced additional support for the right axle shaft.

1 side support distribution

2 Support transmission side

3 Tie reaction

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Support the right axle shaft 1.3 Multijet 90 hp

3.2.2 Crankcase

The base is cast iron.

The cylinders are cut into the base and are available in three size classes

plus a mark.

- Class A

- Class B

- Class C

Plus a surcharge

L 'of the motor shaft is supported by five main bearings (1).

Special ducts formed in the walls of the base, allow the passage of

coolant and lubricating oil.

In the lower part of each cylinder is installed a jet (2) from which the oil is sprayed on the

piston crown to cool and fall to ensure the lubrication of the pin.

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3.2.3 Base lower

The lower base is made of aluminum alloy die-cast, with the bearing caps in

cast iron.

The finishing media and bearing caps are made in conjunction with the

upper crankcase.

Coupling with the upper crankcase is achieved by means of screws and dowels

centering, which guarantee the precision of assembly.

Interposed between the two bases is a bead of sealant to prevent leakage of engine oil.

The figure below shows the upper block (1) and the lower base (2).

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3.2.4 CYLINDER HEAD

The cylinder head is monolithic alloy of aluminum and silicon.

Two camshafts in the head, ductile iron, housed in an overhead, the command is

Mixed-chain gears.

The four valves per cylinder, parallel and vertical, are placed in the appropriate guide

controlled by valves and rocker arms actuated by the cams of the camshaft and maintained at

Contact the valves via hydraulic tappets.

The valve guides are planted in their seats in the cylinder head interference. The

improvement of the internal diameter is achieved, after mounting, with reamer

specific.

Compared to the cylinder heads with pre-chamber, the entire combustion process takes place in the

combustion chamber formed in the piston.

The seal between the cylinder head and the base is metal and there are no riserraggi of

head for the whole life of the engine.

The 90 bhp engine, the combustion system has necessarily been modified to

improve the flows into and out.

The design of the inlet ducts and was modified by increasing the flow capacity while

has been improved volumetric efficiency at high speeds as a result of a reduction in the level

Swirl

The design of combustion chambers has been changed, increasing the diameter and

consequently reducing the compression ratio from 18:1 to 17.6:1.

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3.2.5 Cup and base covers

The oil sump of the base is a structural part of the engine with mechanical functions which

has the task to accommodate the lubrication oil of the engine.

E 'consists of stamped steel and includes a threaded hole with cap to allow oil

motor.

The seal with the base is obtained by a cordon of silicone sealant.

Between the base and cup engine oil is interposed a bulkhead that, in addition to avoiding the

shaking engine oil (due to movement of the vehicle and of the 'shaft), guarantees

that the level remains constant.

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3.2.6 Oil seals on crankshaft

The seal on the front of the motor shaft is formed by a ring seal mounted on the

timing cover.

The rear seal of the motor shaft is formed by an oil seal ring inserted

directly into the recess between the base and crankcase.

3.2.7 Flywheel

The flywheel is made of cast iron with steel ring gear shown.

The flywheel is fixed by means of a flange with bolts to the motor shaft, toward the motor side is

fixed a toothed wheel for the rpm sensor.

1 Flywheel

2 Sprocket reported

3 Pole wheel for speed

Operation

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The flywheel is the organ that makes the uniform rotation of the motor, storing energy

during the active phases (expansion) and releasing it during the passive phases.

The flywheel is designed to allow the engine to idle without stopping or

win the work of friction developed by the latter during the load operation.

3.2.8 Crankshaft

It 's forged steel, rests on five main bearings and its axial clearance is regulated by

housed in two split main bearing center.

Eight crankshaft counterweights give a careful balancing of rotating masses.

A series of ducts along internally the drive shaft for the lubrication of

journals and connecting rod.

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3.2.9 Pistons

The pistons made of aluminum alloy with the silicon anti-friction inserts are divided into three classes

dimensional.

Class A 69.520 + 69.530 (75 hp)

Class B 69.530 + 69.540 (75 hp)

Class C 69.540 + 69.550 (75 hp)

nd (90 hp)

On the piston crown is formed in the combustion chamber "OMEGA" to improve the

combustion efficiency. (see cylinder head)

Inside of the plug is formed a channel through which flows the oil sent

to the sprayers, ensuring a better cooling of the piston itself.

The coupling with the pin is made by means of two bushings copper alloy.

1 Piston

2 electro-

3 Glow plugs

4 Air Inlet

5 Exhaust gas outlet

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3.2.10 Connecting Rods

The connecting rods are made of hardened steel with copper sleeve (1) planted to mate with

the pin (2) of the piston.

The pins of the float type, are retained by two elastic rings expansion (3) that

are based on groove formed within the housing of the plug.

Coupling rod cap with machined surfaces. To withstand the pressure values

specified in 90 hp, the connecting rod bearings above have been changed. See diagram

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3.2.11 Distribution control

The control of distribution is controlled directly through the chain.

1 driven gear

2 Driving gear

3 Mobile Skate

4 shoe drive

5 Chain Distribution

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3.2.12 Tie the timing chain

The tension of the chain distribution is carried out by an automatic tensioner (which limits the

maintenance operations) to oil pressure mounted within the distribution on the

monobloc and acts on the movable shoe.

3.2.13 camshafts in the upper crown

Two camshafts made of cast iron, induction hardening on cam

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The camshaft exhaust side is controlled directly from the chain and transmits the motion

distribution to the shaft suction side, via a pair of straight cut gears.

The camshaft exhaust side also controls the high-pressure pump, while the

suction side controls the vacuum.

3.2.14 Lifter

For each valve is used a hydraulic tappet actuated by a rocker arm in turn

moved from the axis to the camshaft.

The rockers are made so as to avoid serious damage to other organs of the motor in case of

breaking or scalettamento of the distribution chain, in fact, thanks to a section to fracture

deforming predetermined absorb the stresses caused by the contact of the valves with the

pistons.

Intake-exhaust valve diameter 21.47 mm

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3.2.15 preheating unit

characteristics

The device is interfaced to and controlled by the engine control system according to the protocol

EOBD. E 'state project in order to fulfill all the functions of driving and monitoring the state

of operation of the individual glow plugs during the preheating phase of the diesel engine.

The control unit incorporates a protection for high current and voltage surges and is equipped with a

logic

nusibile electronic self resetting.

The device can be mounted, given the characteristics and thermal resistance

external, directly in the engine compartment.

The unit is protected on all terminals from possible electrical connections with inversions

Battery polarity and is constructed to withstand all the stresses present in the car.

The unit provides the following connection terminals:

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Terminal

30

G1, G2,

Name

Direct connection to the battery positive (+ Vbat) to

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G3, G4

86

31

ST

K

A

the power of

the glow plugs

Output for connection of the glow plugs

Power from the engine control unit

Connection to ground (GND)

Input for start signal supplied to the control

motor control

Input for start signal supplied to the control

motor control

Output for the diagnosis directed to the control unit

engine

3.2.16 Turbocharger

The turbocharger (1) is connected to the exhaust manifold; has the purpose to increase the

engine's volumetric efficiency.

E 'consists essentially of two impellers keyed on the same shaft, which rotates on

floating bearings lubricated by a derivation (3) of the engine lubrication circuit.

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1 Turbocharger

2 Waste gate

3 Derivation of the lubrication circuit

4 Pneumatic

The oil used, disposing of the large amount of heat given off by the exhaust gas to the

turbine. On the turbocharger is mounted a valve WASTE - GATE (2) controlled by a

pneumatic actuator (4), which allows to divide the passage of the exhaust gas to the

turbine, depending on the pressure reached at the compressor outlet.

BORG WARNER VNT turbocharger 90 hp

The MJTD 90 hp 1.3 engine features a new generation of turbochargers, the

VNT turbocharger (Variable Nozzle Turbines). The drive of the blades of the

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solenoid valve is. With this technology it is possible to achieve

optimal turbocharger at all speeds.

The aim of a turbocharger

The purpose of a turbocharger is to obtain high torques, and then further performance of the

motor. This is possible by compressing the intake air. Due to the higher density at each stage

Suction can be entered into the combustion chamber of the engine greater

amount of oxygen. The higher content of oxygen improves combustion and is therefore

increase the power.

The thermal energy and kinetic energy of the exhaust gases of the engine is used to operate the

turbine exhaust gas turbocharger. The gas turbine exhaust drives the

compressor. This compresses the air sucked by heating. The air is again

cooled in the intercooler.

Operation

At low engine speeds the vanes of the distributor of the turbocharger are driven

electrically and positioned (i) by depression so that the flow of exhaust gas

impinges on the outer edge of the turbine blades. This causes a narrowing of the flow

of the exhaust gases and leads to an increase of the speed of flow of exhaust gas and the

boost pressure. According to the law of the lever this involves a pair

greater at low speeds.

If the number of revolutions of the engine increases the input section of the exhaust gas is

increased by the displacement of the vanes of the distributor (II). Now the gas particles

more preferably do not affect the outer edge of the vanes of the distributor, but are

distributed along the entire length of the vanes. The turbocharger works with

a lower efficiency, which however is offset by the increased volume of exhaust gas to

high engine speeds.

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If, however, is required the maximum power of the engine (eg. When overtaking) the

electro-pneumatically operated pallet are moved into position for low speed,

which significantly increases the performance of the turbine and hence the pressure of

charge and provides the maximum engine power.

View of the turbocharger

1. Number of revolutions of the engine and low amount of exhaust gas reduced

2. Number of revolutions of the engine high and large amount of exhaust gas

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3.2.17 Intake manifold

The ability cassoncino air is made of plastic material, receives air under pressure, cooled

intercooler, and conveys it directly to the cylinder head.

Shoe and mounted on the sensor overpressure connected to the injection unit,

at the entrance of the manifold is positioned a diffuser for the insertion of the exhaust gases

coming from the valve E.G.R. directed towards cilidri.

3.2.18 Exhaust pipes and silencers

The exhaust gases flow into the engine through the manifold to the turbocharger, and then to

oxidising catalytic converter (1).

In the front part of the discharge pipe is a flexible element (2) for

limit the transmission of vibrations.

The rear portion of the exhaust is constituted by an intermediate pipe (3) and the silencer

rear (4).

Appropriate protections limiting the radiation of heat to the body.

The supporting of the various components is realized by means of supports (5) and snap rings (6)

attached to the underbody.

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3.2.19 Exhaust emission control system

3.3 Catalytic converter

The oxidation catalyst is a device for post-treatment to oxidize the CO, HC and

particulate matter, turning it into carbon dioxide (CO2) and water vapor (H2O).

The catalytic converter consists of a monolith honeycomb ceramic (1), whose cells are

impregnated with platinum (2), substance catalyzing the oxidation reactions.

Operation

The exhaust gases that pass through the cells heat up the catalyst, triggering the conversion

of pollutants into inert compounds.

The chemical reaction of oxidation of CO, HC, and the particulate is effective with

temperatures between 200 and 350 ° C.

In fact above 350 ° C begin to oxidize the sulfur content in diesel fuel, giving rise to anhydride

and sulfur trioxide.

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3.3.1 Plant exhaust gas recirculation (E.G.R.)

This system allows to send a suction part (5 ÷ 15%) of the exhaust gas, in

certain operating conditions.

In so doing lowers the peak temperature in the combustion chamber, containing the

formation of oxides of nitrogen (NOx).

The solenoid valve E.G.R. (1) controlled by the injection control unit (2) performs the function of

re-enter the aspiration of the motor part of the exhaust gases collected from the manifold

discharge (4).

A heat exchanger (3) allows the partial cooling of the exhaust gases

further lowering the temperature of the combustion chamber.

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Solenoid E.G.R.

Injection control unit

Heat exchanger

Exhaust Manifold

Intake manifold air

Operation

The injection control unit, coolant temperature> 20 ° C and the engine

between 800 and 3000 rev / min, the pilot with a square wave signal the solenoid

E.G.R.

The variation of this signal allows the coil of EGR moving a shutter,

thereby regulating the flow of flue gases from the exhaust manifold to the intake manifold; is

results in two outcomes:

less air is introduced;

is lowered the combustion temperature (due to the presence of inert gases), reducing

Consequently, the formation of NOx (nitrogen oxides).

The injection control unit is kept informed on the amount of recirculated gas, from

information from the flow meter, for if a certain RPM is expected

the aspiration of a given quantity of air (Qam) and the value sent by the flow meter (Qar)

is lower, the difference (Qgr) is the value of the amount of recirculated gas.

Qam - Qar = Qgr

Qam - theoretical air quantity stored

Qar - Royal Air Quantity

Qgr - Quantity recirculated gases

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The signal of atmospheric pressure is used in piloting the solenoid EGR for

recognize the condition of travel at height, so as to reduce the amount of gas recirculated

and avoid the smokiness of the engine.

Solenoid E.G.R.

The solenoid valve E.G.R. Pierburg, mounted on the cylinder head, has the task of modulating the

passage of the exhaust gas inlet as a function of the command of the control unit of

injection.

The modulation occurs through the internal solenoid, controlled by the PWM

control unit, which actuates the control rod of the internal valve which, once opened, carries the

gas in the intake manifold.

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Valve body E.G.R.

Gas inlet from the exhaust manifold

Gas outlet to the intake manifold

Positive solenoid

Negative solenoid

3.3.2 vapor recirculation system / crankcase gases

The emission control of the oil vapor is produced by an oil separator (1) that

collects vapors from the basement and cover distribution by

piping (2). The condensed vapors through a pipe (3) back in the cup, while

those not condensed through a pipe (4) are sent to the suction sleeve

turbocharger air.

1 oil separator

2 Output oil vapor from the cover

Return 3 cup condensed vapors

4 suction hose sending fumes

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3.3.3 Engine oil lubrication circuit

The following is represented the engine lubrication system.

Float with a filter screen

Oil pump

oil filter (with replaceable cartridge)

Heat exchanger (water oil) cooling engine oil

Sprayer (lubrication distribution chain)

Switch for engine oil pressure warning light

Hoses turbocharger lubrication

Check engine oil level dipstick

Bulkhead scrape oil and engine oil level maintenance

Timing chain cover

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3.3.4 Group oil filter and heat exchanger

This group integrates both the filter element that the heat exchanger has the laterally cap for the introduction of the oil.

1 Oil filling plug

2 Cover the filter element

3 Oil-water heat exchanger

3.3.5 Engine oil pump

The engine oil is sucked from the cup by means of the vacuum created by the rotation of the

gear keyed on the motor shaft.

The depression is present from the separation partition (1) of the gear until the

suction cup oil.

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The pressure is developed instead from the separation partition (1) in all conduits

oil delivery of the engine (2).

When the pressure exceeds the value of 5 bar, the thrust exerted on the relief valve (6)

wins the reaction of the spring and moves below the valve to open up the duct (8) of

connection between pressure chamber (7) and the low pressure chamber (5).

1 bulkhead separating

Oil delivery pipe 2

3 driven gear

4 Driving gear

5 Room of low pressure

6 relief valve

7 Pressure chamber

8 pipe connection between high and low pressure

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3.3.6 Engine Cooling

Engine cooling system

Water Pump

Engine coolant temperature sensor

Thermostat

Radiator

Electric

Power Tank

Oil cooler engine

Heating radiator inside the car

Heat exchanger the exhaust gases E.G.R.

Recirculation water pipe

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3.3.7 Tank and cooler engine

3.4 Tank Engine cooling power

The reservoir in addition to the function of feeding the circuit absorbs the variations in volume of

coolant, the temperature changes of the engine.

Through a dedicated valve set, contained in the cap pressurized, we obtain:

escape of air from the circuit collection from the pipe coming from the thermostat

entry of air when the circuit is in depression (because of the cooling engine).

Cooler engine

E 'consists of a radiator core and two side trays for the input and the output of the

coolant.

The tubes and fins of the radiator core are made of aluminum, the plastic trays.

3.4.1 Water Pump and Thermostat

Water Pump

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It 'kind of centrifugal vane pump casing and impeller shaft in phenolic resin

steel.

Fixed to the base engine and driven directly by the belt of the services.

Thermostat

EGR-1 output

2 temperature sensor

3 oil filter output

4 out radiator

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Mounted on the rear side of the cylinder head, with the function of keeping the motor to the

optimal temperature

with temperature <80 ± 2 ° C, the thermostatic valve (closed) diverts the liquid directly into

the pump

with temperature> 80 ± 2 ° C, the thermostatic valve (open) conveys the liquid

cooling to the radiator.

Thermostat is mounted on the engine water temperature sensor linked to the central

injection and the control panel

3.4.2 Water Temperature Control Devices

Blowers

The electric cooling, two-speed can increase the capacity of

disposal of the heat radiator and / or air conditioning system of the capacitor.

They are controlled directly by the engine control unit according to a specific logic

operation

3.4.3

3.5 Service command

Constitution

The belt unique command organs motor (5) Poly-V type, controls the alternator (1), the

water pump (3) and, where applicable, the air conditioning compressor (6).

The tensioning is carried out through automatic tensioner (2) which excludes operations

scheduled maintenance.

The crankshaft pulley (4) has an integrated elastic field that reduces the vibrations

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torsional stress on the motor and belt and then on the subsidiary bodies of the

motor.

Alternator

Tensioner

Water Pump

Crankshaft pulley

Drive belt motor organs

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Abarth Grande Punto 2004, Punto Evo 2004 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual