Fiat Bravo 2009 User Manual

LPG
FIATBRAVO
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FIAT BRAVO LPG
The Fiat Bravo LPG version (Petrol- LPG) is dealt with in this appendix.
INDEX
KNOWING YOUR CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SYSTEM FUNCTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LPG TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SOLENOID VALVES AND SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REGULATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PAPER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LPG INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRONIC CONTROL UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LPG/PETROL SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL CUT OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REFUELLING THE CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SCHEDULED SERVICING PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CO2EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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FIAT BRAVO LPG
KNOWING YOUR CAR
INTRODUCTION
The LPG version of the car features two fuel systems: one for petrol and one for LPG.
Like the petrol system, the LPG system is the phased, sequential multipoint type with special injectors.
LPG MULTIPOINT INJECTION SYSTEM
This product is produced in strict collab­oration with prestigious suppliers in the LPG sector. The injection system used on the car is an efficient system in terms of engine performance and is based on the injection of LPG in a gaseous state.
In this system with four injectors, one for each intake manifold, the fuel is injected directly into the engine heat transfer ducts thereby metering the LPG very precisely improving combustion and, at the same time, excluding any possibility of flame re­turn.
By adapting the electronic control tech­nology of petrol engines to meet the spec­ifications of LPG, it has been possible to achieve important results in terms of dri­veability and controlling exhaust emissions.
Engines running on LPG have almost the same torque/power specifications as when running on petrol and, as a result, the per­formance of the car is also comparable.
The system extreme operat­ing temperatures are between –20°C and 100°C.
WHAT IS LPG?
LPG (the abbreviation of liquefied petro­leum gas) is a mixture of gas used as an economical and safe primary energy source.
Its main components are: propane gas and butane gas mixed.
These gases are a product of petroleum refinement and are also present naturally in oil fields and methane-producing de­posits.
In its natural state this mixture is in a gaseous state but, as the pressure in­creases, at ambient temperature, it can easily be turned into a liquid state.
LPG is a fuel with a low environmental im­pact because it reduces the pollution pro­duced by vehicle exhaust gases.
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SELECTING THE TYPE OF FUEL SUPPLY
The car is configured for running inde­pendently on either petrol or LPG.
The engine is always started on petrol with an automatic shift to LPG after about 40 seconds at the first significant acceler­ation.
This is the time required to reach opti­mum conditions (engine coolant temper­ature, minimum revs level) for the switch to LPG. As far as what has been said
is concerned, there must always be some petrol in the tank (at least 1/4 full) in order not to compromise the op-
eration of the fuel pump.
When running on LPG, when the last red LED on gas quan­tity indicator (visible on the
switch) comes on, refuelling is advisable. If the LPG runs out during LPG operation, the system automati­cally switches to running on petrol shown by: the amber LED coming on constantly and the green LED flashing, the fuel level LEDs going out and a buzzer in the switch.
In addition, it is advisable to periodically use up the petrol in the tank (until the re­serve warning light comes on) in order to ensure that the petrol does not become old and possibly deteriorate.
The petrol/LPG switch fig. 1, located on the centre tunnel (next to the gear lever) allows the driver to select petrol or LPG operation at their discretion.
fig. 1
F0Q0804m
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FIAT BRAVO LPG
When painting in an oven, the LPG tank should be removed from the car and later care-
fully refitted by a Fiat Deal­ership. Although the LPG system has numerous safety features, it is advis­able to close the manual tap on the tank every time the car is not in use for a long period, transported on other ve­hicles or moved in an emergency as a result of a breakdown or accident.
Active safety
The car has the same active safety speci­fications as other versions.
The LPG tank meets the legal safety stan­dards of the countries in which the ver­sion illustrated this Supplement is mar­keted.
The car is equipped with
gaseous LPG injection system
designed specifically for the
car: it is therefore strictly prohibited to alter the configuration of the system and components. The use of other components or materials could cause malfunctions and lead to a re­duction in safety therefore, in the case of problems, go to a Fiat Dealership. When towing or raising the car, to pre­vent damage to the gas system parts, follow the instructions in the Owner Handbook in the “Towing the car” chapter.
It should be pointed out that
in some countries (including Italy) there are legal restrictions in force for parking/garaging motor ve­hicles with gas that has a higher den­sity than air; LPG comes under this category.
WARNING
PASSIVE SAFETY/ ACTIVE SAFETY
Passive safety
The car has the same passive safety spec­ifications as other versions. In particular, the canister mountings (located in the spare wheel housing) have been designed to exceed the Fiat safety standards for im­pact tests.
When running on LPG, the flow of gas (in a liquid state) leaving the canister, passes through the dedicated pipe to the pres­sure regulator where there is a safety so­lenoid valve that stops the flow of LPG when the key is turned off or when a change of fuel is selected by the driver (de­cision to run on petrol).
Together with the regulator solenoid valve, a second solenoid valve, in the tank, closes the LPG pipe at the tank outlet.
The two solenoid valves are connected to the inertia switch (Fire Protection Sys­tem).
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SYSTEM FUNCTIONAL DIAGRAM
DESCRIPTION OF THE SYSTEM FUNCTIONAL DIAGRAM fig. 2 1 LPG tank - 2 Multivalve assembly and safety devices - 3 LPG refuelling filler - 4 LPG piping - 5 Pressure regulator - 6 LPG injec- tors - 7 LPG in gaseous state filter element - 8 LPG injection system electronic control unit - 9 LPG-petrol switch and LPG gauge 10 Petrol tank.
10
F0Q0808m
fig. 2
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LPG TANK
The vehicle has a (pressurized) tank A - fig. 3 for LPG in a liquid state that is toroidal in shape and located in the hous­ing for the spare wheel with suitable pro­tection.
The LPG in the tank A is always in a liquid and gaseous state, in physical equilibrium conditions.
The liquid, which cannot be compressed, dilates by around 0.25% for each increase in temperature of one degree. For this reason a suitable space allowing the in­crease in volume of the liquid for all forseeable temperature increases is guar­anteed (e.g. car parked in the full sun in summer) without compromising the in­tegrity of the tank.
In effect, there is a safety valve that auto­matically limits the refilling of the tank (during refuelling) to a maximum level of 80% (liquid) of its total capacity.
Periodically (at least once every six months) it is advis­able to let the LPG in the tank
run out and, at the first refu­elling, check that it does not exceed the maximum capacity of 41 litres (see in­structions in “Capacities” paragraph in this Supplement). If the value is above 41 litres, go to a Fiat Dealer immedi­ately.
LPG TANK CERTIFICATION
The LPG tank is certified in accor­dance with the regulations in force.
In Italy the tank has a life of 10 years from the registration date of the car. If the car has been registered in a dif­ferent country from Italy, the life of the LPG tank and test/inspection procedures may vary depending on the laws in force in that particular country. In any case, when the time limit in the individual country has run out, go to a Fiat Dealer to have the tank replaced.
There is a plate on the tank B - fig. 3 con­taining the following information:
– homologation country identification and
homologation number;
– type of gas designed for (LPG);
– name of canister manufacturer;
– canister test pressure (30 bar);
– maximum refilling percentage (80%);
– tank dimensions;
– nominal tank capacity in litres;
– canister manufacture date (month/year);
– canister serial number.
fig. 3
A
B
F0Q0801m
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SOLENOID VALVES AND SAFETY DEVICES
The system has a solenoid valve located on the pressure reduction unit and a so­lenoid valve fitted inside the multivalve as­sembly on the tank.
The main function of these solenoid valves is to interrupt/allow the flow of LPG to the supply circuit.
The solenoid valves are open when:
– a request to run on LPG has been made;
– the optimum engine running conditions are satisfied (engine coolant temperature, minimum revs level) for running on LPG;
– there is enough LPG in the tank for op­eration;
– the inertia switch has not been triggered.
The multivalve assembly fitted on the tank includes:
– a valve that automatically stops the sup­ply of LPG when the maximum permitted filling level is reached (80% of the total tank capacity);
– a flow limiter which, if a pipe is broken, prevents the complete and sudden escape of LPG;
– a one-way valve, located on the gas re­turn pipe in the tank, which prevents LPG reflux;
– a safety solenoid valve on the LPG sup­ply, which either gives the go ahead or prevents the escape of gas to the pressure reduction unit;
– a manual tap, upstream of the solenoid valve, that separates the tank from the LPG system to allow maintenance opera­tions;
– a fuse pad which, in the case of overheating (temperature above 120°C), totally eliminates the danger of excess pressure making the LPG in the tank flow out as quickly as possible in a controlled manner;
– an analogue gauge showing the level of LPG in the tank.
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REGULATION UNIT
The regulation unit fig. 4 includes:
– cut out solenoid valve with gauze filter;
– pressure regulator.
The cut out solenoid valve opens or closes together with the solenoid valve on the tank. It closes each flow of LPG when the engine is not running on gas.
It also acts as a safety device that prevents the flow of LPG if the inertia switch is ac­tivated.
fig. 4
F0Q0802m
The pressure regulator allows the change of the LPG from a liquid state to a gaseous state via a dilation chamber and maintains the pressure required for the operation of the system at a preset val­ue.
PIPING
The piping for the LPG in a liquid state (from the filler to the tank and from the tank to the pressure regulator) is made from copper and coated in plastic.
The piping for the LPG in a gaseous state (from the pressure regulator to the LPG injectors) is made from rubber.
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PAPER FILTER
The filter fig. 5, located on the pressure regulator outlet pipe, has the task of fil­tering the LPG in a gaseous state during the LPG injectors supply stage.
fig. 5
F0Q0803m
LPG INJECTORS
There are four injectors fig. 6, specially designed for LPG, mounted on the intake manifold near the cylinder head, one for each inlet duct; they are supplied with LPG in a gaseous state at a constant pressure and are controlled by a specific electron­ic control unit.
A gas pressure and temperature sensor that sends an appropriate electrical signal in order to determine the LPG injection time is fitted on the injectors.
fig. 6
F0Q0806m
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ELECTRONIC CONTROL UNIT
The vehicle has a dedicted electronic con­trol unit for the LPG system; it uses the incoming signals from the petrol injection control unit and converts them into sig­nals for the injection of the LPG.
The control unit for the injectors has the same strategy as the petrol control unit (phased, sequential, multipoint).
LPG/PETROL SWITCH
The LPG/petrol switch fig. 7 is located on the centre console near the handbrake lever and includes:
A. LPG/petrol operating mode request button;
B. LPG gauge: 5 LEDs, 4 green and 1 red to indicate the reserve. The red LED on­ly comes on when the last green LED goes out. The red LED indicates the reserve con­dition;
ON. LPG operating mode indicator: green LED, located under button A, on constantly;
OFF. petrol operating mode indicator: yellow LED, located above button A, on constantly.
IMPORTANT When the ignition key is turned to the MAR position the LEDs on the ignition switch come on in accordance with the following logic:
with the petrol operating mode se- lected: yellow OFF LED on;
with the LPG operating mode se- lected: all the LEDs in the switch are on constantly and the green ON LED is flash­ing.
To select the type of fuel system desired (LPG or petrol), press the button A - fig. 7.
To change the type of fuel system, it is ad­visable to operate the button with the ve­hicle stationary and the engine running or, whilst driving, after having released the ac­celerator.
If the switching takes place during accel­eration or pick-up, there may be a brief flat spot (fall in power).
Do not switch between the two operat­ing modes whilst starting the engine.
fig. 7
F0Q0805m
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SWITCH FROM PETROL TO LPG
When running on petrol: press the button A - fig 7, the switch to LPG will take place automatically at the first significant accel­eration.
During switching:
– the LPG gauge B comes on;
– the yellow OFF LED goes out (petrol operating mode);
– the green ON LED comes on switch­ing from intermittent to on constantly (LPG operating mode);
There is a series of 5 LEDs B (1 red and 4 green) on the left side of the switch that display the amount of LPG in the tank.
When the amount of LPG remaining goes below about 1/5 of the capacity of the tank, only the red (reserve) LED remains on to signal the need for refuelling.
IMPORTANT In the case of starting at outside temperatures of below -10°C, the switching times from petrol to LPG in­crease to allow the pressure regulator to become warm enough.
LPG used up
If the LPG runs out, switching to petrol takes place automatically with:
– the yellow OFF LED on constantly;
– the green ON LED flashing;
– an acoustic warning from the switch buzzer (fast frequency).
IMPORTANT The buzzer warns the dri­ver that the engine is running on petrol; therefore they must refuel with LPG be­fore it runs out.
IT IS possible to deactivate the buzzer by pressing switching button A.
Do not switch between the two operating modes whilst starting the engine
Switching from LPG to petrol
When running on LPG: press the button A - fig. 7.
During switching:
– the LPG gauge B goes out;
– the yellow OFF LED comes on con­stantly (petrol operating mode);
– the green ON LED goes out (LPG op­erating mode).
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FUEL CUT OFF SWITCH
In the case of LPG operation as well, the safety switch is triggered if the car is in­volved in an impact immediately cutting off the supply (safety solenoid valve closed) and causing the engine to cut out.
For further information, see the “Fuel cut off switch” paragraph in the “Controls” chapter in the Owner Handbook.
STARTING THE ENGINE
The engine is always started on petrol even with the switch in the LPG position (green LED flashing, yellow LED on con­stantly) and switches automatically soon after.
There must always be some petrol in the tank to protect the petrol pump.
To carry out the starting manoeuvre, see the warnings and advice in the Owner Handbook under the chapter “Starting the engine”.
In this condition it is possible to continue driving running on petrol (excluding the LPG fu-
el system). To stop the buzzer, press button A: the green ON LED will go out and the yellow OFF LED will remain on constantly. Go to a Fiat Dealer as soon as possible to have the system checked.
SYSTEM FAILURE SIGNALLING
The car has an autodiagnostic system ca­pable of signalling any malfunctions in the LPG fuel system through the green ON LED fig. 7 flashing. In the case of faults that could affect the correct operation of the engine, the LPG control unit will au­tomatically switch from LPG operation to running on petrol.
This condition will be shown by:
– the yellow OFF LED on constantly;
– the green ON LED flashing;
– an acoustic warning from the switch buzzer (slow frequency).
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REFUELLING THE CAR
LPG FILLER
The gas filler is located next to the petrol filler cap. It has a one-way valve, located in the actual filler body.
To access the filler B - fig. 8, open the ac­cess flap A and undo the cap C.
Observe the following precautions during the refuelling operation:
– switch off the engine;
– apply the handbrake;
– turn the ignition key to the STOP po­sition;
– do not smoke;
– hand the special adaptor over to the qualified LPG refuelling personnel.
IMPORTANT Before refuelling with LPG, the qualified personnel should make sure that the adapator is correctly tightened onto the filler fitting.
IMPORTANT Depending on the country, there are two types of adaptors for refu­elling pumps. The adaptor that comes with the car in a special case is specifically de­signed for the country in which the car is sold. If you are in a different country, find out what type of adapator is used there.
WHEELS
The car does not have a spare wheel but a tool box that contains the “Fix&Go au­tomatic” quick tyre repair kit, the tow hook and a screwdriver. The box is lo­cated in the luggage compartment, behind the rear seat backrest.
To use the “Fix&Go automatic” kit, see the instructions in the Owner Handbook that this supplement is an appendix of.
fig. 8
F0Q0807m
fig. 9
F0Q0281m
IMPORTANT Only use LPG for mo­tor vehicles.
IMPORTANT Look after the LPG adapator carefully so that it does not get damamged.
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30 60 90 120 150 180
GGGGGG
GG
GGGGGG
GGGGGG
GGGGGG
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FUSE REPLACEMENT
The LPG system components are protected by the following fuses:
– Additional 20A fuse located to the outside of the engine compartment junction unit: LPG control unit power supply (battery positive);
– 7.5A F16 fuse located in the engine compartment junction unit: LPG control unit power supply (ignition-controlled positive) and coil relay for gas solenoid valve power supply.
For all the other fuses, consult the Owner Handbook that this supplement comes with.
SCHEDULED SERVICING PLAN
Additional operations to the Servicing Plan in the Owner Handbook.
Thousands of kilometres
Visually inspect the condition of: LPG piping and connectors and
LPG tank fastening
Replacement of filter inside the pressure regulator
Paper filter replacement (LPG in gaseous state)
Check operation and parameters of fuel supply system using autodiagnostic socket
Check mechanical tappet clearance and restore if necessary
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ENGINE
ENGINE CODE - BODYWORK VERSIONS
Engine code Bodywork version
1.4 16V 192B2000 198AXA1B G00C
IDENTIFICATION PLATE (STAGE 2)
Following the installation of the LPG sys­tem components, a plate (Stage 2) is fitted to the engine compartment front cross­member, that contains the following in­formation:
– Name of manufacturer;
– Homologation number (Stage 2);
– Vehicle type identification codes;
– Vehicle weights;
– Engine type;
– Bodywork version code.
INTRODUCTION
1.4
16V
Engine identification code 192B2000
Cycle Otto
Number of cylinders and position 4 in line
Piston diameter and stroke mm 72 x 80.4
Total capacity cm 1368
Compression ratio 11
LPG Petrol
Max power CEE kW 66 66
HP 90 90
at a speed of rpm 5500 5500
Max torque CEE Nm 128 128
kgm 13 13
at a speed of rpm 4500 4500
Spark plugs NGK DCPR7E-N-10
Fuel
LPG
Unleaded petrol
95 RON
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IGNITION
Static advance, electronic, integrated with the injection.
LPG FUEL SYSTEM
Electronic injection with special LPG injec­tors.
Type: Phased, sequential, multipoint.
Stoichiometric metering of the air/gas mix­ture.
Engine idle speed: 750 ± 50 rpm
The LPG injection system is controlled by a dedicated control unit (connected to the petrol one) using the sensors already on the car.
Modifications or repairs to
the fuel feed system that are not carried out properly or do not take the system’s technical specifica­tions into account can cause mal­functions leading to the risk of fire.
WARNING
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WEIGHTS
(1) If special equipment is fitted (sun roof, trailer towing equipment, etc.) the unladen weight will increase and consequently the
payload will decrease in relation to the maximum permitted loads.
(2) Loads not to be exceeded. The user is responsible for arranging goods in the luggage compartment and/on load carrying plat-
form within the maximum permitted loads.
(3) Lineaccessori Fiat range roof racks, maximum capacity: 50 kg.
Weights (kg)
Unladen weight (with all fluids, fuel tank filled to 90% and without optional equipment):
Payload including the driver (1):
Maximum permitted loads (2) – front axle: – rear axle: – total:
Maximum permitted load on the roof (3):
1.4
16V
1205
510
1000
860
1715
80
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F0Q0003m
DIMENSIONS
fig. 10
AB CDEFGH
4336 974 2600 762 1498
1538
1792
1532
1530 () 1524 ()
Small variations in size are possible depending on the dimensions of the rims () with optional 18” alloy wheels
Dimensions are expressed in mm and re­fer to the vehicle equipped with its origi­nal tyres.
Height is measured with vehicle unladen.
Luggage compartment volume
Capacity with vehicle unladen
(V.D.A. standards): . . . . . . . . . 365 dm
3
Capacity with rear seat
backrest folded over: . . . . . . . . . 1139 dm
3
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CAPACITIES
Petrol
Petrol . . . . . . . . . . . . . . . . . litres 57
– including a reserve of . . . . 8-10 litres
LPG
– maximum refuelling
capacity (*) . . . . . . . . . . . . . . litres 41
(*) The figure already takes into account the 80% tank filling limit and the residual fluid required for the pump and the max­imum permitted capacity. There may be
slight variations to this figure as a re­sult of: differences between network pump supply pressures, pumps with different supply/stop specifications, tank not completely in reserve con­ditions.
It should be remembered that when using a fuel like LPG, the range is very variable because, in addition to the vehicle driving and maintenance conditions, it also de­pends on the different composition of the gas which may vary, not only seasonally, but also from supplier to supplier. LPG is, in effect, a composition of gas (butane and propane) mixed in a way that may not be standardized.
During LPG operation, the “Instant con­sumption” and “Average consumption” readings are not significant, but remain valid for all other functions.
IMPORTANT Only use LPG for mo­tor vehicles.
If, when refuelling with LPG, the tank is filled with more than the 41 litres, seek assis-
tance immediately from a Fi­at Dealer. Periodically (at least once every six months) it is advisable to let the LPG in the tank run out and, at the first refuelling, check that it does not exceed the maximum capacity of 41 litres.
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FUEL CONSUMPTION
The fuel consumption figures given in the table below are determined on the basis of the homologation tests laid down by specific European Directives.
FUEL CONSUMPTION ACCORDING TO DIRECTIVE 2004/3/CE (litres x 100 km)
CO2EMISSIONS
The CO2emission figures refer to combined consumption.
CO
2
EMISSIONS ACCORDING TO 2004/3/CE DIRECTIVE
LPG: 134 g/km
Petrol: 156 g/km
Petrol LPG
Urban 8.6 10.6
Extraurban 5.5 7.0
Combined 6.7 8.3
The range (when running on LPG), referring to combined consumption, is 494 km.
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NOTES
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Fiat Group Automobiles S.p.A. - Customer Services - Technical Services - Service Engineering
Largo Senatore G. Agnelli, 5 - 10040 Volvera - Torino (Italia)
Print no. 604.39.936 - 01/2009 -1
st
Edition
604.39.936 BRAVO GPL GB 7.0 3-12-2008 9:16 Pagina 24
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